Overrun as a Spec: Engineering Texture and COGS in Infused Frozen Desserts

In the rush to diversify edible and wellness SKUs, the leap from gummies to frozen infused desserts—gelato, ice cream, sorbet—demands a new level of engineering. Unlike traditional confections, the microstructure of a frozen dessert governs not just its mouthfeel, but also its cost per serving, cannabinoid distribution, and compliance profile. The food science term for this core variable—overrun—is moving from an afterthought to a data-backed spec that shapes both formulation and finance.

Why Overrun Matters: Texture, Yield, and Dose Consistency

Overrun quantifies the percentage of air incorporated into a frozen dessert during batch freezing. In technical terms, it's calculated as:

% Overrun = (Volume of finished dessert – Volume of original mix) / Volume of original mix x 100%

For a product team, this metric acts as a lever on three fronts:

• Texture and eating quality: Higher overrun means a lighter, creamier bite and increased scoopability; lower overrun delivers intense, dense, chewy gelato.
• Ingredient cost per serving: More air equals more finished units from the same base mix, reducing COGS. But aggressive overrun can dilute flavor or, in the case of infused products, unevenly distribute actives.
• Dosage accuracy: Mechanical control of overrun and mixing is critical to ensure cannabinoids or bioactives remain consistent throughout production and into packaging.

Typical Overrun Ranges by Style

• American ice cream: 80–100% (FDA legal maximum is usually 100%; ultra-premium can be as low as 20–60%)
• Gelato: 20–40% (gelato is typically much denser and more flavor-forward)
• Soft serve/whipped frozen desserts: Up to 100%+

Careful calibration is vital. For example, a gelato with only 25% overrun is about twice as dense (and costly per ounce) as a commodity ice cream at 80%. Getting this wrong throws off not only margin forecasts, but also dosing for functional ingredients.

See an overrun calculation demo and further reading at Ice Cream Technology e-Book and Finamac Blog.

Pasteurization, Shear, and Crystal Control: Engineering Clean Texture

Combination batch freezers—like the Coldelite Compacta Vario 12 Elite—have transformed the field, providing precise control over:

• Pasteurization cycles: For food safety, pasteurization profiles must be validated and recorded. Typical benchmarks:
  • Gelato: 85°C (185°F) with rapid cooling to 4°C
  • Ice cream: 69°C (155°F) for 30 minutes (low-temperature, long-time)
• Shear rate & agitation: Adjustable beater speed enables process engineers to tune the degree of shear, directly influencing air incorporation, fat agglomeration, and crystal size—all fundamental to stable texture and even active distribution.
• Chilling profile (pull temperature): Rapid freezing locks in microstructure and prevents large ice crystals (a common defect in poorly executed infusions).

Choosing machines with programmable cycles, built-in sensors, and automated CIP (clean-in-place) capability lets operators lock in performance batch to batch and maintain audit-ready HACCP records.

Cleaning, Validation & Allergen Control

With edible plants running multiple SKUs—some allergen-free, some dairy, some peanut, some infused—the ability to validate cleaning and changeover between runs is a food safety prerequisite. HACCP documentation and Standard Sanitation Operating Procedures (SSOPs) serve as the backbone for regulatory compliance. Key elements include:

• Pre- and post-batch swabbing to verify allergen removal (protein, peanut, gluten, etc.)
• Documented cleaning protocols and logs specifying detergent, cycle time, and verification methods (visual/pH/ATP test)
• Product contact zone isolation (gaskets, valves, pipework) for multi-allergen facilities
• Equipment designs that support tool-free and effective disassembly and inspection

For more on best practices: Solenis Best Practice Standard Sanitation and CUPhD Food Establishment Guidance PDF.

Process Monitoring: Batch Records, Sensors, and Audit Readiness

As consumer, retailer, and auditor expectations rise, real-time process monitoring is now standard. Modern combo freezers:

• Store time/temp, speed, and overrun data for every batch
• Offer programmable production recipes and lock user-levels (GMP-adjacent)
• Provide download/export of HACCP records and batch histories for every step
• Enable remote/IoT oversight and early warnings on critical control point (CCP) deviation

This traceability is invaluable for:

• Regulatory audits (Board of Health, FDA, brand partners)
• Internal QA trending (texture, dose, allergen clearance over time)
• Demonstrating due diligence in case of consumer complaint or recall

Packaging: Weight Stability & Accuracy at Low Temps

Weight stability gets trickier at frozen storage temperatures: water migration, packaging brittleness, and sublimation can impact both label accuracy and consumer experience. Key tactics:

• Use impact-resistant, cold-stable plastics (like APET with modifiers); source
• Calibrate NTEP-certified filling/weighing systems at operating temperature
• Record weight checks in batch QC docs as part of the HACCP framework

Equipment Price Bands: New vs. Refurb

Investment outlays span the gamut for batch freezers—new, top-end combination freezers start around $30,000 and up, while basic or used models can be sourced from $7,000–$14,500 depending on production size and feature set. For fast-changing SKUs or facilities scaling up, the right used/refurb line can cut ramp-up budgets by half. See price discussion.

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Urth & Fyre: Batch Control, Commissioning, Sanitation SOPs

Urth & Fyre supports edible and frozen wellness manufacturers with:

• Combo pasteurize-and-freeze batch systems—including commissioning and training
• SOP drafting for cleaning, allergen/sanitation, and product changeovers
• Ongoing compliance and workflow consulting, from overrun optimization to QC logging

Learn more about the equipment we recommend for process-controlled frozen dessert production—like the Coldelite Compacta Vario 12 Elite Batch Freezer—and how we help get you audit-ready from day one.

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Ready to dial in overrun, texture, and compliance for your next frozen SKU? Explore our listings and consulting services to level-up your lab’s capability—whether launching new products or optimizing your facility for volume and audit-proofing.