Preparation Methods
The preparation methods for gelato depend on the type and quantity of flavors to be produced, as well as the ingredients used. Let’s explore the ideal organizational setups based on production levels.
1. Production of Gelato with Customized Recipes
For gelato requiring specific and personalized recipes, the following equipment is typically used:
- Mixer/emulsifier
- Combined machine (hot-cold) or batch freezer
- Blast freezer specifically designed for gelato (increasingly considered an essential element in any gelato lab)
This method is ideal for artisanal, made-to-order production or for unique flavors that require separate processing.
2. Production with a Limited Number of Flavors and Small Quantities
For labs focused on a small number of flavors and limited daily output, the setup may include:
- Mixer/emulsifier
- Combined machine (hot-cold) or batch freezer with pasteurizer
- Gelato-specific blast freezer
This configuration is well-suited for small gelato shops or businesses offering a curated selection of flavors with a focus on quality.
3. Medium-Scale Production with a Moderate Number of Flavors
For mid-sized production needs, the recommended setup includes:
- Mixer/emulsifier
- Pasteurizer
- Batch freezer or combined machine
- Gelato-specific blast freezer
- White base and fruit base
This setup is ideal for medium-sized gelato parlors aiming to offer a broader range of flavors while maintaining an efficient production process.
4. Large-Scale Production with a Wide Range of Flavors
For high-volume production and extensive flavor offerings, the optimal configuration includes:
- Mixer/emulsifier
- Pasteurizers
- Maturation tanks
- Batch freezers
- Gelato-specific blast freezer
- Multiple bases: white, yellow, chocolate, fruit
This setup allows for efficient large-scale production while ensuring consistent product quality.
Key ingredients such as flavoring pastes, fruit purées, sauces, and variegates (cream, chocolate, etc.) are essential across all types of production labs.
Final Considerations
Beyond equipment choices, an effective gelato lab must also pay attention to space management, proper storage of raw materials, and production logistics.
- Lab layout: The space should be designed to optimize workflow, reduce unnecessary movement, and maintain a hygienic and functional environment.
- A small/medium gelato lab should be at least 15–20 square meters, including a small storage area.
- A larger artisanal lab for more intensive production should be around 20–30 square meters, plus a storage area of at least 15–20 square meters for ingredients like sugars, pastes, and bases.
- Stock management: Keep ingredients fresh and high-quality, minimizing waste and optimizing purchasing according to demand.
- HACCP system: Implement a food safety plan appropriate for your production scale. The HACCP system is internationally recognized as the standard for food safety and is applicable worldwide. Although implementation and regulation may vary from country to country, the core principle remains the same: identifying and managing critical control points in food processing to prevent risks to human health.
Strategically organizing your gelato production lab helps improve operational efficiency, ensure an excellent final product, and optimize production costs. Equipment and preparation methods should always be tailored to the specific needs of your business, balancing quality and productivity.
Additional Equipment Recommended for All Labs:
- Electronic scale with 2–5 g accuracy
- Freezer at –18°C for frozen fruit and gelato storage
- Refrigerator at +4°C for fresh, perishable ingredients (milk, cream, fresh fruit, etc.)
- Gas burners or induction hob
- Microwave
- Countertop stand mixer (planetary mixer)
- Probe thermometer for temperature control