Sealed Ice Cream Pasteurization and Freezing to Prevent Contamination
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Solution Overview
Problem
The ice cream manufacturing process is prone to contamination from invasive infectious agents like Salmonella and Listeria monocytogenes, particularly due to cross-contamination risks during handling and processing, which compromises food safety.
Innovation Solution
A batch processing method for making ice cream using a machine with a thermal treatment system that pasteurizes the mixture by heating the container walls and then cooling it, incorporating air to create the ice cream product within a sealed processing chamber, minimizing external contact and reducing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ice cream processing methods are used with multiple handling steps, then the ice cream can be produced with various flavors and textures, but the risk of bacterial contamination increases due to cross-contamination during handling and processing
Solution Approach 1:
The processing system is divided into separate sealed modules: a processing chamber for mixing and freezing, a separate storage container, and distinct dispensing mechanisms. This segmentation prevents cross-contamination by eliminating contact between the basic mixture and external utensils or containers during the entire processing sequence.
Solution Approach 2:
The harmful factor of cross-contamination is extracted from the process by removing all intermediate handling steps involving external containers and utensils. The basic mixture remains confined within the sealed processing chamber throughout mixing, freezing, and dispensing operations.
2Reliability
If additional processing steps are introduced to eliminate contamination risks, then food safety can be improved, but the processing time and operational complexity increase
Solution Approach 1:
Multiple functions are merged into a single integrated sealed processing chamber: mixing of ingredients, thermal processing (pasteurization), freezing, and storage all occur within the same confined space without exposing the mixture to external contamination sources. This eliminates the need for separate processing steps and intermediate transfers.
Solution Approach 2:
The processing chamber serves multiple functions sequentially: it acts as a mixing bowl, pasteurization vessel, freezer, and storage container. This multi-functionality eliminates the need for separate equipment and handling steps, maintaining food safety without extending processing time.
3Ease of operation
If multiple handling operations are performed on the basic mixture, then the ice cream can be processed and served, but the number of contamination points increases
Solution Approach 1:
All intermediate handling operations involving external containers and utensils are extracted from the process. The basic mixture is transferred directly from the processing chamber to the dispensing mechanism without contact with any external items, eliminating multiple contamination points while maintaining operational simplicity.
4Reliability
If a sealed processing system is used to prevent contamination, then food safety is improved, but the equipment may require more space
Solution Approach 1:
Multiple processing functions (mixing, pasteurization, freezing, storage) are merged into a single integrated sealed processing chamber, eliminating the need for separate equipment for each function. This reduces the overall space requirement while maintaining the food safety benefits of a sealed system.
Solution Approach 2:
The processing chamber is designed as a multi-functional unit that performs mixing, thermal processing, freezing, and storage operations sequentially within the same confined space, reducing the total equipment footprint while ensuring food safety through continuous sealing.
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 enhances food safety by eliminating bacterial contamination risks, simplifies operations, and allows for efficient production in compact spaces without extending processing times or adding extra steps, ensuring a safe and high-quality ice cream product.
Implementation Method 1
heating the walls of the processing container (2) to a preset preheating temperature
Implementation Method 2
deactivating any infectious agents which may be present in the basic mixture by activating the thermal treatment system in heating mode for a predetermined time in order to (simultaneously) pasteurize the basic mixture
Implementation Method 3
activating the thermal treatment system in cooling mode to cool the basic mixture
Implementation Method 4
activating the rotary stirrer (5) in rotation, so as to allow incorporating air into the basic mixture to make an ice cream type product
Data Source
AI summary
A method for making ice cream including the following steps, performed in the following order: heating the side walls of the processing container to a preset preheating temperature; placing a basic ice cream mixture in the processing chamber after the step of heating the side walls of the processing container to a preset preheating temperature; deactivating any infectious agents which may be present in the basic mixture by activating the thermal treatment system in heating mode for a predetermined time in order to pasteurize the basic mixture inside the processing chamber; keeping the basic mixture, previously subjected to the thermal treatment inside the processing chamber, for a predetermined hold time.