Precise, high-spec thermoregulators support product quality and consistency at Unilever’s Magnum ice cream facility in Gloucester 

Unilever, one of the world’s leading consumer goods companies, operates a world-class ice cream manufacturing facility in Gloucester, home to the production of the Magnum ice cream brand. The facility relies on state-of-the-art automation and highly precise process control to maintain the premium quality and consistent finish that consumers expect from the brand’s signature thick chocolate shell. 

To support the critical chocolate dipping stage of the Magnum production line, Unilever collaborated with its long-term partner, ICS Cool Energy, to deploy high-specification, food-safe temperature control technology. ICS Cool Energy supplied thermoregulator units, helping Unilever ensure precise temperature stability, maximising production uptime and process efficiency on the high-speed line.

Challenge

In food manufacturing, process temperature control is often critical to both product quality and production stability. Even small temperature fluctuations can affect consistency, cycle times and repeatability, particularly in applications where products move through tightly controlled thermal stages. 

The chocolate dipping process is one of the sensitive phases of Magnum ice cream production. To achieve the uniform thickness of the outer chocolate shell, the liquid chocolate must be maintained at a stable and precise temperature just before and during the dipping stage. 

If the temperature deviates, the viscosity of the chocolate changes. Given the high-throughput nature of the Gloucester line, temperature fluctuations can affect batch production, dragging down cycle times and impacting overall factory output. 

Unilever recognised that the line required a process-dedicated, highly reliable temperature control solution designed to the highest hygienic standards. Because the equipment operates directly within a food manufacturing environment, the units had to be constructed to withstand strict washdown regimes and comply with stringent food safety regulations.

Solution

As a trusted, long-term partner of Unilever, ICS Cool Energy was engaged to supply the temperature control solution specified to the demands of the Magnum production line. 

Following a detailed technical assessment, ICS Cool Energy recommended the i-Temp compact 18kW temperature control units (TCU) specified to match the previously supplied equipment already in operation at the site. Constructed with high-grade stainless-steel bodies, internal pipework, and fittings, the units prevent any risk of corrosion and simplify clean-in-place washdown procedures. 

The new thermoregulators have been integrated directly into the chocolate supply loop of the dipping line. They work by precisely regulating the temperature of the heat transfer fluid circulating through the jacketed pipes and vessels holding the liquid chocolate. By continuously monitoring and adjusting the thermal energy delivered to the chocolate jackets, the TCUs maintain the chocolate within a tight tolerance window. 

The units allow specific application and recipe data to be stored and saved. This built-in intelligence automatically adjusts for changes in the ambient air and central factory cooling water temperatures. As a result, a batch of chocolate produced during hot ambient conditions in August will deliver the exact same quality and consistency as one made in January.

Results

The installation of the high-specification stainless steel TCUs has reinforced the reliability of the production line, delivering the thermal precision needed to guarantee a consistent, high-quality product. The sanitary stainless-steel construction has seamlessly integrated into Unilever’s stringent hygiene protocols at Gloucester, ensuring long-term durability and trouble-free operation.

Wojciech at Unilever, said:“This is a process-critical application for us, where stable chocolate temperature is essential to the Magnum dipping line. ICS Cool Energy understood the requirement and supplied a solution that aligned with the needs of the process and the standards of the site. Having worked with them over a number of years, we value their responsiveness and their understanding of what reliable temperature control means in a manufacturing environment.”

Will Coles, Regional Sales Manager at ICS Cool Energy, commented: “In food and beverage manufacturing, temperature control is directly tied to product quality, batch consistency, and food safety. In many food processing plants, operators accept production downtime of up to 20% or more as a “necessary evil” caused by temperature instability and batch failures. By investing in dedicated, high-specification TCUs, Unilever has insulated its process from these vulnerabilities, ensuring continuous, high-efficiency throughput.”  

While the current thermoregulator configuration operates as a heat-only system, ICS Cool Energy and Unilever are already planning the next phase of operational optimisation involving adding dedicated, process-grade ICS Cool Energy chiller to the units. By linking a process chiller to the TCUs, the system will become a fully dynamic heating and cooling circuit.