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1、 General Ice cream production with large inclusions White paper Getting more out than what you put in General Publisher Tetra Pak Processing Systems AB SE 221 86 Lund,Sweden Published October 2017 Tetra Pak International S.A No part of this publication may be duplicated in any form without the sourc
2、e being indicated.3 CONTENTS Introduction _ 4 Who is this booklet for?_ 4 What can be improved?_ 4 The journey _ 5 What makes a successful large inclusion _ 5 Challenges with existing extrusion-line technology _ 6 Addressing a market need _ 7 Solving a problem through the development of novel techno
3、logy _ 7 Prototype to explore the possibilities _ 10 From prototype to production equipment _ 11 Conclusion _ 11 Tetra Pak your processing partner _ 12 4 INTRODUCTION Who is this booklet for?This booklet is for ice cream producers of all sizes seeking a more cost-effective,efficient way of introduci
4、ng large inclusions into extruded ice cream products.Existing production methods are expensive and produce too much waste.We at Tetra Pak would like to share how we chose to address these and other challenges.What can be improved?The market for premium-quality stick ice cream products is expanding r
5、apidly especially for products with large inclusions.Nevertheless,there remains significant room for improvement in adapting extrusion-line production for these delicious products.Existing technologies focus on some of the production challenges,but none offer a solution to them all.We began by targe
6、ting these four areas:Appearance Correct shape and appearance is essential.Products need to be free of dents in the ice cream,protrusions,uneven edges etc.The challenge:Develop equipment that can add large inclusions without compromising the appearance and integrity of the ice cream product.Position
7、ing Inconsistent positioning equals waste.When products fail to be positioned correctly on extrusion-line trays,they are not picked up in the next step of production resulting in significant waste.The challenge:Develop equipment that provides consistent positioning of products and therefore improved
8、 pick-up over existing methods.Capacity Higher capacity means lower production costs.Todays equipment options for large inclusions are not able to run at high capacity.The challenge:Develop equipment that can run at the same capacity as the extrusion line.Simplicity Avoiding nitrogen or other additi
9、onal cooling methods is preferred.Among other things,relying on substances such as liquid nitrogen in production adds complexity and cost.The challenge:Develop equipment that can be mounted,started and is then ready to go.Tetra Pak set out to explore technology that could address all of these areas.
10、Heres what we found.5 THE JOURNEY What makes a successful large inclusion Ice cream producers are continuously seeking to attract consumers by launching new and exciting ice cream products.One way of doing this is to add large inclusions such as cookie dough,brownies,caramel chunks,etc.Some brands h
11、ave innovatively used large inclusions in creating highly-successful products such as ice cream cups and tubs,which are typically 100500 ml.Ice cream producers have long sought to extend large inclusions to extruded products.Traditional production processes,however,are not suited to producing this t
12、ype of product.With the recently-developed technology used in the Tetra Pak Volumetric Bottom Filler,inclusions up to 15 mm can be added to moulded stick novelties that have a level of quality comparable to extruded products.But consumer preference is for extruded stick novelties,which underscores t
13、he need for improved extrusion-line technology for large inclusions.6 Challenges with existing extrusion-line technology When introducing large inclusions into extruded ice cream,inclusion content and particle distribution determine the quality of the product,which also needs to have the right textu
14、re,shape and overall appearance.The market for large inclusions is relatively new,and production methods vary.For extruded stick novelty products,+traditional vertical extrusion and wire cutting are not optimal for ice cream with large inclusions.To begin with,when the wire hits a large inclusion,it
15、 cannot cut through the inclusion,which is pushed in front of the wire,resulting in a highly uneven surface of the product.Furthermore,the impact from this collision between the wire and the inclusion is transferred to the ice cream slice,which causes a significant shift in how the ice cream slices
16、become positioned on the stainless-steel trays of the extrusion line.The uneven positioning of the products then leads to increased waste when the products subsequently fail to be picked up from the trays.This much waste is unacceptable in efficient production.Several attempts have been made with hi
17、gh-speed cutting knives,“scissor cutting”and double-wire cutting,yet these methods have not been able to produce products with large inclusions that have a smooth surface and are correctly positioned on the trays.If the temperature of the extruded ice cream is significantly lowered,to e.g.-12C,the v
18、iscosity of the ice cream becomes much higher,enabling it to better support the embedded inclusions.With low-temperature ice cream,it is then possible to produce extruded products containing soft inclusions,such as cherries,that have good surface quality and are consistently positioned correctly on
19、the trays.However,the extra freezing step required to reach such low ice cream temperatures,combined with the limited range of suitable inclusions,make this solution less attractive.There are also solutions for producing stick products with large inclusions based on nitrogen-cooled moulds.The ice cr
20、eam does not stick to a surface with a temperature below approximately-60C.Therefore,by using liquid nitrogen to cool the mould,it is possible to fill it with ice cream containing large inclusions and then release the product.The nitrogen cooling,however,increases production costs significantly,and
21、the handling of liquid nitrogen adds complexity to the start-up and running of the equipment.7 Addressing a market need It becomes clear that ice cream producers have lacked a fully efficient method for producing high-quality ice cream stick products with large inclusions.In response to this need,we
22、 set out to develop a production method that fulfils the following requirements:Attractive product appearance:well-defined corners and flat,smooth surfaces without holes or protruding inclusions Correct placement of the stick in the product and no risk of damage to the stick Ability to add all types
23、 of commonly used inclusions:soft,medium and hard with sizes up to 25 mm.Soft inclusions can be pieces of fruit such as mango,strawberry or pineapple.Medium inclusions include cookie dough,raisins and brownies.Examples of hard inclusions are whole hazelnuts or almonds,caramel chunks,large chocolate
24、pieces or spherical candies Even distribution of the inclusions in the ice cream product Correct and consistent positioning of the ice cream products on the stainless-steel trays of the extrusion line to minimize waste at the subsequent pick-up of the products No use of nitrogen or other materials,w
25、hich add significantly to production costs Production capacity equal to that of traditional extruded stick products(typically 150 to 200 products per lane per minute)An efficient production method that accommodates large inclusions requires a production cost comparable to that of normal extruded sti
26、ck products,including the cost from the waste.Another issue is that the cost of many types of inclusions is higher than the cost of the base ice cream.Even if the production costs are the same,this can result in a higher raw material cost and,therefore,higher overall cost for the product.Such an add
27、itional cost is counterbalanced by the added value of the product.However,the increased product value also increases the importance of minimizing waste.Finally,the equipment needs to meet the strictest hygienic and safety standards.Solving a problem through the development of novel technology Ice cr
28、eam producers need an efficient production method for high quality ice cream stick products with large inclusions.Therefore,Tetra Pak initiated a technology development project with the following objective:Develop technology for producing stick products on extrusion lines that ensures:Highest qualit
29、y of texture,final shape,inclusion content and distribution in the product Minimized waste rates to keep production and final product cost within a profitable range Expanded available product range for extrusion lines 8 The project team included both ice cream specialists from Tetra Paks ice cream P
30、roduct Development Centre(PDC)in Aarhus Denmark and technology specialists from the processing research&development team.This combination of different competencies combined with a structured stage-gate process for technology development has yielded ground-breaking results.Many ideas were explored an
31、d screened in the first phase of the project,and three concepts were selected for further evaluation:Ultrasonic cutting Inclusion-free zone Vertical rotating wheel These three concepts were further explored in the next phase of the project.Ultrasonic cutting is a very interesting method often used f
32、or cutting sticky,inhomogeneous products.The tests showed that it is possible to cut not only the ice cream but also the inclusions in the ice cream.However,to cut through a hard inclusion such as a hazelnut,a certain pressure is required.The tests showed that for a traditional vertical extrusion,wh
33、ich uses a high cutting speed,it was not possible to obtain a smooth cut through the inclusions without pushing the inclusion.In a horizontal extrusion of e.g.candy bar products,the cutting speed is lower and there is better support of the ice cream during the cut,which improves cutting quality.The
34、inclusion-free zone involves two streams of ice cream one with inclusions and one without which are coextruded.By moving a piston,it is possible to create a particle-free zone.The concept was tested by using computational fluid dynamics(CFD)simulation and a viscoplastic material model for ice cream.
35、The simulations showed how it is possible to optimize the zone with ice cream without inclusions to cover both the area where the stick is inserted and a layer where it is possible to cut through with a normal wire cutter.But with this concept,only about half of the ice cream can contain large inclu
36、sions.There is also a limit to the size of the inclusion.The vertical rotating wheel was explored using a series of tests of the individual steps in the process.The vertical rotating wheel is a wheel with a horizontal axis.It has a number of cavities at its outer surface that have the same shape as
37、the final product see image below.The concept involves these steps:Insertion of the stick into a slot in the cavity Filling the cavity with ice cream with large inclusions Pushing the ice cream out of the cavity with a piston Positioning the product on the stainless-steel tray of the extrusion line,
38、then releasing it from the piston 9 For each step in the process,different solutions were tested and the best one selected.For example,several different methods for releasing the product from the piston were tested including pushing the product off the piston with compressed air through many small h
39、oles in the piston.The most successful method for releasing the product from the piston,however,was to use a heated wire or a heated thin knife.The vertical rotating wheel solves the issue of precisely positioning the products on the stainless-steel trays.The periphery speed of the vertical rotating
40、 wheel is synchronized with the speed of the trays.By adjusting the height of the wheel above the trays so the products precisely touch the tray when fully pushed out in the bottom position of the rotation,the products are positioned on the trays with high accuracy.Evaluation of the three selected c
41、oncepts ultrasonic cutting,inclusion-free zone and the vertical rotating wheel made it clear that the most promising concept was the vertical rotating wheel.It was resolved to build a prototype of this concept in the next phase of the project.The prototype was designed to fit in a standard station o
42、n a Tetra Pak Extrusion Worktable.This made it possible to test the prototype both internally at the ice cream PDC in Denmark,and on a production line at an ice cream production site.10 Prototype to explore the possibilities The prototype has been used to prove the concept and explore the boundaries
43、 of what is possible with the vertical rotating wheel concept.The test with the prototype showed that the requirements for product appearance(well-defined corners and smooth surfaces without holes or protruding inclusions)are fulfilled and that the positioning of the products on the trays is within
44、very close tolerances.In fact,the accuracy is so high that the vertical rotating wheel could provide an advantage in applications with very strict demands for positioning the ice cream slice,e.g.in the production of sandwich products.To maintain high standards for appearance,such products require th
45、at the ice cream is precisely positioned on the biscuit portion of the sandwich.The possibilities and limitations of inclusion type,size and amount have also been tested.And the requirement of handling inclusions up to 25 mm has been exceeded.For instance,it is possible to run the vertical rotating
46、wheel with whole dried apricots measuring approximately 40 mm in diameter and with large candy pieces that are almost spherical with a diameter of 25 mm.The amount of inclusion that can be added has been tested for different types of inclusions.Up to 30 percent in inclusions(by volume)have been adde
47、d with good results.One issue to consider is that if the inclusions are at room temperature when added to the ice cream in the ingredient doser,they will heat up the ice cream.For best results,producing the ice cream as cold as possible out of the freezer is recommended(the actual temperature that c
48、an be achieved depends on the recipe).If large quantities of inclusions are to be added,it is beneficial to keep them in cold storage until just before they are dosed by the ingredient doser.If the inclusions have a high sugar content or are wet,the ice cream will become soft and wetter,which affect
49、s product appearance.We highly recommend running tests with the actual ice cream recipe and inclusion and optimizing these test runs to obtain the best results.The vertical rotating wheel rotates continuously at a speed synchronized with the speed of the stainless-steel trays on the extrusion line.T
50、his provides smooth movements with small accelerations and allows for high production capacities.The normal production speed on extrusion lines is 150 to 200 products per lane per minute,and the vertical rotating wheel can easily achieve these production capacities.Overall,the tests with the prototy
51、pe showed that the vertical rotating wheel enables efficient production of high quality ice cream products with large inclusions at a production cost comparable to that of traditional extruded stick products without inclusions.The level of waste and production capacity are also comparable to that of
52、 stick products without inclusions,and there is no additional cost for liquid nitrogen.Furthermore,avoiding liquid nitrogen affords much easier and safer operation of the equipment.11 From prototype to production equipment After the concept was proven and the possibilities and limits explored with t
53、he prototype,the next step was to design and build equipment suitable for continuous daily production.Compared with the prototype,there are a number of additional requirements for production equipment regarding hygiene and cleanability,operator safety,user-friendliness,start-up and changing time,etc
54、.An integrated washing system has been designed,which allows for quick and easy cleaning and disinfection,and covers have been designed to secure operator safety while still maintaining easy access and operation.A quick-change system,inspired by pit stop techniques in Formula 1 racing,enables changi
55、ng the wheel and other product-dependent sizing parts in only a few minutes.Conclusion As the market for premium-quality stick ice cream products rapidly expands,addressing the limitations of extrusion-line technology offers ice cream producers a competitive advantage.Tetra Pak is determined to prov
56、ide you with the tools necessary to improve your products and advance the industry.We sought to identify what could be improved in production and then began addressing those areas through product development.The result is the Tetra Pak Extrusion Wheel.This is as much the result of a quest to meet sp
57、ecific production needs as it is an example of Tetra Paks continuous dedication to best practices.We developed this technology to increase productivity and reduce waste and,therefore,your production costs.This allows you to push the boundaries of creating new and exciting premium-quality products to
58、 be enjoyed by demanding consumers.12 TETRA PAK YOUR PROCESSING PARTNER Tetra Pak is an innovative partner and possesses unique competence in the processing of ice cream products.At Tetra Paks ice cream Product Development Centre in Aarhus Denmark we offer our customers opportunities to test new ice
59、 cream products and evaluate new recipes with large inclusions.Additional information about ice cream production can be found at:http:/ For further information on innovative solutions to suit your production needs,please contact your Tetra Pak representative at:http:/ 13 Tetra Pak and Protects Whats Good are trademarks belonging to the Tetra Pak G Tetra Pak International S.A,Tetra Pak Processing system AB,2017-10