At Shaw’s there are seven key steps to manufacturing our quality ice cream:

1. Blending
2. Continuous pasteurization/homogenization/cooling
3. Ageing
4. Continuous freezing
5. Packaging
6. Hardening
7. Storage and Distribution

1. Blending- During the first stage of production an ice cream mix must be made by combining the ingredients of our family recipe into a large blender where the ingredients are thoroughly mixed together. These components create a base for all the ice cream flavours that we make.

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2. Pasteurization- This next crucial step is designed ensure the quality that you have come to expect from Shaw’s Ice Cream, and to hydrate proteins and stabilizers. This is accomplished by further processing our ingredients through an HTST pasteuriser. The HTST system is equipped with a heating section, a cooling section and a regeneration section. Mix first enters the raw regeneration section where cold liquid ice cream mix is heated on one side of a plate heat exchanger while the pasteurized hot mix is cooled to as low as possible running counter current on the opposite sides of the plates. Following raw regeneration, mix enters the heating section where a temperature slightly greater than 80C is obtained. The mix is held at this temperature for 25 seconds by flowing through a series of holding tubes. Following the holding tubes mix enters the homogenizer where the mix is forced through a small orifice under suitable conditions of temperature and pressure to reduce fat globule size therefore producing a smoother more uniform product. The mix then flows back through the pasteurized side of the regeneration section and enters the cooling plates where the mix temperature is pulled down to 4C.

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3. Ageing- During this stage of superior mix production, our cooled liquid ice cream mix is held overnight in a refrigerated holding tank where a the temperature of 4 C is maintained. The ageing step is important because it allows time for the fat in the formulation to cool down and crystalize, in addition to fully hydrating proteins and poysaccharides. Ageing improves the whipping qualities of the mix and the overall body of the ice cream.

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4. Continuous Freezing- The mix is now pumped into our flavour tank where Famous flavourings are added. The mix then enters the ice cream machine where it freezes a portion of the moisture in the mix, and whips air into the semi-frozen mix. The barrels on the machine are scraped surface, tubular heat exchangers which are jacketed with a refrigerant. Mix is pumped through these barrels where rotating blades inside keep the ice scraped off the surface of the freezer. Dashers inside the machine help to whip the mix and incorporate air. The air gives the product it’s characteristic lightness, without it, ice cream would be similar to a frozen ice cube. In the matter of minutes ice cream is drawn through pipes coming out of the machine . It is at this time that we add our fabulous assortment of fruits, nuts, candy, cookies, and ripples. This is accomplished by a “fruit feeder” and/or a ripple pump where ingredients are incorporated into the flow of ice cream as it descends out the final pipe where it is packaged.

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5. Packaging- At Shaw’s we package 1, 2, 4 and 11.4 Litre containers of ice cream in a variety of Delicious flavours. All ice creams are packaged by hand and tested for quality assurance.

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6. Hardening- Once the ice cream is packaged it is immediately transferred to our hardening room where the temperature is -30C. The cold temperature, results in quicker hardening of the ice cream. When ice cream becomes solid rapidly, the smoother our product becomes, resulting in a great treat for your tongue.

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7. Storage/ Distribution- The ice cream is stored in our freezers until it is ready for distribution . Special freezer trucks deliver our famous old fashioned ice cream products around the region to ice cream shops, restaurants, candy stores, locally run grocery stores and gift shops. To discuss adding ice cream to your retail operation please Contact us.

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