Ice cream
The production of water-based ice cream involves mixing the ingredients together, followed by crystallisation. It needs to be homogenised, after homogenisation there is a cooling and ageing process. The mixture is left to age for 4-24 hours and during this time all the dry ingredients are hydrated and the product is crystallised. The product is then frozen in a continuous freezer and air incorporation takes place. When the water-based ice cream leaves the continuous freezer at -5˚C, approximately 80% of the water is frozen. The final process is hardening, which freezes out most of the water at -40˚C.
Ice cream is a complex product. Water-based ice cream contains components, such as proteins and carbohydrates. Sweeteners, flavourings, emulsifiers and stabilisers are added during processing to enhance flavour, texture or appearance. Ice cream is over 80% water,. Few Air is incorporated into the product, resulting in finely distributed air cells protected by a layer of fat globules.
Mixing elements for Ice Cream Production
The appropriate agitator will stir the complete content in the vessel / hopper/tank to a homogeneous content which can be used to fill the filling lines with the mold of the ice-cream shape. However, to produce the high quality water based homogeneous ice cream, the dosing of solids is very important. For this, Jongia has its jet-mixer, inline mixer equipment available.
Once the dosing of solids is put into the fluids, the agitator, in most cases a top-entry type with a propeller or a combination of hydroprops will do the job.
Versatile Propeller Mixer for Ice Cream Production
The Propeller is a workhorse in ice cream production, keeping cream, sugar, emulsifiers, and inclusions in uniform suspension inside mix aging and flavor tanks. Its axial flow prevents settling and ensures consistent distribution of every component throughout the batch. Energy-efficient and reliable, it adapts to the viscosity changes typical of ice cream production without loss of performance.
High-Capacity Hydroprop for Ice Cream Production
The Hydroprop delivers outstanding pumping capacity with minimal energy input, making it ideal for large mix aging and flavor tanks in ice cream production. It ensures complete tank turnover, eliminates temperature gradients, and keeps cream, sugar, emulsifiers, and inclusions in a stable, homogeneous state. Its streamlined design cuts operating costs while supporting continuous, high-volume ice cream production.
Robust Flatblade Turbine for Ice Cream Production
The Flatblade turbine generates strong radial flow and turbulence, tackling stable emulsion and gentle handling of inclusions head-on in ice cream production. It breaks up agglomerates, disperses additives, and homogenizes cream, sugar, emulsifiers, and inclusions even when viscosity fluctuates. Its rugged construction handles the mechanical demands of industrial ice cream production with proven reliability.
Efficient Jet Mixer for Ice Cream Production
The Jet Mixer uses a high-velocity liquid jet to achieve rapid homogenization in ice cream production, without introducing strong mechanical shear. It excels in beverage and liquid-phase tanks where fast blending of cream, sugar, emulsifiers, and inclusions is required with minimal foaming or air entrainment. Its simple geometry makes it easy to integrate, clean, and maintain in hygienic processing environments.
High-Flow Hydrofoil for Ice Cream Production
The Hydrofoil generates high-volume axial flow, making it a powerful solution for large mix aging and flavor tanks in ice cream production. It prevents thermal stratification and keeps cream, sugar, emulsifiers, and inclusions in steady motion with minimal turbulence. The optimized blade profile turns drive power into fluid motion efficiently, supporting consistent homogenization at industrial scale.
Reinforced Hydrofoil Pin for Demanding Ice Cream Production
The Hydrofoil Pin combines proven hydrofoil performance with reinforced pins for tougher substrates encountered in ice cream production. Its structural design handles high-viscosity and high-solids zones where standard impellers might struggle, particularly when stable emulsion and gentle handling of inclusions becomes critical. It delivers reliable mixing where cream, sugar, emulsifiers, and inclusions are demanding to handle.
Reliable Axial Flow Turbine for Ice Cream Production
The Axial Flow Turbine is a dependable all-rounder for ice cream production, ensuring even distribution of heat and additives throughout mix aging and flavor tanks. It prevents stagnant zones and keeps cream, sugar, emulsifiers, and inclusions in consistent motion across the vessel. Its cost-effective, robust design makes it a go-to choice for stable, continuous operation in ice cream production.
Heavy-Duty Welded Turbine for Ice Cream Production
Built for maximum durability in continuous ice cream production, this welded turbine eliminates bolted connections for superior mechanical integrity. Its smooth profile resists buildup of cream, sugar, emulsifiers, and inclusions and simplifies cleaning and maintenance in mix aging and flavor tanks. It is the preferred choice for industrial-scale ice cream production that demand long service intervals and high reliability.
Axial Flow Turbine Pin for Challenging Ice Cream Production
Adapted for ice cream production involving fibrous materials or high solids content, this turbine uses reinforced pins to cut through stable emulsion and gentle handling of inclusions. It maintains an effective mixing zone even when the composition of cream, sugar, emulsifiers, and inclusions varies from batch to batch. An essential element for facilities handling inconsistent or demanding substrates in ice cream production.
Anchor Mixer for High-Viscosity Ice Cream Production
The Anchor mixer is designed for ice cream production with high viscosity, where cream, sugar, emulsifiers, and inclusions tend to build up on the tank walls. Its close-clearance blades sweep the walls of mix aging and flavor tanks, promoting heat transfer and preventing local hot spots or fouling. The ideal solution wherever intensive wall-to-wall homogenization is required.
U-Z Turbine for Thorough Ice Cream Production Mixing
The U-Z Turbine combines strong axial flow with a geometry tailored to the demands of ice cream production. It ensures complete homogenization of cream, sugar, emulsifiers, and inclusions in mix aging and flavor tanks while keeping shear forces controlled. A versatile solution for processors who need consistent blending across varying batch sizes and viscosities.
Ribbon Mixer for Intensive Ice Cream Production Blending
The Ribbon mixer is built for the most demanding high-viscosity stages of ice cream production. Its double-helical design creates a complex flow pattern that blends additives fully into cream, sugar, emulsifiers, and inclusions, even when stable emulsion and gentle handling of inclusions comes into play. A critical element for producing ice cream production with perfectly uniform properties.
High-Shear Sawblade for Ice Cream Production
The Sawblade disperser generates the extreme shear forces required to break down agglomerates and solid additives in ice cream production. It produces a fine, homogeneous dispersion of cream, sugar, emulsifiers, and inclusions inside mix aging and flavor tanks, a step that is vital for consistent product quality. Essential where fine particle distribution makes the difference between good and exceptional ice cream production.
Conical Helix Mixer for High-Viscosity Ice Cream Production
The Conical Helix Mixer is engineered for the most demanding high-viscosity stages of ice cream production. Its helical geometry lifts cream, sugar, emulsifiers, and inclusions from the bottom of mix aging and flavor tanks to the top, ensuring full batch circulation even when stable emulsion and gentle handling of inclusions becomes severe. An ideal solution for thick, sticky products that resist conventional impellers.
Ingredients
Each ingredient selected for the production of water-based ice cream has a specific function in terms of its effect on the final structure and eating quality of the product.
Sugar and sweeteners
Sugar is added to provide sweetness and improve texture. A combination of sugars (e.g., sucrose, glucose, fructose) is normally used to obtain the desired sweetness of the final product. Sugars control the amount of frozen water in ice cream and therefore, the softness of the final product. Sweeteners are also permitted for use in ice cream production and are often used in lower- calorie products.
Flavours and colours
Flavours and colours are added to almost all ice cream to enhance the appearance and taste of the product, but these flavours and colours can be natural in origin.
Emulsifiers and stabilisers
Emulsifiers help bind all the ingredients during the manufacturing process and improve the whipping quality during mixing. Stabilizers improve air incorporation. They have a positive influence on the body and texture of the ice cream, contributing to the creaminess and melting properties of the finished product.
What you need
Production requirements include:
- dry store for ingredients and packaging
- mixing/ageing vat
- Agitator and a powder dissolving mixer, Jongia Jet-mixer
- ice cream freezer – batch or continuous
- packing machine/filler
- freezer room
- freezer store (packaged product).
Frequently Asked Questions
What is the production process of water-based ice cream?
The production process involves mixing ingredients, followed by crystallisation. It includes homogenisation, cooling, and ageing for 4-24 hours, allowing dry ingredients to hydrate. The mixture is then frozen, incorporating air, and finally hardened at -40˚C, which freezes out most of the water.
What ingredients are essential for water-based ice cream?
Essential ingredients include sugars for sweetness and texture, flavours and colours for enhancement, and emulsifiers and stabilisers to improve quality. Each ingredient plays a specific role in determining the final structure and eating quality of the product.
How important is the dosing of solids in ice cream production?
Dosing of solids is crucial for producing high-quality water-based ice cream. Accurate measurement ensures a homogeneous mixture, which is essential for achieving the desired texture and taste in the final product. Jongia offers jet-mixer and inline mixer equipment for this purpose.
What equipment is required for ice cream production?
The necessary equipment includes a dry store for ingredients, mixing/ageing vat, agitator, Jongia jet-mixer, an ice cream freezer (batch or continuous), packing machine, freezer room, and freezer store for the packaged product.
How does air incorporation affect the ice cream?
Air incorporation is vital as it results in finely distributed air cells protected by fat globules, contributing to the texture and mouthfeel. The aim is to create a light and creamy product, enhancing overall eating quality.
Food & Beverages Contacts
Sales Director
Tom Pruymboom
Area Sales Manager
Teun van der Spek
