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COMPUTATIONAL ANALYSIS OF HEAT TRANSFER AND FLUID FLOW IN ICE POP PRODUCTION: FORCED-AIR WARMING FOR THE UNMOLDING PROCESS

Abstract:

The global demand for ice pops drives the need for innovative manufacturing processes that enhance efficiency, product quality, and sustainability. This case study addresses a quality issue in an ice pop production plant where damage occurs during the unmolding process. Using Computational Fluid Dynamics (CFD) and conjugate heat transfer simulations, the thermal design of the unmolding process for two ice pop types was optimized. Forced air warming was explored as an alternative to water flow in the unmolding spray cabin to address issues of high-water consumption and slime secretion. Optimization of airflow velocity and temperature involved redesigning nozzle geometry to enhance air delivery efficiency. Experimental validation showed an error margin between 3.5% and 5.2%, confirming the accuracy of the simulations. An optimal extraction temperature of -9 to -10°C was identified for both ice pop types. These findings provide a sustainable and effective solution to improve production quality and resource management in ice pop manufacturing.