Customer Background and Core Requirements

A well-known dairy company in Saudi Arabia specializes in the production of high-end ice cream. With the significant increase in the local market demand for 1L family-sized ice cream, the existing filling equipment faced three major challenges: low efficiency, failure to meet the aseptic standards, and poor packaging consistency. In January 2024, the customer, through a friend's introduction, contacted our company and clearly stated the following requirements:
 
· Production Capacity Target: Stable filling of 600 1L aseptic cartons per hour;
· Aseptic Assurance: Food-grade aseptic filling to avoid contamination risks and comply with Saudi SFDA and international food contact material safety standards;
· Adaptability Requirements: Compatible with various ice cream formulations (including granular, low-fat, high-protein, etc.), and supports rapid model change.
 

Our Solutions: From Technical Customization to Full-Process Services

1. Customized Equipment Design: Precisely Tailored to Ice Cream Characteristics
Addressing ice cream's high viscosity, melt-prone nature, and inclusion of particles, our engineering team implements three core upgrades:
· Servo-driven Filling System: Utilizes German Siemens servo motors, combined with specially designed anti-adhesion filling nozzles, ensuring uniform filling of materials at -18℃, without dripping or bubbling, with precision controlled within ±1.5g;
· Enhanced Aseptic Environment: Integrates UHT ultra-high temperature instantaneous sterilization module + hydrogen peroxide atomization disinfection system. Before packaging, it conducts 360° non-stop sterilization on the inner walls of the carton and the filling area, maintaining an aseptic state for more than 30 minutes;
· Adaptability for Granular Materials: Expands the diameter of the filling channel to 50mm, combined with variable-frequency conveying belts, enabling smooth passage through additives with diameters of ≤8mm, avoiding blockages and downtime.
 
2. Capacity Enhancement: From "Meeting Standards" to "Exceeding Expectations"
By optimizing the layout of the conveying line (using a star-wheel transfer mechanism) and the automation control system (PLC + human-machine interface), after the equipment was actually debugged, it achieved a stable production capacity of up to 720 packages per hour, exceeding the customer's expectations by 20%, and the failure rate during continuous operation for 8 hours was less than 0.5%.
 
3. After-sales Service: Cross-timezone Technical Support
· Installation and Training: Dispatch 3 senior technicians to Saudi Arabia for on-site installation. Complete equipment debugging and operation training within 7 days, and provide an Arabic version of the operation manual;
· After-sales Guarantee: Establish a 24-hour response mechanism. Through the remote monitoring system, provide real-time assistance to customers in solving production problems.
 
Customer feedback: Efficiency increased by 40%, cost reduced by 25%
After the equipment was officially put into production in March 2024, the customer sent an email feedback stating:
"The new equipment not only meets our high-speed filling requirements for 1L ice cream, but also enables an extension of the product's shelf life from the original 3 months to 6 months, and a 60% reduction in the return rate. Currently, the monthly output has increased by 40%, labor costs have decreased by 25%, and the investment return period is expected to be shortened to 10 months."
 

Why Choose Union Machinery?

· Expert Team: End-to-end engineering support from design to commissioning.
· Global Expertise: 11+ years in food machinery, serving 50+ countries.
· Certifications: ISO9001 and CE compliant.
· Custom Solutions: Full-service support, including plant layout optimization.
· Support: 24/7 technical assistance, spare parts availability, 1-year warranty.
 

Industry Application Value

This case demonstrates the outstanding adaptability of our company's food machinery in high-temperature areas. To meet the specific needs of ice cream production enterprises, we offer:
Special solutions for temperature-sensitive products
Fully automatic filling system with carton packaging
Technology for maintaining a aseptic environment
Intelligent production data management system
 
Welcome to visit our product page to learn more about the details of the sterile filling machine technology, or contact the engineer to obtain customized solutions. We provide equipment trial runs and factory visits services for global customers to help your business grow.
 
Union Machinery， A global leader in food packaging, committed to enhancing customer competitiveness through innovative machinery. Complete export certification and 100% on-time project delivery rate.
 
Union Machinery——Make each carton of ice cream your quality guarantee card!