​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​Tetra Pak® Linear Moulder 1500 A2 for high capacity ice cream moulding

Highest capacity on the market with multilane wrapping

  • 43,200 ​ice cream sticks per hour (30 strokes 24 lanes, 720 products per minute)
  • Flexible, modular mould cleaning system with minimum water consumption
  • Robust and hygienic design with smart utility connections
  • Automatic stick inserter with double magazine and reversing in-feed belt
  • Servo-driven and accurate mould drive system, robust chain system – enables safe, high-speed production
  • Efficient brine cooling system ensures even brine flow across machine
  • Unique nozzle plate solution creates turbulence, cools products more efficiently​

Get the right moulding solution thanks to our complete portfolio

The Tetra Pak® Linear Moulder A2 stick novelty freezer enables flexible and efficient automatic continuous linear production of moulded ice products such as ice cream, sherbet, water ice or fruit-juice sticks novelties. It is optimized for high capacities and complex products.
Moulded ice cream sticks

Working principle for Tetra Pak Linear Moulder A2 ice cream moulding machine

The production of moulded stick products is carried out in six main stages: 1. Filling ice cream mix or water ice into moulds 2. Inserting wooden sticks into ice cream 3. Freezing product in cold brine bath 4. Defrosting thin outer layer of product with warm water spray for release from mould 5. Extracting frozen product from mould 6. Coating with chocolate and subsequently dry ingredients, if applicable 7. Lay-down into wrapping machine
Tetra Pak Linear Moulder A2 ice cream moulding machine

Adaptable filling enables a broad variety of different products

The moulder can be fitted with a volumetric top filler, a combination top filler, a volumetric bottom filler, a time elapse top filler, a pencil filler and back suction equipment. By changing the filling method (or sequence of filling methods) it is possible - and relatively simple - to produce an almost infinite variety of products. Pre-set recipes in the automation system recognize and adapt to the filling method that is in place at any given time.
Tetra Pak® Linear Moulder 1500 A2 ice cream moulding machine

High speed production – 30 strokes/minute – secured by five servo drives

The unit carries out a series of different actions: indexing of the moulds, extraction of the product, indexing of the tongs, dipping and gentle lay down to multilane wrapping. Thanks to five built-in servo drives, the timing of these different actions can be controlled down to the millisecond, which is what makes reliable high speed production possible.
Ice cream sticks, production capacity

Highly efficient cooling ensures quality and low costs

The brine tank, nozzle plate and complete cooling system are designed to ensure consistent product quality and minimizing energy consumption. Brine is pumped at -40 through the nozzles of the nozzle plate, ensuring contact with the entire surface of the mould. This carefully designed process gives very efficient heat transfer, making production economical and ensuring reliable product quality.
Brine tank, ice cream moulding machine

Minimizing water usage in mould cleaning system

The linear moulder is designed to remove any products that remain in the moulds after extraction and thereby preventing contamination of the cleaning water. The mould cleaning system consists of four tanks. Completely fresh water is only added at the last spray system and the used water is sent back into the system reducing the amount of fresh water needed by approximately 50%.
Cleaning system, ice cream moulding machine

Features

Adaptable filling

Adaptable filling

Enables a broad variety of different products

The moulder can be fitted with a volumetric top filler, a volumetric bottom filler, a time elapse top filler, a pencil filler and back suction equipment. By changing the filling method (or sequence of filling methods) it is possible - and relatively simple - to produce an almost infinite variety of products. Pre-set recipes in the automation system recognise and adapt to the filling method that is in place at any given time.

Superior mould strip quality

Superior mould strip quality

For maximum durability and product safety

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

Nozzle plate 1500 A2

Ensures consistent product quality and low costs

Brine is pumped at -40 through the nozzles of the nozzle plate, ensuring contact with the entire surface of the mould. This carefully designed process gives very efficient heat transfer, making production economical and ensuring reliable product quality.

Extractor tong

Enhances the reliability of your production

This small but vital component takes hold of the ice cream stick and pulls the product up out of the mould. It can adapt automatically to find the stick, and pulled it up with sufficient force to guarantee the product is removed and never dropped. Typically a wear part, this tong has a documented lifetime of approximately 10 years, and is used in both rotary and linear moulding lines.

Tong surveillance sensor

Tong surveillance sensor

Monitors production and enables rapid corrective action

The sensor checks that a product is always pulled up out of the mould when it should be. If it does not detect a product, the operator is alerted and can make adjustments. To enable the ‘no-product no-wrap’ feature, a signal is sent to the wrapper telling it to wait for a product to arrive rather than creating an empty wrap. All errors are logged and, if they point to the same tong, a replacement can quickly be installed.

Five servo drives

Five servo drives

Enables high speed production (30 strokes/minute)

The unit carries out a series of different actions: indexing of the moulds, extraction of the product, 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 is what makes reliable high speed production possible.

Automatic product removal

Automatic product removal

Saves water during cleaning

The system is designed to remove any products that remain in the moulds after extraction. This prevents contamination of the cleaning water and since it is automatic, does not require monitoring by operators.

Multi-tank flush and cleaning system

Multi-tank flush and cleaning system

Minimizes the need for fresh water

The mould cleaning system consists of four tanks. Completely fresh water is only added at the last spray system, which runs into tank 4, then 3, then 2 and then 1. In other words, used water is sent back into the system reducing the amount of fresh water needed by approximately 50%. Backwards flow ensures all lost product and residue is removed from the first tanks.

Options

Dry coater

Dry coater

Prevents stoppages and product waste

Dry coating is a critical process. If not handled correctly it can lead to errors, waste of expensive ingredients and down time. 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

Combi Top Filler

Expands the range of possible filled products

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

For high quality moulded ice creams

Enabling a greater amount of air to be incorporated in your 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.

Tetra Pak® Automatic Stick Multi

Tetra Pak® Automatic Stick Multi

Reliable performance and high yield

A servo driven conveyor belt prepares the sticks so they can be inserted in precisely the correct position in the product, thus enabling reliable performance and high yield. The unit runs at up to 30 strokes per minute and can also be equipped with a backup magazine so production continues uninterrupted, even if a stick is off spec.

Brine buffer tank

Brine buffer tank

Maintains quality of cooling brine

If the concentration of salt in the brine is too low in the linear moulder, production efficiency will go down. In extreme cases, the plate heat exchanger might freeze up. The brine level therefore needs to be topped up and improved from time to time – and this process is made easier by having a brine buffer tank.

Find out more

Girl with crayons, drawing ice cream

Turning passion into products

Find out more about how we combine a passion for frozen desserts with expertise, experience and equipment to create great ice cream – together with you.

Ice cream models and blue print

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.

Best-practice high-capacity extrusion line

Best-practice lines for ice cream

Our best-practice lines for ice cream combine our proven solutions into the most optimal setup for a specific product at a specific capacity. What this means for you is high yields, product versatility, and highly reliable production – with guaranteed performance.

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