Benefits
Highest capacity on the market with multilane wrapping
- 43,200 ice cream sticks per hour (30 strokes 24 lanes, 720 products per minute)
- Flexible, modular mould cleaning system with minimum water consumption
- Robust and hygienic design with smart utility connections
- Automatic stick inserter with double magazine and reversing in-feed belt
- Servo-driven and accurate mould drive system, robust chain system – enables safe, high-speed production
- Efficient brine cooling system ensures even brine flow across machine
- Unique nozzle plate solution creates turbulence, cools products more efficiently
Features
Adaptable filling
Enables a broad variety of different products
The moulder can be fitted with a volumetric top filler, a volumetric bottom filler, a time elapse top filler, a pencil filler and back suction equipment. By changing the filling method (or sequence of filling methods) it is possible - and relatively simple - to produce an almost infinite variety of products. Pre-set recipes in the automation system recognise and adapt to the filling method that is in place at any given time.
Superior mould strip quality
For maximum durability and product safety
Our ice cream mould strips are designed, manufactured and quality assured in order to withstand the harsh production environment and stress caused by frequent temperature fluctuations, all without jeopardising product quality and safety.
Nozzle plate 1500 A2
Ensures consistent product quality and low costs
Brine is pumped at -40 through the nozzles of the nozzle plate, ensuring contact with the entire surface of the mould. This carefully designed process gives very efficient heat transfer, making production economical and ensuring reliable product quality.
Extractor tong
Enhances the reliability of your production
This small but vital component takes hold of the ice cream stick and pulls the product up out of the mould. It can adapt automatically to find the stick, and pulled it up with sufficient force to guarantee the product is removed and never dropped. Typically a wear part, this tong has a documented lifetime of approximately 10 years, and is used in both rotary and linear moulding lines.
Tong surveillance sensor
Monitors production and enables rapid corrective action
The sensor checks that a product is always pulled up out of the mould when it should be. If it does not detect a product, the operator is alerted and can make adjustments. To enable the ‘no-product no-wrap’ feature, a signal is sent to the wrapper telling it to wait for a product to arrive rather than creating an empty wrap. All errors are logged and, if they point to the same tong, a replacement can quickly be installed.
Five servo drives
Enables high speed production (30 strokes/minute)
The unit carries out a series of different actions: indexing of the moulds, extraction of the product, indexing of the tongs, dipping and lay down. Thanks to five built-in servo drives, the timing of these different actions can be controlled down to the millisecond, which is what makes reliable high speed production possible.
Automatic product removal
Saves water during cleaning
The system is designed to remove any products that remain in the moulds after extraction. This prevents contamination of the cleaning water and since it is automatic, does not require monitoring by operators.
Multi-tank flush and cleaning system
Minimizes the need for fresh water
The mould cleaning system consists of four tanks. Completely fresh water is only added at the last spray system, which runs into tank 4, then 3, then 2 and then 1. In other words, used water is sent back into the system reducing the amount of fresh water needed by approximately 50%. Backwards flow ensures all lost product and residue is removed from the first tanks.
Options
Dry coater
Prevents stoppages and product waste
Dry coating is a critical process. If not handled correctly it can lead to errors, waste of expensive ingredients and down time. This optional new generation dry coater can be emptied on the fly, enabling production to continue uninterrupted, even if the chocolate is not at exactly the right temperature - such as, during the start-up phase.
Combi Top Filler
Expands the range of possible filled products
Available in either a pneumatic or servo driven version, this equipment makes it possible to produce water ice, Ice cream and slush ice, and to have inclusions. It also enables filling with two colours - either two per mould or two per row. The volume of filled product can be easily adjusted between production runs.
Tetra Pak® Volumetric Bottom Filler
For high quality moulded ice creams
Enabling a greater amount of air to be incorporated in your viscous filled products, this filler lets you produce high quality moulded ices with a premium feel. It can also handle larger inclusions up to 15mm, and with filling at down to -5°C, the inclusions remain evenly distributed throughout the product. A cold start temperature reduces the time required in the rotary moulder, thereby increasing line capacity.
Tetra Pak® Automatic Stick Multi
Reliable performance and high yield
A servo driven conveyor belt prepares the sticks so they can be inserted in precisely the correct position in the product, thus enabling reliable performance and high yield. The unit runs at up to 30 strokes per minute and can also be equipped with a backup magazine so production continues uninterrupted, even if a stick is off spec.
Brine buffer tank
Maintains quality of cooling brine
If the concentration of salt in the brine is too low in the linear moulder, production efficiency will go down. In extreme cases, the plate heat exchanger might freeze up. The brine level therefore needs to be topped up and improved from time to time – and this process is made easier by having a brine buffer tank.
Ice Cream Video Care
Get full visibility of your ice cream line
Ice Cream Video Care lets you visually monitor inaccessible and “hidden” areas of ice cream production lines. Featuring up to 16 cameras, the solution enables improved quality control and troubleshooting – by making it easier to locate the root cause of quality issues, it becomes possible to reduce downtime and product waste. Ice Cream Video Care provides access to live video as well as recordings.
Ice Cream Line Insight™
Reduce waste through data insights
Ice Cream Line Insight™ gives you all the intelligence you need to reduce product waste. The system collects data from the machines in your ice cream production line, and tells you where and why products are wasted. You also get data on energy consumption from each separate machine so you, for example, can calculate energy cost per ice cream product.
High capacity linear moulding line for 43,000 sticks/hr
A robust designed and highly automated linear moulding line that combines highest capacity at the lowest possible production cost.
Ice cream Product Development Centre
At the Tetra Pak Ice Cream PDC you can experiment with the latest ice cream processing solutions in a complete production environment at semi-industrial scale.
