メリット
中容量のテトラパック® ロータリーモールダー 27 A4は、より安全で信頼性が高く、より収益性の高い製造を実現するために刷新されています。その「オープン」ブラインの革新的なデザインが、洗浄困難なエリアを削減し、汚れや流出を可視化し、サービスへのアクセス改善することで、運用環境の衛生状態を保ちます。サーボ駆動のオートメーションシステムにより、精度と信頼性が向上します。同時に、生産増量とダウンタイムの削減が見込めます
主なデータ
モールドにミックスを充填し、冷凍してスティックを挿入する高速ユニット（コーティングにディップするオプション付き）
処理能力
最大 21,600 製品/時
用途
スティックが挿入された成形アイスクリーム、シャーベット、氷菓または果汁アイス製品
発酵の仕組み
アイスクリームミックスまたは果汁ミックスが、成形テーブルのモールドに供給されます。ミックスが低温ブラインバスを通過して冷凍され、十分に硬くなったところで、スティックが挿入されます。次に、温かいブラインが薄い外層を解凍して、モールドから製品を抽出できるようにします。その後、製品はチョコレートや乾燥材料でコーティングされ、マルチレーンラッパーのペーパーレーンに丁寧に置かれます。
発酵の仕組み
アイスクリームミックスまたは果汁ミックスが、成形テーブルのモールドに供給されます。ミックスが低温ブラインバスを通過して冷凍され、十分に硬くなったところで、スティックが挿入されます。次に、温かいブラインが薄い外層を解凍して、モールドから製品を抽出できるようにします。その後、製品はチョコレートや乾燥材料でコーティングされ、マルチレーンラッパーのペーパーレーンに丁寧に置かれます。
特長
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
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
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
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
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
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
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!
オプション
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
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
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.
Ice Cream Video Care
Get full visibility of your ice cream line
Ice Cream Video Care lets you visually monitor inaccessible and “hidden” areas of ice cream production lines. Featuring up to 16 cameras, the solution enables improved quality control and troubleshooting – by making it easier to locate the root cause of quality issues, it becomes possible to reduce downtime and product waste. Ice Cream Video Care provides access to live video as well as recordings.
Ice Cream Line Insight™
Reduce waste through data insights
Ice Cream Line Insight™ gives you all the intelligence you need to reduce product waste. The system collects data from the machines in your ice cream production line, and tells you where and why products are wasted. You also get data on energy consumption from each separate machine so you, for example, can calculate energy cost per ice cream product.
成形アイスクリームの型を破る
テトラパックロータリーモールダー 27 A4 は、従来の設計を刷新することで、比喩的にも実質的にもアイスクリームのモールディングを新たな高みへと導きます。改善された食品の衛生、製品品質、レベルアップしたオートメーション、これらは、アイスクリーム業界が何十年も待ち望んでいた変化です。
アイスクリームのプロダクトディベロップメントセンター
テトラパックのアイスクリーム PDC では、準商業規模の完全な環境で、最新のアイスクリームプロセッシングソリューションをお試しいただけます。
