Attachment D.1.

6 - Ice-Cream Processing

Description

Ice-cream is manufactured on the Killeshandra site on contract for a number of

customers and own-brand product is also produced. Ice cream is manufactured to
required specifications for the customer depending on the flavour or packaging size of
the product.

The Ice-cream manufacturing area is located is the same building as the UHT process.
This is due to the similarity of the beginning of each process i.e. the optimal blending
of the skim, cream and other ingredients into a milk based intermediate. The desired
flavours are then added to the mixture to give the right flavour and texture for the
customer.

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The mixture is now ready for freezing and is transferred to freezer barrels and chilled
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in order to induce the formation of ice-crystals in the mixture. Once freezing is

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completed and the Ice-cream has the desired consistency it can then be packaged.
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Volumes produced include 1-litre and 1-pint versions. The packaged product must
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then be boxed and transferred to cold storage ready for dispatch and shipping in
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refrigerated lorries to the customer.

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Flow Diagram

Skim Cream Ingredient Addition

Milk Base

Mixed Product

Pasteurisation

Flavour Addition

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Freezer Barrels
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Ice-Cream Filling
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Tunnel Freezer
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Frozen Storage
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Process Control

There is a huge amount of process control associated with Ice-Cream processing on

site. These can be provided to the Agency on request.

Control Parameter Control Equipment Control Method

Product Temperature Thermometer Automatic PLC
Metal Detection Metal Detector Alarm
Product Flow Flow-meter Automatic PLC
Cold Store Temperatures Thermometer Automatic PLC
Product Coding Visual Inspection Manual

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Potential Emissions / Abatement

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Again, the main emission generated during the process is the wastewater generated
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during the washing of the Ice-cream Plant and its associated lines. This includes
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mainly washing of lines, storage silos etc. associated with the Ice-cream Plant. The
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wastewater is taken via effluent drains on the site to the Wastewater Treatment Plant.
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There is a flow meter that measures all daily wastewater flows from the UHT / Ice-
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cream area of the site.

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Throughput
The Ice-cream Plant produces approximately 200,000 litres per month in summer-
time and 100,000 litres per month in winter-time

Laboratory Facilities
The Ice-cream laboratory tests are carried out in the UHT Lab. Mina tests are total
solids, fat content, over-run, temperature and micro-testing in the Micro Laboratory.

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