Case study · frozen
A Devon ice-cream producer's Union Jack lolly mould.
A three-colour lolly with a wooden stick, blast-frozen, extracted by warm-water dip, wrapped by hand. Sequenced fill drove the mould design.
Customer
A Devon ice-cream producer
A Devon ice-cream producer had a seasonal Union Jack lolly line that had, historically, been hand-scooped and hand-shaped — labour-intensive and inconsistent. They asked for a cavity mould that would let them fill sequentially in three colours, freeze in a blast cabinet, and extract clean with a stick central to every lolly.
The challenge
What we had to solve.
Sequenced multi-colour fill needs a cavity that holds each colour cleanly between fills — no bleeding, no lifting. And the stick had to land central on every lolly, with no post-freeze reseating. The cavity form had to make both happen reliably.
The approach
What we did.
We designed the cavity with defined internal steps to catch each colour boundary, and a stick-channel jig that clipped over the tray during fill so every stick landed central. Grade was a freezer-tolerant food-contact silicone, sized to the blast cabinet shelf.
Outcome
How it works now.
Line rate went from 40 lollies an hour hand-shaped to 200 an hour tray-poured, with consistent colour boundaries. The producer runs the tray through peak season and orders replacement trays as they wear.
Details
The specifics on this build.
Product
Three-colour Union Jack ice-cream lolly with wooden stick.
Route
Hand-poured food-contact silicone, cavity tray with matched stick-channel jig.
Grade
Freezer-tolerant food-contact platinum-cure silicone.
Cleandown
Hand wash, warm water, food-grade detergent.
Related services
How this fits our capability.
Silicone moulds for ice-cream, gelato and lollies
Multi-cavity food tooling for higher yield per pour
Bespoke food-mould cavities, not a catalogue
At a glance
The idea in a picture.
Where food-grade silicone is used
Swipe to see the whole diagram
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No call centre and no middlemen. When you contact TCI Culinary, you speak to the team who design, build and check your mould.
- A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
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- The same team on every jobDesign, production and aftercare come from the people you see here.
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Thomas LaneManaging Director
George PrestonDesign & Project Manager
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