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The existing piston homogeniser was equipped with a 75 hp motor and theoretically capable of processing up to 60 gallons per minute.
In practice, throughput had to be reduced to just 15–20 gallons per minute due to excessive heat generation that exceeded the cooling capacity of the plate heat exchanger.
This restricted flow rate significantly limited batch processing speed and reduced overall production efficiency.
Fristam’s solution
Fristam proposed replacing the homogeniser with the Fristam FCM Colloid Mixer, a high-performance inline mixing solution designed specifically for emulsifying oils into viscous food products such as cheese sauces.
Compared to conventional piston homogeniser technology, the FCM represented a significantly lower capital investment while offering reduced energy demand and simplified maintenance. A full-scale production trial was arranged to validate performance under real operating conditions.
Trial set-up
1. Equipment integration
The Fristam FCM was installed inline within the existing cheese sauce production loop. No upstream or downstream equipment modifications were required.
2. Emulsification configuration
Canola oil was introduced into the cheese base upstream of the FCM. The mixer was operated using a 40 hp drive configuration suitable for high-viscosity emulsification.
3. Process flow conditions
Product flow was gradually increased to production operating levels while monitoring temperature stability and pressure conditions across the mixer.
4. Cleaning and hygiene verification
The FCM was included in the plant’s standard clean-in-place cycle to verify full internal cleaning coverage without disassembly.
The Fristam FCM delivered stable, repeatable oil-in-water emulsification while significantly improving overall production efficiency. The processor increased operating flow rates from restricted homogeniser levels to 50 gallons per minute, allowing batch throughput to increase by up to 2.5 times per shift.
Energy demand was reduced by nearly 50% due to the lower installed motor power, while excessive heat generation — previously a limiting factor — was eliminated. This enabled continuous production without overloading the existing cooling system.
In addition to process improvements, the FCM required substantially lower capital investment compared to piston homogeniser technology, reducing upfront equipment costs by approximately 84%. Maintenance requirements were also simplified through a fully CIP-capable design, eliminating frequent dismantling and reducing downtime.
Following the successful trial, the customer purchased the installed FCM unit and invested in an additional mixer to support further product lines within the facility.
