Gentle, Reliable
Ingredient Dosing
with the FDS Nano Pump

Gentle, reliable ingredient dosing is critical in confectionery applications where product quality, consistency, and hygiene cannot be compromised. For one caramel-and-nut ice cream bar manufacturer, achieving that level of performance required moving beyond their existing pumping technology.

The Challenge:
A leading confectionery manufacturer producing caramel-and-nut ice cream bars was experiencing ongoing production and quality issues with their existing progressive cavity pumps. The application required hygienic transfer and precise dosing of a high-viscosity caramel product containing whole nuts, but the pumps in place were unable to meet performance and reliability expectations.

The processor encountered several critical challenges. The progressive cavity pumps could not withstand the demands of continuous operation, running approximately six hours per day, five days per week, resulting in frequent breakdowns and unplanned downtime. Production stoppages caused ice cream bars on the line to defrost, leading to significant product waste.

In addition, the pumps were damaging the product. Nuts intended to remain in the 5–7 mm range were being sheared, negatively impacting both texture and consumer experience. Mechanical seal failures were also common, increasing maintenance time and costs.

Most concerning, quality control inspections revealed rubber particles in the finished product originating from worn progressive cavity pump components. To avoid contamination risks, large batches of product had to be scrapped. The manufacturer needed a hygienic, reliable pumping solution capable of handling viscous caramel, transferring and dosing nuts gently, and supporting consistent, uninterrupted production.

The Solution:
Fristam worked closely with their OEM to evaluate the multi-stage process and identify a more suitable pumping technology. Based on the product characteristics and operating requirements, Fristam recommended two sizes of FDS Series twin screw pumps, for their gentle handling, hygienic design, and ability to manage both bulk transfer and precise dosing.
To validate performance, Fristam arranged a trial using an FDS1 twin screw pump and an FDS Nano3 pump to transfer caramel with nuts between barrels. The trial confirmed that the twin screw design could move the product smoothly without shearing nuts or damaging product integrity.

Following the successful trial, the manufacturer implemented the following solution:
• 1 Fristam FDS1 twin screw pump for bulk transfer
• 6 Fristam FDS Nano3 twin screw pumps for continuous dosing
• 1 Fristam FDS Nano pump for low-flow feeding to the cooling tunnel

The Solution in Operation:
Stage 1 – Bulk Transfer with FDS1
The FDS1 twin screw pump transfers room-temperature caramel with a viscosity of approximately 5,000 cP and 5–7 mm nuts from the bulk tank to the dosing system. The twin screw technology gently conveys the product without shearing solids or clogging, unlike progressive cavity or gear pumps. A steady flow rate of approximately 100 L/h ensures consistent upstream supply.

Stage 2 – Continuous Dosing with FDS Nano3
Six FDS Nano3 pumps deliver precise, continuous dosing of caramel and nuts to 24 production lines through four distribution pipes. Operating at low speeds with gear motors, the pumps maintain accurate flow rates between 65 and 135 L/h at 3–5 bar. The result is smooth, pulsation-free dosing and uniform product distribution across all lines.

Stage 3 – Low-Flow Feeding with FDS Nano
Installed beneath a cooking vessel, the FDS Nano hygienic dosing pump feeds product into the cooling tunnel at extremely low flow rates. Unlike traditional gear pumps, the FDS Nano provides contamination-free, hygienic operation while maintaining gentle product handling.
The Benefits of Fristam FDS Twin Screw Pumps:
• Gentle handling preserves nut size and product texture
• Reliable operation eliminates unplanned downtime
• No mechanical seal failures, reducing maintenance costs
• Fully hygienic design minimizes contamination risk
• Accurate, pulsation-free dosing improves product consistency
• Suitable for both bulk transfer and low-flow applications

Gentle, reliable ingredient dosing is critical in confectionery applications where product quality, consistency, and hygiene cannot be compromised. For one caramel-and-nut ice cream bar manufacturer, achieving that level of performance required moving beyond their existing pumping technology.

The Result:
With Fristam FDS twin screw pumps in place, the manufacturer restored full production capacity and eliminated the recurring failures associated with their previous pumping technology. Maintenance requirements were significantly reduced, as the pumps have required no service since installation. Product quality improved through preserved nut integrity, consistent dosing, and elimination of contamination risks, resulting in less waste and greater process confidence.
Based on these results, the manufacturer has committed to standardizing Fristam pumps across all production lines as part of a five-year factory upgrade plan.

Let’s Talk About Your Process:
If you’re looking for a progressive cavity pump alternative or need a hygienic solution for pumping caramel, nuts, or other viscous, shear-sensitive products, Fristam can help. Our FDS Series twin screw pumps, including the compact FDS Nano, are engineered for reliable performance, precise dosing, and full CIP capability in demanding food and confectionery applications.

Contact Fristam or your local authorized Fristam distributor to learn how our hygienic pumping solutions can improve efficiency, reduce maintenance, and protect product quality.