Challenging Pump Applications, Meet Your Match

The ultimate guide to knowing when to use twin screw pump technology —don’t let viscosity slow you down

Knowing which hygienic pump technology is best suited for an application can make all the difference in reaching plant productivity goals. Now that Unibloc^® Hygienic Technologies (UHT) has expanded its offering to include twin screw pump technology, it’s an opportune time to understand where twin screw pumps truly excel and why certain applications practically demand their unique capabilities. As a twin screw pump manufacturer, this blog post examines which applications justify the initial investment and makes the case for using them in your most challenging applications.

Understand the twin screw pump advantages.

Twin screw pumps operate on a fundamentally different principle from other positive displacement pumps. Two precisely machined screws intermesh to create sealed cavities that gently carry product from inlet to outlet. The dynamic duo provides a smooth, continuous flow with minimal shear.

This gentle handling comes with impressive versatility. Twin screws produce consistent, nearly pulse-free flow. They're also designed for clean-in-place operations, which reduces the labor (and cost!) required per unit of pumped product.

Gooey, gunky, and glorious: twin screw pumps love a challenge.

Twin screw pumps distinguish themselves in high-viscosity applications, pumping product with up to 1,000,000 centipoise (cP) viscosity. They often outperform other pumps in high-viscosity applications, depending on the key factors for pump selection.

Nut butters, thick lotions, and cooked bean preparations represent viscosities that can overwhelm some pumps, forcing operators to reduce throughput or accept frequent maintenance.

In high-viscosity product applications, twin screw pumps deliver high flow rates and can significantly reduce, or eliminate in many applications, the need for heating systems or dilution.

Push for productivity in high-pressure applications.

Long piping runs, pipe bends, and vertical lifts increase friction losses within a pipeline system. Combined with viscous product, the friction losses can be too much for many pumps. Operators will be disappointed with a flow rate that is lower than needed to meet production targets. In the worst cases, the system will deliver almost no flow at all.

One remedy is to increase the diameter of the process piping and shorten pipe runs. However, such changes may be difficult or impossible given a plant’s layout. A better solution is a twin screw pump. Its ability to generate high discharge pressures sets it apart from other hygienic pumps.

The reason that twin screw pumps have high discharge pressure lies in their robust mechanical design and excellent hydraulic balance. They convey product with minimal pulsation and primarily manage forces in the axial direction. This reduces deflection, maintains clearances, and allows twin screw pumps to operate at reliably higher pressures.

Clean up your maintenance schedule with CIP compatibility.

Facilities that prioritize cleaning efficiency will find twin screw pumps particularly valuable. Unlike pumps requiring disassembly for cleaning, twin screws pumps can remain in place during cleaning, serving as both product conveyors and cleaning solution pumps.

This capability reduces labor costs, minimizes contamination risks, and shortens cleaning cycles—advantages that become more significant as facilities handle increasing numbers of product changeovers.

Other hygienic pumps are also compatible with CIP processes, but the twin screw design has an advantage. Because of its gearing and short screw diameter, a twin screw pump is capable of high speeds up to 3600 RPM.

Higher RPM creates strong turbulence that is more effective at removing product from the pump. In contrast, other types of hygienic pumps—while CIP-capable—may need to be cleaned out of place when the product is highly viscous and fatty, such as ground meat.

Preserve product integrity with gentle handling.

Out of all hygienic pump types, twin screw pumps are perhaps the most gentle. The cavities created by the intermeshing screws advance product in a direct path that minimizes shear. For the same reason, twin screw pumps preserve product integrity. Like AODD and lobe pumps, twin screw pumps can transfer solid particles up to 45 mm without damaging them.

Twin screw pumps are ideal for applications involving shear-sensitive products and entrained solids, such as:

• Personal care products – Gels, lotions, and emulsions can experience separation if they are not handled gently.
• Dairy – Yogurt with fruit inclusions needs the fruit to be undamaged.
• Confections – Chocolate-based products require gentle handling to prevent emulsification or texture degradation.
• Meat – Ground meat must remain intact for consumer acceptance.
• Pet Food – Consumers want to see whole proteins, vegetables, and grains.

Of course, twin screw pumps are not the only type of pump suited for these applications. Lobe pumps and AODD pumps also provide low shear and preserve the integrity of solids.

Nevertheless, there is a twist: if the application also requires a very high discharge pressure or flow rate, then a twin screw pump is the best option. It makes even more sense when considering our Unibloc Twin Screw Pump, because it has unique design features that minimize maintenance requirements compared to pumps supplied by other twin screw pump manufacturers (watch the video).

Smooth out production with nearly pulse-free operation.

Because of their consistent pressure output, twin screw pumps are useful for filling applications where pulsation can cause problems with precise flow control and metering. Gear and lobe pumps are also excellent at pulse-free filling, but for high-speed filling, twin screw pumps are unmatched.

Boost productivity by wasting less product.

An important benefit of a twin screw pump is the ability to run in reverse. This feature is useful during a cleaning cycle: operators can clear the pump of product before initiating CIP cleaning. By wasting less product, processors can maximize productivity, especially with valuable products.

Lower your cost of ownership with UHT innovation.

Unibloc Hygienic Technologies designed its twin screw pump specifically to address common application challenges and lower the total cost of ownership. External timing adjustment eliminates the downtime associated with internal maintenance, while one-way screw reassembly prevents costly misalignment issues.

In addition, because UHT’s Twin Screw pumps contain fewer parts and a design that is simpler to tear down, a Unibloc Twin Screw can be cleaned and re-assembled in far less time than the hours required by competitive, older twin screw designs.

An advanced cooling system reduces the risk of heat-related failures that can occur during demanding operations.

Perhaps most importantly, UHT's diverse pump portfolio means our experts can recommend the optimal solution for each specific application, whether that's a twin screw pump or a simpler alternative. In fact, UHT is the only leading pump manufacturer that offers all four of the primary hygienic pump technologies: AODD, gear, lobe, and twin screw. Our application engineers are in a unique position to recommend the best type of pump for your application, not just the type of pump we happen to sell.

Make an application-based decision.

The decision to specify a twin screw pump should be based on specific application requirements rather than general pump performance. Consider twin screw technology when your situation calls for a combination of requirements:

• Very high discharge pressure up to 360 psi (24.8 bar.)
• Very high flow rates 1200 gallons (4542 liters) per minute.
• Gentle product handling.
• Consistent, nearly pulse-free flow.
• Efficient CIP operations.

Evaluate your current challenges: Do you need higher flow rates? Are you experiencing product damage with existing pumps? Struggling with high-viscosity materials? Spending excessive time on cleaning operations? These issues may indicate applications where twin screw technology can provide measurable benefits.

Contact us to discuss how your process may benefit from all the advantages of a twin screw pump from Unibloc Hygienic Technologies.

Proven Pump Performance: For Those Who Demand More

With thousands of pumps installed around the world, UHT pump technology is proven to outperform, outlast, and cost less to operate and maintain by the world’s toughest processors – who simply can’t afford surprises.