Scribd
Upload
254 views4 pages

Overrun Calculations

This document discusses methods for calculating overrun percentages in ice cream production. It defines overrun as the percentage increase in volume from the original mix. Several equations are provided to calculate overrun by volume when particulates are and aren't present. The document also discusses calculating overrun by weight, mix density, target package weights, and developing an overrun table for quick reference during manufacturing.

Uploaded by

Muhammad Munirul Alam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
254 views4 pages

Overrun Calculations

This document discusses methods for calculating overrun percentages in ice cream production. It defines overrun as the percentage increase in volume from the original mix. Several equations are provided to calculate overrun by volume when particulates are and aren't present. The document also discusses calculating overrun by weight, mix density, target package weights, and developing an overrun table for quick reference during manufacturing.

Uploaded by

Muhammad Munirul Alam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 4

Overrun calculations

In looking at calculating overrun in ice cream, it is important to remember the


definition of overrun; that is, it is the % increase in volume of ice cream greater than
the amount of mix used to produce that ice cream. In other words, if you start off with
1 litre of mix and you make 1.5 litres of ice cream from that, you have increased the
volume by 50% (i.e., the overrun is 50%). Equations are as follows:

Figuring plant overrun by volume, no


particulates
% Overrun = (Vol. of ice cream - Vol. of mix used)/Vol. of mix used x 100%

Example : 500 L mix gives 980 L ice cream,


(980 - 500)/500 x 100% = 96% Overrun

80 L mix plus 10 L chocolate syrup gives 170 L chocolate ice cream,

(Note : any flavours added such as this chocolate syrup which become homogeneous
with the mix can incorporate air and are thus accounted for in this way : )

(170 - (80 + 10))/(80 + 10) x 100% = 88.8% Overrun

Figuring plant overrun by volume, with


particulates
Example : 40 L mix plus 28 L pecans gives 110 L butter pecan ice cream,

110 - 28 = 82 L actual ice cream.

% Overrun = (Vol. of ice cream - Vol. of mix used)/Vol. of mix used 


= (82 - 40)/40 x 100% = 105% 

(Note : The pecans do not incorporate air.)

Figuring package overrun by weight, no


particulates
 % Overrun = (Wt. of mix - Wt. of same vol. of ice cream )/Wt. of same vol. of ice
cream x 100%

Must know density of mix (wt. of 1 L), usually 1.09 - 1.1 kg. /L.

(see example below)

Example : If 1 L of ice cream weighs 560 g,


% Overrun = (1090 - 560)/560 x 100% = 94.6% Overrun

(Note : Figuring package overrun by weight if the ice cream has particulates in it
gives very little information because both the ratio of ice cream to particulates and
the air content of the ice cream affect the final weight.)

Figuring mix density


The density of mix can be calculated as follows: 

1 / ((% fat/100 x 1.075) + ((% T.S./100 - % Fat/100) x 0.63) + (% Water/100)) = Wt.


(kg)/ litre mix

Example - Calculate the weight per litre of mix containing 12% fat, 11% serum solids,
10% sugar, 5% corn syrup solids, 0.30% stabilizer, and 38.3% T.S.

1.0  / ((0.12 x 1.075) + ((0.383 - 0.12) x 0.63) + 0.617) = 1.096 kg/L of mix

Figuring target package weights, no


particulates
Weight of given vol. of ice cream = Wt. of same vol. of mix / (Desired overrun / 100
+ 1)

Example : Desired 90% Overrun, mix density 1.09 kg/L


net wt. of 1 L = 1.09 kg / ( 90/100 + 1) = 573.7 g

Also, density of ice cream = density of mix / (Overrun/100 + 1)

Example: Density of mix 1100 g/L,

@100% Overrun, density of ice cream = 1100 g/L / (100/100 + 1) = 550 g/L
Figuring target package weights, with
particulates
Example : Butter brickle ice cream; density of mix 1.1 kg/L; overrun in ice cream
100%; density of candy 0.748 kg/L; candy added at 9% by weight, (i.e. 9 kg to 100 kg
final product)

In 100 kg final product, we have:

9 kg of candy (or 9 kg / 0.748 kg/L = 12.0 L)

91 kg of ice cream (or 91 kg / (1.1 kg/L / (100/100 + 1)) = 165.4 L)

So, 100 kg gives a yield of 12 + 165.4 = 177.4 L

1 L weighs 100 kg / 177.4 L = 564 grams 

(Note : In many cases, ice cream of different flavours is frozen to the same weight. As
a result, overrun of actual ice cream in product varies.)

Developing an Overrun Table for Use When


Manufacturing Ice Cream
To develop an overrun table to determine overrun quickly by weight when making ice
cream, all you need is a cup with a fixed volume that is convenient for filling ice
cream into (like a steel measuring cup, for example, with a flat top that would be easy
to scrape level) and an ordinary gram balance. Then, using the equation from above,
you can calculate what the weight of the cup would be for a series of different
overruns, and then make up a table. Then when you are running ice cream, just keep
weighing the cup and checking against the table for the overrun in the cup.

% Overrun = (Wt. of mix - Wt. of same vol. of ice cream )/Wt. of same vol. of ice
cream x 100%

So, lets say your cup holds 100 mL. Fill the cup with mix and weigh it. Let's say the
net weight (minus the weight of the empty cup) is 110 g. Lets say the empty cup
weighs 30 g.
The net weight of the cup at 5% overrun would be:
.05 = (110 - x)/x, solve for x and you get 104.8, so the gross weight would be 134.8 g.

{In case your algebra is rusty, to solve for x, follow this example:
.05 = (110-x)/x
x = (110-x)/.05
x = 110/.05 - x/.05
x = 2200 - 20x
x + 20x = 2200
21x = 2200
x = 2200/21 = 104.76}

Likewise for 10%, 0.1 = (110 - x)/x, solve for x and you get 100, so the gross weight
would be 130 g.

Keep going up to 150% or so, then make a table:

Overrun%           Weight of cup + ice cream (grams)

0                              140
5                              134.8
10                            130
.
.
.
150                            74

You might also like