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Masosine pump technology from Watson-Marlow Pumps has lowered decibel levels, reduced cycle times and cut energy consumption at UK pie manufacturer Pukka Pies.

Pukka Pies replaced pneumatically operated air pumps with Masosine SPS 2.5 pumps to transfer meat fillings at its headquarters in Syston, Leicestershire, from where it produces more than 60 million pies every year.

Simon Kemp, the company’s maintenance manager, said: ‘We were using a pneumatic air pump to transfer pre-cooked meat from a 200-litre-capacity mixing bowl to a depositor feed hopper ready to fill the pies.

‘In the first instance, the pump was very noisy and we wanted to improve the working conditions for our bakery operatives.

‘We also found that the meat mixture – which is rich, thick and full of meat chunks and therefore must not be damaged – was problematic for the pumps we had on site.

‘We needed to find a pump that could suction lift the mixture from the mixing bowl up to the depositor feed hopper, while maintaining product integrity,’ he added.

Watson-Marlow introduced Pukka Pies to the SPS 2.5 model, an economic pump ideally suited to high-pressure, hygienic operations in sectors such as food manufacture.

The pump’s exclusive sinusoidal rotor overcomes the limitations of conventional rotary lobe pumps to produce powerful suction with low shear, low pulsation and gentle handling, all of which contribute significantly to lower noise output.

‘With the installation of the first Masosine SPS 2.5, we managed to lower noise from 94 decibels peak to 74 decibels peak,’ said Kemp.

The process of transferring meat to the top-level depositor feed hopper is controlled by Pukka Pies’ own variable-speed-drive system.

In combination with the SPS series pump, which features excellent suction lift for the dense pie fillings, the new system is delivering a further benefit: 20 per cent faster pumping times.

Kemp continued: ‘Furthermore, since the installation of our first Masosine pump around two years ago, we now use far less compressed air – to the tune of 660 litres per minute.

‘This obviously equates to significant savings in our energy consumption,’ he said.

The Masosine pumps at Pukka Pies consist of stainless steel power frames and bearing houses with elevated baseplates and wheels to assist with mobility and to reduce friction.

They also feature a right-angle gearbox to reduce footprint.

Kemp added: ‘We strip the pumps between product changes and at the end of each working day in accordance with a strict cleaning schedule, so it’s great that the Masosine pumps are so easy to dismantle and clean.

‘It only takes around 20 minutes before we are ready to go again, which is quicker than using our previous air pumps.

‘Crucially, the sine pumps are stripped and cleaned by machine operatives, rather than trained engineers,’ he said.

Pukka Pies now has a number of SPS pumps on site, including several pumps operating with a flooded suction and three that utilise the suction-lift capacity of the sine pump.

‘The different fillings must not be broken up by the pumping operation,’ said Kemp.

‘We need to retain sizeable pieces of meat to maintain the necessary quality levels.

‘Fortunately for us, the large pumping chambers within the Masosine SPS pumps preserve and maintain product integrity, even for fragile product such as pre-cooked meat or chicken,’ he added.

Since installation, Pukka Pies has reported no reliability or maintenance issues, with the pumps operating every day between 08:00 and 17:00, transferring around 200 litres of pre-cooked meat every 20 minutes.

SPS series pumps offer capacity up to 91.2m/hr and pressures up to 15bar thanks to their heavy-duty construction.

They can safely pump high-viscosity products, while their simple design allows economical inline maintenance.

With a single shaft and rotor, there is no need for the complex timing gears and multiple seals associated with conventional rotary lobe pumps, according to Watson-Marlow.

Watson-Marlow Fluid Technology Group

Watson-Marlow Fluid Technology Group (WMFTG) is the world leader in niche peristaltic and sinusoidal pumps and associated fluid path technologies. Founded on nearly 60 years of supplying engineering and process expertise and with over one million pumps installed worldwide, our pumps are tried, tested and proven to deliver.

WMFTG is a wholly owned subsidiary of Spirax-Sarco Engineering plc (LSE: SPX), a global organisation employing approximately 4,800 people worldwide. Watson-Marlow Fluid Technology Group comprises nine established brands, each with their own area of expertise, but together offering our customers an unrivalled breadth of solutions for their pumping applications:

  • Watson-Marlow Pumps: peristaltic tube pumps for biopharm and process industries
  • Watson-Marlow Tubing: precision tubing for pumping and other purposes, in a range of materials
  • Bredel: high flow, high-pressure hose pumps
  • Alitea: unique peristaltic solutions for OEM customers
  • Flexicon: aseptic filling and capping systems
  • MasoSine: gentle sinusoidal pumps for food, chemical and cosmetics applications
  • BioPure: advanced single-use tubing connector systems
  • Asepco: aseptic valves for the biopharmaceutical industry
  • FlowSmart: high purity sanitary gaskets, silicone transfer tubing and reinforced silicone hoses for the biopharmaceutical industry

Watson-Marlow Fluid Technology Group is an international operation based in Falmouth, Cornwall, UK. Watson-Marlow Fluid |Technology Group has offices in Argentina, Australia, Austria, Belgium, Brazil, Chile, China, Canada, Denmark, France, Germany, India, Italy, Japan, South Korea, Malaysia, Mexico, the Netherlands, New Zealand, Poland, Russia, Sharjah UAE, Singapore, South Africa, Sweden, Switzerland, Taiwan, USA and Vietnam.

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