Abstract

Overrun is a critical concept in soft serve ice cream production, referring to the amount of air incorporated into the product during freezing and churning. Expressed as a percentage, overrun determines the texture, taste, volume, and profitability of soft serve ice cream. This article explores the technical definition of overrun, its significance in the soft serve industry, and its associated advantages and disadvantages.

1. Introduction

Soft serve ice cream relies on a delicate balance of ingredients, freezing temperatures, and air incorporation to achieve its characteristic creamy and light texture. Overrun, the percentage increase in product volume due to added air, directly impacts the sensory qualities and economic efficiency of soft serve products. This article examines the mechanisms behind overrun and its role in both product quality and operational considerations.

2. Defining Overrun

Overrun is calculated as:

For example, a mix that doubles in volume after air incorporation has 100% overrun. In the soft serve industry, typical overruns range from 25% to 65%, depending on the machine, recipe, and desired product characteristics.

3. Mechanism of Air Incorporation

During the freezing process, air is introduced into the ice cream mix through either gravity-fed systems or air pump machines. Gravity-fed systems incorporate a fixed amount of air naturally as the mix flows into the freezing cylinder, resulting in lower overruns (25-35%). In contrast, air pump machines allow for precise control over air levels, often achieving higher overruns (35-65% or more).

4. Benefits of High Overrun

1. Economic Efficiency

   • Increased Yield: Higher overrun increases product volume, allowing operators to produce more servings from the same amount of mix. This reduces cost per serving and improves profitability.
   • Lower Raw Material Usage: Since air replaces some of the volume, less mix is consumed per serving.

2. Light and Creamy Texture

   • High overrun creates a lighter, smoother product texture, which many consumers associate with creaminess and luxury.
   • Ideal for cone servings and dipping, as the texture holds well at high overruns.

3. Improved Machine Efficiency

   • High overrun reduces the freezing load on the machine by incorporating more air, resulting in energy savings.

5. Drawbacks of High Overrun

1. Compromised Taste and Mouthfeel

   • Excessive air incorporation can dilute the flavour, making the product taste less rich.
   • Consumers may perceive high-overrun soft serve as overly airy or insubstantial.

2. Structural Instability

   • High overrun can lead to faster melting and reduced structural integrity, especially in warmer climates or during extended serving periods.

3. Limitations for Custom Products

   • High-overrun settings are less compatible with low-fat or custom recipes, which may require specific textures and densities.

6. Benefits of Low Overrun

1. Rich and Dense Texture

   • Low overrun results in a denser, more indulgent texture, which is often preferred in premium or artisanal products.
   • Ideal for products like exotic tropical fruits such as Durian or Cempedak, which come with strong aroma taste, you do need to perform the ice cream by using Low Overrun. 
     

2. Enhanced Flavour Perception

   • Lower air incorporation intensifies flavours, providing a more robust taste experience.

3. Versatility with Custom Recipes

   • Low-overrun settings accommodate recipes with unique stabilisers or alternative ingredients, such as vegan or high-fat products.

7. Drawbacks of Low Overrun

1. Higher Cost Per Serving

   • Low overrun reduces product volume, increasing the cost of raw materials per serving.

2. Operational Challenges

   • The denser product may exert more strain on soft serve machines, potentially leading to higher wear on components like motors and compressors.

3. Limited Serving Applications

   • Low-overrun soft serve may not be as visually appealing for cones or swirled presentations due to its heavier texture.

8. Balancing Overrun for Optimal Results

Operators must consider consumer preferences, production costs, and equipment capabilities when determining the ideal overrun. A balance of medium overrun (e.g., 35-50%) often provides the best compromise between texture, taste, and profitability.

Key Factors to Consider:

• Target Market: Premium products may benefit from lower overruns, while high-volume operations often prioritise higher overruns for cost efficiency.
• Machine Type: Air pump machines offer precise control over overrun, while gravity-fed systems are more limited.
• Recipe Composition: Ingredients such as fat content, stabilisers, and sweeteners impact the product's ability to hold air and maintain quality.

9. Conclusion

Overrun plays a pivotal role in the production and profitability of soft serve ice cream. While higher overruns can improve cost efficiency and create lighter textures, lower overruns enhance flavour and provide a denser, premium product. By understanding the nuances of overrun and its implications, operators can tailor their soft serve offerings to meet both consumer expectations and business goals.

 Choosing the right machine is the first step that you need to perform. From gravity feed, tube pump, airpump, gearpump model. This is directly affected your cost of good sold.