Modern pump solutions and targeted system optimisation can help ice cream and confectionery producers to achieve consistent chocolate coating performance while supporting reliable, hygienic and efficient production.
In premium ice cream production, consistent chocolate coating is critical for both product appearance and brand perception. One Italian manufacturer of coated ice cream snacks recently improved coating quality and production reliability by upgrading its pumping technology and optimising its enrobing process. The company produces small ice cream bars coated with chocolate and chocolate-based frost containing inclusions such as dried fruit and decorative particles.
To achieve a visually uniform finish, the coating system relies on a stable falling film of chocolate. Operating at approximately 40°C and viscosities between 500 and 2,000 mPas, the process places high demands on flow stability and gentle product handling. Previously, pneumatic diaphragm pumps created pulsation in the chocolate flow, leading to uneven coating thickness, increased noise levels and frequent blockages when conveying inclusions.
The choice of Fristam FDS double screw pumps
Mechanical seal reliability was also a concern, contributing to maintenance challenges and production downtime. To address these issues, the manufacturer installed two Fristam FDS double screw pumps, equipped with air-pressurised shaft seals and slow-speed gearmotors. In addition to the pump upgrade, the coating system was further optimised with a buffer tray and adjustable regulating slits, allowing precise control of chocolate film thickness and flow stability.
The results were immediate. The twin screw pumps delivered smooth, pulse-free flow, producing a uniform chocolate curtain across all products. Coating consistency improved significantly, inclusions were conveyed reliably without clogging, and noise levels on the production floor were reduced. The air-pressurised seal concept also eliminated concerns around chocolate leakage and improved hygienic performance.
By switching to hygienic twin screw pump technology, the manufacturer achieved higher product quality, improved process control and greater operational stability. Reduced maintenance requirements and lower unplanned downtime further strengthened production efficiency. This project highlights how modern pump solutions and targeted system optimisation can help ice cream and confectionery producers achieve consistent chocolate coating performance while supporting reliable, hygienic and efficient production.
