Ice cream to-go - from cup filling to popsicles

Today we would like to look at different ways of distributing artisan ice cream not classically in the ice cream café or kiosk, but in alternative forms and distribution channels.

In cups and household packs, as ice-cream-on-a-stick or even via so-called vending machines. And yes, it is a business - after all, more than 80 % of German ice cream turnover is made by the industry with these forms of sales (see also our blog post "Ice Cream Facts Check Germany").

The industry is showing us how it's done: Ice cream to go is a huge business! From small 100ml or 150ml single-serving cups to 500ml stock portions to popsicles, from Häagen-Dasz to Ben & Jerry's and various niche suppliers (from organic to vegan lupine) to various own brands of food retailers. 

We tell you: The classic ice cream parlour can do that too - and with better, more artisanal, honest ice cream quality.

Cup filling

In principle, there is no need to differentiate in the recipe between ice cream for the ice cream counter and ice cream for filling into cups - the ice cream parlour does not need to change its recipes, does not need to use any other raw materials and can produce all its varieties - including any well-known "special varieties" - for filling into cups.   

However,two small peculiarities have to be taken into account: 

First of all, ice cream for filling should have a much higher air mark-up than counter ice cream - while counter ice cream rarely has more than 40-45% air mark-up, bottled ice cream should have more than 50%. Why? Bottled ice cream is usually consumed straight from the freezer at -18°C, while counter ice cream is rarely enjoyed colder than -14°C. The higher air mark-up ensures that the ice cream is more freshly churned. The higher air impact ensures that the ice cream is pleasant to eat even at -18 °C and does not become "hard as nails". An additional advantage for the ice-cream maker: he sells "more air" to the customer - and since this costs nothing, the cost of goods is reduced. This is easily achieved by taking the ice cream out of the ice cream machine at a much "warmer" temperature. However, the ice cream is then of course much more sensitive - in order to preserve the ice cream (and the air it contains!) quickly afterwards, the use of a blast freezer is indeed absolutely necessary.

The second special feature is that ice cream filled in cups must have a longer shelf life than counter ice cream - because while counter ice cream is usually consumed within a few days, filled ice cream must have a considerably longer shelf life. How can this be achieved? Firstly, by pasteurisation followed by a ripening phase of at least 6 hours, during which the binding agents stabilise the ice cream mix as best as possible. Cold production is generally not recommended for longer storage. Treating the ice cream mix with an emulsifying stick (e.g. the Carpigiani Turbomix or the Casagrande Micronizer) also "forces" the various components of the ice cream to combine better and gives the ice cream more stability.

Filling technology

Once the ice cream has been made ready for filling, the filling itself must now take place. There are basically three ways to do this:

The simplest, but most cumbersome, time-consuming and least accurate option is to simply spread the ice cream into the cups by hand using the spatula. This is suitable for first attempts, but not recommended for larger quantities on a permanent basis.

Secondly, Carpigiani offers a special filling door for the ice cream machines of the Labotronic series - if you use this door instead of the "normal" front closure, you can dispense the ice cream into the cups in portions using a lever. However, here too the dosing is done manually - an extremely high accuracy of dosing is difficult to achieve.

The ideal solution is a Special, automatic filling line - here the ice cream is filled directly from the machine into the filling hopper and from there it is filled automatically, quickly and precisely into the cups by means of an (adjustable) piston stroke - with a filling accuracy of +/- 3 % if handled correctly. But beware: a "normal" filling machine, as used e.g. in confectionery, does not work with frozen goods such as ice cream - the magic word is a special plastic for the filling piston. The price for a professional filling machine with accessories is surprisingly low and pays for itself accordingly quickly.

Regardless of the filling method, if desired, the cups can also be hygienically sealed individually in special sealing machines - a prerequisite for distribution in many food retail outlets, for example.

New, innovative distribution channels

Now that the ice cream has been produced, what are the distribution channels? 

On the one hand, there is the simple to-go or take-away distribution in your own ice cream parlour - either via an attractive freezer tower, or simply a freezer for self-service. This costs little, is simple and effective. 

Secondly, it is easy and quick to offer an ice cream delivery service - and the practical portion sizes mean that customers are sure to be happy to buy several different flavours at once. This way, the supply of delicious ice cream from your favourite ice cream parlour is always secured even in times of crisis - and the ice cream parlour continues to earn money "contactless".

Furthermore, you can now also sell your ice cream through partner shops and locations: You provide them with a freezer and sell the ice cream through the partner. In this way, you quickly generate an astonishing amount of new turnover, and with a fair calculation, both partners can earn good money with the distribution.

If you want to think a bit "bigger", then distribution via food retailers is also an option - from the big chains (EDEKA, ReWe and Co) to regional grocery shops. If you even produce organic ice cream, then organic (super) markets are of course also an option. The demands on production quantities, manufacturing processes and labelling are high - but there are technical aids such as the Calybra scale, which, in addition to automatically checking and correcting the recipes, also automatically creates the correct labels for the cups with all the necessary information (batch number, best before date, list of ingredients, nutritional values, etc.).

And lastly, an unusual option: set up vending machines at strategic points - these cost a certain amount, but they are safe, work fully automatically (insert money - select - take out sundae), cost no staff and are available 24 hours a day. All you have to do is refill and collect the money. Some of our customers already use this - you would be surprised how many young people, for example, take an ice cream with them on Saturday night after the disco...

Popsicle 

Finally, another thought for you: Who doesn't know the ice cream industry's perennial favourite, the famous Magnum? You can also make popsicles (whether in Magnum or other shapes) by hand with just a few technical aids. The easiest and most effective way is with the Fantastick moulds from Carpigiani. Here, you simply fill the ice cream mix into the silicone moulds of the matrix (these are available in different shapes), place them in the blast freezer for approx. 30 minutes and then simply pull the individual popsicles out of the moulds cleanly. 

If you then dip the ice cream blanks in a liquid glaze and perhaps even sprinkle them with small pieces of pistachio, nuts or fruit, then you have created a fine, handcrafted and high-quality alternative to the industrial product. You can then sell the "plug-in ice cream" quite simply via the display case - with ready-made ice cream inserts for the normal ice cream display cases.

Ice-To-Go - new, innovative sales channels!

So you see: there are an incredible number of ways to sell ice cream in bottled form or as a popsicle. It is not difficult, it opens up new sales opportunities for you, and it is much less dependent on the normal counter or café business.

Have we aroused your interest? Contact us - we will be happy to help you!

Your Alois Krä GmbH