FDS Nano Pumps Caramel With Nuts, Reducing Operating Costs & Boosting Efficiency

The Challenge: Outdated Pumps Disrupting Production

A leading American confectionery manufacturer in Italy faced serious production issues when their progressive cavity pumps failed to keep up with demand. Their popular caramel and nut ice cream bars required a hygienic, reliable, and efficient pumping solution, but their existing setup caused:

• Frequent Breakdowns: The progressive cavity pumps couldn’t sustain the heavy-duty operation (6 hours/day, 5 days/week). Production stoppages led to wasted product as ice cream bars defrosted on the line.
• Product Damage: The pumps sheared nuts too small, compromising the intended 5-7mm size for taste and texture.
• High Maintenance Costs: The pumps’ mechanical seals frequently failed, increasing maintenance downtime and costs.
• Contamination Risks: Quality control discovered rubber particles in the final product—fragments from the worn-out progressive cavity pump parts. Large batches had to be scrapped to avoid contamination.

With these issues piling up, the manufacturer needed a high-performance, hygienic pump capable of handling caramel pumping, nut transfer, and dosing with precision. Fristam Pumps provided the perfect solution!

Fristam’s Game-Changing Pumping Solution

Fristam’s hygienic pump specialists, alongside the OEM, assessed the multi-stage process and recommended two advanced twin screw pumps: the Fristam FDS1 and the FDS Nano3. To prove their effectiveness, Fristam arranged a free trial. The pumps were tested by transferring caramel with nuts between barrels. The result? No shearing, no damage—just smooth, reliable pumping.

Following the successful trial, the manufacturer ordered:

• 1 x Fristam FDS1 pump for bulk transfer.
• 6 x Fristam FDS Nano3 pumps for continuous dosing.
• 1 x Fristam FDS Nano for cooling tunnel feeding.

The Solution in Action

Stage 1 – Bulk Transfer with Fristam FDS1
The FDS1 twin screw pump transferred room-temperature caramel (5,000 cP viscosity) with 5-7mm nuts from the bulk tank to the dosing line.
Unlike progressive cavity or gear pumps, the twin screw design gently handled the caramel mix without shearing nuts or clogging.
A steady 100 L/h flow rate ensured smooth production.

Stage 2 – Precise Dosing with Six Fristam FDS Nano3 Pumps
Each dosing pump accurately delivered caramel and nuts to 24 production lines through 4 pipes.
Slow-running gear motors enabled continuous dosing, maintaining a precise 65-135 L/h flow at 3-5 bar.
No pulsation, ensuring a uniform product appearance.

Stage 3 – Low-Flow Pumping with Fristam FDS Nano
Installed under a cooking vessel, the FDS Nano hygienic dosing pump fed the cooling tunnel at an exceptionally low flow rate.
Unlike traditional gear pumps, the FDS Nano ensured hygienic, contamination-free operation.

The Results: Efficiency, Cost Savings, and Quality Improvement

The Fristam FDS twin screw pumps completely transformed the production process. The manufacturer saw:

• Increased Efficiency: Production resumed at full capacity without pump failures or delays.
• Significant Cost Reduction: Since installation, the FDS pumps have required no maintenance, eliminating the ongoing costs of mechanical seal replacements.
• Product Quality Improvement: The integrity of the caramel-nut mixture was preserved, contamination risks eliminated, and product waste reduced.

Why Fristam Pumps Are the Best Choice for Hygienic Applications

The Fristam FDS series, including the innovative FDS Nano, sets a new standard in hygienic pumping technology:

• FDS Nano (launched 2024) – a compact twin screw pump ideal for dosing, caramel transfer, and low-flow applications (5-500 L/h).
• Handles high-viscosity products (up to 1,000,000 cP) and up to 70% air entrainment.
• Achieves CIP (Clean-in-Place) speeds up to 4,000 rpm, ensuring optimal hygiene.

The manufacturer has now committed to standardizing all production lines with Fristam pumps as part of a five-year factory upgrade plan.
Searching for a Reliable Hygienic Pump? If you need a progressive cavity pump alternative or a solution for pumping nuts, caramel, dosing lines, or hygienic processing, Fristam Pumps delivers unmatched reliability, efficiency, and hygiene.Get in touch today to learn how Fristam’s twin screw and dosing pumps can revolutionize your production process!