Tetra Pak® Ice Cream Filler A3

Highest flexibility with lowest TCO

  • Product flexibility and quick changeovers, without jeopardising quality
  • Costs minimized by high yield dispensing of cones, cups and lids; low give-away on chocolate spraying and ice cream filling
  • Efficient freezer and accurate ingredients doser combine to ensure low TCO
Tetra Pak® Ice Cream Filler A3

Tetra Pak® Ice Cream Filler A3

The most consistent product quality

  • An even layer of chocolate covering the whole cone interior
  • A preserved crunchiness – no soggy cones
  • The exact and desired amount of chocolate in each cone

The most flexible and trouble free ice cream filler

  • Easy to change line capacity – no adjustments
  • Easy to switch equipment's and sub-units for fast product changeovers
  • Reliable and easy operation

Great savings by minimizing product losses

  • Reduced waste and better overall economy
  • The exact amount of chocolate every time
  • Saves up to 9 kilograms of chocolate per hour

Features

Cone dispenser

For reliable, efficient dispensing

This dispenser is designed to operate reliably even when the cones used are not the highest quality or have, for example, folded edges. The cones are separated and dispensed from the stack, rather than being allowed to drop. This controlled action prevents the cones sticking together, as well as eliminating a number of other common problems.

Accurate chocolate sprayer

Reduces giveaway and saves money

Thanks to individual volumetric dosing, exactly the right amount of chocolate is sprayed into each cone. Just enough to chocolate can be used to coat the cone and protect it from moisture, but no more. An airless spray nozzle ensures an even distribution of chocolate.

Modular filling valve system

Modular filling valve system

Enables production of many different products

basic set up is a side-by-side filler for two flavours of ice cream with inclusions up to 10mm. With additional modules, these two flavours can be combined in a variety of ways. For example, in concentric, windmill, swirl, core ripple and outside ripple patterns - all with or without inclusions. The filling valve can of course run just one flavour as well.

Exchangeable nozzles

Exchangeable nozzles

Easy to produce a range of filling patterns

The filling nozzles are clamped on, and are to swap when you want to make a different filling pattern. For example, smooth surface, fluted surface, swirled surface, and swirled with ripple. Multi-rosette nozzles are also available for decorative effects.

Dynamic distribution

Dynamic distribution

Gives high dosing accuracy with low giveaway

The incoming ice cream is agitated while being divided into the number of lanes needed for filling. This, combined with highly accurate fill valve control ensures that exactly the right amount of ice cream is fed into each cone or cup, with a standard deviation below 1.5%.

Valve with back suction

Valve with back suction

Enables wet top decoration without quality issues

Individual top decoration valves with back suction make it possible to decorate your product with fruit sauce or chocolate, without drips. From a pump station the liquid is fed to the valves and dosed with a nozzle for a controlled amount of time. When ready, the last drops are sucked back into the nozzle to prevent mess.

Lid dispenser

Enables high flexibility and yield

Suction cups pick up the lids individually from a vertical magazine. Both the suction cups and the magazine itself are quick and easy to swap when you want to change to a different type and/or size of lid.

Cone sleeve crimper

Cone sleeve crimper

Locks the cone lid in position

When the lid has been placed inside the top of the cone sleeve, the lid crimper folds the paper down around the edges. It presses the excess paper firmly enough to lock it in position, so there is not risk of the lid coming loose. There is a crimping head for each lane, optimised – together with the lamella inserts - for the exact lid size.

Options

Exchangeable modules

Exchangeable modules

Enables production of cups, tops and squeeze-up tubes

By adding and removing certain modules, it becomes possible to make other products. If producing cups or tubs, a cup or tub dispenser replaces the cone dispenser. A pressing device– the equivalent of a crimping device for cones - is used to click the lids in place. On the other hand, a chocolate sprayer is not needed.

Dry ingredient dozer

Dry ingredient dozer

Enabling crunchy top decoration

A large range of dry ingredients can be dosed on top of the ice cream filling and topping sauce. The volume is “time-elapse” adjustable from the recipe.

Printer system

Printer system

Enabling date coding on all products

A carriage module enables the printer head to move across the product lamella and thus pass all lanes for each index. The printer - typically an ink-jet system – can print the desired text in up to three lanes.

Pick and place device

Pick and place device

For gentle product transfer at high speeds

In order to transfer products even more safely and efficiently to the hardening tunnel, you can exchange the belt outlet conveyor for a pick-and-place device. When defining the interface, the difference in distance between products at the ‘pick up’ and ‘place’ positions is fully flexible. The trailing movement is also synchronized with the tray tunnel to secure gentle product handling.

When we transfer with a Pick & place, we take an array of typically 4 x 6 cone products and move them from the filling machine over to the tray tunnel (extrusion line). The challenge is that the distance (pitch) between the products is not the same in the ‘pick-up’ position as in the ‘place’ position. Therefore the array changes distance between the products in 1 or maybe 2 directions, and they are always moved closer together in that transfer.