What overrun percentage is typical for commercial ice cream?

Overrun is the percentage volume increase of ice cream over the mix volume due to air incorporation during freezing. Premium full-fat ice cream typically contains 20–50% overrun — less air produces a denser, creamier product. Economy ice cream for bulk/foodservice use may have higher overrun (80–100%) to reduce ingredient cost per litre. Most national food standards specify a minimum mix weight per litre of finished ice cream, which effectively limits the maximum overrun permitted. The continuous ice cream freezer's overrun setting is controlled by the back-pressure valve on the freezer — overrun is a key quality parameter that should be monitored and recorded during production.

Does small-scale ice cream production require a continuous freezer or a batch freezer?

Batch freezers (ice cream maker machines) are used in smaller-scale operations — artisanal gelato shops, small ice cream parlours, and small production units. A batch freezer produces one batch at a time; production rate is limited by the batch size and the time per batch (typically 10–20 minutes). Continuous freezers run at high throughput continuously and are the standard for commercial and industrial ice cream production. The minimum economically practical continuous freezer starts at approximately 100–200 litres per hour of finished product, which is the threshold for commercial ice cream plants. Below this scale, a batch freezer system is more appropriate and more cost-effective.

Ice Cream Production Machine Manufacturers

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Ice cream production process and equipment

Ice cream production begins with mix preparation — blending dairy ingredients (milk, cream, skim milk powder), sugars, stabilisers, emulsifiers, and flavourings in a mix tank, then pasteurising and homogenising the blend. The mix is then aged (held at low temperature to allow fat crystallisation and stabiliser hydration) before freezing. The continuous ice cream freezer is the central machine — it rapidly freezes the mix under mechanical agitation, incorporating air (overrun) to give the finished ice cream its volume and texture. The partially frozen, aerated product exits the continuous freezer at approximately -5°C and is filled or extruded into its final format (tubs, bars, sticks, cones, or sandwiches) before being hardened (blast frozen to below -18°C in a hardening tunnel or hardening room). A stick-bar line incorporates a stick insertion mechanism and moulded bar format; a tub filling line fills cups or cartons; a novelty line may include dipping in chocolate coating and wrapping.

Ice Cream Production Machine Manufacturers

Ice cream production process and equipment

Ice Cream Production Machine Manufacturers

Ice cream production process and equipment

Frequently asked questions

What overrun percentage is typical for commercial ice cream?

Does small-scale ice cream production require a continuous freezer or a batch freezer?

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