Effizienzsteigerung in der Käseproduktion mit Fristam FDS Doppelschraubenpumpe

The Challenge: Efficient, Hygienic Curd Transfer in a Modern Cheese Plant

A prominent French dairy manufacturer set out to build a cutting-edge cheese production facility in Brazil. Their vision was a fully automated plant equipped with integrated control systems to monitor and manage operations in real time. Critical to this initiative were three core objectives:

1. Operational efficiency
2. Minimal maintenance downtime
3. Gentle handling of delicate cheese curds to preserve product quality.

One of the primary challenges was finding a hygienic pump to transfer different cheese types—from stringy, high-moisture cheeses to semi-soft varieties—all from shared processing vats. The system had to protect curd integrity, handle a wide viscosity range, and remain cost-effective. For a solution, the manufacturer turned to Fristam Pumps.

The Solution: Installing the Fristam FDS-4 Twin Screw Pump

Here’s why the Fristam FDS Double Screw Pump was selected for cheese curd handling:

• A Fristam FDS protects curd structure during cheese manufacturing: delivering high flow rates while maintaining a low shear, protecting the integrity of the cheese curds.
• A a wide range of dairy product viscosities can be handled with a Fristam FDS: Designed to pump a wide range of cheese textures, from soft and stringy to semi-solid and high-moisture curds, without compromising product quality.
• Fristam FDS Double Screw Pumps have a hygienic design, ideal for dairy applications: Engineered specifically for hygienic processing environments, meeting the stringent 3-A hygiene standards required in cheese and dairy production.
• The FDS is self-priming with integrated CIP functionality: Built for Cleaning-in-Place, the FDS seamlessly integrates into automated cheese production lines, removing the need for additional CIP pumps, valves, or complex pipework. This simplifies the process design and reduces both the upfront cost and long-term running costs.
• Fristam Double Screw Pumps improve cleanability and reduces downtime: Fully CIP-compatible construction that replaces manual cleaning and ensures a thorough and repeatable internal clean to minimise contamination.

Why It Worked: Technical Performance in Dairy Environments
In production, the Fristam FDS pump operates at 400 RPM, ensuring gentle product handling with minimal shear forces. During the CIP cycle, it ramps up to 1,000 RPM, allowing for thorough internal cleaning without disassembly or external cleaning loops. This speed variation ensures effective hygiene while preserving curd structure, reducing fat loss and curd fines typically lost to whey during processing.
The outcome was a marked improvement in yield, with more curd retained in the final product. Additionally, the pump’s robust stainless-steel construction and maintenance-friendly design contributed to fewer breakdowns and lower servicing costs.

Key Benefits Delivered

• Maximised Yield: The Fristam FDS pump reduced cheese fines and fat loss, which led to greater curd retention and higher overall product recovery.
• Lower Maintenance Burden: Durable construction and simplified cleaning processes extended pump life and cut operational costs.
• Streamlined Cleaning: Built-in Cleaning-in-Place (CIP) functionality eliminated the need for additional cleaning equipment.
• Exceptional Flexibility: The FDS handled a wide range of viscosities and cheese types using the same equipment, allowing quick changeovers with minimal disruption.

The Outcome: ROI in Under a Year
By adopting the Fristam FDS-4 twin screw pump, the manufacturer realised immediate improvements in efficiency, hygiene, and yield. The integration with their automated plant control system enhanced traceability and process control, resulting in stable output and consistent quality across multiple cheese varieties.
Due to reduced downtime, lower maintenance needs, and improved product recovery, the investment paid for itself in less than 12 months—delivering long-term cost savings and production advantages.

Scientific Insight: Optimising Curd Transfer and Product Quality
Studies published in journals such as Journal of Dairy Science and LWT – Food Science and Technology highlight that curd damage and fat loss are often the result of excessive shear and agitation during transfer. Minimising shear forces during pumping is therefore critical to maintaining yield and ensuring consistent texture in cheese products.
Further research confirms that equipment designed to accommodate high-moisture and soft curds must support gentle laminar flow while offering full cleanability to meet hygiene regulations such as those defined in 3-A Sanitary Standards.