Taking ice cream design to the next level
Our Multi Section Extrusion Nozzle enables excellent repeatability – the designs not only look better to start with, the products continue to look the same, day after day. And that’s just one of the benefits this new innovation brings.
“It’s always been tricky to make two-colour ice cream products. Repeatability is difficult, the production setup is complicated with all its hoses and clamps, and product changeover is time-consuming. It usually involves a considerable amount of product waste. What we’re introducing now basically turns allthese problems into opportunities,” product manager Steen Gyldenløv says.
The Multi Section Extrusion Nozzle is 3D-printed in metal detectable plastic. The unit consists of two parts: a distributor that distributes two ice streams into twelve separate flows (2x6), and a nozzle that defines the design and shape of the product. One of the many smart design details is that customers don’tneed to replace the distributor to change product – they simply replace the nozzle. As a result, exploring new designs becomes a small-investment venture.
Elsebeth Baungaard, portfolio manager and one of the masterminds behind the innovation, explains:
“We have patented the solution, and one of the patent claims is about the distributor – how it facilitates advanced flow control and how each inlet distributes the product into six separate flows. The patent claims also include the modular design and the titanium tip of the nozzle, which ensures that we don’t chip the plastic. We’re first movers here. The distributor is the most complex item our supplier has ever printed, so testing the designs is an exciting and iterative process. The process as such is that we send them CAD files, and they return the 3D-printed items a few days later. Then we test, discuss and adjust. We have a close cooperation with DTI.”
“It is quick and efficient today and over time, as we build up more knowledge, we will be able to streamline the process even more. And all this is of course beneficial to our customers. Getting a new design into production used to take a long time and be very costly. Now, we can test, change and optimise much quicker and easier,” Steen adds.
Tetra Pak’s Ice Cream Product Development Center (PDC) is where the product designs are tested and fine-tuned. Here, it is possible to create conditions that are identical to the customer’s. This means the risks connected to product development are substantially reduced: the results achieved at the PDC are the results the customer can expect at their own plant.
Traditionally, two-colour ice cream products are usually categorised as so-called “funny faces” – think animals, clowns, cartoon characters and the like – targeted to the kids’ segment. The Multi section extrusion nozzle opens up many possibilities beyond that.
“The fact that we take repeatability to a new level is great for funny faces. Customers will be able to produce true-to-original designs that look exactly the same, every time. And as the solution is so versatile, the potential is huge. Customers can, for example, explore fruit-based, low-calorie or vegan products aimed at more adult target groups,” Steen says.
Another benefit for the customer is the high level of hygiene. The material is FDA-approved and smooth, and unlike today’s steel solutions there are no welding seams where bacteria can grow. This minimises the risk of product contamination. The solution is also CIP:able.
And this is just the start.
“We will continue to build up empiric knowledge on how we can optimise designs and help customers realise their ideas. So we’ll keep on in, together with our customers,” Elsebeth concludes.
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