A simple guide to using sinusoidal pumps in the confectionery industry

MasoSine in confectionary manufactureWhat type of pump is best suited to confectionery production?

MasoSine sinusoidal pumps have become the de facto standard for handling challenging media such as chocolate and caramel – as well as the delicate ingredients used in inclusions (products such as raisins, marshmallow, dried fruits and biscuit), offering a low shear, gentle pumping action.

What are the differentiating features of MasoSine pumps?

The MasoSine exclusive single shaft and sinusoidal rotor are the centerpieces of an innovative, simple design. With the shaft and rotor there is no need for the complex timing gears and multiple seals found on conventional rotary lobe pumps, for example. MasoSine pumps produce powerful suction (up to 0.85 bar), but with low shear and gentle transfer capabilities.

Will a MasoSine pump damage inclusions and particulates?

Benefiting from large pumping chambers and the gentle wave action of the sinusoidal rotor, the low shear and gentle action of a MasoSine Pump is unrivalled in its ability to preserve and maintain the integrity of solids, as well as highly viscous bases like caramel and chocolate. Specific pump model selection is dependent on the maximum size of the solids, viscosity, pressure and flow rate.

What about handling different viscosities?

MasoSine pumps are able to cope with viscosities that vary by up to 8 million centipoise, ensuring there is almost no impact on end product integrity and that the packaged product looks appealing. What’s more, the superior viscous handling characteristics mean these ingredients are no problem for MasoSine pumps.

A good example is in the production of caramel, which is a challenge for most pump technologies because of the viscosity issues. This can be seen at Kinnerton Confectionery where we installed a Masosine SPS 200 pump. With a capacity up to 99 m³ per hour and pressures up to 15 bar, the SPS series is ideal for viscous applications such as caramel, gelatine and glucose.

Is it possible to pump sweet spreads and chocolate?

Yes – viscous media like chocolate or even chocolate spread can be transferred without any of the problems associated with alternative pump types. For example at Kessko in Germany, a MasoSine pump transfers two tonnes of hazelnut spread (containing soft solids) – every hour.

The sinusoidal design of the rotor creates four chambers with each turn, through which the sweet spread is pumped from the inlet port to the higher-pressure discharge port. The pumphead gate prevents any liquid from 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 perfect for pumping liquids containing soft solids or viscous media with almost zero pulsation and lowest NPSHR/NIPR to reduce the risk of running the pump under cavitation.

What are the benefits of low shear?

The smooth, undulating contour of the unique MasoSine pump rotor transports confectionery blends through the pump whilst maintaining the product’s integrity, viscosity profile, texture, colouration and value – even at high flows.

Do MasoSine pumps offer hygienic handling?

Certification and standards are important and correct pump choice will 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. Our own MasoSine pumps meet stringent levels of certification such as FDA or EG 1935 standards as well as 3A and EHEDG depending on customers demand.

Is pulsation an issue with MasoSine technology?

The single rotor design of MasoSine pumps maintains constant volumetric displacement throughout the pumping cycle, providing a smooth and consistent flow profile without the pulsation spikes associated typically with rotary pumps.

 

By selecting a MasoSine pump – will I see a return on my investment? 

Yes! We work closely with customers to demonstrate how our positive displacement pumps - which are low shear, low maintenance and energy efficient, especially with highly viscous products - can deliver significant process efficiencies over the lifetime of the equipment. This ensures a swift return on investment and impressive TCO (total cost of ownership) characteristics.

How do MasoSine pumps compare to other PD pumps?

Other positive displacement pumps like AODD (air operated double diaphragm) pumps, damage the product by pumping it through several one-way valves. Additionally, AODD pumps increase energy consumption in the form of electrically generated compressed air.

Lobe pumps affect the product by shearing and tearing, reducing NPSHR/NIPR and in turn increasing the risk of cavitation. Furthermore lobe pumps have two shafts and two sealing systems, both with potential to fail in operation with viscous products.

As explained above, MasoSine sinusoidal pumps move the product gently through the pump from suction to discharge, therefore handling within the pump is minimal, irrespective of viscosity. To prove that our pumps are virtually unaffected by increasing viscosity, we have created a set of flow/viscosity versus energy requirement performance graphs known as Mee curves.

The Mee curves demonstrate that in viscous fluid applications, smaller motor drives requiring less power are required, in turn saving energy, so reducing your carbon dioxide output. Furthermore energy savings end up in reduced manufacturing costs of your product.

How can the wrong pump affect products?

An incorrectly specified pump can lead to frequent breakdowns, downtime and expensive delays in production. All of this has a huge impact on the bottom line.  However, it is product integrity which is most critical to food manufacturers. The wrong choice of pump can cause damage to the product which ultimately affects customer relationships and supermarket contracts. 

Are all types of pump fit for purpose?

The short answer is ‘no’!  However, by selecting a correctly specified positive displacement pump (our experienced applications engineers can help), it is possible to virtually eliminate damage caused by impellers, vanes, lobes or valves.

For those who remain unconvinced, we now help lower any commercial risk though free, on-site trials across the full range of our pumps.

Is there ever a case for ‘cheapest is best’?

The market is very cost conscious and when times get tough there is a tendency for our less well-informed customers to fall into the trap of ‘cheapest is best’.  This is not always the right solution for the application. 

It is important to look at overall product performance, reliability and suitability for the application. There's no point in buying a cheap product if it ultimately ’costs’ more in terms of maintenance, installation or indeed integration into a machine or system.

Can energy bills be reduced by using a MasoSine pump?  

Yes, as mentioned earlier, our Mee curves demonstrate that in viscous fluid applications, smaller motor drives requiring less power are required (sometimes up to 50 per cent less energy is used). We will be publishing a white paper on this topic later in 2015.

Is it possible to reduce maintenance?

MasoSine pumps are simple, fast and economic to maintain thanks to their one rotor, one shaft, one seal concept. They have been designed to be fully maintainable in the field without the need for skilled labour. What’s more, parts are fully interchangeable between pumps, and overhauls can be performed inline within minutes, bringing the pump back to ‘as new’ condition. Gone are the costly repairs associated with sending pumps back to the factory for rebuild.

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