Tetra Pak Inc.

Aug. 23, 2007
Molding machine creates multi-layer, stick ice cream novelties

Tetra Pak has launched the Hoyer Rollo IM high capacity molding machine for automatic, continuous production of ice cream, sherbet or fruit-juice stick novelties with up to 20 lanes of 56 mm (2.2 in) wide stick products. According to the company, the Hoyer Rollo IM has been developed to meet the growing market for flexible and reliable equipment that can handle a wide range of new, commercially attractive product ideas.

Reportedly easy to set-up, a narrow in-line design of the Hoyer Rollo IM allows for a production room layout with additional equipment such as filling and back suction stations and multiple lines with easy access for manual add-ins. The compact equipment is said to be ideal for high capacity production of multi-layer products made of water ice and /or ice cream mix combinations.

The Hoyer Rollo IM provides performance with high capacity and guaranteed high total line yield of more than 97.5%. Tetra Pak offers two models – up to 15,000 sticks/hour or 30,000 stick/hour. Actual capacity will depend on factors such as the number of lanes, product volume and recipe as well as the capacity of the wrapping and packing line.

Between extraction and lay-off, the stick novelties may be coated with chocolate or similar. Furthermore, dipped products may also be coated with dry ingredients.

The PLC-controlled program with pre-set product recipes secures quick change-over and start-up times. All in-line functions, including drive and the filling equipment are controlled via the PLC from one central control panel. The stainless steel PLC cabinet is mounted on side of brine tank and has a touch screen for recipe set-up and information.

The fully welded, stainless steel brine tank of the Hoyer Rollo IM is designed for products needing extended freezing time, such as thick water ice sticks. The brine distribution system with nozzle plates gives an even freezing with even shell thickness on split ice at maximized freezing capacity.

Re-circulated warm water is used for defrost at extraction to minimize the risk of contaminating the product with brine and eliminate mould corrosion as no warm brine is in contact with the stainless steel moulds. The moulds are also cleaned with water on every cycle, leaving no mix flavor from residue in the moulds from multi layer products.

Main production stages involve:

  • Filling of ice cream into the moulds
  • Insertions of wooden sticks into the ice cream
  • Freezing of the bars in a cold brine bath at -40 ºC (-40 ºF)
  • Defrosting of a thin outer layer of the bars with warm water spray at +15-25 ºC (+59-77 ºF)
  • Extraction of the frozen bars from the molds
  • Lay-off for wrapping