C - JET
The most advanced generation of aerated ice cream equipment
This equipment will be produced in the United States and Brazil
The ice cream market
Estimated at $ 57 billion per year by 2017, this market is expected to reach $ 69 billion by 2022, a growth of 20 percent over five years.
It is a market divided between homemade ice cream (made and sold locally), industrial (factory-made and distributed to points of sale) and soft ice cream (ice cream sold at fast food stores such as McDonald's or Dairy Bars). The share of each varies greatly from country to country, however industrial ice cream has the highest percentages because it is produced on a large scale by equipment such as C-JET.
Industrial ice cream is produced by small, medium and large companies, each with areas of scope proportional to its production capacity. Its main characteristics are to create a high incorporation of air (up to 130%) and long shelf life.
The Importance of Air Incorporation
Large-scale ice cream production requires a large distribution network and for this the product must pass through at least two levels of sale, starting with a distributor and subsequently several resellers under it. In addition, transportation and storage are also complex. This requires the product to have low production cost so that the final price is accessible to most consumers.
Injection of air into the ice cream causes it to double its volume (100% more air) and often to exceed (130%), substantially widening the return margin so that it can be divided between distributors and resellers and cover the transportation and storage infrastructure costs. The ice cream industry, however, still retains a good share of the profit, especially when analyzing the total amount calculated on large quantities produced.
The air injected into the ice cream, thus, plays a fundamental role in its composition. For its quality to be preserved, all components of ice cream need to be balanced so that these large amounts of air are retained by it, without losing nutritional characteristics, taste and creaminess.
The continuous freezers of aerated ice cream
Considered the locomotives of the ice cream industry, they are characterized by beating and freezing the product in an continuous process, pulling the mixture (also called a syrup) from a refrigerated tank on one side and dispensing the aerated ice cream thru a simple extrusion tube on the other side.
The mixture is beaten in a cylinder surrounded by a strong cooling system. Within this cylinder there is a rotating device containing blades used to scrape the ice cream that freezes on its walls. A pump injects more mixture, together with air, into that cylinder as the ice cream is extracted.
New beating and aeration cylinder
The C-JET has a special stainless steel beating cylinder, while conventional equipment use brass or other coated materials that can contaminate the ice cream with toxic oxides over a certain period of time. The stainless steel cylinder has a much larger area than the brass equivalents, to ensure excellent heat exchange and give more space for perfect incorporation of air into the ice cream.
The thickness of the cylinder wall in the C-JET is small and controlled (little variation in thickness along the cylinder). The smaller the thickness, the greater the rate of thermal exchange between the cooling gas circulating around the cylinder and the ice cream that is beaten inside it. Brass cylinders or other materials have great thicknesses and this impairs speed.
The C-JET beater is equipped with a unique mechanism for mixing the ice cream with air, ensuring bubbles are very small in size and evenly distributed throughout the product. Conventional machines generally form bubbles of varied dimensions and some of larger dimensions, which end up "bursting" at the exit of the machine and causing failures in the packaging.
The C-JET scraping system acts in small areas in a delicate way, removing small scrapings at each turn of the beater, as opposed to conventional scrapers that remove large layers of frozen ice cream, hampering subsequent aeration and increasing wear of the cylinder wall.
New air and mixture pumps
The C-JET line use separate air and mixture pumps, each injecting the exact amount of these components into the beating cylinder. This ensures that the ice cream leaves the machine always with the same percentage of air incorporated.
Conventional machines use the same pump to inject both mixture and air, but the variation of the amount of air incorporated in the ice cream is high and this needs to be frequently regulated during the production.
In order for air to be incorporated into the ice cream during the beating process, the internal pressure of the cylinder must exceed 3 times the atmospheric pressure (3bar) and be kept constant. This pressure can reach 10 bar when automatic packaging is required. The exclusive air pump also ensures that even the highest pressure is reached, keeping it constant throughout the process.
The exclusive mixture pump, in turn, also allows you to pull the liquid from tanks far away from the machine and completely empty them. Conventional machines that use the same pump for air and mixture, cannot empty the tanks to completion and also suffer from variations in distance from the tanks to the machine.
For the production of “açai” (a typical tropical berry), the mixture pump can be custom made from special ceramics.
New computerized system
Conventional equipment use commercial electronic controllers adapted to the functions that an ice cream machine demands. This causes two problems:
1. The control screens are difficult to use because they are made for a multitude of applications, requiring the operator to use many keys or steps to insert data.
2. The operation is slow and generally incomplete, requiring the placement of additional mechanical buttons or electronic mechanical safety circuits.
The C-JET has received an on-board computer exclusively designed to produce ice cream in continuous mode, easily configurable by the operator through a high resolution "touch" screen panel, including the following functions:
- Intelligent start of one component at a time, avoiding overload in the electrical network. These components are also turned off in sequence.
- It reads all the parameters of the refrigeration system to avoid damages such as possible liquid strokes in the refrigeration compressor, for example.
- Choice of: internal pressure of the beating cylinder, percentage of incorporation of air in the ice cream, quantity to be produced, temperature of the ice cream etc.
- Ice cream beating effort detection to avoid locking or damaging the electric motor. Hot gas is automatically injected to partially melt the ice cream that eventually freezes to excess which could block the beater.
- Monitoring of any faults in all equipment with automatic or programmed corrective actions.
- Preventive maintenance program according to the number of operating hours of each component.
Following the worldwide trend of industrial environments that need to be shown to the end consumer to associate the product with the hygiene and technology used in ice cream manufacturing, the C-JET is designed to have a strong impact on the production line.
Its large tempered glass panel with "touch" controls eliminates the clear plastic screens used in conventional machines as well as allows cleaning with no damage. No crevices, seams or screws in this region.
The production visualization, as well as its configuration, is done with a high resolution color display, where videos of corrective or preventive maintenance can also be displayed.
The air and mixture pumps are built into the front of the equipment, making only the parts necessary for connections to the supply pipes visible.
The closing side panels of the machine are curved to give greater rigidity, in addition to having no apparent screws or points where water may enter.
Even fully open, the C-JET features a very clean design, with an integral structure with fully washable stainless steel. All components inside are protected against moisture and water jets.
The cooling water and electrical connection outlets are positioned at the highest point at the rear of the machine to facilitate couplings with high industrial piping so as not to block the floor with pipes and electrical cables.
Decrease in the number of people involved in the ice cream manufacturing process. The electronic control unit of the equipment performs several functions of monitoring and decision making, requiring little intervention of the operator. Once the desired parameters for the ice cream have been set the equipment manages all the components so that the production regime is unchanged for many hours at a time.
Lower energy costs per kilogram of ice cream produced due to the high thermal exchange between the refrigerating gas and the ice cream (controlled and thin-walled cylinder), the beating and scraping efficiency of the ice cream inside that cylinder (less rotations of the beater to freeze and incorporate air) and to the precise control of the refrigeration system (increase or reduction of cold according to the need, without wasting energy).
Resale value guaranteed because it is compact equipment of high production and equipped with state-of-the-art technology with all control systems included. It is a module of production of ice cream of high efficiency and low cost when compared to conventional industrial equipment.
Cleaning facilitated by the CIP (clean in place) system and fully removable parts for better hygiene at the end of production.
|Consumption of electricity||18 kW.|
|Electrical Installation||220 V - 380 V, Threephase, 60 Hz.|
|Equipment Dimensions||Length = 1500 mm, Width = 800 mm, Height = 1900 mm.|
|Net Weight||700 kg.|
|Production Capacity||300 up to 900 liters per hour.|
Medium and large ice cream industries.
C-JET coupled to the Finamac lines of:
Pasteurizers, for heat treatment of the mixture before the beating of the ice cream.
ICE POP machines for the production of aerated ice pops.
Packaging machines, for the production of cones, cups and ice cream pots.
Incorporators, for ice cream with syrups, chocolate flakes or solid granules in general.