Sine pumps make light work of
sticky situations
Confectionary products are
arguably among the most challenging when it comes to pumping operations. The
inherently viscous nature of substances such as chocolate, caramel, fondant,
thick cream, syrups and liquid sugar present confectionary production engineers
with more than a dilemma or two when it comes to pump selection: after all,
getting it wrong can lead to a myriad of problems that include downtime and
repair or replacement, and all the associated costs these bring.
The trend being adopted by increasing
numbers of confectionary manufacturers is to opt for positive displacement pump
technology rather than traditional choices such as gear pumps, for example.
Why? Well, the gentle and low shear product handling capability of pumps such
as MasoSine models from Watson-Marlow provide important benefits when
transferring or moving viscous confectionary. These pumps comprise a sinusoidal
rotor that delivers a smooth, wave-like
action. In addition, the single rotor design offers very low propulsion, while
large pumping chambers help preserve and maintain product integrity.
In use, confectionary substances
are pumped from the inlet port to the higher-pressure discharge port. The rotor
– unlike on rotary lobe pumps, which have multiple shafts – is powered by just
a single motor shaft. The scraper gate prevents any liquid flowing back from
the discharge side to the lower-pressure suction side of the pump. Since the
chamber volume does not change, the system is well suited to pumping liquids
containing soft solids or viscous media, such as chocolate spread. The pump’s
ability to operate under high vacuum, virtually eliminates shaft seal problems.
EDUCATED CHOICE
While it’s true that an
incorrectly specified pump can lead to frequent breakdowns, downtime and expensive
delays in production, all of which impact on the bottom line, it is perhaps
product integrity which is most critical to confectionary manufacturers. The
wrong choice of pump can cause damage to the product which ultimately affects
customer relationships and retailer contracts.
Certain pump types are simply not
fit for purpose. The benefit of positive displacement technology is that it
avoids damage caused by impellers, vanes, lobes or valves found on common alternative
pump types.
A case in point can be seen at
Fakenham-based Kinnerton Confectionery. Here, MasoSine positive displacement
pump technology has replaced a gear pump that was damaging product on an Easter
egg production line. The company’s white chocolate Easter egg was designed to
be mixed with dried raspberry. However, when the fruit first went through the
mixer, it was squashed by the gear pump – in effect producing ‘pink’ chocolate
Easter eggs. A MasoSine MR125 completely solved the problem – even subsequently
introduced biscuit pieces were damage-free.
When inclusions such as raisins,
biscuit or cereal are present, a pump must be able to handle these solids
without blocking and causing damage. Getting this right results in a
significant improvement in batch consistency and virtually eliminates the
wastage of spoiled end-product and raw ingredients. Other factors that need to
be considered include flow rate, system pressure, product abrasiveness,
temperature, suction conditions and the size of any inclusions.
CLEAN SWEEP
While the inherent
characteristics of the MasoSine pump not only ensure there is no damage to the
product – it is also exceptionally easy to maintain and clean – vital in an
industry bound by stringent certification and standards. Hygiene is critical to
confectionary processes, where correct pump choice will help prevent bacterial
growth, batch contamination and ultimately, wasted product. Pumps need to be
capable of being cleaned-in-place (CIP), in-line and at full velocity. One solution is the new Stainless Steel Power
Frame which is now available for the SPS range of pumps. This upgrades the
range to 3A certification for CIP – but at no additional cost. The message is
clear: Confectionary plants should only buy pumps which meet strict levels of
certification such as USDA food handling, plus FDA, and NSF Class VI standards.
Ease of cleaning and maintenance
is of course all part of the total cost of ownership (TCO) equation now
familiar across many industries. It’s a common failing, particularly in tough
economic trading conditions, for the less well-informed to fall into the trap
of ‘cheapest is best’. This is far from correct in a sector such as
confectionary where it is important to look at overall product performance,
reliability and suitability for the application. There's little point in buying
a cheap product if it ultimately costs more in terms of maintenance,
installation or integration into a machine or system.
MasoSine pumps have full
steam-in-place and clean-in-place compliance and can be stripped down in less
than 10 minutes. Such factors also contribute to calculating the return on
investment figure required for almost all capital expenditure requests.
The ability to deliver low shear,
low maintenance pump solutions for confectionary production lines and ensure
accurate metering of additives, flavourings and colorants - delivers
significant process efficiencies over the lifetime of the equipment. Take the
manufacture of caramel, for example. This is a real challenge for most pump
technologies because of the viscosity issues. Gentle pumping action is a
necessity so as not to caramelise the sugars and change the colour of the
product. This process may also require a pulse-free flow which can make other
parts of the process more efficient, such as flow metering or heat exchangers,
for instance.
Again, using Kinnerton as an
example, this plant’s use of a Masosine SPS2 high flow pump with capacity up to
4m³/hr and pressures up to 15 bar makes it well matched for viscous
applications such as caramel, gelatine and glucose – ultimately providing rapid
payback.
APPLY AND RELY
In the confectionary industry, pump
reliability is clearly important. If a pump fails then a machine or entire
production line generally grinds to a halt. If the replacement part does not
arrive fast enough the financial consequences of the damage can reach untold
levels.
In order to best serve continuous
throughput and maximise productivity, the Kessko sweets and chocolate factory
in Bonn, Germany insists on only appointing suppliers capable of offering rapid
response to potential downtime situations. Kessko is a long-time user of
MasoSine SPS pumps, largely because these advanced units can run untouched for
many years without any need to replace parts. And when wearing parts such as
liners and scraper gates do eventually need changing, Kessko says the spares
are both low cost and easy to substitute. One of the critical applications for
MasoSine SPS technology at Kessko is on a high volume filling line, where the
equivalent of 2 tonnes of hazelnut spread is pumped every hour. Downtime due to
the slow arrival of spare parts is simply not an option.
Among the other benefits of sine
pump technology identified by Kessko is the absence of any foam build-up. Difficult
liquids are drawn up with powerful suction force, allowing them to flow evenly
and quickly without any foam generation.
In conclusion, confectionary
plants demand many things from their process equipment and much of this is
concerned with safeguarding reputations through maintaining product integrity. The
only pumps fit for this purpose are those able to demonstrate value for money,
low TCO, reliability, ease of maintenance, and conformity to recognised
industry standards. Increasingly, all roads are leading to sine pump
technology.
www.wmpg.co.uk
