Dear Friend
My names is Lee Williams from the Gelato-Artisan Academy in Calstock, Cornwall in the UK. I will try to assist you with your two questions, but at this point I'm not sure if you have a continuous freezer or an artisan batch freezer? This will not effect the advice here.
If you were starting from scratch today,(you say you have already got the equipment), I would suggest you simply buy a 3-in-1 Ice cream maker, such as the Icetech TP5 made by Frigogelo Italy. This type of machine would give you 10 Ltrs of both pasteurised mix and finished Ice cream every 10 mins. So 100Ltrs ph. Ready to go into your pots. Your artisan ingredients would not need to be aged as you would be using the 'shock freeze' method now empolyed by many top Artisan producers throughout the World. Aging is usually essential if you are using powders as these need to be re-hydrated and the fats can crystallise badly. Using Smimed Milk Powders as a total replacement to fresh liquid milk or using concentrated butter/vegetable fats in place of fresh dairy creams will make ageing essential, but not for a whole 12 hours, this is 'over doing it in most cases'. Because a 3-in-1 machine uses the 'shock freeze' method, the pasteurised mix at a tempurature of 80/85C is cooled super fast reduceing the mix to -7/9C in less that 6/10 mins. All the issues associated with 'fat crystallisation' normally associated with a rapid cooling phase are removed and negated. The Artisan can produce perfect stable mix into Gelato/Ice cream time after time. You would also benefit by flavouring the 'white base' whilst it's hot, this makes the flavouring addatives mix perfectly in particular nut fats and pre-paste chocolates.
If you already have the equipment you mention then we must work with that:
So may I ask why you have been told you must age for 12 hours? Why you have a ratio of Pasteurised to Ageing storage of 50/50?
Most Factories who operate a 100 Ltrs batch Pasteurisation vat would consider makeing every 2/3 hours and then moving the cooled or cooling mix over to an ageing vat. You would use the cooking vat to make only, (1-2 hours max) and move the mix to Ageing tanks. So if you did this 3 times in a working day you would need ageing/storage tanks of 300 Ltrs. If used in rotation and if some mixes were aged over night (12 hours due to 'down time') you would need extra vats. If your Pasteuriser will also hold the mix at a chill tempurature then you dont realy need the Ageing vats other than as Flavouring/holding vats to realise the Pasteuriser to do its job 'cook Ice cream'. To be clear most Artisans using fresh milk & cream as you suggest is your intention, have no need to age for more than 1-2 hours, 4 hours being a luxury in terms of 'time'. Modern combind Stabiliser/Emulsifiers need little more than this 'resting time' to do their work.
I would assume you are going to flavour your 3 batches 'cold', if so you would be starting with at least 2 x 50 Ltrs of base mix. If you draw this off in a hygienic manner into S/S pails of 10/20 Ltrs in size, you add your flavours. If you have a Batch Freezer you pour each in as needed. If you have a Continuous Freezer you pour them back into the feeding vat ( one of the 2 x 50 Ltrs tanks).
I see no reason why you shouldn't make 12 each day the only decider of all production is your finished product storage, a point usually missed by producers until it arrives!
Should you need further help or clairification please contact me through the DSc site.
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