Introduction to the Tunnel Type Fully Automatic Ice Cream Cone Production Line
In the fast-evolving world of food processing and automation, cel tunnel type fully automatic ice cream cone production line stands out as a revolutionary solution. Designed for large-scale cone production, this line delivers precision, viteză, and consistent quality. It is an essential investment for manufacturers seeking to scale operations without compromising product integrity.
The market for ice cream cones has witnessed exponential growth globally, driven by both seasonal demands and the increasing popularity of ice cream-based desserts. From crisp waffle cones to delicate rolled cones, the tunnel type system offers a seamless and high-output solution for mass production.
What Is a Tunnel Type Fully Automatic Ice Cream Cone Production Line?
A tunnel type cone production line is a fully automated machine system designed to bake and shape cones in a continuous tunnel oven environment. It combines several critical stages: batter feeding, coacerea, rolling or molding, and cone collection. The entire process is controlled through advanced PLC systems, ensuring precise operation and minimal manual intervention.
Compared to rotary or semi-automatic systems, tunnel-type models are distinguished by their:
- Continuous tunnel baking system
- Higher production capacity
- Customizable mold sizes
- Fuel efficiency (usually LPG or natural gas)
- Longer operational lifespan
These systems are ideal for medium to large-scale production plants and can be integrated into complete frozen dessert production lines.
Key Components of the Tunnel Type Cone Production Line
1. Batter Mixing System
- Automatic or semi-automatic mixer
- Stainless steel tank with temperature control
- Smooth batter texture for consistent baking
2. Feeding System
- Pneumatic or servo-controlled dosing units
- Uniform batter distribution
- Minimizes wastage and ensures even cone shapes
3. Tunnel Baking Oven
- Length varies by model (from 7m to 12m+)
- Heat evenly distributed by top and bottom burners
- Advanced insulation to reduce heat loss
4. Molding or Rolling Device
- Precision molding for sugar cones, conuri de waffle, or flat cones
- Roller shapes are customizable
- Synchronizes with baking system speed
5. Cooling & Collection Conveyor
- Food-grade stainless steel mesh conveyor
- Allows cones to cool naturally before packaging
- Reduces breakage and warping
6. Control Panel
- Touchscreen PLC interface
- Recipes programmable for various cone types
- Fault alarm system and real-time diagnostics
Technical Specifications and Model Comparison Tunnel Type Fully Automatic Ice Cream Cone Production Line
| Model | Putere (KW) | Capacitate (PCS/H) | LPG Consumption (M³/H) | Machine Size (MM) | Greutate (KG) |
|---|---|---|---|---|---|
| DT-37×2 | 3.37 KW | 3500–4000 | 6–7 | 7300 × 2100 × 2000 | 4000 |
| DT-45×2 | 3.37 KW | 4000–5000 | 8–10 | 8700 × 2100 × 2000 | 5000 |
| DT-53×2 | 3.37 KW | 5000–6000 | 10–12 | 10300 × 2100 × 2100 | 5800 |
| DT-61×2 | 4.07 KW | 6000–7000 | 14–16 | 11000 × 2100 × 2000 | 6500 |
| DT-69×2 | — | 7000–7500 | 16–18 | 12300 × 2100 × 2000 | — |
Note: Capacities may vary based on cone size and recipe specifications.
Advantages of Tunnel Type Fully Automatic Ice Cream Cone Machines
1. High Production Output
The tunnel design allows for simultaneous baking across multiple molds, leading to production rates of up to 7,500 cones per hour.
2. Uniform Baking and Cone Consistency
With top and bottom LPG burners precisely calibrated, cones receive even heating throughout the baking tunnel, eliminating common issues like underbaked spots or overcooked edges.
3. Eficiența energetică
Tunnel ovens are enclosed systems that reduce heat loss. Modern models offer 15–20% fuel savings compared to open-frame alternatives.
4. Automated Process Control
PLC and HMI panels simplify operation. Recipes can be stored, system diagnostics run in real-time, and operators are alerted to faults instantly.
5. Flexible Cone Shapes and Sizes
Interchangeable molds support various cone types, including:
- Flat-bottom cones
- Pointed sugar cones
- Waffle cones
- Rolled cones (cuchuflí style)
6. Hygienic Design
All food contact surfaces are made from 304 sau 316 oţel inoxidabil, ensuring compliance with food safety standards such as HACCP, ISO, and CE certifications.
Applications and Cone Types Supported
The tunnel type fully automatic cone machine is versatile and supports a wide range of cone styles and sizes:
Supported Products:
- Mini sugar cones
- Waffle cones (flat or curled)
- Double-layer cones
- Printed cones (with branding)
- Chocolate-lined cones
Industries Served:
- Industrial ice cream manufacturers
- Franchise dessert chains
- Frozen dessert packaging companies
- Export-oriented food processors
Customization and Optional Features
Mold Customization
Each client can request customized mold dimensions (diameter, depth, texture, and tip) to match their brand needs.
Integrated Chocolate Coating
Optional chocolate-lining stations can be added at the cooling stage for cones that are pre-lined internally with chocolate.
Automatic Stacking & Packing
The system can be integrated with cone-stacking arms and flow-wrapping packing machines for end-to-end automation.
Installation, Întreţinere, and Operation Tunnel Type Fully Automatic Ice Cream Cone Production Line
Installation
- Requires flat concrete flooring
- LPG or natural gas access
- 3-phase power (custom voltages available)
Sfaturi de întreținere
- Daily cleaning of batter nozzles and baking plates
- Monthly lubrication of mechanical arms
- Quarterly inspection of LPG lines and burners
Training and After-Sales
Most manufacturers (ca DT Food Machine Co., Ltd.) provide:
- On-site installation
- Staff training
- Spare parts package
- 12–24 month warranty
Cost and Return on Investment (ROI)
Although initial investment in a tunnel type production line can range from $40,000 to over $150,000 USD, the ROI is typically realized within 6 la 12 months due to:
- Reduced labor costs
- Low product rejection rates
- High-speed production
Real-Life Applications and Client Case Studies
Case 1: Ice Cream Factory in Mexico
A client in Mexico installed a DT-53×2 model to produce 6,000 cones/hour. Their production doubled while labor dropped by 30%. ROI was achieved in just 9 months.
Case 2: Southeast Asia Exporter
A Filipino cone supplier using the DT-69×2 line increased export capacity and now serves over 12 țări.
Frequently Asked Questions (FAQ)
Q1: How many operators are needed?
Answer: Only 1–2 operators are needed per shift for tunnel models, thanks to full automation.
Q2: Can this line produce waffle cups?
Answer: Da, with mold changes and adjustment to roller shape.
Q3: What type of gas can be used?
Answer: LPG is standard, but natural gas conversions are available.
Q4: How long is the machine lifespan?
Answer: 10–15 years with regular maintenance.
Q5: Is the machine CE-certified?
Answer: Da, most manufacturers offer CE and food-grade certifications.
Workflow of the Tunnel Type Ice Cream Cone Line
To fully understand the efficiency and value of a tunnel type fully automatic ice cream cone production line, let’s walk through a complete production cycle:
Step 1: Batter Preparation
Operators mix flour, zahăr, water, oil, and other ingredients in a dedicated mixing tank. For high-volume setups, continuous mixing systems are used to feed batter directly to the dispenser.
Step 2: Automatic Dosing
The batter is automatically pumped and dosed into pre-heated mold plates. Dosing is precisely controlled to ensure every cone is uniform in thickness and weight.
Step 3: Tunnel Baking
As the mold plates enter the heated tunnel, cones are baked on both sides. The dwell time is adjusted based on cone size, texture, and recipe—typically between 60 la 90 seconds per cycle.
Step 4: Rolling or Molding
Upon exiting the tunnel, the flat baked sheets are still pliable. They are automatically rolled or pressed into the cone shape using a high-speed rolling mechanism or mold press.
Step 5: Cooling and Conveying
Freshly formed cones are soft and hot. They pass through a conveyor system with built-in air cooling to harden and stabilize their shape, preventing breakage.
Step 6: Stacking and Collection
Finished cones are stacked uniformly and transferred to packaging—manually or via integrated pick-and-place robotic arms.
Comparison with Rotary and Semi-Automatic Cone Machines
| Feature | Tunnel Type | Rotary Type | Semiautomat |
|---|---|---|---|
| Capacitatea de producție | Up to 7,500 cones/hour | 1,000–2,500 cones/hour | 500–1000 cones/hour |
| Labor Requirement | 1–2 people | 2–3 people | 3–5 people |
| Eficiența energetică | High | Medium | Low |
| Automation Level | Deplin | Medium | Low |
| Suitable For | Large factories | Medium-scale production | Small businesses/startups |
| Cone Uniformity | Excellent | Bun | Moderate |
| Mold Change Flexibility | High | Medium | Low |
| Initial Investment | High (High ROI) | Medium | Low |
Concluzie: For businesses aiming for large-scale output and consistent quality, tunnel type machines are the clear choice.
Troubleshooting and Common Issues Tunnel Type Fully Automatic Ice Cream Cone Production Line
Even the best systems may encounter issues. Below are common tunnel line problems and solutions:
| Issue | Possible Cause | Soluţie |
|---|---|---|
| Cone edges are burnt | Overheating or mold misalignment | Adjust burner temperature; check mold seals |
| Cone tips not sealed | Low batter volume or roller pressure issue | Increase batter dose; calibrate roller |
| Cones cracking after cooling | Rapid cooling or low moisture in batter | Adjust cooling fan speed; modify recipe |
| Uneven cone size | Dosing unit clogged or faulty | Clean nozzles; recalibrate dosing unit |
| Gas burner does not ignite | Blocked LPG line or valve issue | Clean line; check gas pressure and ignition |
Preventive maintenance and weekly calibration help prevent most of the above issues.
Packaging Integration and End-of-Line Automation
Automatic Cone Stacking Systems
- Aligns cones vertically in pre-defined stacks
- Reduces manual sorting
- Synchronizes with downstream packaging units
Flow Wrapping Machines
- Wraps cones in protective film (PET/PP)
- Suitable for single cones, twin packs, or family packs
- Heat-seal or cold-seal wrapping options available
Cartoning and Box Packing
- Places cones into cartons for distribution
- High-speed robotic systems optional
- Customizable for different box sizes
Quality Control Vision Systems
- Inspects each cone for defects (formă, size, cracks)
- Integrated with rejection mechanism for defective cones
Global Demand and Market Trends
The market for industrial ice cream cones is growing steadily:
- Asia-Pacific: Driven by increased consumption of frozen desserts in India, China, and Southeast Asia.
- America de Nord & Europa: Demand for premium and chocolate-lined cones is rising.
- Middle East & Africa: Expanding food service industries and export opportunities.
Market Insights (2025 Forecast):
- CAGR of 6.5% din 2022 la 2027 for ice cream cones
- Shift toward custom-branded cones
- Higher demand for eco-friendly packaging
Popular Cone Trends:
- Gluten-free cones
- Multi-color swirl cones
- Chocolate-lined waffle cones
- Printed logo cones
Top Manufacturer Spotlight: DT Food Machine Co., Ltd.
DT Food Machine Co., Ltd. is a leading global manufacturer of tunnel type fully automatic cone production lines. Known for its reliability, precision engineering, and innovation, DT has served over 70 countries worldwide.
Why Choose DT Food Machine?
- Over 20 years in food machinery design
- CE, ISO, and SGS certified
- Full technical support and training
- OEM customization available
- Excellent spare parts availability
Best-Selling Models:
- DT-53×2 – Medium-to-large scale production, energy efficient
- DT-61×2 – High-output model for large-scale exporters
- GGDCL-69×2 – The latest high-efficiency model with modular design
How to Choose the Right Model for Your Business-Tunnel Type Fully Automatic Ice Cream Cone Production Line
Choosing the correct machine depends on production goals, buget, available space, and cone type. Here’s a simple guide:
| Your Requirement | Recommended Model |
|---|---|
| New startup, 3,000–4,000 cones/hour | DT-37×2 |
| Growing manufacturer, 5,000+ cones/hour | DT-53×2 |
| High-output export, 7,000+ cones/hour | DT-69×2 |
| Energy optimization needed | DT-45×2 or DT-61×2 |
| Limited space or height constraints | DT-37×2 (Compact size) |
Always request a free machine layout consultation și product sample test before finalizing a purchase.
Final Words
The tunnel type fully automatic ice cream cone production line is an essential asset for any industrial ice cream manufacturer. With cutting-edge baking systems, customizable molds, robust engineering, and intelligent control systems, it offers unmatched efficiency and product quality.
Whether you’re scaling production for a regional brand or aiming to export cones globally, this tunnel line is your gateway to high-volume, consecvent, and profitable cone production.