Granulated Ice Cream Premix Concentrate Without Cold Chain
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Solution Overview
Problem
The manufacture of ice cream is energy-intensive, and the distribution of frozen confections requires a cold chain that is costly and challenging over long distances, necessitating local production facilities with high investment and skilled labor.
Innovation Solution
The use of granulated concentrates made from concentrated oil-in-water emulsions with high fat content, which are stable at low moisture levels, allowing for storage and transport without freezing, and can be reconstituted into ice cream premixes using simple dissolution and dispersion at the point of sale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional ice cream manufacturing and distribution is used, then product quality is maintained, but energy consumption is high and cold chain requirements are costly
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: (1) production of granulated concentrate with pre-emulsified fat at the central factory, and (2) simple reconstitution at local outlets. This segmentation allows the energy-intensive emulsification to be performed once at the central facility rather than repeatedly at each local outlet, significantly reducing overall energy consumption while maintaining product quality through standardized concentrate formulation.
Solution Approach 2:
The fat emulsification and fine droplet formation are performed in advance at the central manufacturing factory, creating a stable granulated concentrate that can be stored and transported without freezing. This preliminary action eliminates the need for complex homogenization equipment and energy-intensive processing at local outlets, reducing overall energy consumption while ensuring consistent product quality through pre-prepared emulsion.
2Ease of operation
If local production facilities are built closer to point of sale, then cold chain requirements are reduced, but investment and skilled labor requirements increase
Solution Approach 1:
The complex emulsification and fat droplet formation processes are extracted from local outlets and consolidated at the central manufacturing factory. Local facilities only need simple reconstitution equipment to dissolve granules in water, eliminating the need for expensive homogenizers and complex processing equipment at each outlet, thus reducing investment requirements while maintaining ease of operation.
Solution Approach 2:
The invention replaces expensive, complex, long-lasting homogenization equipment at local outlets with a simple, inexpensive reconstitution process using basic mixing equipment. The granulated concentrate acts as a stable intermediate product that can be stored indefinitely without freezing, allowing local facilities to operate with minimal equipment investment while maintaining product quality.
3Stability of the object's composition
If high fat content emulsion is used to bind powder into granules, then moisture content remains low and storage stability improves, but emulsion concentration becomes difficult to handle
Solution Approach 1:
The invention optimizes the fat content parameter in the emulsion to a specific range (65-87% by weight) that balances two competing requirements: high enough fat content to bind powder into stable granules with low moisture content for long-term storage, but not so high that the emulsion becomes unmanageable. This parameter optimization enables the granules to be stored indefinitely without freezing while remaining easy to handle during manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces energy consumption and equipment needs, maintains product quality, and allows for efficient production of high-quality ice cream without complex homogenization equipment, while eliminating the need for a frozen supply chain.
Implementation Method 1
combining, in a granulation step, the powder and the emulsion to form a mixture with a moisture content of less than 10% by weight of the mixture, wherein the emulsion binds the powder into granules
Implementation Method 2
using an homogenizer operating at high pressures in ice cream manufacturing to generate small oil droplet sizes (ca. 0.3 micron) in an ice cream premix
Implementation Method 3
The granules can then be dispersed and/or dissolved in an aqueous liquid at a location close to point of sale resulting in a high quality premix
Data Source
AI summary
Disclosed is a process for manufacturing a concentrate for making a premix for a frozen confection, wherein the concentrate is in the form of granules. The process comprises the steps of: (a) forming an oil-in-water emulsion wherein the fat droplets in the emulsion have an average particle size (D3,2) of less than 1 micron, the emulsion comprising fat in an amount of at least 65% by weight of the emulsion; (b) providing powder comprising saccharides, non-saccharide sweetener and/or protein; (c) combining, in a granulation step, the powder and the emulsion to form a mixture with a moisture content of less than 10% by weight of the mixture, wherein the emulsion binds the powder into granules; and (d) recovering the granules from step (c).