Tetra Pak's Hoyer DeepBlue system for low temperature ice cream has revealed a window of opportunity for cost effective new product development.

Microform technology means the ice cream is not only smoother in texture and creamier in taste compared to traditional products, but it is also ideal for shaping. This is the result of the cold kneading and freezing process, exclusive to Tetra Pak, it claims. Microscopic ice crystals and air bubbles are then created forming a fine-structured ice cream. The product is then cooled down to between -12°C and -15°C and becomes viscous. This makes the ice cream perfect for moulding.

The Hoyer DeepBlue technique allows higher margins by reducing the amount of expensive ingredients, such as cream fat or butterfat, that need to be used. Alternatively, costly ingredients can be replaced by cheaper vegetable fats.

The firm claims that the system also saves money with shorter throughput times, fewer product transfers, economical space requirement and improved hygiene.

Tetra Pak manager for component sales, Alan Stack, says: "Overall, the new process allows the creation of healthier products, raising the potential for increased consumer spending on ice cream."

Tetra Pak is launching two Hoyer DeepBlue complete production lines: one for filling cups and containers; and the other for extruding between sandwich biscuits.