Operators Master Training Course

MASTER TRAINING COURSE For Line Operators

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Introduction

Ice Cream Structure

Mix Preparation

Freezing

A short introduction on Why the Ice Cream ?

You will get Basic knowledge of main components of Ice Cream Structure and their key functionalities

You will learn about the mix preparation flow (equipment functions, flow parameters, heat exchange process) and know the key parameters that should be under control.

You will learn more about the main components of the freezer and their respective functions.

You will understand how much the Freezing process is linked to Ice Cream Structure.

MASTER TRAINING FOR OPERATORS

LEARNING OBJECTIVES



Practical Session

One practical session around the different parts of a Freezer, to learn the good practices on dismantling a dasher and a beater

3

Ice cream is the only food you eat frozen!

✓ Ice cream makes you happy ! ✓ Most european consumers say that ice cream is fun to eat (71%) ✓ Two out of three people think that ice cream is great for socializing (63%)

Why the Ice Cream?

✓ The consumer associates ice cream with pure enjoyment

 Ice Cream is made of  Water (55% to 65%)

 Components:  50% AIR (in volume)

 100% WEIGHT

Components

 Fat (8% to 16%)

 MSNF = Milk Solid Non Fat (9% to 12%)

 Sugars/Sweeteners (12% to 18%)

 Stabilizers  Emulsifiers (0,2 to 0,5%)  Flavors/Colors (others...)

 What is Ice Cream ?

Ice cream…

the phases of matter:

Unfrozen Phase MATRIX

Air Bubble coated by fat

A ir b?ubble LIQUID phase

SOLID phase

GAZEOUS phase

Air Bubble (inside)

A?ir

Ice ?

Crystal

Ice ?

Crystal

A ir B?ubble Optic microscopy

Microscopy electronic 6

20 µm

 Link between Ice Cream TEXTURE and its STRUCTURE Ice cream texture is linked to its microstructure

Classify the 5 following products by increasing hardness:

Softness

1

2

3

4

5

Hardness

 Link between Mix formulation and Ice Cream STRUCTURE Let's see an Example of composition of different Frozen Desserts…

WATER ICE

SORBET

ICE CREAM

PREMIUM IC

OTHER INGREDIENTS

OTHER INGREDIENTS

OTHER INGREDIENTS

OTHER INGREDIENTS

14%

MSNF

MSNF 10%

SUGAR 18%

SUGAR 18%

FAT 8% SUGAR 16%

WATER 73%

WATER 68%

No Fat

WATER 61%

FAT 12%

SUGAR 16% WATER 56%

More Fat Less Water

No Air

More Air

 Ice Cream Making = mix [ making & ageing ]+ freezing INGREDIENT FORMULATION

- Water - Fat

MIXING

HOMOGENIZATION

PASTO-COOLING

- Emulsifiers - Stabilizers - Flavours, Colours - Customizing ingredients

FREEZING

FILLING

HARDENING

COLD STORE

10% Fat

- MNSF (proteins) - Sugar & Carbohydrates

AGEING

50% Air 90% Sugar solution

5 % Fat 22% Ice crystals 23% Unfrozen phase

TEXTURE & TASTE

 FATS Types 1. Structural role

Stabilization of air cell structure

✓ Increase whipping ability ✓ Improve melting resistance

2. Sensory role

Dairy fats (Animal) ✓ Cream, whole milk ✓ Butter oil (AMF), butter ✓ Whole powder milk

Vegetable fats ✓ Coconut oil (RCO) ✓ Palm oil

Creaminess, Smooth texture ✓ Enhance desired taste

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 Milk Solid Non Fat (MSNF) - Proteins source Types

Milk (liquid or dehydrated) 1. Structural role

Body & Texture

Solids of skim milk

✓ Proteins (35%) (caseins, whey proteins)

✓ Stabilize air/oil/water interface ✓ Lactose (50%) ✓ Minerals

2. Sensory role

Smooth texture ✓ Give chewiness

✓ Vitamins

 SUGAR and CARBOHYDRATES

Types

Solid or liquid form: Common sugar (sucrose)

1. Structural role

from beet or cane

Bulking agent (total solids)

Glucose syrups

✓ Main part of unfrozen phase (matrix)

Bind water

Invert sugars

(hydrolysis of sucrose)

2. Sensory role

Dextrose, Fructose

Sweetness (Relative Sweetness) ✓ Increase flavour perception ✓ Decrease stiffness (scoopability) of ice cream

Lactose

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 Freezing Point (FP) Key parameter for

AMOUNT OF ICE

Freezing-point is the temperature point at which a liquid solution starts to freeze.

Effect of salt on the road

More solute = lower freezing point = freezing later

Solid (frozen) water

Liquid water solution

Examples adding salt in water or alcohol in water

The result of the solution has a lower freezing point than the pure solvent or solid. This is why the sea water (a mixture of salt in water) doesn’t freeze; it remains liquid at temperatures below 0 °C (32 °F), the freezing point of pure water.

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 Effect examples of SUGARS on Ice Cream TEXTURE

+ SMOOTH

Bind water ↑

+ SCOOPABLE Freezing Point

↓

+ CREAMY

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 Relative Sweetness (RS)

Sugars are sweet … but not all sugars are equally sweet Relative Sweetness definition:

Sucrose is taken as reference and the

“Relative Sweetness” of each sugar

is given in comparison to sucrose in given conditions.

+

Relative Sweetness (RS)

Freezing Point

Dextrose

+

++

Fructose

+++

++

Sucrose

++

+

Maltose

+

+

Lactose

+

+

Effect significant or more significant than other carbohydrates

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 EMULSIFIERS Structural role

Oil / Water

Types

Oil / Water

✓ Produce Stable emulsion of 2 liquids that do not mix naturally,

✓ Promote

Vegetable fat origins

Partial clustering

of fat globules, during the process

✓ Mono-diglycerides ✓ Polysorbate

Natural Emulsifiers ✓ Phospolipids from egg yolk

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 Stabilizers (hydrocolloïds)

Structural role

Gelling agent and thickener by controlling mobility of water ✓ The mix viscosity increases

Water – non-viscous

Viscosity build-up

-

Gelling effect

Gelling

+

Keeping quality ✓ Shape retention

Source: DuPont

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 STABILIZER (hydrocolloids)

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 STABILIZER Properties

Properties

Locust Bean Gum (LBG)

Guar

Carrageenan

Alginate

Xanthan

CMC

Mix viscosity Heat shock stability Cold soluble

●

pH stability

Low

Acceptable

Colloidal stabilisation

High

Cost in use

Source: DuPont

Standard Std utilization use

Complementary use

Special use

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 How to calculate overrun easily?

OVERRUN CALCULATION

1,15 DENSITY

VOLUME AIR X 100 VOLUME MIX

OVERRUN =

Mix Density

1000

VOLUME OF MIX

X Mix Volume

-1 X100 = 115 %

Weight of ice cream

536

IC Volume = ((Overrun/100 + 1) x IC weight) / Density

WEIGHT of IC

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 To sum-up Ice Cream is made of

 Water

Components:

 Fat (dairy fats or vegetable fats)

Creaminess and smoothness. The Backbone of Ice Cream.

 MSNF (proteins, lactose and minerals)



100% WEIGHT

50% AIR

Product Stability (emulsifier properties) - adding texture and body.

 Sugars/Sweeteners

Foaming texture

Sweetness intensity and smoothness. Impact the amount of ice.

Components

 Stabilizers Maintain the shape and a longer shelf life.  Emulsifiers  Flavors/Colors (others...)

Flavours (such as fruits) add aroma and influence the taste of the final product.

Colours influence the appearance of the product.

 Ice Cream Making = mix [ making & ageing ]+ freezing INGREDIENT FORMULATION

- Water - Fat

MIXING

HOMOGENIZATION

PASTO-COOLING

AGEING

FREEZING

FILLING

HARDENING

COLD STORE

10% Fat

- MNSF (proteins) - Sugar & Carbohydrates - Emulsifiers - Stabilizers - Flavours, Colours - Customizing ingredients

90% Sugar solution

50% Air

5 % Fat 22% Ice crystals 23% Unfrozen phase

TEXTURE & TASTE

 Working principles of Mix Plant a f ter h eat treatment d ue t o h igher sen sibility to heat

LIQUID

ingredients

DRY

ingredients

Transfer to freeze 

Pump

Pump - Turbo mixer - High shear mixer…

Mixing Tank

Hydration Tank

Homogenizer

 Dispersion

 Hydration

 Homogenization

Plate Heat Exchanger  Heat Treatment + Cooling to 4°C

Ageing Tanks  Maturation 27

 Mix Preparation 1. Hot water

• Hot water 131°- 149° F

2. Sugars & Syrups

• All form of sugars (Sucrose, inverted sugar, glucose, maltodextrine...), liquid or solid form

3. Stabilizers & Emulsifiers • Blend (Emulsifier+Stabilizer) 4. Powders & Proteins

• Milk derivates, protein and cocoa powders, some thick products

5. Fats

• Cream & Liquid fats (Coconut oil - Butter oil – Fresh milk)

6. Other ingredients + Rework

• Nuts, Pistachio, Nougat pasta

Mixing tank

Hydration tank

Achieve the temperature of mix to 140°F / 20 mins

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BATCH COMMON SET-UPS

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CIRCULATION LOOP: COMMON SET-UPS

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 Homogenization ✓ Homogenization breaks down the fat globules into smaller droplets to create an homogeneous and

Before

After

<10 microns

<1 micron

stable fat-in-water emulsion

✓ Process in 2 stages

2 examples of HOMO

Mean 2ųm Range 1-10ųm

Mean 0.5ųm Range 0.2 -2 ųm Many clusters

Mean 0.5ųm Range 0.2 - 2 ųm No clustering 32

 Homogenization Why 2 stages?

Pressure 1st stage

Pressure 2nd stage

2030-2900 psi

To reduce size of fat globules Forcer

Impact ring

435 psi

To prevent fat cluster formation

Seat

Fat globules ✓ 2000 times increased numbers ✓ 10 times increased surface ✓ 20 times decreased distance

Hydraulic actuator 1st stage

2nd stage

Reduce the fat diameter by 10 33

 Impact of homogenization on freezing process Example of BAD and GOOD homogenization process

 Poorly coated air bubbles with « uncontrolled fat clusters » at the surface are created. Very unstable. The uncoated areas result in « degasification » and loss of volume, leading to shrinkage.

 GOOD with proper mix preparation prior to homogenization « fatty plates at the air bubble surface » are created resulting in flexible and stable air bubbles (well coated) 34

 Heat Treatment (Pasteurization) Working principle of plate heat exchanger

Potential problems • Increased mix viscosity • Burning (due to foaming)

• Food safety

Three types

• Dissolve/active ingredients

• Batch pasteuriser • Continues (HTST pasteurizer) • Ultra High Temperature (UHT)

(destroy pathogenic micro-organisms) (emulsifiers and stabilizers)

133°F / 30 min 172-194°F / 25-50 sec 290°F / 4-12 sec

HTSC = High Temperature Short Time

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 Heat Treatment (Pasteurization) - 3 functions 2

Holding tube

• Ensures the effectiveness of heat treatment (« residence time ») • Destroy pathogenic microorganisms

1 Pre-heating To reduce energy utilization, regeneration is recommended by :

3

Cooling

• Dissolve/active ingredients (emulsifiers and stabilizers)

• Direct mix / mix exchange

valve

• Direct exchange between hot mix

from homogenizer and pasteurized mix

• Mix immediately cooled after

T°C: 181°F 30s

homo-pasteurization at 4°C / 39.2°F (2°C), before pumped to the ageing tanks.

• Prevent the growth of micro-

organisms

• Increase the mix viscosity

HOMO

MIX +140°F

MIX +162°F

MIX +39°F

(consistency)

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 Heat Treatment – Divert Valve System Working principle of divert valve system

149F

T°C < 178°F

T°C SENSOR

T°C ≥ 178°F 83181F

• Temperature sensor at the end of holding tube

167F

162F 39F

• Single seat valve

to divert the mix < 178°C to the balance tank 37

 EMULSIFIERS HYDROPHILIC head

NO EMULSIFIER

LIPOPHILIC tail fat clusters ca. 50 µm

Fat Fat Globule

WITH EMULSIFIER

PROTEIN DESORPTION

PARTIAL CLUSTERING of FAT GLOBULES

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INGREDIENT FORMULATION

MIXING

HOMOGENIZATION

PASTO-COOLING

AGEING

FREEZING

FILLING

HARDENING

COLD STORE

Key Parameters MICROSTRUCTURE TO BE ACHIEVED AFTER AGEING

RECIPE

MIX MATRIX

COMPOSITION

MIX PREPARATION

HOMOGENIZATION

AGEING

✓ Total Solids (%)

Order of addition

Pressure

T°C = 39°F

✓ % Fats

Dispersion

Fat size particles

At least 4h

✓ Proteins (MSNF)

✓ Sugars ✓ Stabilizers &

Emulsifiers

Hydration

+ Food safety : HEAT TREATMENT 41

 FREEZING: A critical point of Ice Cream Process

Ice crystallisation

 Ice cream structure building:

partial agglomeration and rearrangement of fat globules on air/soluble phase surface

Air bubble introduction

 High impact on ice cream texture: achieving uniform and smooth texture 42

 Ice Cream Making = mix [ making & ageing ]+ freezing INGREDIENT FORMULATION

- Water - Fat

MIXING

HOMOGENIZATION

PASTO-COOLING

- Emulsifiers - Stabilizers - Flavours, Colours - Customizing ingredients

FREEZING

FILLING

HARDENING

COLD STORE

10% Fat

- MNSF (proteins) - Sugar & Carbohydrates

AGEING

50% Air 90% Sugar solution

5 % Fat 22% Ice crystals 23% Unfrozen phase

TEXTURE & TASTE

 How the mix is transformed into ice cream?

Ice C rystals

Unfrozen phase

Unfrozen phase

Air bubble

Fat globules

Air Bubble coated by fat

Freezing Microstructure

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 Freezers History

One of the first ice cream factories developed starting from 1940

Mrs Marshall’s Ice Cream maker 1880 (Courtesy of the London Canal Museum, www.canalmuseum.org.uk)

Current freezer Tetra Pak and Wcb 2016

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 Tetra Pak Continuous Freezer Separator NH3 Panel control Cylinder

Air system Air inlet

Ice Cream Outlet

Dasher motor Mix flow meter Ice Cream pumps

Mix Inlet

Mix pump

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‫الدورة التدريبية الرئيسية لمشغلي الخطوط االنتاجية‬

Panel control

‫التطبيق العملي‬

‫التجميد‬

‫تحضير الخلطة‬

Air Mass Flowmeter

Mix Inlet

Ice Cream Outlet

‫تركيبة االيسكريم‬

‫مقدمة‬

Separator NH3

Mix flowmeter Mix pump

Air inlet Cylinder Dasher motor Ice Cream pumps 48

 Inside the Barrel

Front of freezer side

✓ one can not see inside ✓ one can not hear failures in factory context Regular inspections to be done

Rotation anticlockwise

50

 Dasher inspection WCB

TETRAPAK

DASHER ‫البرميل‬

REFRIGERANT ICECREAM WCB

TETRAPAK

BLADES

BEATER

95,5cm 47,5cm

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 Inside the Dasher – Freezing process

Barrel Barrel

Dasher

Ripening

MICROSTRUCTURE VIDEO

v

Scraper blades

Vapourizing ammonia SOURCE: TETRA PAK

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 Scraper blades inspection Cylinder Pin and blade Minimum 32 mm

125°

Max 0,5 mm

Hoyer

0,1 to 0,2 mm

 Check for blades width  Replace immediatly blades below minimum width 53

 Tetra pak – dasher assembly video

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 Tetra Pak Freezer pumps

Pump is in normal pump operation The center wheel (star wheel), mounted on a pneumatically piston

(red colour is compressed air)

Pump in CIP position

The centre wheel is pulled out of pump position, and free flow of detergent through the pump is obtained

SOURCE: TETRA PAK

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 Pump inspection : The pump leakage (=loss of efficiency) depends on: Viscosity of the mix ✓ Pressure difference over the pump ✓ Mechanical condition of the pump ✓ Mechanical adjustment of the pump

✓

Pressure difference over the pump

Half-moon

Real flow rate Theoritical flow rate 480 l/h

500 l/h

FLOW 57

‫الدورة التدريبية الرئيسية لمشغلي الخطوط االنتاجية‬

‫التطبيق العملي‬

 WCB Freezer Pumps

‫التجميد‬

‫تحضير الخلطة‬

‫تركيبة االيسكريم‬

‫مقدمة‬

Waukesha metal lobe ✓ All WCB Equipment freezers utilize Waukesha metal lobe Waukesha pumps as standard. ✓ The rotors of these pumps are made of the non-galling lead-free Waukesha “88” alloy. ✓ This alloy allows the rotors run at a very close tolerance without touching, which provides extremely long rotor life. ✓ These pumps are fully CIP-able and have by-pass covers that allowing the necessary high flow during CIP. ✓ A magnetic flow meter is used to provide very accurately closed loop control of the mix flow.

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 Tetra pak pump - video

61

 Refrigeration components Suction valve

(constant pressure suction valve)

Level control

(Control liquid valve supply)

Hot gas line Liquid separator Scraped Heat Exchanger (cylinder)

Hand valve + spring valve

Oil drain line

 Refrigeration components - Pipings

Hot gas line

Ammonia Gas back to compressor (low pressure)

Liquid Ammonia from Cooling Plant (High pressure)

 Cylinder walls Freezing cylinder/barrel

SOURCE: TETRA PAK

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 Refrigeration system : cooling principles How it works?  Liquid refrigerant floods the freezer barrel  Liquid refrigerant floods the freezer barrel  While evaporating, liquid refrigerant takes the heat from the product.

The product cools down and freezes.  Ice crystals start solidifying on the barrel inner surface. Blades continuously scrape off those crystals from the surface.

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 Refrigeration cycle COOLING PLANT 160 psi

Condensor

The gas returns to the cooling plant to be compressed again for a new refrigeration cycle



0,30 psi

The separator collects the refrigerant vapor (gas) The refrigerant evaporates (boils) around the barrel

Receiver



Compressor

The cooling plant provides the freezer with liquid refrigerant at high pressure

Suction valve

 

Separator

Level control

Evaporator

THE FREEZER

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 Refrigeration control: T°C / Pressure gauge

WCB example, front of freezer side

Evaporation Pressure : 58 psi

HOYER example, inside of freezer walls

T°C Suction NH3 : -18°F

T°C Evaporation NH3 : -6.8°F

T°C NH3 Liquid : 73°C

Pressure : 6psi

Pressure : 22psi

Pressure : 123psi 67

 How to control the transformation

during the Freezing phase ?

Refrigeration system 4 . I CE C REAM TEMPERATURE

 Key process parameters

1 . C REAM F LOW 2 . O VERRUN Amount of air 3 . VI SCOSITY Dasher speed

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 Potential ISSUES affecting process parameters 1 . I CE C REAM F LOW ✓ High/low ice cream flow

2 . O VERRUN ✓ Fluctuation

What can be wrong?

3 . VI SCOSITY

✓ Fluctuation of viscosity

of overrun

4. I CE C REAM TEMPERATURE ✓ IC T°C < Set-up

✓ Viscosity drop

✓ Too high/low ✓ Unstable ice cream flow (pump efficiency)

Skating/ice formation

✓ IC T°C > Set-up

✓ Overrun not stabilized in Ice cream

69

 Potential CAUSES affecting process parameters 1. I CE C REAM F LOW

2. O VERRUN

What can be wrong?

3. VI SCOSITY

✓ Back-pressure too high

✓ Leakage of air circuit

✓ Variability of mix flow rate

✓ Variability of mix flow rate

✓ Variability of mix flow rate

✓ Pressure of mix inlet

✓ Bad air regulation

✓ Maintenance of belts and dasher motor

✓ Lack of overrun

✓ Air pressure too low

✓ Overrun > set-up

✓ Barrel pressure variation

✓ Overrun unstable

✓ Ageing time < 4h

✓ Pumps

✓ Homogenization issues (heads, pressure) ✓ Recipe formulation

4. I CE C REAM TEMPERATURE ✓ IC T°C < Set-up

✓ IC T°C > Set-up

✓ Evaporation T°C not correct

✓ Worn blades / barrel surface ✓ Suction valve incorrect opening ✓ Barrel pressure variation ✓ High/low level of liquid refrigerant

✓ T°C of mix > 4°C ✓ Evaporation T°C not correct ✓ Recipe formulation (%solids, sugars) ✓ Barrel pressure not correct 70

Freezer Extras

Freezer Extras

Freezer Questions

Inclusions Inclusions are the ingredients that we put into an ice cream product after freezing like cookies, nuts, chocolate chips, etc

Inclusions are dosed into the ice cream using Ingredient Feeders.

GRAM IF

Tetrapak IF

Hopper: Place to fill the ingredients Blender: Different styles mix different inclusions better. Examples are blade blenders and pin blenders.

Funnel Rotor: Turns in the direction of ice cream flow. It has tight tolerances to keep the ice cream from coming up through the funnel.

Auger: Different sized augers are used for different inclusions, it pulls the ingredients forward

Ingredient feeders lay the inclusions on top of the ice cream stream Questions: 1) What will happen if the ice cream flow stops?

2) What will happen if the blender isn’t turned on?

3) What if the rotor is ran too fast?

Too slow? How do you know what the correct speed is?

Inclusion Handling Some Inclusions are sensitive to temperature. Warming up will cause clumping.

This clumping can cause some sensory defects but will cause operational problems like clogging.

Net Content (Weight Vs Volume) Which is more important, Weight or volume?

VOLUME! Ice cream is released by volume, not weight. We cannot sell ice cream below volume because that’s what we tell customers on the packaging. We ALWAYS should be just above volume targets.

What makes and loses us $$$Money? Weight or volume?

WEIGHT!!! We make our product weigh less by adding Air which does not cost us anything. We should target below just below target weight so we can make more ice cream. You can take out weight without taking away volume Can we make our ice cream as light as we want?

Absolutely NOT. There is a lower reject limit on the checkweighers for a few reasons 1) To meet standard of identity for ice cream 2) To Meet the nutritional information 3) To avoid Short counts 4) To preserve product quality

 Operational video

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INGREDIENT FORMULATION

MIXING

HOMOGENIZATION

PASTO-COOLING

AGEING

FREEZING

FILLING

HARDENING

COLD STORE

Key Parameters

RECIPE COMPOSITION ✓ Total Solids (%) ✓ % Fats ✓ Proteins (MSNF) ✓ Sugars

✓ Stabilizers &

emulsifiers

MIX MATRIX

FREEZING

MIX PREPARATION HOMOGENIZATION

AGEING

Order of addition

Pressure

T°C = 40°F

Dispersion

Fat size particules

At least 4h

Hydratation

+ Food safety : HEAT TREATMENT

ICE CREAM FLOW OVERRUN VISCOSITY

ICE CREAM T°C

TEXTURE & TASTE

82

 Operational video

84

Froneri Hygiene

Hygiene and Dry Floors During Operation Dry Floor ‘Obsession’ & Team Effort

Spills Managed Differently

Hygiene and Dry Floors During Operation More Plastic for Waste

More Plastic for Waste

Hygiene and Dry Floors During Operation Floor Scrubbers & Investment in Hygiene

Hose ManagementRestricted Access

Waste Management- Giveaway/Process Control PSA Zone: Invest in Accuracy

All Physical Waste is Weighed & Accurate

Flexible Fast Changeovers Changeover Parts Organized

Changeover Parts Kitted for the Week

Front Line Leadership Routines Supervisors are on floor >80% of time & “Own” their results

“Big White” (Shift Mgr) was on the floor and actively involved all day long

Two Packaged- Side Employees came over to squeegee floor while starting up (without being asked) and stayed until line was running and floors were spotless No mentality of: We’ll clean it up once we’re done…

Captured Shoes & Routine to Entry

Why Do we need to do this?

1.2 Million dollars of micro destruction 2020 Recall - $250,000 lost because we couldnt see a leak 300 foreign body complaints year to date

THIS IS OUR KITCHEN

Being a Machine Operator • Own Safety and GMPs on your line • Own your line Hygiene • Own Productivity • Don’t run to make Waste

• Always get better, Improve your team and line • Help your supervisor supervise

Training course for line operators

THANKS FOR YOUR INVOLVEMENT

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MASTER TRAINING COURSE For Line Operators