6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Deluxe Ice Cream Bar Freezer Pack:

Feasibility and Costs

Stephanie Bezilla

Sarah Burch

Britt Smart

Lizalyn Smith

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Frozen Dessert Industry

• $20.3 Billion/Year Industry

• 91% U.S. Households Consume

• 50% Sold in Supermarkets; 50% Sold in Retail Outlets (Restaurants, Parlors)

• 1.6 Billion Gallons Produced/Year

• 5.7 Gallons/Year Consumed per Person

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

You Want It, We Got It Objective

• Motivation– Increase Ice Cream Bar Sales Volume– Increase Klondike Market Share in Frozen

Dessert Industry

• Problem– Feasibility of 5-6 Hour Individual Bar

Cooler– Estimate Manufacturing and Testing Cost

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Assumptions

• Klondike Deluxe Ice Cream Bar

• -5°C to 0°C Ideal Ice Cream Service Temperature

• -10°C to 0°C Typical Freezer Temperature

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Cooling Refrigerant:Ice Substitute Outperforms Ice

• Ice Substitute Equilibrium:

3 Hours at 25°C

• Ice with Salt Equilibrium:

0.5 Hour at 18 °C

Blue Ice and Water

0

5

10

15

20

25

30

35

0 50 100 150 200 250

Time (min)

Te

mp

era

ture

(d

eg

C)

Ice with Salt and Water

-15

-10

-5

0

5

10

15

20

25

30

0 5 10 15 20 25 30 35 40

Time (min)

Tem

per

atu

re (

deg

C)

*At Test Start, Ice Substitute Was Not Completely Frozen

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Test Set-Up

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Future Testing:CMC Based Gel Pack

• 6 Hour Prototype Test– Ice Cream Bar– 2 CMC Gel Packs

• Final Temperature Equal to 0°C• Heat Transfer Analysis of Final Design

(Sodium Carboxymethylcellulose)

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

5-6 Hour Cooler is Feasible

• First Law of Thermodynamics– Heat Flow Rate is Conserved

Qice = miceciceΔT = QH20 = mH20cH20ΔT

cice = 23500 J/kg-K

Tair

Tstyrofoam

Tice

Surface Convection, Qku

Styrofoam Conduction, Qk

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

5-6 Hour Cooler is Feasible• Ideal Ice Volume Calculation

Above Equation Yields Ideal Ice Volume of ~8E-5 m3 (4.9 in3)

• FreezeMore Ice Volume = 1.42E-4 m3

(8.7 in3)

t

TVc

R

TTiceiceice

k

121

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

5-6 Hour Cooler is Feasible

• Assumed No Phase Change of Ice Substitute• Ice Cream and Ice Modeled as Same

Temperature• Convection Eliminated in Cooler

Compartment (No Air Inflow)• Radiation Negligible Due to Insulation

Styrofoam (No Perceptible Outside Coolness to Container)

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Cost Analysis

• 2 Month Promotion Time – Late Spring Optimal– Cooler Attached to Each 6-Pack

• Estimated 5 Million (6-Packs) Sold During Promotion Time

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Manufacturing Cost $0.67 per Unit

Cost Per Unit Total Cost

Insulation $ 0.04 $ 200,000

Plastic Shell $0.52 $ 2,600,000

Gel Packs $0.05 $ 232,600

Labor $0.05 $ 250,000

Design NA $ 16,000

TOTAL $0.67 $ 3,298,600

* Initial Capital Investments Not Included in Cost Estimate

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

25% Growth in Sales

• 80% of People Initially Surveyed Would Use Cooler

• For Each Free Cooler, At Least One More Six-Pack Would Be Sold

• Increase in Sales by 5,000,000 Six-Packs

• Increases Klondike Sales by 25%

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

What Would You Do For A Klondike Bar?:

Recovering Cooler Cost• $0.17 Added to Six-Pack for 1 Year

Covers Manufacturing Costs

• Money Due to Promotion = Profit!!!!

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Cost/Benefit Ratio

Product PictureProduct Fun-mate6-PackerLunchmateFreezemore RatingCapacity (Qt) 2.3 4 7 0.15 0Handle 1 1 1 0 0.01Price ($) 7.99 9.99 14.99 0.00 -0.5Material Used 1 1 0.5 1 0.5Cold Pack 0 0 0 1 1

Total -3.485 -4.485 -7.235 1.5

FreezeMore Has Positive Rating!

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

FreezeMore Cooler Prototype• CMC Gel Pack

• High Density Polyethylene Plastic Outer

• Klondike Ice Cream Bar

• Styrofoam

• Rubber Seal

Ice Cream Bar

CMC Gel Pack

Insulation Styrofoam

HDPE Plastic

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

CMC Gel-Pak Benefits

• Non-Toxic– FDA Approved for Food Use

• Durable– “True Gel” (Permanent Phase Change)– No Gel Deterioration Over Time

• Efficient– 20% Greater Cooling Capacity Than Ice

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

HDPE Plastic Outer Benefits

• FDA Approved for Food Storage

• Inexpensive ($0.32/lb)

• Freezes Well (Up to -70°C)

• Low Conductivity

• Strong (Yield Strength = 21.8 MPa)

• Can be Injection Molded

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Klondike Ice Cream Bar

• Cooler Made Specifically to Size of Ice Cream Bar

• Increases Brand Loyalty

• Increases Repeat Buyer Volume

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Styrofoam Insulation Benefits

• Low Conductivity (k=0.25 W/m-K)

• Inexpensive ($0.04/unit)

• FDA Approved for Food Storage

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Conclusions• 5-6 Hour Cooler is Feasible• Estimated Manufacturing Cost per Cooler is

$0.67 – Cost Recoverable with Six-Pack Price Increase of

$0.17 for One Year

• Estimated 25% Growth in Sales• Recommended Prototype Materials

*CMC Gel Pack *HDPE Plastic Outer

*Styrofoam *Klondike Ice Cream Bar

6 June 2002 Freezemore, Inc. Freezemore@umich.edu

Questions?

FreezeMore Prototype Proposed FreezeMoreCAD Design