Hygienic Twin-Screw Pump Dedicated to Nutritional Supplement Production

1. Industry Pain Points & Product Positioning

1.1 Seven Core Pain Points of Explosion-Proof Workshops for Nutritional Supplements

1. High explosion risks caused by organic solvent extraction

   Ethanol, propylene glycol and acetone are widely used as extraction solvents in medicinal & edible plant extraction, volatilizing to form Class IIB flammable mixed gas and classifying workshops as Zone 1 and Zone 2 hazardous explosive areas. Conventional conveying equipment only refits explosion-proof motors without complete machine explosion-proof certificates. Pump bodies, seals and pipelines lack matched anti-static and flameproof structures. Electric sparks and fluid static electricity generated during operation easily trigger flash explosions, failing simultaneous inspections of work safety supervision and health food GMP.
2. Active nutritional ingredients are intolerant to shear force and prone to failure & scrapping

   Probiotics, lactic acid bacteria, peptides, anthocyanins, unsaturated fish oil and plant polysaccharides are extremely sensitive to mechanical shear force. Centrifugal pumps deliver materials via turbulent stirring, directly destroying probiotic cell membranes and degrading small-molecule active substances; lobe pumps squeeze materials to cause fish oil stratification and enzyme deactivation; rubber stators of single screw pumps swell and precipitate plasticizers after contacting alcohol and ketone solvents, contaminating finished supplements and being explicitly prohibited in high-end dietary supplement production lines.
3. Organic matter accumulates in dead spaces, leading to batch scrapping due to excessive microorganisms

   Nutrient stock solutions, collagen paste and compound syrups are rich in protein, sugar and plant organic matter. Conventional pump cavities feature right-angle dead spaces, blind holes and rough inner walls that easily trap materials. Long-term static fermentation breeds mold, heterobacteria and pathogenic bacteria, resulting in unqualified microbial testing of whole batches of nutritional supplements. Health food GMP mandates fully automatic closed-loop CIP cleaning, while traditional pumps contain blind cleaning zones and cannot complete full IQ/OQ/PQ cleaning validation.
4. Wide span of material morphology & viscosity leads to poor adaptability of single equipment

   Workshop media cover four categories of materials: low-viscosity extraction solvents and probiotic fermentation broths; medium-viscosity oral liquids and compound nutrient syrups; high-viscosity collagen paste, fish oil substrates and concentrated herbal paste; compound nutrient slurries containing herbal fibers and fruit & vegetable particles. Standard pumps only adapt to a single viscosity range, forcing enterprises to purchase multiple pump specifications and raising comprehensive costs of equipment procurement, spare parts inventory and manual maintenance.
5. Organic solvents corrode seals, triggering dual hidden dangers of explosion and hygiene

   Workshops adopt 75% ethanol disinfection and circulating acid-alkaline CIP cleaning daily. Ordinary NBR nitrile rubber seals rapidly swell and leak after contacting alcohol and ketone solvents. Solvent leakage elevates flammable vapor concentration in workshops and aggravates explosion risks; meanwhile, leaked impurities mix with nutrient materials to cause off-odors and heavy metal precipitation in supplements. Aseptic filling sections require instantaneous SIP high-temperature sterilization, so seals must simultaneously meet three requirements: solvent resistance, acid & alkali resistance and high temperature resistance.
6. High-value loss of active raw materials leads to rising production costs

   Raw materials such as peptides, fish oil, plant extraction stock solutions and live probiotic liquids carry high unit prices. Conventional pumps lack bidirectional conveying functions, leaving high-value materials trapped inside pipelines and pump chambers unrecoverable. Massive raw material loss occurs under long-term continuous production and compresses corporate production profits.
7. Strict dual compliance thresholds for explosion protection and cleanliness

   Nutritional supplement production must simultaneously meet explosion-proof electrical safety codes and health food GMP cleanliness standards. Equipment needs complete machine explosion-proof & anti-static performance, pharmaceutical-grade sterile dead-space-free materials without material migration risks and fully traceable cleaning records. Ordinary industrial pumps and food-grade sanitary pumps cannot satisfy two sets of mandatory compliance requirements at the same time.

1.2 Professional Product Definition

1.3 Classification of Similar Pump Types

1. Ordinary sanitary twin screw pump: Without explosion-proof motors, explosion-proof junction boxes and anti-static grounding structures. Only applicable to clean workshops with pure water and solvent-free nutritional supplements, strictly forbidden in organic solvent extraction explosion-proof zones.

2. Single screw sanitary pump: Rubber stators directly contact extraction solvents such as ethanol and acetone, prone to swelling, odor absorption and mold growth. Fully phased out in high-end probiotic and medicinal & edible plant extraction production lines.

3. Centrifugal pump: Ultra-high shear force inactivates probiotics and degrades plant active polysaccharides. Only usable for CIP clean water circulation, prohibited for conveying finished nutrient stock solutions and pastes.

4. Lobe pump: Obvious flow pulsation squeezes and breaks fish oil emulsified systems and herbal particles, with simple explosion-proof matching and insufficient filling metering accuracy.

5. Explosion-proof sanitary twin screw pump for nutritional supplements: Exclusive standard equipment for explosion-proof clean production lines of plant extraction, probiotics and fish oil dietary supplements, integrating three major functions: complete machine explosion-proof & anti-static performance, low-shear active ingredient protection and sterile cleanability.

2. Working Principle

2.1 Plain-Language Working Principle

2.2 Professional Principle Adapted to Explosion Protection & Active Ingredient Preservation of Nutritional Supplements

1. Suction Stage: An enlarged large-diameter feed inlet reduces negative-pressure air intake in pipelines to avoid probiotic deactivation by oxygen and massive volatilization of extraction solvents. Closed cavities block outward diffusion of ethanol and acetone vapor, lowering flammable gas concentration in workshops at the source and mitigating explosion risks.

2. Closed Conveying Stage: Materials move integrally via laminar flow with ultra-low shear force, achieving ≥99% survival rate of intact probiotics without shear degradation of peptides, anthocyanins and unsaturated fatty acids. Non-contact screw operation generates no metal debris to eliminate heavy metal ion precipitation contaminating nutritional supplements. Closed cavities restrict organic solvent volatilization and ease workshop explosion control pressure.

3. Discharge Stage: Pump output flow has a linear correlation only with screw rotational speed, unaffected by fluctuations in material viscosity and solvent concentration, delivering pulse-free pressure to guarantee precise and stable metering of aseptic oral liquids and soft capsule filling. Closed cavities prevent jet leakage of high-pressure solvents and nutrient paste to avoid massive accumulation of flammable vapor.

4. Explosion-Proof Isolation Logic: Three independent zones including power explosion-proof motor, transmission gearbox and material flow channel are completely separated. All explosion-proof electrical components are fully sealed and encapsulated to block ethanol and acetone vapor from invading motor and junction box cavities, eliminating internal electric sparks igniting flammable mixed gas.

2.3 Basic Applicable Technical Parameters

1. Applicable viscosity range: 1 cPs (extraction ethanol, purified water) ~ 120,000 cPs (collagen paste, fish oil substrate, concentrated herbal paste)

2. Allowable size of soft herbal/nutrient particles: ≤10 mm (herbal fragments, fruit & vegetable fibers, nutrient granules)

3. Applicable medium temperature: -10℃ ~ 92℃, instantaneous resistance to 135℃ SIP high-temperature aseptic sterilization

4. Explosion-proof standard: Standard Ex d IIB T4 (universal for ethanol extraction), optional Ex d IIC T6 for high-risk sections with high-concentration acetone extraction

5. Output pressure fluctuation: ≤±2%, suitable for high-precision aseptic oral liquid and soft capsule filling processes

6. Self-priming height: ≤2.8 m, adapting to low-position discharging of extraction tanks and fermentation kettles

7. Active ingredient protection index: ≥99% survival rate of probiotics after conveying

3. Trinity Exclusive Structural Design

3.1 Full-Range Explosion-Proof Drive Assembly (Core of Explosion Safety)

1. Flameproof Variable-Frequency Explosion-Proof Motor

   Standard Ex d IIB T4 flameproof grade with IP66 high-humidity anti-corrosion protective housing, adapting to high-temperature, high-humidity and organic solvent vapor corrosion environments in nutritional supplement clean workshops. Thickened flameproof shell with fully sealed internal winding encapsulation prevents outward transmission of flames generated by internal cavity explosions. Shell surface temperature stays below the critical ignition temperature of ethanol and acetone to eliminate spontaneous combustion risks.
2. Complete Set of Explosion-Proof Electrical Matching Components

   Equipped with flameproof sealed junction boxes and flame-retardant explosion-proof cable glands. Fully sealed structures block organic solvent vapor from invading electrical cavities. Matched with an explosion-proof PLC variable-frequency control cabinet built with intrinsically safe control elements, it can interlock with workshop ethanol/acetone flammable gas alarms for automatic shutdown and acousto-optic alarm when gas concentration exceeds limits. It supports docking with factory MES systems to fully record conveying rotational speed, pressure and operation duration and meet full-process traceability requirements of GMP.
3. External Isolated Explosion-Proof Gearbox

   The gear cavity is completely physically isolated from the nutritional supplement flow channel, filled with NSF H1 special explosion-proof pharmaceutical-grade lubricating grease without risks of oil leakage contaminating active materials. Precision synchronous helical gear transmission realizes permanent zero-contact screw operation free of friction sparks. The box body is independently grounded to export static electricity generated by transmission friction.
4. Complete Machine Equipotential Anti-Static System

   The pump body, screws, sanitary inlet/outlet pipelines and explosion-proof anti-static hoses are all metal-connected to the factory grounding grid with complete machine grounding resistance ≤4 Ω. Static electricity generated by high-speed fluid flow is exported in real time to eliminate static ignition hazards of organic solvent vapor, complying with mandatory anti-static specifications for Zone 1 and Zone 2 explosion-proof workshops.

3.2 Pharmaceutical-Grade Sterile Wetted Components for Nutritional Supplements (Core of GMP Compliance)

1. Wetted Material Standard: Integrally forged 316L/1.4404 stainless steel with integral solution annealing and passivation treatment, resisting corrosion from plant organic acid, ethanol, acetone and acid-alkaline CIP cleaning liquid. Cast stainless steel is discarded to avoid internal pores trapping protein, sugar and herbal residues that breed heterobacteria. Hastelloy C276 is optional for high-end strong-acid herbal extraction sections to enhance acid corrosion resistance.

2. Graded Inner Wall Polishing Process

   Ordinary oral liquid and nutrient syrup production lines adopt mirror polishing Ra≤0.6 μm; sterile probiotic and high-end export dietary supplement workshops adopt EP electrolytic polishing Ra≤0.4 μm. Extremely smooth inner walls resist adhesion of protein, sugar paste and plant grease, inhibiting biofilm and mold attachment with material residual ≤10 CFU/g to easily pass GMP CIP cleaning validation.

3. Nutritional Supplement Specific Large-Channel Low-Shear Screw Profile

   Integrated design with wide pitch and rounded tooth tops delivers oversized flow channels for complete passage of herbal fibers and fruit & vegetable nutrient particles without extrusion and crushing. One-piece molded screws without welding or surface coating avoid coating peeling and contamination of active raw materials under long-term 135℃ SIP high-temperature sterilization. Precisely optimized screw gaps minimize shear force to preserve activity of probiotics and peptides.

4. Streamlined Dead-Space-Free Integrated Pump Cavity

   Integrally formed smooth flow channel with full rounded transitions without right angles, blind holes or embedded fastening screws. No residual liquid remains after shutdown, and acid-alkaline CIP cleaning liquid can fully flush the cavity to eliminate risks of organic matter residual fermentation and excessive heterobacteria.

3.3 Exclusive Pharmaceutical-Grade Sealing System Resistant to Ethanol & Acetone

1. Peroxide-cured EPDM ethylene propylene diene monomer: Suitable for probiotic fermentation broth, water-based oral liquids and nutrient syrups with no odor or small-molecule precipitation, resisting hot water and weak acid & alkali cleaning, the first choice for normal-temperature fermentation sections.

2. PTFE encapsulated seals: Core configuration for ethanol and acetone plant extraction sections, resisting long-term immersion of all organic solvents without swelling or plasticizer precipitation, standard configuration for extraction explosion-proof workshops.

3. HNBR hydrogenated nitrile butadiene rubber: Suitable for high-temperature concentrated herbal paste, hot nutrient stock solution after pasteurization and high-temperature CIP circulating cleaning with excellent high temperature and solvent aging resistance.

4. FKM fluoroelastomer: Applied to working conditions of high-concentration acetone, high-acid plant extraction liquid and strong alkaline disinfection cleaning.

3.4 Explosion-Proof Clean Quick-Disassembly Matching Structure

1. Standard ISO2852 sanitary Tri-Clamp inlet and outlet without threaded dead spaces, matching sterile clean pipelines of nutritional supplement workshops. Enlarged inlet pipe diameter reduces negative-pressure air intake to avoid probiotic deactivation by oxygen and massive solvent volatilization.

2. Snap-on quick-disassembly pump housing enables complete disassembly within 5 minutes without special tools, supporting offline manual disinfection and GMP disassembly & inspection verification. Complete pipeline cleaning can be realized when switching different material varieties to prevent cross-contamination.

3. Built-in explosion-proof overflow pressure relief valve: Automatically relieves pressure when pipeline pressure exceeds standard to prevent jet leakage of high-pressure extraction solvents and nutrient paste and avoid explosion risks caused by massive accumulation of flammable vapor.

4. Matching explosion-proof anti-static pharmaceutical-grade delivery hose interfaces with fully conductive pipelines to continuously eliminate fluid static electricity, adapting to extraction explosion-proof sections.

4. Six Core Competitive Advantages under Nutritional Supplement Working Conditions

4.1 Complete Machine Full Set of Explosion-Proof Certificates Eliminate Explosion Hazards of Organic Solvent Workshops

4.2 Ultra-Low Shear Laminar Conveying Fully Preserves Active Nutritional Substances

4.3 Pharmaceutical-Grade Dead-Space-Free Sterile Structure Adapts to Full-Automatic CIP/SIP Sterilization

4.4 Pulse-Free Stable Volumetric Conveying Improves Aseptic Filling Metering Accuracy

4.5 Wide Viscosity Adaptability + Bidirectional Residual Material Recovery Greatly Reduce Comprehensive Production Costs

4.6 Integrated Explosion Protection & Cleanliness Simultaneously Meet Dual Compliance of Safety Supervision & GMP

5. Comparison of Mainstream Pump Types under Explosion-Proof Working Conditions of Nutritional Supplements

6. Five Precise Selection Dimensions

6.1 Selection by Explosion-Proof Zoning & Extraction Solvent (Top Safety Priority)

1. Low-alcohol extraction and oral liquid filling Zone 2 (ethanol concentration ≤15%): Standard complete Ex d IIB T4 explosion-proof model, universal for most nutritional supplement extraction workshops.

2. High-concentration acetone/high-alcohol extraction and distillation recovery Zone 1 (high flammable vapor concentration): Upgrade to Ex d IIC T6 high explosion-proof grade with PTFE fully encapsulated solvent-resistant sealing assemblies.

3. Clean workshops with only pure water and solvent-free probiotics: Ordinary pharmaceutical-grade twin screw pumps are acceptable without explosion-proof configuration.

6.2 Matching Seals & Screw Structure by Conveyed Nutrient Media

1. Water-based probiotics, clarified oral liquids and nutrient syrups: EPDM seals and standard wide-flow-channel rounded screws.

2. Concentrated extraction liquids containing herbal fibers and fruit & vegetable particles: Special wide-pitch screws to improve complete passage rate of particles.

3. Ethanol/acetone plant extraction sections: PTFE encapsulated solvent-resistant seals; long-term high-solvent operation with EPDM is forbidden.

4. High-temperature concentrated herbal paste and hot-melt fish oil substrates: Optional HNBR high-temperature resistant & solvent-resistant seals.

6.3 Selection by GMP Cleanliness Grade

1. Ordinary oral liquid and syrup production lines: Ra≤0.6 μm mirror polishing with 3-A and FDA material certifications.

2. Sterile probiotic, export medicinal & edible plant and soft capsule aseptic workshops: EHEDG certification, EP electrolytic polishing Ra≤0.4 μm, double-end flushed mechanical seals supporting instantaneous SIP high-temperature sterilization.

6.4 Selection by Process Functional Configuration

1. Fixed-speed explosion-proof model: Material transfer between extraction tanks and fermentation kettles via fixed pipelines.

2. Explosion-proof servo variable-frequency model (mainstream in nutritional supplement workshops): Matched with fully automatic aseptic filling machines for precise dosing and one-click switching of multiple material varieties.

3. Mobile explosion-proof pump: Equipped with mobile stainless steel base to extract fish oil and plant extraction stock solutions from 200L raw material drums.

6.5 Mandatory Selection Taboos

1. NBR nitrile rubber seals are strictly prohibited for conveying any nutritional supplements containing ethanol and acetone organic solvents, as solvent-induced swelling precipitates impurities that contaminate active raw materials.

2. 304 stainless steel is forbidden for wetted parts; long-term corrosion by plant organic acid and ethanol causes pitting corrosion and excessive heavy metal ions, failing USP VI material standards.

3. Simple single-end mechanical seals are prohibited; organic solvent vapor easily penetrates motor ends and damages the complete machine explosion-proof isolation structure, triggering explosion hazards.

4. High-speed operation is forbidden when conveying probiotics and herbal particle materials, as excessive rotational speed generates high shear to inactivate live bacteria and crush plant fibers.

5. Modifying ordinary pumps only by replacing explosion-proof motors is forbidden without complete machine explosion-proof certificates, leading to production suspension penalties upon safety supervision inspection and rejection by GMP audits.

7. Exclusive Matching Accessories for Explosion-Proof Clean Workshops of Nutritional Supplements

1. FDA/USP VI pharmaceutical-grade explosion-proof sanitary Tri-Clamp fittings and PTFE solvent-resistant sterile gaskets without swelling or small-molecule precipitation after long-term ethanol/acetone immersion.

2. Sterile flushing pipelines for mechanical seals and CIP split-flow adapters adapting to acid-alkaline disinfection and solvent recovery circulation processes.

3. Explosion-proof anti-static pharmaceutical-grade delivery hoses with full conductive performance to export fluid static electricity, specially designed for organic solvent extraction explosion-proof sections.

4. Nutritional supplement dedicated explosion-proof PLC variable-frequency control cabinet preset with two operating programs: low-speed active ingredient preservation conveying mode and high-speed CIP cleaning mode, supporting docking with MES traceability systems.

5. Original factory FDA-certified solvent-resistant spare seals, quick-disassembly disinfection maintenance kits and periodic grounding continuity testing accessories.

8. Installation, Commissioning & Operation Maintenance Specifications (Dual Standards of Explosion Protection & GMP)

8.1 Mandatory Explosion-Proof Installation Specifications (Key Inspection Items for Safety Supervision & GMP)

1. Horizontal pump installation with horizontal deviation ≤0.1 mm/m to prevent accumulation of protein, sugar paste and herbal residues inside cavities and breeding of heterobacteria and anaerobic bacteria.

2. Short and straight feed pipelines with minimal elbows and reducers; inlet pipe diameter one grade larger than outlet to reduce negative-pressure air intake and avoid probiotic deactivation by oxygen and massive volatilization of organic solvents.

3. Complete equipotential grounding of pump body, sterile pipelines and anti-static hoses with grounding resistance ≤4 Ω; grounding continuity tested weekly and records filed into GMP archives.

4. Flame-retardant cables adopted for all explosion-proof wiring with fully locked and sealed explosion-proof cable glands; exposed wiring, open lap joints and damaged cables are prohibited.

5. High-risk Zone 1 acetone extraction workshops equipped with dual-component ethanol/acetone flammable gas alarms interlocked with explosion-proof pumps for automatic shutdown; workshops maintain forced negative-pressure ventilation to lower accumulation concentration of flammable vapor.

8.2 Nutritional Supplement Dedicated Process Commissioning Parameters

1. Conveying rotational speed for probiotics, herbal particles and fish oil paste: Low-speed operation at 50~160 rpm to maximize shear force reduction and preserve active nutrients.

2. CIP cleaning circulation rotational speed: High-speed operation at 800~1200 rpm relying on high-velocity water flow to flush protein, sugar scale and herbal residues inside cavities.

3. Conveying working pressure controlled at 0.2~0.6 MPa; high pressure squeezes and crushes herbal fibers, damages fish oil emulsified systems and accelerates solvent leakage and volatilization.

8.3 Periodic Inspection Plan (Dual-Dimension Check of Explosion Protection & Hygiene Cleanliness)

1. Weekly: Inspect sealing integrity of explosion-proof junction boxes and complete machine grounding continuity; check seal faces for leakage of nutrient paste and solvents and record into equipment GMP operation & maintenance ledgers.

2. Monthly: Inspect EP mirror polishing layers of screws for scratch wear caused by granular media; calibrate lubricant liquid level of explosion-proof gearboxes; test interlock automatic shutdown function of flammable gas alarms.

3. Quarterly: Recheck complete machine explosion-proof performance, calibrate synchronous gear clearance to guarantee zero-contact friction-free screw operation throughout the cycle; synchronously test dust particle and microbial indicators in clean areas.

8.4 Replacement Cycle of Wearing Parts (Accelerated Aging under Organic Solvent Working Conditions)

1. PTFE and EPDM solvent-resistant seals: Mandatory replacement every 6 months due to accelerated aging by ethanol and acetone in extraction working conditions.

2. Special pharmaceutical-grade lubricating grease for explosion-proof gearboxes: Full replacement every 12 months to eliminate risks of lubricant leakage contaminating nutritional supplements.

3. Sterile PTFE gaskets and conductive layers of anti-static hoses: Regular replacement every 4 months to maintain explosion-proof anti-static performance and sterile tightness.

8.5 Dual Operation Taboos (Explosion Safety + GMP Cleanliness & Hygiene)

1. Dry running without medium is strictly forbidden; mechanical seals will be damaged within 30 seconds, and organic solvent vapor penetrating explosion-proof motor cavities creates major explosion hazards.

2. High-speed operation is prohibited when conveying probiotics, fish oil and herbal particle materials, as high shear directly causes failure of active substances and scrapping of finished products.

3. Industrial concentrated strong acid and alkali detergents cannot be used to clean pump bodies, which corrode the passivation layer of 316L stainless steel and trigger heavy metal ion precipitation, failing USP VI material standards.

4. Removing explosion-proof shells, canceling grounding circuits and replacing non-explosion-proof electrical accessories are prohibited, violating explosion safety regulations.

5. Mixed use of uncertified third-party seals without FDA/USP VI certification is forbidden, which swell and contaminate active raw materials of nutritional supplements after contacting ethanol and acetone, leading to scrapping of whole batches.