Benefits

The medium-capacity Tetra Pak® Rotary Moulder 27 A4 is innovation for safer, more reliable and more profitable production. Its revolutionary “open” brine tank design supports hygiene of the operating environment by eliminating hard-to-clean areas, making it easier to see dirt and spills, and improving service access. The servo-driven automation system allows for greater precision and reliability – while simultaneously creating potential for higher volumes and reduced downtime

 

Quick facts

High-speed unit for filling mixture into a mould, freezing mixture and inserting sticks, with options for dipping in coatings

 

Capacity

Up to 21,600 products/hour

 

Applications

Moulded ice cream, sherbet, water ice or fruit juice ice products on a stick

rotary moulder 27A4 benefits

How it works

An ice cream or fruit mixture is fed into moulds on the mould table. A cold brine bath freezes the mixture, with sticks inserted when it is sufficiently hardened. A warm brine then defrosts a thin outer layer to enable extraction from the moulds. The product can then be coated with chocolate and/or dry ingredients before it is gently placed in the paper lane of a multi-lane wrapper.

How it works

An ice cream or fruit mixture is fed into moulds on the mould table. A cold brine bath freezes the mixture, with sticks inserted when it is sufficiently hardened. A warm brine then defrosts a thin outer layer to enable extraction from the moulds. The product can then be coated with chocolate and/or dry ingredients before it is gently placed in the paper lane of a multi-lane wrapper.

Features

Conical brine tank

Conical brine tank

Improved hygienic standards

Thanks to a revolutionary open design, our brine tank eliminates hard-to-clean areas where bacteria can accumulate. For your operators, what they see is what they clean. It’s easier to spot spilled product or dirt, meaning it can be taken care of immediately. You can thereby improve the hygiene of your whole production environment, providing greater assurance of food safety for your consumers as well as workplace safety for your personnel.

Extractor tong

Extractor tong

Robust for reliable production

This vital component removes the product from the mould, adapting automatically to find the stick and pull with sufficient force to ensure the product is never dropped. Our updated tong features fewer parts and a moulded plastic arm for a more robust design that’s easier to clean. The plastic arm is both metal and x-ray detectable. With an increased opening area, it also allows for greater variances in stick quality.

Adaptable filling

Adaptable filling

Flexibility for product variety

The rotary moulder provides flexibility for everything from classic to premium products. It can be fitted with a volumetric top filler, a volumetric bottom filler, a time elapse top filler, a pencil filler and back suction equipment. Changing the filling method(s) makes it simple to produce an almost infinite variety of products, with pre-set recipes in the automation system that adapt to the filling method in place.

Nozzle plate 27 A4

Nozzle plate 27 A4

Even flow for consistent quality

The Tetra Pak Rotary Moulder 27 A4 minimises risks of freezing “dead zones” that negatively impact product appearance and quality. Using calculations based on computational fluid dynamics, we have re-designed the nozzle plate to ensure a more even flow. Together with frequency-driven pumps that optimise flow at reduced running costs, this enhances heat treatment across the table to ensure uniform freezing between lanes.

Superior mould table

Superior mould table

Total durability and product safety

Our ice cream moulds are designed, manufactured and quality assured to withstand the harsh production environment and stress caused by frequent temperature fluctuations, all without jeopardising product quality and safety.

Ergonomic operator platform

Ergonomic operator platform

Simplified monitoring and service

An operator platform with flexible layout provides better oversight and improved service accessibility without increasing the footprint of the line. The ergonomic set-up offers a better visual overview of the equipment, with easy up and down, making production monitoring a more natural part of the daily workflow. It also makes it easier to access pumps, the defrost system and the drain point for routine maintenance needs.

Five servo drives

Five servo drives

Precise, high-speed production

The next-level automation system is updated with full servo control of mould indexing and extractor functions, along with 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 enables reliable production at speeds of up to 30 strokes per minute!

Options

Automatic stick multi

Automatic stick multi

Reliable performance, high yield

A servo-driven conveyor belt prepares the sticks, so they can be inserted in precisely the correct position in the product. This enables reliable performance and high yield – in a unit that runs at up to 30 strokes/minute. You can also equip the solution with a backup magazine to make sure production continues uninterrupted, even if a stick is off spec.

Dry coater

Dry coater

Maximum uptime, minimum waste

Dry coating is a critical process. If handled improperly, it can lead to errors, waste of expensive ingredients and downtime. 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

More filled product possibilities

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

Tetra Pak® Volumetric Bottom Filler

High-quality product potential

Enabling a greater amount of air to be incorporated in 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.

Breaking the mould for moulded ice cream

By innovative the traditional design, the Tetra Pak Rotary Moulder 27 A4 takes ice cream moulding to new heights, both figuratively and literally. With improved food hygiene, product quality, and next-level automation – this is the change the ice cream world has been waiting for decades for. 

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.

Explore our moulding range

Tetra Pak Linear Moulder 1500 A2

Tetra Pak® Linear Moulder 1500 A2

Tetra Pak® Linear Moulder 1500 A2

Tetra Pak® Linear Moulder 1500 A2 ice cream moulding machine, highest capacity on the market with multilane wrapping

Tetra Pak Rotary Moulder 27 M3

Tetra Pak® Rotary Moulder 27 M3

Tetra Pak® Rotary Moulder 27 M3

Tetra Pak® Rotary Moulder 27 M3 is a moulding unit for filling ice cream mixture into a mould, freezing and inserting sticks (and can apply a coating)

Tetra Pak Rotary Moulder 23 M2

Tetra Pak® Rotary Moulder 23 M2

Tetra Pak® Rotary Moulder 23 M2

Tetra Pak® Rotary Moulder 23 M2 is a moulding unit for filling ice cream mixture into a mould, freezing and inserting sticks (and can apply a coating)

Tetra Pak Rotary Moulder 35 A2

Tetra Pak® Rotary Moulder 35 A2

Tetra Pak® Rotary Moulder 35 A2

Tetra Pak® Rotary Moulder 35 A2 is a high-speed unit for filling ice cream mixture into a mould, freezing and inserting sticks (can also apply a coating

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