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Phase 2 · 500 tubs/day · premium pre-pasteurized mix

Pre-Pasteurized Mix Process Flow Chart

Cold-side finishing plant. After receiving, ingredients split into parallel cold storage (top row) and dry/frozen storage (bottom row). The optional sorbet blend path runs along the bottom row and curves back up to rejoin pre-freeze QA on the main line.

Layout: Top row = main dairy processing line (01 → 02A → 03 → 05 → 06 through 15). Bottom row = parallel storage + optional sorbet blend (02B and 04). Teal arrow shows where sorbet path rejoins main line at step 05. Dashed grey lines are material feeds, not sequential steps.

Phase 2 — Premium Pre-Pasteurized Mix Manufacturing Flow 500 TUBS/DAY · PARALLEL STORAGE AFTER RECEIVING · COLD-SIDE FINISHING PLANT · SCROLL → SUPPLIER-CONTROLLED: Pasteurization + homogenization by premium dairy supplier Removed: 60-gal pasteurizer · PMO package · homogenizer · plate chiller · 5-ton crash chiller Normal flow Bottleneck Material feed Sorbet rejoins chilled mix + puree dry/frozen + packaging premium base → tank puree + syrup sorbet mix → QA inclusions tubs/lids membranes retains harden before divert 01. RECEIVING + COA Ingredients · COA · temp · lot release gate INSPECT BOL + PO Manifest, seals, lots COA attached Truck condition Equipment: Pallet jack Probe thermo ×2 TEMP 34–40°F Probe dairy mix Frozen stays frozen Reject if abused Equipment: IR thermometer ROUTE Split paths Cold → cooler Dry → shelving Frozen → freezer Equipment: COA / lot log 02A. COLD STORAGE Walk-in fridge · 6×8 min · 8×10 preferred HOLD 34–40°F Premium dairy base Opened chilled inputs Temp alarm/log Equipment: Walk-in refrigerator BUFFER 1–3 days 42.5 gal/day dairy 128 gal = 3 days Container footprint Equipment: Shelving / pallets PULL Day SKU FIFO by lot Stage production batch Allergen separation Equipment: Temp data logger 02B. DRY + FROZEN STORAGE Parallel path · packaging · inclusions · frozen DRY ≤75°F 4 NSF shelves min Tubs/lids/membranes Cases + dry inputs Equipment: NSF wire shelving FROZEN 0°F 20 cu ft min Fruit puree / mochi Bark / cookies Equipment: Ingredient freezer STAGE Per SKU Pull inclusions Verify lot codes Prep tools Equipment: Sealed bins Allergen scoops 03. DAY TANK TRANSFER 2×75-gal cold tanks preferred · 1×75 min PUMP 5–10 GPM Low-shear transfer Tri-clamp / tubing ≤10 min load Equipment: Sanitary pump HOLD 75 gal tank 47.9 gal max fill 64% fill ratio Gentle agitation Equipment: 75-gal day tank ×2 TEMP ≤40°F Refrigerated tank No hot-side cooldown Digital monitoring Equipment: Hoses / gaskets 04. SORBET BLEND Optional · puree + syrup if not buying base SYRUP 20–30 gal Sugar + stabilizer High-shear disperse Hydrate gums Equipment: Pre-blend tank PUREE Pasteurized Lilikoi / strawberry Brix + pH check Blend cold Equipment: High-shear mixer FINAL 47.9 gal Transfer to day tank Short hold if needed No dairy contact Equipment: pH meter Refractometer 05. CONDITION + QA Short hold · receiving QA replaces pasteurization HOLD 0–4 hr Dairy 0–2 hr base Flavor add 1–4 hr Sorbet 15–60 min Equipment: Day tank + agitator QA Before freeze Temp, sensory Brix/pH for sorbet Allergen clearance Equipment: QA kit RECORD Batch log Mix + inclusion lots COA linked Hold if off-spec Equipment: Batch record system 06. BATCH FREEZE Main bottleneck · B-10-class preferred LOAD 42–48 gal 22 batches/day 2.5 gal/batch 10–12 min target Equipment: B-10 batch freezer FREEZE 12.5–15 gal/hr Draw temp by SKU 35% dairy overrun 20% sorbet overrun Equipment: Backup freezer plan DISCHARGE Semi-frozen Pace to inclusion Record runtime Overrun check Equipment: Draw temp tools 07. INCLUSIONS Vibratory doser · ELF 400 · spread table DOSE ±2–5 g Graham, bark, mochi Cookies, li hing Calibrate daily Equipment: Vibratory doser RIBBON ELF 400 PB ribbon/variegate 0.25–14 oz deposits Peanut tools Equipment: Unifiller ELF 400 FOLD 20–31 sec Vibratory spread Single fold Avoid overmixing Equipment: Spread table Portion scales ×2 08. FILL 14 OZ TUBS Semi-auto filler 150–200+ tubs/hr FILL 14 oz tubs 120/hr minimum 150–200/hr preferred Net weight target Equipment: Semi-auto filler CHECK Start + routine First 5–10 tubs Every 15–30 min After adjustment Equipment: Tub check scale FLOW Keep pace B-10: 114–137/hr No warm-room wait Move to sealer Equipment: Staging bench 09. SEAL + LID + CODE Membrane TE · snap lid · TIJ coder SEAL 250–300/hr Heat-sealed membrane Tooling matches tub Seal check Equipment: Cup sealer LID Assisted Snap-on lid press Structural protect Reduce fatigue Equipment: Lid press CODE TIJ coder Lot + best-by Backup coder ready Case code if needed Equipment: ANSER U2 + backup 10. IN-PROCESS QA Weight · seal · code · visual · retains WEIGHT Every 15–30 min Precision scale Underfill quarantine Overfill adjust Equipment: Checkweigher VISUAL Seal/code Lid seated No contamination Inclusion spread Equipment: QA log / hold tags RETAIN After hardening 2 tubs/lot Same thermal history Store by lot Equipment: Retain containers 11. BLAST HARDEN Roll-in blast · ~500 lb/day · 24–30+ trays RACK 30–40 trays 16–20 tubs/tray Airflow gaps 2 racks minimum Equipment: Rolling racks ×2–3 HARDEN -20 to -30°F 437.5 lb product/day ~500 lb incl. pkg High airflow Equipment: Roll-in blast freezer TRANSFER Core target No warm case-pack Move to walk-in Protect texture Equipment: Trays ×30–40 12. FINISHED FREEZER 8×10 walk-in preferred · -10°F or colder STORE -10°F or below FIFO by SKU/lot Temp alarm/log Door discipline Equipment: Walk-in freezer BUFFER 2–5 days 42 cases/day 210 cases/week 8×10 preferred Equipment: Shelving / pallets REACH-IN 2–3 units Retains / samples Local picking Reduce door opens Equipment: Reach-in freezers 13. CASE PACK + SHIP Case after hardening · pallet jack · staging CASE After harden 12 tubs/case ~42 cases/day Mark SKU + lot Equipment: Packing table STAGE Short window Pre-cool vehicle Protect cold chain No warm dwell Equipment: Staging area SHIP Traceable Case/pallet log Temp at handoff FIFO release Equipment: Pallet jack 14. SANITATION COP + optional CIP · cold-side controls COP Parts + utensils Filler nozzles Depositor parts Drying racks Equipment: 3-comp sink / COP CIP 10–20 GPM Day tanks / pump 20–30 gal wash If closed-transfer Equipment: Portable CIP cart ALLERGEN PB last Dedicated tools Validated clean Swab if needed Equipment: ATP/allergen swabs 15. RECORDS + RELEASE COA · batch record · QA · release VERIFY Complete file COA attached Receiving temp log Batch sheet Equipment: Batch record system RELEASE QA signoff Weights OK Seal/code OK Freezer temp OK Equipment: Release checklist TRACE Lot linkage Mix + incl + pkg Retains stored Shipment record Equipment: Lot reconciliation
Top row: main dairy line. Bottom row: parallel storage + sorbet blend. Teal = sorbet rejoins. Amber = bottleneck. Dashed = material feed.

Process Walkthrough

Each step lists equipment and operating procedure

01Receiving + CoaIngredients · COA · temp · lot release gate▸
Equipment used
Pallet jack
Probe thermo ×2
IR thermometer
COA / lot log
  1. INSPECT: Manifest, seals, lots; COA attached; Truck condition.
  2. TEMP: Probe dairy mix; Frozen stays frozen; Reject if abused.
  3. ROUTE: Cold → cooler; Dry → shelving; Frozen → freezer.
02ACold StorageWalk-in fridge · 6×8 min · 8×10 preferred▸
Equipment used
Walk-in refrigerator
Shelving / pallets
Temp data logger
  1. HOLD: Premium dairy base; Opened chilled inputs; Temp alarm/log.
  2. BUFFER: 42.5 gal/day dairy; 128 gal = 3 days; Container footprint.
  3. PULL: FIFO by lot; Stage production batch; Allergen separation.
02BDry + Frozen StorageParallel path · packaging · inclusions · frozen▸
Equipment used
NSF wire shelving
Ingredient freezer
Sealed bins
Allergen scoops
  1. DRY: 4 NSF shelves min; Tubs/lids/membranes; Cases + dry inputs.
  2. FROZEN: 20 cu ft min; Fruit puree / mochi; Bark / cookies.
  3. STAGE: Pull inclusions; Verify lot codes; Prep tools.
03Day Tank Transfer2×75-gal cold tanks preferred · 1×75 min▸
Equipment used
Sanitary pump
75-gal day tank ×2
Hoses / gaskets
  1. PUMP: Low-shear transfer; Tri-clamp / tubing; ≤10 min load.
  2. HOLD: 47.9 gal max fill; 64% fill ratio; Gentle agitation.
  3. TEMP: Refrigerated tank; No hot-side cooldown; Digital monitoring.
04Sorbet BlendOptional · puree + syrup if not buying base▸
Equipment used
Pre-blend tank
High-shear mixer
pH meter
Refractometer
  1. SYRUP: Sugar + stabilizer; High-shear disperse; Hydrate gums.
  2. PUREE: Lilikoi / strawberry; Brix + pH check; Blend cold.
  3. FINAL: Transfer to day tank; Short hold if needed; No dairy contact.
05Condition + QaShort hold · receiving QA replaces pasteurization▸
Equipment used
Day tank + agitator
QA kit
Batch record system
  1. HOLD: Dairy 0–2 hr base; Flavor add 1–4 hr; Sorbet 15–60 min.
  2. QA: Temp, sensory; Brix/pH for sorbet; Allergen clearance.
  3. RECORD: Mix + inclusion lots; COA linked; Hold if off-spec.
06Batch FreezeMain bottleneck · B-10-class preferred▸
Equipment used
B-10 batch freezer
Backup freezer plan
Draw temp tools
  1. LOAD: 22 batches/day; 2.5 gal/batch; 10–12 min target.
  2. FREEZE: Draw temp by SKU; 35% dairy overrun; 20% sorbet overrun.
  3. DISCHARGE: Pace to inclusion; Record runtime; Overrun check.
07InclusionsVibratory doser · ELF 400 · spread table▸
Equipment used
Vibratory doser
Unifiller ELF 400
Spread table
Portion scales ×2
  1. DOSE: Graham, bark, mochi; Cookies, li hing; Calibrate daily.
  2. RIBBON: PB ribbon/variegate; 0.25–14 oz deposits; Peanut tools.
  3. FOLD: Vibratory spread; Single fold; Avoid overmixing.
08Fill 14 Oz TubsSemi-auto filler 150–200+ tubs/hr▸
Equipment used
Semi-auto filler
Tub check scale
Staging bench
  1. FILL: 120/hr minimum; 150–200/hr preferred; Net weight target.
  2. CHECK: First 5–10 tubs; Every 15–30 min; After adjustment.
  3. FLOW: B-10: 114–137/hr; No warm-room wait; Move to sealer.
09Seal + Lid + CodeMembrane TE · snap lid · TIJ coder▸
Equipment used
Cup sealer
Lid press
ANSER U2 + backup
  1. SEAL: Heat-sealed membrane; Tooling matches tub; Seal check.
  2. LID: Snap-on lid press; Structural protect; Reduce fatigue.
  3. CODE: Lot + best-by; Backup coder ready; Case code if needed.
10In-Process QaWeight · seal · code · visual · retains▸
Equipment used
Checkweigher
QA log / hold tags
Retain containers
  1. WEIGHT: Precision scale; Underfill quarantine; Overfill adjust.
  2. VISUAL: Lid seated; No contamination; Inclusion spread.
  3. RETAIN: 2 tubs/lot; Same thermal history; Store by lot.
11Blast HardenRoll-in blast · ~500 lb/day · 24–30+ trays▸
Equipment used
Rolling racks ×2–3
Roll-in blast freezer
Trays ×30–40
  1. RACK: 16–20 tubs/tray; Airflow gaps; 2 racks minimum.
  2. HARDEN: 437.5 lb product/day; ~500 lb incl. pkg; High airflow.
  3. TRANSFER: No warm case-pack; Move to walk-in; Protect texture.
12Finished Freezer8×10 walk-in preferred · -10°F or colder▸
Equipment used
Walk-in freezer
Shelving / pallets
Reach-in freezers
  1. STORE: FIFO by SKU/lot; Temp alarm/log; Door discipline.
  2. BUFFER: 42 cases/day; 210 cases/week; 8×10 preferred.
  3. REACH-IN: Retains / samples; Local picking; Reduce door opens.
13Case Pack + ShipCase after hardening · pallet jack · staging▸
Equipment used
Packing table
Staging area
Pallet jack
  1. CASE: 12 tubs/case; ~42 cases/day; Mark SKU + lot.
  2. STAGE: Pre-cool vehicle; Protect cold chain; No warm dwell.
  3. SHIP: Case/pallet log; Temp at handoff; FIFO release.
14SanitationCOP + optional CIP · cold-side controls▸
Equipment used
3-comp sink / COP
Portable CIP cart
ATP/allergen swabs
  1. COP: Filler nozzles; Depositor parts; Drying racks.
  2. CIP: Day tanks / pump; 20–30 gal wash; If closed-transfer.
  3. ALLERGEN: Dedicated tools; Validated clean; Swab if needed.
15Records + ReleaseCOA · batch record · QA · release▸
Equipment used
Batch record system
Release checklist
Lot reconciliation
  1. VERIFY: COA attached; Receiving temp log; Batch sheet.
  2. RELEASE: Weights OK; Seal/code OK; Freezer temp OK.
  3. TRACE: Mix + incl + pkg; Retains stored; Shipment record.

Consolidated Equipment List

All equipment by step

StepEquipment / control
Receiving + CoaPallet jack
Receiving + CoaProbe thermo ×2
Receiving + CoaIR thermometer
Receiving + CoaCOA / lot log
Cold StorageWalk-in refrigerator
Cold StorageShelving / pallets
Cold StorageTemp data logger
Dry + Frozen StorageNSF wire shelving
Dry + Frozen StorageIngredient freezer
Dry + Frozen StorageSealed bins
Dry + Frozen StorageAllergen scoops
Day Tank TransferSanitary pump
Day Tank Transfer75-gal day tank ×2
Day Tank TransferHoses / gaskets
Sorbet BlendPre-blend tank
Sorbet BlendHigh-shear mixer
Sorbet BlendpH meter
Sorbet BlendRefractometer
Condition + QaDay tank + agitator
Condition + QaQA kit
Condition + QaBatch record system
Batch FreezeB-10 batch freezer
Batch FreezeBackup freezer plan
Batch FreezeDraw temp tools
InclusionsVibratory doser
InclusionsUnifiller ELF 400
InclusionsSpread table
InclusionsPortion scales ×2
Fill 14 Oz TubsSemi-auto filler
Fill 14 Oz TubsTub check scale
Fill 14 Oz TubsStaging bench
Seal + Lid + CodeCup sealer
Seal + Lid + CodeLid press
Seal + Lid + CodeANSER U2 + backup
In-Process QaCheckweigher
In-Process QaQA log / hold tags
In-Process QaRetain containers
Blast HardenRolling racks ×2–3
Blast HardenRoll-in blast freezer
Blast HardenTrays ×30–40
Finished FreezerWalk-in freezer
Finished FreezerReach-in freezers
Case Pack + ShipPacking table
Case Pack + ShipStaging area
Sanitation3-comp sink / COP
SanitationPortable CIP cart
SanitationATP/allergen swabs
Records + ReleaseRelease checklist
Records + ReleaseLot reconciliation
Removed hot-side systems

This flow excludes the 60-gal pasteurizer, PMO package, two-stage homogenizer, rapid plate chiller, and 5-ton crash chiller.