Unibloc® and Flotronic® Pumps Revolutionize Chocolate Processing

It’s certainly the right time of year to think about chocolate in a variety of ways – how it tastes, how it smells – even how it’s made! And that brings us to how both Unibloc® lobe pumps and Flotronic® AODD+ (air-operated double diaphragm) products are found alongside the finest chocolatiers in the world in their process facilities.

But chocolate by its nature is not an easy product to produce – or to pump – as it’s a viscous material, with potentially abrasive sugars, that requires precision temperature control during processing. Consider two case histories, one from Unibloc and the other from a Flotronic customer, to learn how engineers overcame challenges in downtime, seal life, energy efficiency and overall pump productivity.

Unibloc Pumps: Tackling Seal Wear and Maintenance Challenges

One of the recurring challenges in chocolate processing is the wear and tear on pump seals due to viscous materials and operational stress. A long-time Unibloc OEM customer initially faced these issues with the double o-ring seals of standard lobe pump configurations built into its chocolate processing systems. Its customers were finding that they needed to replace these seals every two weeks, a wasteful task that forced regular and costly production stoppages.

The Unibloc Solution: Upgrading to FoodFirst Technology

A simple upgrade from a traditional Unibloc lobe pump to a Unibloc FoodFirst design solved the problem. A FoodFirst lobe pump is based on a front-loaded QuickStrip® innovation that enables a wide variety of improvements. Unibloc Hygienic Technologies had launched the QuickStrip features on its larger units initially; now the feature extends to products ranging from the 300 Series to the larger 600 Series.

• The patented front-access design allows seals to be replaced without disassembling the rotor housing, preserving critical tolerances and minimizing errors.
• This easier and faster access to the rotor housing eliminates the common problem of over- or under-torquing rotor bolts during maintenance.
• Additionally, the FoodFirst upgrade mitigates risks associated with improper maintenance, such as common scratches and gouges during maintenance that routinely damage housings and create tiny contamination crevices in the pump.
• FoodFirst lobe pumps preserved the customer’s ability to run pumps continuously while maintaining consistent flow rates, such as when moving chocolate into hoppers for cereal bar coating. Operating at controlled speeds of 100-125 RPM prevents caramelization and ensures the integrity and quality of the final product.

Flotronic AODD+ Pumps: The Sweet Spot for Chocolate Processors

You may have seen an AODD before, but a Flotronic AODD+ is a totally different design from other AODDs that makes it ideal for the challenges of chocolate processors.

When processing chocolate that contains items such as whole almonds or hazelnuts, maintaining product quality without clogging or damage is crucial. A French confectionery manufacturer came to us for a solution, seeking a pump capable of transferring warm chocolate (viscosity of 6,000 CPS) with whole almonds up to 13mm in size at a flow rate of 2m³/hr.

The Flotronic food grade AODD+ pump proved to be the ideal solution. With its large-bore manifolds and 25mm internal ball clearances, this pump effectively handled the viscous chocolate and whole almonds without damaging the almonds themselves, a problem common to other pump technologies. The almond-friendly design ensures minimal shear, preserving the texture and quality of the final product.

Customization Options for Improved Performance

Here’s where the Flotronic solution was perfect for chocolate processors: to enhance performance in chocolate applications, the Flotronic AODD+ was equipped with a heated jacket. This feature maintains chocolate at the desired temperature, preventing solidification and ensuring smooth flow. Moreover, the tool-free One-Nut® design, only available on a Flotronic pump, simplifies cleaning and inspection, essential for maintaining hygiene standards in food processing.

Compliance and Durability

Constructed from 316L stainless steel and compliant with FDA and EC 1935/2004 regulations, the Flotronic AODD+ meets the rigorous demands of chocolate processing. Its durable materials ensure long-term reliability in high-viscosity applications.

What’s Your Taste? Lobe or AODD+?

Unibloc Hygienic Technologies offers a range of solutions, so there’s no need to limit a choice to one or the other when you can have both.

For process engineers in chocolate production, reliability and efficiency are paramount. Unibloc and Flotronic pumps bring unique strengths to chocolate applications, addressing industry challenges like seal wear, energy efficiency, and handling of viscous materials or inclusions.

Unibloc FoodFirst technology and energy-efficient designs deliver unparalleled durability and maintenance cost savings for a lower Total Cost of Ownership, while Flotronic AODD+ pumps ensure gentle handling of inclusions and ease of maintenance.

By selecting the right pump for your specific needs, you can enhance production efficiency, reduce downtime, and maintain the highest quality standards for your chocolate products.

To learn more about upgrading to a Unibloc FoodFirst lobe pump or understanding the differences between a traditional AODD compared to a Flotronic AODD+, contact us today.