The Daniatech team started a dialogue to understand the company’s needs – with respect for the small ice cream producer’s special ethos. The selection process drew upon a long experience with many different production designs, helping the customer to consider and technically evaluate requirements now and for the future. The final choice fell upon a Daniatech 400 l ProcessMaster to do the job.
The ProcessMaster range represents the next generation of mixing solutions for the process industry. Virtually maintenance-free, it is more compact in its design and highly optimised for energy-efficient high-shear mixing.
“With this newly installed batch pasteurizer, a ProcessMaster 400 l, we expect to reduce our energy emissions by half while increasing production volume.” – Martin Jørgensen, owner of Skarø Is.
The essential workings of a ProcessMaster unit are quite simple; a vacuum draws powder from the funnel into the mixer, instantly wetting it. Simultaneously, a powerful, high-shear mixer and scraper agitator generate a controlled vortex within the tank. And it is this combination of vortex and vacuum that effectively separates air from liquid, rapidly generating a perfectly homogeneous dispersion. Each unit features an insulated jacket to enable fast heating and cooling using steam or ice water, while, for extra quick heating, direct steam valves can be specified.
Today, instead of using five machines that run for 24 hours, Skarø Is can produce the same volume with a single, fully automated Daniatech ProcessMaster that operates for only five hours, and the final product is highly stable and homogeneous, air and lump-free ice cream. But that is just the tip of the iceberg.
“To put it briefly, it means that we can produce higher quality ice cream with less energy.” – Martin Jørgensen, owner of Skarø Is
A key focus area for Skarø Is is finding ways to reduce its environmental impact. Of course, with locally sourced, organic ingredients, central elements of a sustainable business model were already in place. Now, these benefits could be matched with energy-efficient machinery. Here, with the ProcessMaster in place, surplus heat from freezers can be stored in tanks and used for pre-heating of the ice cream mix, which in turn presents significant energy savings.
“Previously, we spent around EUR 5.500 on power each month – now we only have to spend perhaps EUR 2.700.” – Martin Jørgensen, owner of Skarø Is
These savings, coupled with new capabilities such as the ability to monitor and control the production from a remote location, have moved Skarø Is to the forefront of low-volume, artisan ice cream production – simultaneously preparing the company for an exciting future of growth.
For this company, we delivered:
400 l ProcessMaster that functions as a pasteuriser
- Dynamic mixer head
- Cooling/heating jacket
- Reusing glycol from freezers
- Immersion heater
- Vacuum system
- Vacuum inlet from a funnel
- Vacuum inlet from milk storage tanks
- Heat exchangers at both product inlet and outlet
- Fully automated control
- Remote access