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Application Overview In USDA-regulated egg processing, maintaining sanitary conditions while minimizing downtime and equipment wear is critical. For one large, long-established egg processor, daily pump teardowns for cleaning had become a major source of maintenance burden, lost production time, and added cost, until they turned to Fristam for help.
The Challenge A long-established egg processor in Iowa, USA produces dried, liquid, and frozen egg products in their state-of-the-art USDA-regulated facility. Their previous positive displacement (PD) pumps, however, required daily teardown for cleaning. Constant disassembly caused wear, cavitation, and vibration, leading to frequent rebuilds, sometimes every six months, and ongoing maintenance costs. USDA inspections also required daily verification of pump cleanliness, adding labor and downtime to every shift.
When Fristam learned about the issues the processor was experiencing, they proposed replacing the existing PD pumps with Fristam FKL Series positive displacement pumps designed for full clean-in-place (CIP) operation. The response from the company president was straightforward:
“Prove to us that your pump will handle all our fluid egg products gently and efficiently and effectively clean in place to USDA standards without teardown or disassembly.”
The Solution Fristam installed an FKL-75 pump at the facility for an initial trial. With a maximum flow rate of up to 93.6 gallons per minute, the FKL-75 was well suited to the processor’s liquid egg applications while maintaining gentle, low-shear handling. The results spoke for themselves. The pump’s tight tolerances and patented balanced rotor design provided excellent suction capability, reducing cavitation and eliminating vibration across the line. It handled every product, including whole egg, salted yolk, sugar yolk, and yolk blends, gently and efficiently.
Because the FKL is fully CIPable, it required no disassembly or rotor removal for cleaning. During the CIP cycle, the pump ran with a bypass to manage excess flow, ensuring complete internal cleaning and consistent results.
After several weeks of daily USDA inspections, the FKL consistently met all cleanability standards, allowing inspections to be reduced from daily to weekly.
Based on the success of the trial, the processor expanded the installation, adding both FKL-75 and larger FKL-150 models across the facility. Ultimately, they replaced approximately 10 existing positive displacement pumps with Fristam FKL PD pumps.
The Benefits Switching to Fristam FKL pumps delivered clear, measurable improvements:
According to the company president:
“The FKL pump has eliminated virtually all vibration, which improves the life and operation of the pump, as well as other equipment in the process. It has proved to clean perfectly and drastically reduce our maintenance costs and downtime for cleaning or rebuilding.”
The Result Satisfied with the performance of the initial FKL-75 trial, the processor purchased additional FKL pumps and scaled up to FKL-150 models where higher flow was required.
“The benefits of the FKL pump have exceeded our expectations to the extent that within a year of the first install, we’ve replaced every critical process pump in our facility with a Fristam FKL.”
Fristam FKL Series positive displacement pumps help egg processors achieve superior cleanability, gentle product handling, and reduced maintenance, while eliminating the need for daily teardown and rebuild cycles.
Contact Fristam or one of our Authorized Distributors to learn how FKL pumps can improve cleanability, reliability, and operating efficiency in your process.
