Cola-Hersteller pumpt fruktosereichen Maissirup und CIP mit FKL

Optimising Cleaning Solutions for Hygienic Pumping of High-Fructose Corn Syrup.

The Challenge: Efficiently Pumping High-Fructose Corn Syrup and CIP Fluids
A leading cola manufacturer needed to replace its high-fructose syrup transfer pumps with a more efficient solution—one that could seamlessly handle both product transfer and CIP cleaning.

Their current process was costly, labour intensive and wasn’t optimal for Health and Safety.

Labour Intensive Cleaning: The existing pumps required full disassembly for daily manual cleaning, losing 3-4 production hours weekly (200 annually). Skilled engineers had to perform this simple task due to the technical expertise needed for disassembly and reassembly, making it an inefficient use of their time.

Damaged Parts: Beyond the time burden, employees frequently dropped and damaged expensive pump components during reassembly, resulting in high maintenance costs.

Health & Safety Risks: Additionally, the exposure to harsh cleaning chemicals was flagged as a health & safety risk to workers, further highlighting the need for CIP-compatible pumps.

To combat these challenges, the beverage manufacturers global engineering team introduced a new hygienic pump standard declaring that ‘all newly installed pumps must be capable of transferring both product and CIP fluids without disassembly’.
However, finding a pump that could handle both high-viscosity fructose syrup and low-viscosity CIP solutions proved challenging. The high-fructose corn syrup (500 cP) required a flow rate of 190-285 litres per minute at 3-5 bar pressure, with operating temperatures of 27-32°C. In contrast, the CIP solution (1 cP) needed high-speed pumping for effective system cleaning.

The Solution: CIP-Ready Hygienic Pumping with the FKL
To overcome these challenges, the manufacturer implemented the FKL Circumferential Piston Pump [Link to product] with double mechanical seals. Designed for full Clean-in-Place functionality, this pump eliminates the need for disassembly while ensuring thorough internal cleaning, reducing maintenance time and improving operational efficiency.
Unlike other pumps that require increased internal clearances for rotor-in CIP, compromising performance, the FKL maintains tight tolerances for optimal efficiency, gentle product handling, and minimal shear—all while achieving a complete clean.

Results: Increased Productivity and Cost Savings
By upgrading to the FKL, the manufacturer achieved seamless and efficient product transfer while adhering to strict hygiene standards. Key benefits include:

• Approximately 200 hours of saved production time annually
• Significant labour cost reduction
• Elimination of €2,900 in yearly rotor replacement expenses
• Enhanced employee safety by reducing exposure to harsh chemicals

Switching to a fully CIP-compatible pump has proven to be a game-changer for food and beverage processing, delivering substantial operational and financial advantages while ensuring the highest standards of safety and product quality.

Looking for a Hygienic Pump Solution?
If your food or beverage processing facility requires high-performance, hygienic pumps capable of handling sticky, high-viscosity products like high-fructose corn syrup, while supporting CIP cleaning, we can help. Contact us today to learn more about our CIP-optimised pumps and how they can enhance your production efficiency.