Overall Process
Final Product:6000 kg Mango Ice Cream
Operation:Batch Process (8-hour cycle time)
Mass Flow Rate:6000 kg / 8 h = 750 kg/h (final product)
* Key Properties:
Cp_mix (liquid): 3.8 kJ/kg·K
Cp_icecream (frozen): 1.8 kJ/kg·K
Latent Heat of Steam (at 90°C): 2283 kJ/kg
Overrun: 30%
Refrigeration COP: Chilling (COP=3.5), Freezing (COP=2.0), Hardening (COP=1.5)
1. Raw Material Preparation & Mixing
Function:Combine dairy, powders, and sugar.
* Incoming Streams:
Fresh Milk/Cream Blend: `4200 kg / 8h = 525 kg/h` @ 4°C
Sweeteners: `900 kg / 8h = 112.5 kg/h` @ 25°C
Stabilizers/Emulsifiers: `30 kg / 8h = 3.75 kg/h` @ 25°C
*Equipment:High Shear Mixer
* Power: 15 kW (operates 100% during 8h batch)
*Energy Input:15 kW * 8 h = 120 kWh/batch (Electrical)
* Outgoing Stream:Uniform Base Mix:(525 + 112.5 + 3.75) = 641.25 kg/h` @ ~6°C
(slight heating from motor)
2. Pasteurization (Plate Heat Exchanger) with Regeneration
Function:Heat to 75°C (hold 30s), then cool to 4°C.
* Incoming Stream:Base Mix: 641.25 kg/h@ 6°C
* Process:
1. Regeneration (Section 1):Cold mix (6°C) is pre-heated by hot pasteurized
mix (75°C). Assume 85% efficiency.
* Pre-heated Mix Temp: `6 + 0.85*(75-6) = 6 + 58.65 = 64.65°C`
* Pasteurized Mix is pre-cooled to: `75 - 58.65 = 16.35°C`
2. **Heating (Section 2 - Steam):Pre-heated mix (64.65°C) is heated to 75°C.
* `Q_heat = m * Cp * ΔT = 641.25 kg/h * 3.8 kJ/kg·K * (75 - 64.65)K =
25,200 kJ/h`
* Steam Required (90°C, latent heat=2283 kJ/kg): `(25,200 kJ/h) / (2283
kJ/kg) = 11.04 kg/h`
* **Utility Input:** Steam @ 90°C, `11.04 kg/h`
* **Utility Output:** Condensate @ ~90°C, `11.04 kg/h`
3. **Holding Tube:** Holds at 75°C for 30 sec.
4. **Cooling (Section 3 - Chilled Water):** Pre-cooled mix (16.35°C) is cooled
to 4°C.
* `Q_cool = m * Cp * ΔT = 641.25 kg/h * 3.8 kJ/kg·K * (16.35 - 4)K =
30,000 kJ/h`
* Chilled Water Duty ( assume ΔT=5°C for water, Cp=4.18 kJ/kg·K):
`m_water = Q_cool / (Cp * ΔT) = 30,000 / (4.18 * 5) = 1,435 kg/h` of
chilled water
* **Utility Input:** Chilled Water @ 1°C, `1,435 kg/h`
* **Utility Output:** Chilled Water Return @ ~6°C, `1,435 kg/h`
* **Outgoing Stream:** Pasteurized & Cooled Base Mix: `641.25 kg/h` @ 4°C
3. Homogenization
Function:Break fat globules under high pressure (200 bar).
* Incoming Stream:Pasteurized Mix: `641.25 kg/h` @ 4°C
*Equipment:High-Pressure Homogenizer
*Power:25 kW (operates 100% during 8h batch)
*Energy Input: `25 kW * 8 h = 200 kWh/batch` (Electrical)
*Adiabatic Heating:~15-20°C rise per 100 bar`. At 200 bar, temperature rises to
`4°C + 35°C = 39°C`.
*Outgoing Stream:Homogenized Mix: `641.25 kg/h` @39°C (requires immediate cooling)
4. Aging / Cooling
Function:Cool mix from 39°C to 4°C and hold for crystallization.
*Incoming Stream:Homogenized Mix: `641.25 kg/h` @ 39°C
*Equipment:Aging Tank with Cooling Jacket
*Cooling Load: `Q_cool = m * Cp * ΔT = 641.25 kg/h * 3.8 kJ/kg·K * (39 - 4)K =
85,300 kJ/h`
* Refrigeration Input (COP=3.5):** `E_compressor = Q_cool / COP = 85,300 / 3.5 =
24,370 kJ/h = 6.77 kW`
*Agitator Power:1.5 kW
*Total Energy Input (Electrical): (6.77 + 1.5) kW * 8h = 65.8 kWh/batch
*Outgoing Stream:Aged Base Mix: `641.25 kg/h` @ 4°C
5. Flavoring (Mixing)
Function:Add mango pulp to base mix.
*Incoming Stream 1:Aged Base Mix: `641.25 kg/h` @ 4°C
*Incoming Stream 2:Sweetened Mango Pulp: 870 kg / 8h = 108.75 kg/h @ 4°C
*Equipment:Mixing Tank with Agitator
*Power:5 kW (operates 25% during 8h batch)
*Energy Input: 5 kW * 0.25 * 8h = 10 kWh/batch (Electrical)
*Outgoing Stream:Flavored Mix: (641.25 + 108.75) = 750 kg/h @ 4°C
6. Freezing (Batch Freezer)
Function:Freeze mix, incorporate air (30% overrun).
*Incoming Stream:Flavored Mix: 750 kg/h@ 4°C
*Equipment:Batch Freezer (Ammonia Refrigeration)
* Heat Removal (Q_freezing):
* Sensible (4°C to 0°C): 750 * 3.8 * 4 = 11,400 kJ/h
* Latent (50% water freeze): (750*0.5) * 334 = 125,250 kJ/h
* Sensible (0°C to -6°C): 750 * 1.8 * 6 = 8,100 kJ/h
* Total Q_freezing = 144,750 kJ/h
*Refrigeration Input (COP=2.0): E_compressor = 144,750 / 2 = 72,375 kJ/h = 20.1 kW
*Scraper Motor Power:4 kW
*Total Energy Input (Electrical): (20.1 + 4) kW * 8h = 192.8 kWh/batch
*Outgoing Stream: Soft Ice Cream: 750 kg/h @ -6°C (Volume expands by 30%)
7. Packaging
Function:Fill and seal ice cream into containers.
*Incoming Stream: Soft Ice Cream: `750 kg/h` @ -6°C
*Equipment:Horizontal Form-Fill-Seal (FFS) Machine
*Power: 10 kW (main motor, pumps, sealing jaws)
*Compressed Air: 50 NL/min (auxiliary)
*Energy Input (Electrical):10 kW * 8h = 80 kWh/batch
*Outgoing Stream: Packaged Ice Cream: 750 kg/h @ -6°C (now in final packaging)
8. Hardening (Blast Freezer)
Function: Rapidly freeze product to -22°C.
*Incoming Stream:Packaged Ice Cream: `750 kg/h` @ -6°C
*Equipment:Blast Freezer (Spiral Conveyor, Ammonia Refrigeration)
*Heat Removal (Sensible only):Q_harden = m * Cp_frozen * ΔT = 750 kg/h * 1.8
kJ/kg·K * (-6 - (-22))K = 750 * 1.8 * 16 = 21,600 kJ/h
*Refrigeration Input (COP=1.5): E_compressor = 21,600 / 1.5 = 14,400 kJ/h = 4.0 kW
*Fan Power (for high air velocity): 15 kW
*Total Energy Input (Electrical):(4.0 + 15) kW * 8h = 152 kWh/batch
* Outgoing Stream:Final Product - Hardened Mango Ice Cream:750 kg/h@ -22°C