Rapid Ice Cream Freezing With Dynamic Mixing and Small Crystals

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Solution Overview

Problem

Current ice cream production methods take significant time to chill ice cream from room temperature to freezing, often requiring static freezing steps that lead to larger ice crystals and a less smooth texture, and involve the use of stabilizers and emulsifiers to extend shelf life and improve texture, which can result in undesirable flavor changes and increased production costs.

Innovation Solution

A system and method for rapidly cooling ice cream from room temperature to freezing in under two minutes using a refrigeration cycle with low startup times and a pod-machine interface that employs a mixing paddle with increasing rotational speed to create small ice crystals, eliminating the need for static freezing and stabilizers, while using retort sterilization to maintain product freshness and shelf stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If static freezing is used to chill ice cream from room temperature, then the ice cream can be frozen, but the freezing time is long and large ice crystals are formed resulting in less smooth texture

Engineering Contradiction:

Improvefreezing temperatureVSAvoidfreezing time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The patent employs a dynamic freezing process where the ice cream mixture is continuously agitated and moved during freezing, rather than using static freezing. The system includes a freezing drum that rotates and a spray system that moves the mixture dynamically, preventing large ice crystal formation and reducing freezing time while maintaining smooth texture.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses periodic spraying of the ice cream mixture onto the freezing drum surface, followed by periodic scraping and collection. This cyclic process of spraying, freezing, scraping, and recirculating allows continuous heat transfer and prevents ice crystal growth, achieving rapid freezing without sacrificing texture quality.

Inventive Principle:

Principle #19Periodic action

2Duration of action of stationary object

If stabilizers and emulsifiers are added to extend shelf life and improve texture, then the ice cream can be stored longer, but the flavor changes undesirably and production costs increase

Engineering Contradiction:

Improveshelf lifeVSAvoidflavor change

Core Design Contradiction:

Duration of action of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The patent removes stabilizers and emulsifiers from the ice cream formulation entirely. Instead of using these additives to extend shelf life and improve texture, the invention relies on the dynamic freezing process and proper formulation of base ingredients to achieve the desired product characteristics without harmful additives that cause flavor degradation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent modifies the freezing process parameters (temperature, agitation speed, spray rate) to achieve rapid freezing that creates small ice crystals and stable texture without requiring stabilizers. The process parameters are optimized to produce a texture that naturally resists deterioration during storage.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If stabilizers and emulsifiers are added to improve texture, then the texture can be enhanced, but the production cost increases

Engineering Contradiction:

Improvetexture stabilityVSAvoidproduction cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent eliminates the need for expensive stabilizers and emulsifiers by using a dynamic freezing process that inherently produces stable texture through controlled ice crystal formation. This removal of additives directly reduces production costs while maintaining or improving texture quality.

Inventive Principle:

Principle #2Taking out (Extraction)

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

The method produces ice cream with predominantly small ice crystals (<50 μm) for a smooth texture, reduces production time, and allows for room-temperature storage of ice cream mixes for extended periods without the need for stabilizers, resulting in improved taste and cost efficiency.

Implementation Method 1

based on a refrigeration cycle with low startup times

Methodology Applied

Scientific EffectRefrigeration cycle:

Implementation Method 2

pod-machine interface that is easy to use and provides extremely efficient heat transfer

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

employing a mixing paddle with increasing rotational speed to create small ice crystals

Methodology Applied

Scientific EffectMechanical churning: Stirring

Implementation Method 4

Pasteurization is a process in which food (e.g., dairy or milk) is treated with mild heat, usually to less than 100° C. (212° F.), to eliminate pathogens and extend shelf life

Methodology Applied

Scientific EffectPasteurization: Heat Treatment