Fristam FDS Increases Filling Speed of Cosmetics by 400%, Saving €185k

Cosmetics Manufacturer saves €185,000 annually, after installing FDS Double Screw Pump!

A major cosmetics manufacturer aimed to enhance production across multiple product lines, including gels, lotions, and creams. A key challenge was increasing the container fill rate from 15 units per minute to 75 units per minute during the final packaging stage. This required efficiently transferring products from totes to filler machines.

In addition to increasing flow rates, the manufacturer needed a pump capable of creating sufficient suction and lift to draw product directly from totes. With no additional static inlet pressure and the potential difficulty of top unloading, finding the right solution was challenging.

Several pump options were explored.

Initially, a competitor tried to use a circumferential piston pump, but it failed to generate the necessary suction to pull product from the totes. An air-operated diaphragm pump was then considered. While the AOD provided a stronger suction than the positive displacement pump, it could not achieve the required flow rate and its pulsing flow made it unsuitable for consistent, even dosing or handling the gentle product.

The manufacturer approached Fristam for a solution.

After reviewing the application data and considering the requirements of: high flow rates, strong suction, gentle product handling, transfer of different viscosities with one pump – the Fristam FDS Double Screw Pump was identified as the ideal choice!

To meet production demands, the customer installed two Fristam FDS size 2 pumps, each mounted onto mobile carts with variable speed drives. This setup allowed the pumps to be moved to different areas within the facility as needed. The FDS pumps’ broad operational range enabled precise adjustments to accommodate viscosities from 5,000 to 250,000 cps.

After installation, the Fristam FDS pumps exceeded expectations. They efficiently emptied totes and met the production target, significantly boosting throughput. The improved system is estimated to save the manufacturer approximately €185,000 annually in labour costs, thanks to the dramatic increase in production efficiency.

If you’re seeking to optimize production processes in the cosmetics industry, consider the advanced capabilities of the Fristam FDS double screw pump!