General Freezer Training

Session
 Overview of Training Session
Introduction
 Overview of Training Session
 History
 What is ice cream?
 Freezer Theory of Operation
 Modes of Operation
 Control Loop Description

Safety
 Identifying potential hazards
 Safe Operation & Maintenance

Screen Operation
 Allen-Bradley
 EXOR

“Hands On” Training

Dasher Removal & Installation

 Safety
 Dasher removal Cherry-Burrell

Scraper Blade & Seal Inspection

Dasher Blade & Seal Replacement

Continuous Process Ice Cream Freezers
History:

• The first continuous process ice cream freezer was introduced in 1928.

• Mechanically, the freezing tubes and dashers have remained similar to those
used in the early models, providing the same high quality ice cream.

• Stainless steel is now utilized where ever possible to improve sanitation. The
WCB Ice Cream freezers carry the 3A authorization.

• The WCB Ice Cream freezers feature PLC controls that improve product
consistency and simplify the operation.

• These freezers are user friendly and designed for ease of installation and
maintenance.
Continuous Process Ice Cream Freezers
• Ice cream freezer capacity ratings are based on the following:
– Butterfat 10.5%
– Total Solids 37.5%
– Sugar 15.0%, of which 85% is sucrose, 0.3% is stabilizer
– Mix Temperature 40°F. (4.4°C.)
– Overrun 100%
– Draw Temperature 22°F.(-5.5°C.)
– Ref. Evaporating Temp. -28°F.(-33.3°C.)

• These capacities will vary with different mix formulations and with
overrun percentage.

• Here are a few examples of how the overrun percentage can change the
rated capacity:
100% overrun
mix rate of 100 gph + air rate of 100 gph = 200 gph of ice cream
20% overrun
mix rate of 100 gph + air rate of 20 gph = 120 gph of ice cream
120% overrun
mix rate of 100 gph + air rate of 120 gph = 220 gph of ice cream
 Ice Cream Freezer Operation

Mix Supply
• Mix is supplied to the freezer by a centrifugal booster pump (stuffing pump) that assures
a positive inlet pressure to the mix pump.

Mix Pump
• The mix pump provides the motive force to maintain a constant flow of mix in to the
freezing cylinder.
• There are two (2) types of mix pumps offered on the WS freezers.
– WCB Ice Cream non-contact metal lobe pump
– FAR rubber lobe pump (Crepaco style)
• The FAR rubber lobe pump can be used as a metering pump, but the addition of a flow
meter improves the accuracy.
• The WCB Ice Cream pump is used in conjunction with a flow meter to provide accurate
mix flow control. The unique rotors of the Waukesha pump provide extremely long life.
• The either pump is driven with direct drive gearmotor for efficiency and low maintenance.
• The speed of the mix pump is regulated with a variable frequency inverter.
 Ice Cream Freezer Operation
(continued)
Mix Flow Control
• A magnetic flow meter is used on the WCB Ice Cream freezers utilizing the WCB Ice Cream pump.
• The magnetic flow meter measures the flow of the mix to the freezing cylinder.
• The signal from this meter is used by the PLC’s mix flow control loop to maintain the desired flow
rate.
• The PLC sends a signal to a variable frequency inverter, that controls the speed of the motor
driving the mix pump.
• A mass flow meter can be used in place of the magnetic flow meter to provide automatic
compensation for mix density variations due to rework product.
• The mass flow meter continually monitors the mass flow and mix density.
• The PLC than uses this information to automatically compensate for the air suspended in the
rework mix.
• The output of the air mass controller will be lowered proportionally to maintain the desired
overrun percentage.
 Ice Cream Freezer Flow Diagram
Plant Air Filtration Overrun Air
Supply Control

Mix Freezing
Flow Cylinder
Meter

Mix
Tank Booster
Pump Mix Product Pump or Product
Pump Hold Back Valve
 Ice Cream Freezer Operation
(continued)

Automatic Overrun air Control

 The PLC uses the actual mix flow rate and overrun setpoint to calculate the needed
overrun air flow rate. The PLC than sends a signal to the to the air mass controller for
that amount of air. In turn the air mass controller meters the correct amount of overrun
air in to the flow of mix.
Overrun Air Supply
 It is important to inject only sanitary dry overrun air in to the mix.
 Remember, standard ice cream is 50% air.
 Sanitary air is provided through the filtration and drying of the plant air supply.
 It is recommended to install additional microbial filters at the freezer to assure air quality.
 A carbon filter may be added to remove undesired flavors and odors from the air.
Pre-aeration
 Many freezer are equipped with a pre-aerator for emulsification of the overrun air and mix
before entering the freezing cylinder. Pre-aeration will improve product texture and
consistency, while decreasing novelty shrinkage and package weight variations on bulk
production.
 Ice Cream Freezer Operation
(continued)

Freezing Cylinder
 The mix and overrun air are now ready to enter the all-important freezing
cylinder. The freezing cylinder is a removable heat transfer tube made of pure
nickel with a hard chrome plated finish for excellent heat transfer and
maximum life.
Dasher
 There are two types of dashers a closed or solid dasher and an open or
whipping dasher.
 These dashers will handle a variety of frozen product formulations while
insuring proper air incorporation during freezing.
 Ice Cream Freezer Operation
(continued)

Dasher Drive
 A properly sized dasher drive will assure that the dasher rotates at the proper speed to
insure proper air incorporation and scraping of the walls. 
 The dasher drive works in conjunction with the refrigeration system to assure proper
viscosity control and final product temperature.
 The load on the dasher motor is monitored with a current or watt transducer. The product
viscosity (stiffness) is measured in percent of dasher motor load, with the full load of the
motor being 100%.
 The actual product viscosity or motor load is compared by the PLC to the desired setpoint.
 If the product is too soft or too warm, the PLC will instruct the refrigeration backpressure
valve to open.
 This will lower the temperature around the freezing tube and lower the product
temperature.
 If the product is too stiff or too cold, the temperature on the jacket is automatically raised by
means of closing the refrigeration backpressure valve.
 Ice Cream Freezer Operation
(continued)

Product Pump
WCB Ice Cream freezers are fitted with a product pump or product hold valve at the
discharge of the freezing cylinder.

 The pump is used to automatically maintain the desired cylinder pressure.

 A pressure transducer is used to measure the actual pressure in the freezing cylinder.
 The PLC uses this pressure value to control the the cylinder pressure by varying the
speed of the product pump.

 The product hold valve is used maintain a constant cylinder pressure and isolate
the freezing cylinder from down stream pressure changes. The control of this
valve may be either automatic or manual depending on the controls of freezer.
 Automatic control - A pressure transducer is used to measure the actual pressure in the
freezing cylinder.
 The PLC uses this pressure value to control the cylinder pressure by varying the air
pressure to the product hold back valve.
 Manual control – The operator adjusts the air pressure to the hold back valve with a
pressure regulator
 Modes of Operation
 Sanitize
The sanitize mode is used to clean or sanitize the freezer prior to production.
 Fast-Fill or Quick-Fill
The Quick-Fill mode is used to flood the freezing cylinder with pure mix and push out any sanitizing
solution.
 Run
The Run or freeze mode is used to produce product.
 Hold
The hold mode is used stop production for a short period of time.
 Purge or Flush
The Flush mode is used flush the freezing cylinder between production runs and at end production.
 Stop
The Stop mode is used to shut-down the freezer at the end of production.
 CIP
The CIP mode is used to clean the freezer after production.
 Control Loop Description
Mix Flow Control
The operator enters the desired mix flow rate in gph or LPH.
The mag-flow meter monitors the mix flow and the PLC automatically varies the
speed of the mix pump to maintain the desired flow rate.

Overrun Air Control

The operator enters the desired overrun percentage.
The PLC uses the signal from the mag-flow meter and overrun setpoint to
determine the correct amount of air.
The PLC then sends a signal to the air mass controller for that amount of air. In
turn the air mass controller than meters the correct amount of overrun air in to the
flow of mix.
 Control Loop Description
(continued)
Viscosity Control
Motor Load
The operator enters the desired viscosity percentage.
A current or watt transducer monitors the dasher motor load and the PLC automatically
throttles the refrigeration back pressure valve to maintain the proper viscosity setpoint.
Temperature
The operator enters the desired product temperature.
An RTD monitors the product temperature and the PLC automatically throttles the
refrigeration back pressure valve to maintain the proper temperature setpoint.

Cylinder Pressure Control (automatic)

Product Pump
• The operator enters the desired cylinder pressure.
• A pressure transducer is used to measure the actual pressure in the freezing cylinder.
• The PLC automatically varies the speed of the product pump to maintain the desired cylinder
pressure.
Product Hold Back Valve
 The operator enters the desired cylinder pressure.
• A pressure transducer is used to measure the actual pressure in the freezing cylinder.
• The PLC uses this pressure value to control the cylinder pressure by varying the air pressure
to the product hold back valve.
 Safety
Potential Hazards
• Mechanical
• Dashers - removal and installation, blades
• Pumps
• Electrical
• Control voltage
• Power voltage
• Wet environment
• Refrigerant
• Ammonia or freon
• Pressure
• Refrigerant relief valves
• Product
• Air
Recommendations

• Use lockout/ tagout whenever possible

• Keep panels, doors (gaskets), guards in good condition

 Allen-Bradley Style Screens
for Cherry-Burrell & Crepaco Freezers
 Main Menu

• To activate the color touch screen

press any button image on the
screen face.
• Very little pressure is required for
activation.
• The screen can perform only one
operation at a time. All screens
can be located from the
“PRODUCTION SCREEN” screen.
• The “PRODUCTION SCREEN”
screen is shown on the right.
 Sanitize Mode

The Sanitize mode is used to sanitize

the freezer prior to starting production.
Follow these steps to sanitize the
freezer:

• Select the Sanitize mode by pressing

“Sanitize” button on the Main Menu
screen.
• You will be prompted to press the “Start”
button to start the sanitize cycle.
• Press the “Stop” button to end the
sanitize cycle.
 Fast-Fill or Quick-Fill Mode

Fast-Fill mode is used to flood the freezing

cylinder with pure mix, after sanitize is complete.
Fast-Filling the freezing cylinder forces out any
remaining sanitizing solution from the freezing
cylinder and floods the cylinder with pure mix to
start the freezing process. Follow these steps to
fast-fill the freezing cylinder:

• Select the Fast-Fill mode by pressing

“Fast-Fill” button on the Main Menu screen.
• To select the fast-fill press “Select”
• You will be prompted to press the “Start”
button to start the fill cycle.
• When pure mix flows from the freezing
cylinder press “Run”, which automatically
starts the run mode.
• Or press the “Stop” button to end the fill
cycle.
 Production

The operator must enter the following

desired freezer operating parameters
before running production:

• Mix flow rate

• Overrun air %
• Product viscosity or Temp
• Cylinder pressure

Follow these steps to enter the setpoints

from the information menu:

• Press the white area below the graph for

large changes or the arrow up/down keys.
• To enter the desired setpoint press the
“Enter Setpoint” button under the desired
parameter and a pop-up number pad will
appear.
• Enter the desired setpoint using the
number buttons follow by pressing the
return arrow button.
 Run Mode

The Run mode is used to produce the

finished product. The run mode can be
started automatically from the Fast-Fill
mode by pressing “Run” when the cylinder
is full of pure mix or going to the following
from the Run screen:

• Select the Run mode by pressing “Run”

button.

• To select the run press “Select” – the

“Start” will flash.

• Press this “Start” button to start cycle.

• Press the “Stop” button to end the run

cycle.
 Recipe Feature

The recipe data menu can be accessed

from either the information or run screens
by pressing the “Recipe” button.
 Recipe Feature
(continued)

Follow these steps to create a product recipe:

• Select a blank recipe number

• Press the “Recipe Name” button
• An alphanumerical keyboard will be displayed
• Enter the desired product name using this keyboard
• Press “Enter”
• Press “Recipe Data” to return to the recipe data
screen
• The operating parameters can be entered by either of
the following methods.
• Method #1- Enter each of the freezer operating
parameters individually by pressing that
parameter and entering the desired value (a
numeric keypad will pop-up for entry).
• Method #2- Press the “Capture SP” button to
load all of the parameters, when the desired
product is being produced.
• Press the “Save Recipe” button to save the recipe.
 Recipe Feature
(continued)
Either of the two following methods
can be used to recall and load a
recipe:

• Scrolling the recipe list by pressing

the “Next” and “Previous” until the
desired recipe is found and than
pressing the “Transfer SP” button
to installed the desired operating
parameters.

• Selecting the desired product

recipe from the stored recipe list by
first pressing the “Recipe Sel.”
button to display the list, than
selecting the recipe by number and
returning to the recipe data screen.

• Press the “Transfer SP” button

when the desired product recipe is
displayed.
 Purge or Flush Mode

The “Purge” mode is used to flush the freezer

between flavor changes and at the end of the
production run. Follow these steps to purge
the freezer:

• Put water in mix supply tank.

• Select the Purge mode by pressing “Purge”

button on the Main Menu screen.

• To select the purge cycle press “Select”

• You will be prompted to press the “Start”

button to start the purge cycle.

• Press the “Stop” button to end the purge cycle.

 CIP Mode

The “CIP” mode is used to clean the

freezer after production. Follow these
steps to CIP the freezer:

• Connect any need lines or piping.

• Select the CIP mode by pressing

“CIP” button on the Main Menu
screen.

• To select the CIP cycle press “Select”

• You will be prompted to press the

“Start” button to start the CIP cycle.

• The CIP will automatic stop when the

CIP preset as timed out or press the
“Stop” button to end the CIP cycle.
The setup menu is used to access the
cylinder manual, ingredient feeder test, Setup 1
cylinder pump down and setup
screens.
 Setup Screen 2

The setup screen is used to select

the following:

• Tuning
• Pumpdown

• CIP total time, time on and time off

• Reset of cylinder hour meters

 Pump Down Screen

The cylinder pump screen is used to pump

down (evacuate) the refrigerant from the
freezer. Follow these steps to pump down
the freezer:

• Close the liquid and hot gas hand shut-off

valves.

• Do not close the suction return shutoff valve.

• To select the pump down press “Select”

• You will be prompted to press the “Start”

button to start the pump down.
The manual screen is used to manual force the
digital and analog outputs. Pressing the
“Enable” button at the lower right hand corner
of the screen activates the manual screen. Manual Screen
The cylinder manual screen is shown to the
right.
Check Valves
MIMIC Screen
Refrigeration Valve
Pressure Transducer
EXOR Style Screens for Crepaco Freezers
 Screen Operation
EXOR

The WS automatic freezer utilizes a

color touch screen operator
interface. The “main menu” screen
is shown. Simply press the high-
lighted button to the select the
desired function.

Example
• Press “Product Menu” to access
the the recipe screen.
• Press “Production” to access the
production or run screen.
• Press “Cleaning” to access the CIP
screen.
 Screen Operation
EXOR (continued)

• Product recipes can be created,

stored and retrieved from the
“Product Menu” screen.
• The operator can up load the
current freezer operating
parameters and save them
under a product name creating
a product recipe.
• That recipe can be recalled and
down loaded in to the freezer at
a later time.
 Screen Operation
EXOR (continued)

• The “Production” screen is used run

production.
• The freezing barrel is filled with mix.
• The freezing cycle is started.
• The freezer automatically goes from
the freeze cycle to the production
mode.
• The actual mix flow rate, overrun air
percentage, motor load and cylinder
pressure can be monitored and the
setpoint adjusted from this screen.
• The production mode can be placed
in “Hold” or “Stop”.
• The freezer can be flushed at the
end of a run from this screen.
 Screen Operation
EXOR (continued)

• The “Cleaning” screen is used to

either sanitize or CIP the freezer.
• The “Cleaning Setup” screen can be
accessed from this screen.
• The sanitize or CIP cycle is started,
placed in “Hold” and stopped from
this screen.
 Screen Operation
EXOR (continued)

• The “Mimic” screen displays the

entire freezing process starting at
the customer’s supply pump to the
exit of finished product from the
product pump.
• The status of the control signals and
the actual measured values for the
following is displayed:
• Mix temperature
• Mix flow rate
• Cylinder pressure
• Product temperature
 PLC Setup
EXOR (continued)

• The the following can be selected

from the “PLC Setup” screen:
• Type of pressure transducer
• Type of mix flow control
• Air flow control

• The “PLC Initialization” can be

accessed from this screen.
 PLC Initialization
EXOR (continued)

• The PLC is initialized for the

particular freezer from the “PLC
Initialization” screen.
• All data stored in the PLC can be
saved by pressing the “Save All”
button in the Save All PLC Data
section of the screen.
• The PLC data can be restored after
a PLC program update by pressing
the “Update PLC Program” button.
• The PLC data can be simply
restored by pressing the “Load All”
button.
 Control Loop Tuning
EXOR (continued)

• The “Mix Flowrate Tuning” screen is

used to tune the mix flow PID
control loop.
• The proportional band, integral time
and derivative time values can be
tuned from this screen.
• These values effect the response
and stability mix pump.
 Control Loop Tuning
EXOR (continued)

• The “Motor Load Tuning” screen is

used to tune the viscosity PID
control loop.
• The proportional band, integral time
and derivative time values can be
tuned from this screen.
• These values effect the response
and stability refrigeration back
pressure valve.
 Control Loop Tuning
EXOR (continued)

• The “Product Temperature Tuning” screen is

used to tune the temperature PID control loop.
• The proportional band, integral time and
derivative time values can be tuned from this
screen.
• These values effect the response and stability
refrigeration back pressure valve.
 Control Loop Tuning
EXOR (continued)

• The “Cylinder Pressure Tuning” screen is used

to tune the cylinder pressure PID control loop.
• The proportional band, integral time and
derivative time values can be tuned from this
screen.
• These values effect the response and stability
product pump.
 Calibration
EXOR (continued)

• The “Calibration” screen maximum values

for the air flow #1, air flow #2, motor load,
cylinder pressure, mix temperature and
product temperature.
• The “Mix Flow Calibration” screen is
accessed from this screen.
 Calibration
EXOR (continued)

• The “Mix Flowrate Calibration” screen allows

maximum and minimum mix flow rates with
corresponding pump speed percentages to be
entered, which allows the linearization mix
flow.
 Diagnostics
EXOR (continued)

Test Screen
• The status of the digital and analog inputs
can monitored from the “test” screen.
• All of the digital outputs can be forced on or
off from this screen.
• All of the analog can be simulated form this
screen.
Screen Operation
• Press the “start” button to enable the
outputs.
• Toggle the “on/off” button to the digital
output status.
• Press the numeric display at the right of the
analog output to enter the desired output
value.
• The name of the output selected will be
display at bottom of the screen.
• Press the “stop” button to disable the
outputs.
Question & Answer
Period