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TECHNICAL REPORT68-36--GP

DEVELOPMENT OFICE CREAM PLANT, CON-TINUOUS FLOW, PORTABLE

by

Bruce B. Thomasand

Frederick W. FrankeFood Service Equipment Division

March 1968

General Equipment & Packaging LaboratoryU. S. ARMY NATICK LABORATORIES

Natick, Massachusetts

rORL.ORD

The development of a self-contained, continuous flow, icecrean plant was authorized as a Commander's List prcj;ect by theU. S. Army Materiel Commano in the second quarter of Fis-al Year1966. Mr. Bruce B. Thomas, Food Service Equipment Zivision,general Equipirnt and1 Packaging La:.rator%, served as projectofficer. and Hr. rrederik- W. Franke was the alternate projectofficer.

Acknowledgment is accorded to perscnnel 3` the Laborator-i

SuD-ort Office for their assistance in the evaluation of the Icontinuous flow ice cream plant.

EDWARD A. .EBESKY, Ph. D.Acting DirectorGeneral Equipment • Packa-ing La:or2tory

APPROVED:

ZL: ih. SIELI:EG, Ph. D.Scientific Director

CLIFYORD 7. RIORDANCoione-. , QM4CCc-nmanding

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TABLE OF CONTENTS

Page

Abstract iv

Statement of Objective I

Development of Continuous Flow Ice Cream Plant 1

Results 4

Conclusions 7

Recommendations 7

ii

ABSTRACT

Development of a continuous flow, portable, ice cream plantwas ,midertaken to meet requirements for a unit with a minimum outputof 50 gallons of ice cream per hour that could be transportable bya 2-1/2-ton vehicle.

The main components of the plant were to be a continuous flowfreezer, refrigeration system, mix tank, pump, and mounLting base.These individual -components were available commercially, but acomplete, portable plant had never been built with its own refrigera-tion system.

After initial design of the units, two plants were built bycommercial sources and tested by the manufacturers. Further evalua-tion was conducted at the U. S. Army Natick Laboratories. Resultsof tests indicated satisfactory operation of the experimental proto-types, and that the design concepts and available hardware wereacceptable.

iv

DEVELOPMENT OF ICE CREAM PLANT, CONTINUOUS FLOW, PORTABLE

Statement of Objective.

The present ice cream machines available for military field useare of the "batch" type which produce approximately three 2-1/2-gallonbatches of ice cream per hour. To produce any large quantity of icecream, it would be necessary to operate several machines at one time.This type of operation is inefficient and requires a large number ofmachines and personnel.

.ae obj rztive of a continuous fltw ice cream plant (Figures 1and 2) now under development, is to produce ice cream in excess of50 gallons per hour. The rated conditions for producing the 50 gallonsper hour were established at 1000 F. and an overrun* of 90 percent.

An additional objective is a complete, self-contained plant,capable of being transported by a standard 2-1/2-ton military vehicle.The refrigeration system was to be provided with an air-cooled condenser.Electric power would be supplied at the operational site.

Development of Continuous Flow Ice Cream Plant.

Initial investigation of continuous ice cream freezers revealedthat the freezer units were available as commercial items from twomanufacture-rs. Each of these manufacturers has produced these freezersin excess of 20 years. These freezer units are highly developed andh-ive proved reliable 3.ri usp throughout the comnerciat j,-e cicm inciustry.Other components required for the plant were commercially available,although they had never been assembled as a unitized sysCem.

Discussions held with each of the two manufaczurers revealed thatthe self-contained, continuous flow, ice cream plant was feasible andthat a compact unit could be fabricated. Contracts were awarded to eachcompany to produce one prototype unit of the ice cream plant. Theseunits were manufactured and tested at the vendors' plants prior toshipment to these Laboratories for further evaluation.

*Overrun, as applies to ice cream making, is the ratio of air to liquidmix, by volume of the finished product. It is the volume of the finishedproduct over and above the volume of liquia. mix used to make the product.

Example: One gallon of liquid ice cream mix will produce two gallons byvolume of finished product 100 percent overrun.

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Both units were evaluated at these Laboratories for ease of

operation, location of ccmponents, ease of maintenance, structuralintegrity, and ease of cleaning.

The two prototypes were procured with different components andmethods of fabrication. One unit had a solid plate over the frame-work for the operator to walk on, and the other unit was left open

for cleaning, since the operator did not have to walk on the unitto operate it. One unit had a refrigerated mix tank for storage(Fig4re 3) and the other a funnel-type mixer (Figure 4) for easilydissciving the powdered ice cream mix. In addition, one unit was

b)ilt with welded piping, while the other unit had piping that could5e completely dismantled for clearing.

Results.

Both of the units performed well with the exception that whenusing some ice cream mix the plants would not produce a full 50gallons-per-hour output with a mix temperature of 900 F. and an am-bient temperature of 1000 F. Design performance figures for bothfreezers ,ere prorated from data on ammcnia performance. Operationwith R502 (refrigerant) showed that the capacity of the plants wasnot s,;fficient to cover all variations in ice cream mixes. Fi-v amix temperature of 70° F., however, the requirement of 50 gallons-per-hour output could be met using military ice cream mix perMilitary Specification MIL-I-705C.

Operation of one unit was hampereý when the hot air from theair-cooled condenser blew over the fre zer .nd the operator whilethe unit was running (air flow direction wtis correcte at U. S.Army Natick L•oratories).

When operating each unit with dry powder ice cream mix, it wasdifficult to dissolve the powder in the mix tank. Although anagitator is supplied in -he tank to keep the mix from stratifyingprior to use, this is not sufficient for initial dissolving ofpowdered mix. The dissolving of the mix was accomplished satis-factorily in an outside pan or by using a funnel-mixing devize.

Cleaning both units was found to he satisfactory. The compar-ison of welded piping versus coupled piping can only be resolvedsatisfactorily after extended field operation. This matter is moreof a convenience factor than that of meeting sanitary requirements.

Rerirculat'n7 .umis between the mix tank and the freezer werevery Tu.;:fa! fror cleaz';!,, the units as well as providing very con-sistent opera-Ion of the freezer-s.

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Conclusions.

The continuous flow ice cream plant is acceptable for produc-tion of large quantities of ice cream.

The plant is suitable for transport by a 2-1/2-ton truck andneeds only shelter, electrical power, and potable water supply toset it up for operation. Freezer cabinets are required as aseparate item, for hardeniiag the ice cream after it leaves thefreezer.

Capacity of units is very good at 1000 F. ambient, with a mixtemperature below 700 F. The freezers were not designed to beefficient with mix temperatures above 700 F. There 5s no problemin operating with high mix temperatures, but the capacity of theunits will be slightly below the initial requirement of 50 gallons-per-hour output.

In areas whexe refrigeration is available to cool the mix priorto use, the capacity of the units woulc. increase to 100 gallons-per-hour output.

The ice cream plants are suitable for continuous (24 hours perday) operation, and production is limited only by cleaning require-ments and minor periodic maintenance.

Recommendations.

The cer:tiruous flow ice cream plant should be specified withfunnel mixing devices for dissolving the powdered ice cream mix.

The capacity requirements should be stated as 50 gallons-per-hour output at 90 percent overrun, with a mix temperature of 700 F.,while operating in an ambient temperature of 1000 F.

Air flow from the air-cooled condenser should be directed awayfrom the unit so that cool air is drawn over the freezer and operator.

The type of piping should not be specified until field use hasdetermined whether welded or coupled piping is more suitable.

Skids for ice cream plants can be either open-frame or steel-plate covered, depending on whether the operator must stand on theskid or on the floor beside the unit.

Refrigerated mix tanks are not required for the continuous flowice cream plants since they will be used for volume production, andthere will be no requirement for mix storage in the tanks.

7

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Secusit ClassificationDOCUMENT CONTROL DATA - R&D

(SUMIty rja..dflcah0, lidCJ.. ftdy Of 41"* and Wd&a*, JWWnfta~f me0b. sales SI60% 9e .Os'.m ntpeet is Ceb.fi.E)I ORIGINATING ACTIVS-Y (Ce-P, W m@~ 20 ACPOnT S6CURITY C LASSIrICA TION

U. S. Army Natick Laboratories UnclassifiedNat ick. Massachusetts

3 REPORT TITLE

Development of Ice Cream Plant, Continuous Flow.' Portable

4- DESCRIPTIVE NOTES (Ty"7 of eu*e aE iscktiv. doae)

S AUTHOR(S) (Last narae. Owt name. inirtal)

Bruce B. Thomas and Frederick W. Franke

S. FEPor DATE 741 TOTAL NO. OF PAGES I7b. M*O_ OF REFS

March 1968 71-00le. CONTRACT OR GRANT NO. 94ý ORIGINATOR'S REPORT UNMI4E•S)

I 68-36-GPh. PROJECT NO.

c. 96. 011hEs JPetrT NO(S) (Any ot"r w-Mbreh *wrmay be assilned

d.

10. AVAIL ABILITY/'IIMITATION NOTICES

This document has been approved for public release and sale; its distributionis unlimited.

II. SUPOL EMENTARY NOTES 12. ;PONSORING MILITARY ACTIVITY

U. S. Army Natick LaboratoriesNatick, Massachusetts 01750

13. ABSTRACT

-Development of a continuous flow, portable, ice cream plant was undertakento meet requirements for a unit with a minimum output of 50 gallons of ice crea,per hour that could be transportable by a 2-1/2-ton vehicle.

The main components of the plant were to be a continuous flow freezer,refrigeration system, mix tank, pump, and mounting base. These individualcomponents were available commercially, but a complete, ?ortable plant had

never been built with its own refrigeration system.

After initial design of the units, two plants were built by commercialsources and tested by the manufacturers. Further evaluation was conducted atthe U. S. Army Natick Laboratories. Results of tests indicated satisfactor"operation of the experimental prototypes, and that the design concepts andavailable hardware were acceptable.

tI .1

DD I. 1473 UNCLASS IF EDSecurity Classification

!

UNCLASSIFIEDSecurity Ch ss•i'icution

j4 LINK A LINK 0 LINK C

KEY WORDS _.,

Ice cream plant 9 10Continuous flow 0 0Portable 0 0Manufacturing 8Ice Cream 2Kitchen equipment and supplies 4

Armed Forces equipment 4

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