The ROI of Flowability (and How to Prevent Hopper Clogs)

Written by Randall Martin
on June 19, 2024  |  4 min. read

Real talk: Inefficient flow and clogging issues can bring production lines to a grinding halt, leading to costly downtime, extensive cleaning efforts, and product losses. One factor we see many manufacturers overlook when it comes to operational efficiency is the flowability of ingredients, particularly powders like protein isolates.

That’s why I’m always excited to share about innovations that can make your operations smoother (no pun intended). 

So, let’s explore how protein flowability improvements can positively impact your ROI (and reduce production headaches for you and your team).

Poor Flowability = Lower ROI

If you are responsible for handling powder proteins in your plant, you’re likely all too familiar with clogging, bridging, and rat-holing in your hoppers and feeders. 

While the negative impact of flow issues is well-known (especially if you’ve ever been the one to use a mallet on your hopper or spend hours taking apart your equipment), the financial toll is often underestimated. 

According to industry experts, poor flowability can cause 20–50% production variations and up to 10% downtime. 

Moreover, when clogs occur, manufacturers frequently face lengthy shutdowns, during which you’re paying for labor to disassemble, clean, and reassemble equipment like your extruders. 

Between your lost finished product, lost ingredients, and lost time, it only leads to one thing — lost money and a low ROI.


Quantifying ROI With Flow X

PURIS has seen flowability negatively impact numerous plants. That’s why we developed Flow X, our premium pea protein isolate engineered for exceptional flowability.


Flow X’s unique properties, including its optimized particle size and shape and its low moisture content, contribute to its superior flow characteristics. By incorporating Flow X into your production lines, you can experience numerous benefits, including:

  • Reduced downtime and increased throughput
  • Minimized maintenance requirements and associated costs
  • Improved product consistency and quality
  • Enhanced operational efficiency and cost savings
  • Calculating the ROI of Superior Flowability



Take this example…

Let's examine a scenario many manufacturers can relate to to illustrate the potential return on investment (ROI) of incorporating Flow X into their production lines.

flow-x info graphicSuppose your facility experiences downtime due to clogging and flow issues with your current protein powder. By replacing traditional protein powder with our innovative FlowX, you can achieve a remarkable 52.7% reduction* in feeder variation. FlowX's free-flowing nature ensures consistent delivery, minimizing clogs and inconsistencies in your production process. This translates to a more reliable product output and potential cost savings due to reduced material waste and improved production efficiency.

Furthermore, the reduced maintenance requirements and minimized product wastage contribute significantly to the overall ROI. While the upfront cost of Flow X may be higher than some conventional protein powders, its superior flowability can quickly offset this investment through increased operational efficiency, reduced labor costs, and minimized product losses.

*Based on real-world testing through a twin screw feed system.

Implementing Superior Flowability 


superior-flowabilityAt PURIS, we understand that every production line and product formulation is unique. That’s why our team of experts is dedicated to working closely with manufacturers to select the most appropriate flowability-enhancing ingredients based on their specific requirements.

Whether you’re a large industrial producer or a smaller manufacturer, we can help you transition to superior flowability solutions like Flow X. Our consultative approach ensures seamless integration into your existing production processes, maximizing the benefits of improved flowability.

If you’re ready to experience the advantages of superior flowability and optimize your operations, I encourage you to explore Flow X.

Request your sample today, and let’s discuss how we can help you achieve a higher ROI and streamline your production processes.


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