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Kapiti Fine Foods

The challenge

Our client operated a small and successful super premium ice cream line, but there was no possibility for expansion in their existing premises. They wished not only to increase production of their super premium products using state-of-the-art processing equipment, but also to commence production of higher volume, lower cost ice cream.



The Solution

In a purpose built processing hall added to their existing milk factory we installed a complete new ice cream processing plant, from ageing tanks onwards. As well as three ageing tanks the plant included: two sets of flavour tanks; two ice cream freezers incorporating the latest high quality ice cream technology (the first in the country); two automatic rotary fillers capable of handling containers ranging in size from 100ml to 2 litres; coding and conveying system; spiral freezer for rapid hardening, with automatic placement of containers on the freezer belt; discharge conveyor and semi-automatic shrink wrapping of stacked containers. We also installed a product recovery system, CIP system and all services. After the new plant was commissioned and production transferred from the existing plant, we relocated and installed the existing production line in the new ice cream factory.



Process

ICE CREAM

Key Processes Implemented

  • 500 l flavour tanks
  • 8,000 l ageing tanks
  • CREAM freezers, each capable of producing 900 l/h super premium (1,700 l/h standard) ice cream
  • Rotary carton/bottle fillers
  • Shrink wrapping machine
  • Spiral blast freezer