An ice cream processing line is a series of equipment and machinery used to manufacture ice cream in a commercial setting. The line typically includes the following steps:

Mixing: The raw ingredients, such as milk, cream, sugar, stabilizers, and flavorings, are combined in a large mixing tank. The ingredients are blended together to form the ice cream base.

Homogenization: The ice cream base is passed through a homogenizer, which breaks down fat globules and ensures a smooth and consistent texture.

Pasteurization: The ice cream base is heated to a specific temperature to kill any harmful bacteria present. This step is crucial for food safety.

Aging: The ice cream base is allowed to age at a controlled temperature for a specific period. This aging process enhances the texture and flavor of the ice cream.

Flavoring and Additions: Once the ice cream base has aged, additional flavorings, such as fruit purees, chocolate chips, or nuts, can be added. These additions are mixed into the base to create a flavored ice cream.

Freezing: The ice cream base is pumped into a continuous freezer, where it is rapidly frozen while being agitated. This freezing process creates small ice crystals and incorporates air, giving the ice cream its creamy and smooth texture.

Packaging: The frozen ice cream is then transferred to a packaging machine, where it is filled into containers, such as tubs or cones. The packaging is sealed to prevent air and moisture from entering.

Hardening: The packaged ice cream is moved to a hardening room or blast freezer, where it is stored at very low temperatures to further solidify and stabilize the product.

Labeling and Coding: The packaged ice cream containers are labeled with important information, such as the flavor, ingredients, nutritional content, and expiration date. Coding is applied to track production and ensure traceability.

Storage and Distribution: The finished ice cream is stored in a frozen storage area before being distributed to retailers or consumers.

Quality Control: Throughout the processing line, quality control tests, such as sensory evaluation, viscosity measurement, and microbiological analysis, are conducted to ensure the ice cream meets safety and quality standards.

Cleaning and Sanitization: The processing line and equipment are thoroughly cleaned and sanitized between production runs to maintain food safety and prevent contamination.

Each step in the ice cream processing line is carefully controlled to create a consistent and delicious end product. Modern processing lines include automation and advanced technology to increase efficiency and maintain product quality.




Production technology:
Preheating → mixing of ingredients → sterilizing and homogenizing cooling (< + 5 ℃ ripening > 4 hours) → continuous freezing (air-3 ℃ - 6 ℃) → adding dry materials and fruit mixture → injection molding, injection and extrusion into cup or egg roll (flavoring material) → freezing → continuous hardening → (- 20 ℃) → frozen storage - 25 ℃ (0-9 months)






1. Ice cream mix preparation module containing

2. Water heater

3. Mixing and processing tank

4. Homogeniser

5. Plate heat exchanger

6. Control panel

7. Cooling water unit

8. Ageing tanks

9. Discharge pumps

10. Continuous freezers

11. Ripple pump

12. Filler

13. Manual Can filler,

14. Wash unit




DESCRIPTION

-Formulation:
The ingredients used in ice cream production are: fat;milk solids-non-fat (MSNF);sugar/non-sugar sweetener;emulsifiers/stabilisers;flavouring agents;colouring agents.


-Weighing, measuring and mixing:
Generally speaking, all dry ingredients are weighed, whereas liquid ingredients can be either weighed or proportioned by volumetric meters.


-Homogenisation and pasteurisation:
The ice cream mix flows through a filter to a balance tank and is pumped from there to a plate heat exchanger where it is preheated to 73 – 75deg for homogenisation at 140 – 200 bar, the mix is pasteurised at 83 – 85deg for about 15 seconds then cooled down to 5deg and transferred to an ageing tank.


-Ageing:
The mix must be aged for at least 4 hours at a temperature between 2 to 5degc with continuous gentle agitation. Ageing allows time for the stabiliser to take effect and the fat to crystallise.


-Continuous freezing:
•to whip a controlled amount of air into the mix;
•to freeze the water content in the mix to a large number of small ice crystals.


-Filling in cups, cones and containers;
-Extrusion of sticks and stickless products;
-Moulding of bars
-Wrapping and packaging
-Hardening and cold storage