Gelato freezer utilizes precise temperature control technology (normally -14°C to -18°C) to govern the size of ice crystals within the ice cream in the 10-30 micron, creating a 60%-80% finer texture than the 50-100 micron ice crystals included within a typical ice cream machine (-22°C to -25°C). Gelateria La Carraia, an Italian leading brand, installed Carpigiani LB502 (power 3.5kW) and saw same-store sales daily increase by 30%, since melting time of the product increased from 25 minutes to 40 minutes, and incidence of customer re-purchase increased by 22%. In a 2023 paper that appeared in the journal Frozen Food Technology, Gelato freezer’s constant freezing technology reduces the standard deviation of milk fat distribution from 0.8% to 0.3%, so that each batch’s error in fat concentration is less than ±0.5%.
The most significant advantage is energy efficiency maximization, with the new Gelato freezer, such as the Taylor C709, possessing a variable frequency compressor, reducing energy consumption by 35% compared to the traditional version, with a savings of more than 1,200 euros per unit annually in electricity bills. Us chain Sweetgreen reduced the cost of producing one ball of ice cream from $0.18 to $0.11 using six ElectroFreeze Af400s (120 litres per hour) increasing gross margins by 19 per cent. From an environmental aspect, Gelato freezer with R290, e.g., Gram C90, reduces its carbon footprint by 50%, complies with EU F-Gas legislation and saves on potential fines of €9,000 per unit per year.
The automation systems significantly improve operating efficiency, with Bravilor Bonmatin’s Gelato freezer in combination with a smart scheduling system reducing manual handling time by 70%. For example, pre-set hardness sensor (error ±0.5%) automatic adjustment of freezing cycle reduces yield fluctuation from 15% to 4%. The case of the 2022 Tokyo ICE Cream Show proved that Robomart Ice-7 utilized AI to predict sales (92% accuracy), reducing raw material loss from 18% to 6%, saving $12,000 a month. In addition, modularity in the design of Gelato freezer (e.g., Nissei CJS-800) allows for easy disassembly and cleaning, reducing sanitary handling time from 45 minutes to 12 minutes and reducing bacterial contamination risk by 85%.
Being able to create product diversity, multi-chamber technology of Gelato freezer, such as Haagen-Dazs customized model, is able to treat three formulations simultaneously (temperature difference control ±0.3°C), reducing the development cycle for new products from six weeks to 10 days. Singaporean brand Udders launched its low-sugar range with Cattabriga Victory+ (25%-35% air expansion), reducing the sugar level from 22g/100g to 12g/100g and increasing its market share by 14%. In supply chain resilience, Gelato freezer with remote monitoring such as Coldelite Smart 4.0 reduces failure response time from 48 hours to 4 hours, extending equipment life by 30% and reducing maintenance costs by 25%. In the Nielsen 2024 report, the ice cream brand integrated with Gelato freezer was built with an average return (ROI) of 18-24 months, demonstrating an excellent balance between quality and cost.