Liquid sweeteners are non-Newtonian enough in practice that viscosity surprises are common. Most issues trace back to temperature, solids content or the presence of crystals.
Temperature is the main lever
Viscosity falls sharply as temperature rises. A syrup that pumps easily at 35 C may be sluggish at 15 C. Warm storage tanks and trace-heated lines keep flow predictable, but excessive heat accelerates colour formation, so set a working range and stay inside it.
Solids and composition
Higher dry solids mean higher viscosity. Blends with more maltose or higher-DE glucose tend to flow differently from high-fructose syrups at the same solids. When a supplier changes grade, re-check pump settings.
Metering and filling
- Dose by mass where possible
- Calibrate flow meters at the actual line temperature
- Allow settle time after tank agitation before filling
- Check fill weights at start, middle and end of a run
Crystallisation and blockage
Partial crystallisation raises viscosity and can block filters and nozzles. Keep containers closed, avoid cold spots in lines and flush with warm water at the end of production.
Monitoring
Log temperature, Brix and pump pressure together. A drift in pressure at constant temperature usually means a change in solids or a partial blockage, and catching it early avoids a stopped line.
Related reading: Glucose syrup DE values.
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