FDS Twin Screw Pump Transformed a High-Pressure Butter Filling Line

The Challenge: Frequent Downtime & Rising Maintenance Costs

At one of its key production sites in Brazil, a multinational dairy producer was facing persistent operational challenges on a critical filling line for milk butter with sea salt. The product required delicate handling at high viscosity (15,000 cps) and cold temperatures (3°C / 37.4°F), flowing at 6 tons per hour with discharge pressures up to 15 bar / 218 PSI.

Despite the importance of this filling line to daily production, the existing pump technology consistently fell short of operational demands. It required frequent maintenance — nearly every two weeks — which led to unplanned downtime and restricted the line’s overall capacity. Operating dangerously close to its maximum pressure threshold, the pump was at constant risk of mechanical failure. Critical plastic wear components, responsible for preventing product slip, deteriorated rapidly under the abrasive effects of salted butter, compromising both flow control and process efficiency. Additionally, the excessive wear on the pump’s scrapers increased slip rates, reduced product yield, and introduced the risk of inconsistent fill volumes. These compounding issues not only disrupted production schedules but also drove up maintenance costs and eroded plant efficiency.

The Fristam Solution: Purpose-Built for Demanding Applications

The plant’s engineering team partnered with Fristam Pumps, seeking a hygienic pumping solution that could withstand the demands of viscous, abrasive dairy applications while delivering reliability and efficiency.

Fristam recommended its FDS Twin Screw Pump, specifically configured for this process with:

• 4” inlet size to handle high flow rates
• 300 RPM operation for optimal shear control
• 7.5 kW drive to ensure sufficient power at high pressures

Why the FDS Twin Screw Pump?

• Designed for High-Viscosity, Abrasive Products — The robust stainless-steel construction and precision-machined twin screws resist wear, eliminating issues caused by salt abrasion on plastic components.
• Handles High Pressures with Ease — The FDS operates comfortably at pressures up to 15 bar, with capacity to spare, ensuring consistent performance under demanding conditions.
• Gentle, Low-Shear Product Handling — Protects the integrity of sensitive dairy products, maintaining product quality and reducing risk of damage.
• CIP/SIP-Ready with Minimal Maintenance — The hygienic design supports full clean-in-place (CIP) and sterilize-in-place (SIP) cleaning, reducing cleaning time and ensuring sanitary operation.
• Extended Run Time Without Downtime — Built to deliver long-term reliability, minimizing maintenance requirements and maximizing operational uptime.

The Benefits – Switching to the FDS pump provided:

• Increased uptime and higher production capacity
• Lower maintenance costs and fewer spare part orders
• Streamlined operations to meet growing demand
• Space savings due to the FDS’s more compact design

The Results: Maintenance Eliminated, Production Maximized

Since its installation in December 2022, the Fristam FDS Twin Screw Pump has exceeded expectations:

• No unplanned maintenance required—a significant improvement over the previous two-week maintenance cycle.
• Full production capacity achieved—the filling machine now operates at its designed throughput, with no slowdowns due to pump limitations.
• Operational savings of approximately $3,000 per month—reduced maintenance, increased uptime, and higher production efficiency have delivered rapid ROI.
• Improved process consistency and product quality—thanks to the FDS’s smooth, pulse-free flow and precise control.

This case underscores how the right pump technology can unlock real production gains and cost savings in high-demand food processing environments.

Why Choose Fristam?

With decades of experience serving the food, dairy, beverage, and pharmaceutical industries, Fristam Pumps delivers engineered solutions built for performance, durability, and hygienic design. Our pumps are designed in collaboration with process engineers to solve real-world challenges, from abrasive products to pressure-sensitive applications.

We don’t just sell pumps — we provide process solutions that maximize uptime, protect product integrity, and reduce total cost of ownership.

Discover how Fristam can help you overcome your toughest processing challenges.

Are pump maintenance issues in your process system affecting production capacities and costs? Contact Fristam or one of our Authorized Distributors to learn how our twin screw pumps can revolutionize your operations.