AODD Pumps Can Put The ‘Pop’ In Soda Production

Source: PSG

Their features and benefits make them ideal for the many liquid-transfer points in the soft drink production chain.

Although per-capita consumption of carbonated soft drinks in the U.S. has been on a steady decline since peaking in the 1990s, the average American still consumes more than 41 gallons of the fizzy drinks annually— the equivalent of 437 12-ounce servings, or 1.2 cans a day. To address this decline, major soft drink conglomerates have been expanding their product portfolios to include beverages such as juice drinks and, to a greater extent, energy drinks that have become popular with millennials.

The result is that billions of gallons of soft drinks are produced and consumed annually. It also means that soft drink producers must employ the best systems and technologies in order to meet production quotas that can be strained if the manufacturing process experiences any inefficiencies or breakdowns.

Air-operated double-diaphragm (AODD) pumps can help streamline the soft drink manufacturing process by optimizing liquid-transfer operations at several critical points along the production and supply chain.

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Image 1. Specific AODD pumps can offer a number of operational benefits that make them better-suited for soft-drink production than centrifugal pumps, including sealless design, dry-run capability, shear sensitivity and higher energy efficiency. (Images courtesy of PSG)

The U.S. landscape is dotted with soft drink production facilities, known as canning and bottling plants, that use ingredients such as high fructose corn syrup, various concentrates, flavorings and phosphoric acid (which adds acidity to the final beverage) to create products that are ready for consumption.

In many instances, the large multinational corporations that dominate the global soft drink market contract with bottling companies to produce their beverages in accordance with their highly guarded, tried-and-true formulas. Mom and pop operations also produce, for example, small-batch root beers and ginger ales on a much smaller scale, but these operations still require canning and bottling companies.

All of these soft drink production operations require the manufacturing process to not deviate from strict protocols—or the finished product will not live up to a company’s long-established standards for look, mouth feel and—most important—taste.

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Image 2. From the time raw materials—including concentrates, corn syrup, flavorings, phosphoric acid and more—arrive at the soft drink manufacturing and bottling plant to the point where finished products are put in bottles and cans, a large number of liquid-transfer operations must be completed successfully.

Achieving the desired end product requires carbonated soft drinks to be manufactured using a strict regimen:

  • Common tap water is treated at the production facility to remove any impurities that may affect the drink’s taste or color. The water’s alkalinity level also is adjusted to meet a regulated pH level.
  • The treated water is sterilized to destroy any bacteria or organic compounds. A small amount of chlorine is used to complete the sterilization process.
  • After the sterilized water “rests” in a storage tank for a few hours, it passes through an activated-carbon filter for dechlorination. From there, the completely sterilized water is transferred to a dosing station.
  • Arriving at the facility in drums and totes, the pre-mixed concentrate that gives a soft drink its color, flavor and sugar content is pumped into the dosing station, where it combines with the water. The amounts of concentrate used at this stage are usually determined by weight, not volume, so the batch tank is placed on a load cell or scale, and the pump turns off when a pre-programmed weight is pumped into the tank.
  • This concentrate/water mixture moves to the batch tank where it is blended to form the soft drink’s base. It is then flash pasteurized—a process that uses ultraviolet radiation to quickly heat and cool the mixture to remove impurities.
  • At a precise temperature, the mixture is passed through a carbonator that adds carbonation to the product at predetermined levels according to the beverage’s recipe. Generally, juice drinks require far less carbonation than traditional soft drinks or carbonated energy drinks.
  • The finished carbonated product is transferred to filling lines, where it is injected into bottles and cans of at high flow rates. When filled, the containers are sealed with pressure-resistant closures like aluminum caps or twist-off plastic tops.
  • The cans and bottles (which must be labeled) are packed into cartons or trays before being placed on larger pallets for shipment to distributors.
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Transfer pumps are required at several junctures along the production and supply chain. For many years, centrifugal-style pumps were the main choice for soft drink bottlers and canners. The lower purchase price of centrifugal pumps, compared with the cost of positive-displacement (PD) pump technologies, was the key determinant in their selection.While centrifugal pumps may have a lower upfront cost than PD pumps, they feature some operational inefficiencies that usually lead to higher ancillary costs during the pump’s life. Centrifugal pumps are not self-priming, which hampers their efficiency at startup. They can encounter operating issues when pumping at higher flow rates, especially when handling higher-viscosity liquids like corn syrup. They also are unable to deadhead, which can lead to pump damage in a dry-run condition.

Centrifugal pumps also have mechanical seals, which can lead to costly leaks, and their mechanical seals generally cost more to repair than some other pump technologies. Seal damage and breakage can be caused by the heat generated during dry-run operation. Double mechanical seals are required for tacky or sticky concentrates, which increases costs and operational complexity, and requires a water flush for cleaning. Centrifugal pumps are also powered by electrical motors that must be kept dry during operation, which can be problematic when the product pumped is a liquid.

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Image 3. This air distribution system (ADS) helps reduce AODD pump air consumption by up to 60 percent while providing higher flow rates per standard cubic foot per minute (SCFM) of air that is used.

The Solution

Considering some of the potential shortcomings of centrifugal pump operation, AODD pumps may be a better choice for the numerous liquid-handling links in the carbonated soft drink production chain. Some AODD pumps have been engineered to meet the highest standards for operation in the manufacture of carbonated soft drinks.

For example, one company’s AODD pumps possess the ability to safely and efficiently pump a wide range of viscosities and shear-sensitive products, and they work well with corn syrups, phosphoric acids, concentrates and flavorings that play a major role in soft drink production. The wetted-path material is 316L stainless steel with interior-polish levels that range from 0.8 to 1.3 micrometers (μm) (31.5 to 51.2 microinches [μin]) for ease of cleaning.

Some of these are the only pumps in the industry to have earned certification by 3A Sanitary Standards Inc.—which is dedicated to advancing hygienic equipment design for the food, beverage and pharmaceutical industries—for both clean-in-place (CIP) and clean-out-of-place (COP) sanitizing operations. The free-draining flow path, wash-friendly clamp bands and CIP capability simplify cleaning and have enabled these models of AODD pumps to earn certifications from a number of regulatory agencies in the hygienic industry, including 3A, European Hygienic Engineering & Design Group (EHEDG), U.S. Food and Drug Administration (FDA) CFR 21.177, U.S. Pharmacopoeial Convention (USP) Class VI and European Commission (EC) regulation 1935/2004.

Other features and benefits of these specific AODD pumps, which are available in sizes from 1/2 to 3 inches (13 millimeters [mm] to 76 mm), include:

  • availability of multiple sanitary elastomers
  • sealless design for superior product containment
  • delicate, shear-sensitive operation
  • self-priming or dry-priming operation capabilities
  • damage-free dry-run capability
  • flow rates from 15 to 245 gallons per minute (gpm) (57 to 927 liters per minute)
  • solids passage up to 3 inches (76 mm)
  • high energy efficiency

Additional features include next-generation diaphragm and air distribution system (ADS) technology that can further optimize the operation and reliability of pump models.

The design of the diaphragm combines food-grade plastics and elastomers with a stainless-steel core in a patented configuration that uses no adhesives or nylon fabric, which can contaminate process fluids in the event of a breech.

The diaphragm features an unbroken fluid-contact surface with no product-trap areas. As a result, the diaphragm has exceptional CIP capability and greatly reduces contamination risks.

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Image 4. One type of diaphragm has been designed with an integrated stainless-steel core that uses no adhesives or nylon fabric, which eliminates product-entrapment areas and greatly reduces contamination risks.

The elimination of the outer piston reduces a common abrasion point, which results in longer diaphragm life. Its large internal piston and full-stroke shaft provide greater fluid-transfer displacement while simultaneously allowing the pump to achieve twice the dry vacuum when compared with short-stroke CIP-capable diaphragms.

The availability of a stainless-steel ADS allows certain pumps to be used in a wider range of hygienic or sanitary liquid-handling operation in food-and-beverage manufacture.

This technology achieves up to a 60 percent savings in air consumption over competitive AODD pumps, while providing higher flow rates per standard cubic feet per minute (SCFM). It also costs 50 percent less to operate than electronically actuated ADS units, is submersible and features plug-and-play operation. It has fewer operating parts, which equates to less downtime for repair or simple maintenance.

Market demands place tremendous pressure on soft drink manufacturers to ensure no deviation occurs in the production process that may alter the formulas beloved by consumers. That is why AODD pump technology is a wise choice for the many liquid-transfer points in soft drink production and packaging. AODD pumps can help guarantee that product quality is preserved, while also adding the benefit of lower operating and maintenance costs to the producer’s bottom line.

Tom Zuckett is a regional manager for Wilden Pump & Engineering Co. LLC and PSG. He may be reached at 330-923-2848 or tom.zuckett@psgdover.com.

Grant Gramlich is the Americas–market manager hygienic for PSG. He may be reached at 714-478-5893 or grant.gramlich@psgdover.com.


AODD Pumps Can Put the “Pop” in Soda Production

Source: Fruit Processing

Wilden® Saniflo™ Hygienic™ Series (HS) and FDA AODD pumps possess a long list of features and benefits that make them ideal for the many liquid-transfer points in the soft-drink production chain.

Though per-capita consumption of carbonated soft drinks, aka “soda pop,” in the United States has been on a steady decline since peaking in the 1990s, the average American still consumes more than 41 gallons of the fizzy drinks annually, which is the equivalent of 437 12-ounce servings, or 1.2 cans a day. To address this decline, though, the major soft-drink conglomerates (Coca-Cola Co., PepsiCo, etc.) have begun expanding their product portfolios to include items that fit the new soft-drink definition, beverages such as juice drinks and, more significantly, the energy drinks that have become extremely popular with Millennials.

All of this means that billions and billions of gallons of soft drinks, both of the traditional variety and the newer formulations, are being produced and consumed annually. It also means that soft-drink producers must identify and employ the best systems and technology in order to meet production quotas that can be put under strain if the manufacturing process experiences any inefficiencies or breakdowns.

This white paper will illustrate how one type of pumping technology – air-operated double-diaphragm, or (AODD) – can help streamline the soft-drink manufacturing process by optimizing liquid-transfer operations at several critical points along the production and supply chain.

The Challenge

The U.S. landscape is dotted with soft-drink production facilities, more commonly known as canning and bottling plants, that take such regularly required ingredients as high-fructose corn syrup, various concentrates, different flavorings and phosphoric acid (which adds acidity to the final beverage) and converts them into finished products that are ready for consumption. In many instances, the large multinational companies that dominate the global soft-drink market contract with bottling companies to produce their soft drinks in accordance to their highly guarded, tried-and true formulas. There are also littler mom-and-pop operations that produce their, for example, small-batch root beers and ginger ales on a much smaller scale, but still require the assistance of the canning and bottling company.

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In order to ensure that soft drinks, juices, teas and energy drinks have the look, mouth feel and, most importantly, taste that consumers have grown to know and love, a series of critical manufacturing operations must be performed to exacting standards. Along the way, there are many important liquid-transfer points that require the use of the proper pumping technology.

What all of these soft-drink production operations have in common is that the manufacturing process must follow strict protocols that cannot be deviated from lest the finished product does not live up to the company’s long- established standards for look, mouth feel and, most importantly, taste.

Achieving the desired end-product requires carbonated soft drinks to be manufactured according to a strict regimen:

  • Common tap water is treated at the production facility so that any impurities that may affect the soft drink’s taste or color are removed. The water’s alkalinity level is also adjusted so that its meets a regulated pH level.
  • The treated water is sterilized in order to destroy any bacteria or organic compounds it may still contain. A small amount of chlorine is used to complete the sterilization process.
  • After the sterilized water “rests” in a storage tank for a few hours, it is run through an activated-carbon filter that de-chlorinates it. From there, the completely sterilized water is transferred to a dosing station.
  • The pre-mixed concentrate – which arrives at the facility in drums and totes – that gives the specific soft drink its color, flavor and sugar content is pumped into the dosing station, where it combines with the water. The amounts of concentrate used at this stage are usually determined by weight, not volume, so the batch tank is placed on a load cell or scale and when a pre-pro-grammed weight – say, 500 pounds (227 kilograms) – is pumped into a tank before the pump turns off.
  • This concentrate/water mixture is then moved to a batch tank where it is carefully blended to form the base of the soft drink and then flash pasteurized, which is a process that uses ultraviolet radiation to quickly heat and cool the mixture to ensure that any impurities are removed.
  • At a precise temperature, the mixture is passed through a carbonator that adds carbonation to the product at predetermined levels according to the recipe for the soft drink. Generally, juice drinks require far less carbonation than traditional soft drinks or carbonated energy drinks.
  • The finished carbonated product is transferred to filling lines where it is injected into bottles and cans of varying volumes at high flow rates. When filled, the containers are sealed with pressure-resistant closures like aluminum caps or twist-off plastic tops.
  • The filled cans and bottles (which must also be labeled first) are then packed into cartons or trays before being placed on larger pallets for shipment to distributors, who ensure they find their way to store shelves and into the hands of consumers.

Transfer pumps are required at several junctures along this production and supply chain, and for many years, the pump technology of choice for bottlers and canners of soft drinks was the centrifugal-style pump. For many bottlers and canners, the lower purchase price of centrifugal pumps when compared to the cost of positive-displacement (PD) pump technologies is the key determinant in their selection.

However, while centrifugal pumps may have a lower up-front cost than PD pumps, they do feature some operational inefficiencies that usually lead to higher ancillary costs during the lifetime of the pump. Upon closer inspection, centrifugal pumps are not self-priming, which hampers their efficiency at startup. Also, they can encounter operating issues when pumping at higher flow rates, especially when handling higher-viscosity liquids like corn syrup, and they are unable to deadhead, which can lead to pump damage if a dry-run condition is encountered.

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Wilden® Hygienic Series (HS) Pumps have been redesigned with a more efficient flow path that ensures desired flow rates are met while reducing the risk of product entrapment.

Centrifugal pumps also have mechanical seals, which can lead to costly leaks, while their mechanical seals generally cost more to repair than some other pump technologies. Seal damage and breakage can be caused by the heat that is generated during dry-run operation. Double mechanical seals are also required for tacky or sticky concentrates, which creates additional costs, increased operational complexity and the need for a water fllush for cleaning. Centrifugal pumps are also powered by electrical motors that must be kept dry during operation, which can be problematic when the product being pumped is a liquid.

The Solution

Taking all of the potential shortcomings in centrifugal pump operation into consideration, a much better choice for the numerous liquid-handling links in the carbonated soft-drink production chain is the AODD pump. Specifically, the Wilden
®SanifloHygienic Series (HS) and Saniflo FDA AODD Pumps from Wilden®Pump and Engineering Company, located in Grand Terrace, CA, USA, have been engineered to meet the highest standards for operation in the manufacture of carbonated soft drinks. Wilden, a global leader in the design and supply of AODD pumps for use in hygienic applications, is a product brand of PSG®, a Dover company, Oakbrook Terrace, IL, USA.

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Among the many operational benefits that Wilden® Saniflo FDA Series AODD Pumps provide to soft-drink manufacturers are their availability in many materials of construction that meet U.S. Food & Drug Administration regulations for hygienic manufacturing.

Wilden’s HS and FDA AODD pumps possess the versatility to safely and efficiently pump a wide range of viscosities and shear-sensitive products, and are perfect for the corn syrups, phosphoric acids, concentrates and flavorings that play such a major role in the production of soft drinks. The HS model employs a straight-through flow design and both have Triclamp®-style fittings that ensure that desired flow rates are achieved. The wetted-path material is 316 L stainless steel with interior-polish levels that range from 0.8 to 1.3 μm (31.5 to 51.2 μin) for ease of cleaning.

Wilden HS pumps are some of the only pumps in the industry to have earned 3A certification for both clean-in-place (CIP) and clean-out-of-place (COP). The free draining flow path, wash-friendly clamp bands and CIP capability simplify cleaning, and have enabled Wilden’s HS and FDA AODD pumps to earn certifications from a number of regulatory agencies in the hygienic industry, including 3A, EHEDG, FDA CFR 21.177, USP Class VI and EC 1935/2004. Saniflo FDA models are also available in various materials of construction to meet FDA compliance in diverse applications.

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The Pure-Fuse Diaphragm has been designed with an integrated stain-less-steel core that uses no adhesives or nylon fabric, which eliminates product-entrapment areas and greatly reduces contamination risks.

Other features and benefits of HS and FDA AODD pumps, which are available in sizes from 1/2” to 3” (13 mm to 76 mm), include:

  • Availability of multiple sanitary elastomers
  • Seal-less design for superior product containment
  • Delicate, shear-sensitive operation
  • Ability for self-priming or dry-priming operation
  • Damage-free dry-run capability
  • Flow rates from 15 to 245 gpm (57 to 927 L/min)
  • Solids Passage up to 3” (76 mm)
  • Highest energy efficiency on the market

Additionally, Wilden has also designed and developed next-generation diaphragm and air distribution system (ADS) technology that can be used to further optimize the operation and reliability of its HS and FDA pump models:

  • Pure-Fuse Diaphragms — This innovative design com-bines food-grade plastics and elastomers with a stain-less-steel core in a patented configuration that uses no adhesives or nylon fabric that can contaminate process fluids in the event of a breech. The diaphragm features an unbroken fluid-contact surface with no product-trap areas. As a result, Pure-Fuse has exceptional CIP capability and greatly reduces contamination risks. The elimination of the outer piston also reduces a common abrasion point, which results in longer diaphragm life. Finally, the Pure-Fuse’s large internal piston and full-stroke shaft provide greater fluid-transfer displacement while simultaneously allowing the pump to achieve twice the dry vacuum when compared to short-stroke CIP-capable diaphragms.
  • Stainless-Steel Pro-Flo® SHIFT ADS — The availability of the stainless-steel Pro-Flo SHIFT ADS allows the HS and FDA pumps to be used in a wider range of hygienic or sanitary liquid-handling operation in food-and-beverage manufacture.

The operation of the Pro-Flo SHIFT ADS also represents a major breakthrough in achieving energy-efficient operation for AODD Pumps. Thanks to its revolutionary design, the Pro-Flo SHIFT allows Wilden AODD pumps to achieve up to a 60 % savings in air consumption over competitive AODD pump technologies, while providing higher flow rates per SCFM. The Pro-Flo SHIFT also costs 50 % less to operate than electronically actuated ADS units, is submersible and features plug-and-play operation. It also has fewer operating parts, which equates to less downtime for repair or simple maintenance.

Conclusion

Though carbonated soft-drink consumption in the U.S. has been inexorably declining, it still remains the most popular drink among the country’s inhabitants. The category has also been buttressed with the new fruit-juice and energy-drink formulations that annually keeps it a multi- billion-dollar industry.

No matter the design or formulation of soft drinks, however, they will only resonate with the consuming public if they achieve long-held standards for appearance and taste. That puts tremendous pressure on soft-drink manufacturers to ensure that there is no deviation in the production process that may alter the formulas that are beloved by consumers. That’s why AODD pump technology, specifically the Hygienic and FDA from Wilden, are a wise choice for the many liquid- transfer points in soft-drink production and packaging. AODD pumps can help guarantee that product quality is preserved, while also adding the benefit of lower operating and maintenance costs to the bottom line of the producer.

Sueli Roel BackesAuthor:
Sueli Roel Backes
Market Manager, Food & Beverage, EMEA for Wilden® and PSG®
www.wildenpump.com
www.psgdover.com


Why you Should Consider AODD Pumps for Chemical Industry Processes

Process Worldwide

For decades, centrifugal pumps were the standard choice for the process industry. Now, advancements in overall efficiency and the ability to handle a wide array of unique chemicals combine to make the air-operated double-diaphragm (AODD) pump a first choice for chemical processors.

Content of the Article:

Page 1: Spun Out: Why you Should Consider AODD Pumps for Chemical Industry Processes

Page 2: A Short History of Air Distribution Systems

Page 3: The Right Pump for Each and Every Medium, Be if Thick or Thin

Page 4: What is the Right Pump for Chemical Companies?

Page 5: Why AODDs Can Do More: Working Beyond the BEP

Page 6: Pump Users Looking for Alternatives


Building Applications Knowledge Can Unlock Value in Pump Selection

Pumps & Systems

Leveraging this expertise solves customer problems and creates a sustainable competitive advantage.

By Nate Maguire, PSG

First of Two Parts

In industrial business-to-business equipment markets, manufacturers are faced with an increasingly difficult operating environment. Energy price volatility, the increasing costs of regulatory compliance and public demands for improved environmental stewardship with regard to scarce resources are three prominent factors now impacting industrial organizations around the world.

In confronting these challenges, manufacturers must adapt in numerous ways, including investing in next-generation technologies.

Smart supervisory control and data acquisition (SCADA) systems can reduce downtime through proactive monitoring, and energy-efficient pump technology delivers operating cost savings, hedges against energy-price fluctuations and helps companies meet their environmental stewardship goals by reducing carbon emissions.

However, the adoption of any new technology can dramatically increase the complexity of business operations at a time when cost pressures and economic headwinds threaten to curtail growth and profitability. Further, these technology investments require knowledge and expertise to build, operate and maintain. Many industrial producers, like most businesses, face resource constraints and are operating with leaner staffing levels than ever before. As a result, they are finding they do not possess the in-house expertise to effectively select, build, operate and maintain increasingly complex equipment and systems, and often are forced to turn to third-party organizations with specialized expertise for support.

Pump manufacturers in particular, along with their related distributors, engineering firms, consultants and other third parties, are stepping up to supply this critical applications expertise to end-user customers. Properly deployed applications expertise can unlock value for industrial producers, and organizations that build superior expertise in their markets can gain a significant competitive advantage.

The Challenge

Industrial manufacturers are facing an increasingly difficult business environment, one that is often impacted by these and other critical factors:

  • Energy-price volatility
  • Regulatory compliance legislation and associated costs
  • Public/customer expectations for enhanced resource stewardship

Energy-Price Volatility

Price volatility is defined in the energy industry as how quickly or widely electricity and/or natural gas prices change over a given time period.

Prices are governed by supply and demand, where demand is impacted by factors such as weather patterns, economic conditions and consumer behavior. In recent years, price volatility has increased in the energy market. To protect against this volatility, many companies “hedge,” or buy, a commodity at a price that is locked in over a set period of time.

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Image 1. Air-operated double diaphragm (AODD) pumps in operation at a ceramic plant in Spain (Images courtesy of PSG)

While this may improve peace of mind for the operator, hedging is costly and doesn’t create value for the operator beyond reducing energy- cost volatility.

The severity and potential impact of price volatility is such that in its 2015 report titled, “The New Normal,” the World Energy Council (WEC) said, “The uncertain impact of volatile energy and commodity prices […] has now established itself as the number-one issue for energy leaders worldwide.”

The good news is that global energy leaders have recognized this challenge and are beginning to take measures to address it.

According to Francois Moisan in WEC’s triennial 2016 report, “Energy Efficiency: A straight path towards energy sustainability,” the increase in energy-efficiency legislation around the world “signifies a strengthening and consolidation of the industrial commitment to energy efficiency.”

The report does also indicate, however, that more “can and should be done to improve the efficiency of energy production and use.” This is noteworthy for industrial manufacturers because, as the WEC also points out, “industrial electric motors and electric motor-driven systems consume almost half of the total electricity and account for 70 percent of the total (amount of) electricity consumed in industry.”

For many industrial companies where energy represents a significant portion of operating costs, price volatility will continue to be a challenge. These companies will be self-served to evaluate energy-saving technology, but will only reap the greatest rewards if they do so by taking into account the intricacies of equipment in the specific applications in which they operate.

Only by developing and using the proper applications expertise will they be able to identify and choose the technology that is best suited to mitigate the cost risks associated with energy volatility.

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Image 2. A stainless steel AODD pump in a glue and adhesive manufacturing facility in the Netherlands

Regulatory Compliance

Regulatory compliance is by definition a necessity for businesses in the modern world. These laws collectively shape the environment in which businesses operate. The number of federal regulations in the U.S. has been growing steadily for several decades, requiring more and more investments by many businesses in order to maintain compliance. In fact, a study by George Mason University shows that “the effects of federal regulation on value added to the (U.S.) GDP for a panel of 22 industries…over a period of 35 years…dampened (GDP by approximately) 0.8 percent per year since 1980, eliminating $4 trillion in growth by 2012.”

Two prominent examples in the industrial-manufacturing universe are the motor-efficiency regulations that have been developed by the U.S. Department of Energy (DOE) and the International Electrotechnical Commission (IEC) in Europe.

The bottom line is that regulations are an unavoidable requirement for doing business in almost any jurisdiction in the world.

Many advances in technology have been geared toward meeting the demands of a stricter regulatory environment (See Sidebar: Motoring Ahead), but will be optimized only if they are applied with the appropriate applications expertise. For example, the misapplication of a pump (for example, incorrectly sizing the pump for its application) will likely lead to far greater energy consumption than can be saved from improvements in motor technology.

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Image 3. An eccentric disc pump moving carbonated-beverages at a bottling plant in Hungary

Expectations for Resource Stewardship

A phrase that has gained stature over the past two decades in all forms of business is “corporate social responsibility,” or CSR, which is commonly characterized as “business practices involving initiatives that benefit society.”

An article in the June 18, 2016, issue of the International Journal of Business and Management titled, “Corporate Social Responsibility and Consumer Buying Behavior in Emerging Markets,” stated that “consumers now want companies to behave ethically in addition to providing quality product[s]...”

The obvious implication is that those companies that are perceived to be inattentive or irresponsible stewards regarding shared resources (for example, community water supplies or air quality) risk a political and social backlash that could impact the company’s standing and ability to do business in the communities in which it operates.

Therefore, it should not be surprising that a report from Harvard Business School titled, “The Impact of Corporate Social Responsibility on Investment Recommendations,” revealed that “recent research shows spending money on corporate social responsibility is no longer seen as a detriment to a company’s profitability. Stock analysts now view such expenditures as essential to a company’s long-term brand and value.”

To improve CSR standing, more and more companies are investing additional time and resources toward incorporating new technologies, changing operating practices and even adjusting business strategies to assuage the corporate-responsibility demands of the buying public.

Indeed, these resources can only be optimized by developing and applying expert knowledge of the business, its systems and the local environment in which it operates. Businesses that develop and use this knowledge will help satisfy the needs of the public while achieving positive outcomes in resource stewardship.

In summary, today’s industrial-equipment providers face an increasingly difficult operating environment, which includes energy price volatility, the increasing costs of regulatory compliance, and public demands for improved environmental stewardship.

To address these market dynamics and achieve positive business outcomes, many companies are purposefully developing and leveraging applications expertise, especially when selecting critical pumping technologies and systems.

Part 2 of this article, which will appear in the August 2017 issue of Pumps & Systems, will identify some of the best ways that applications knowledge can be gained and then implemented to develop the best pumping systems for unique—and critical—industrial-manufacturing applications.

Nate Maguire is senior director of business development for PSG, a Dover company. He can be reached at 909-222-1309 or nate.maguire@psgdover.com. Headquartered in Oakbrook Terrace, Ill., PSG is comprised of several pump brands. For more information on PSG, please visit psgdover.com.


Wilden® Saniflo™ Hygienic™ Series Pumps & Pure-Fuse Diaphragms on Display at IFT17

Grand Terrace, CA - May 17, 2017 - Wilden®, part of PSG®, a Dover company and a worldwide leader in air-operated double-diaphragm (AODD) pump technology, is pleased to announce that it will be exhibiting in booth 4801 at the upcoming Institute of Food Technologists' 2017 IFT Annual Meeting & Food Expo (IFT17). IFT17 - which brings together the industry's largest collection of food ingredient, equipment, processing, technology and packing suppliers - will be held from June 25-28 at the Sands Expo Center in Las Vegas, NV, USA.

Wilden-HygienicAt the show, Wilden will be featuring its high-performing Saniflo™ Hygienic™ Series (HS) AODD pumps, which have been designed to meet and exceed the strictest international regulatory guidelines for food-and-beverage applications. Saniflo HS pumps feature excellent product containment and a straight flow-through design that contributes to performance and enables clean-in-place (CIP) capability, critical to hygienic-process success. These pumps also offer self-priming, dry run and deadhead capabilities, and are ideal for handling shear-sensitive products. In addition, Wilden Saniflo HS pumps are one of the few North American made AODD pumps that are validated by both 3-A in the area of CIP and EHEDG cleaning protocol.

Wilden Saniflo HS pumps are available in four sizes from 25 mm (1”) to 76 mm (3”) and feature flow rates from 144 lpm to 874 lpm (38 gpm and 231 gpm). These pumps are available with the Pro-Flo® SHIFT Air Distribution System (ADS) for outstanding energy efficiency. They also exceed all CE, ATEX, USP Class VI, 1935/2004/EC and FDA CFR 21.177 requirements.

Wilden will also have its Pure-Fuse Diaphragms on display in the booth. Pure-Fuse diaphragm technology incorporates a one-piece design that eliminates product-trap areas between the outer piston and diaphragm that can harbor bacteria, a critical consideration for food-and-beverage applications. This patented design also provides an unbroken fluid-contact surface for exceptional CIP capability and reduced contamination risks. Pure-Fuse combines food-grade plastics and elastomers with a stainless-steel core using no adhesives or nylon fabric that can contaminate process fluids in the event of a breech. In addition, by eliminating the outer piston Pure-Fuse diaphragms experience greatly reduced abrasion, which results in longer diaphragm life.

Wilden Pure-Fuse diaphragms are constructed of food-grade Wil-Flex™ (Santoprene™) that meets all FDA CFR 21.177, EHEDG, 1935/2004/EC and 3-A requirements. Wil-Flex features wide temperature limits, excellent flex life, high abrasion resistance and outstanding durability, even when handling acids, caustics and other aggressive fluids. Pure-Fuse diaphragms are available in 25 mm (1"), 38 mm (1-1/2"), 51 mm (2") 76 mm (3") sizes with a temperature range from -40°C to 107°C (-40°F to 225°F).

For more information about Wilden, please visit wildenpump.com. Wilden is a product brand within PSG, a Dover company. For more information on PSG, please visit psgdover.com.

About Wilden Pump and Engineering:

Jim Wilden revolutionized the pumping industry when he invented the air-operated double-diaphragm (AODD) pump in 1955. Since then, Wilden AODD pumps have proven to be trustworthy solutions to pumping applications in a wide variety of industries. Wilden pumps are part of PSG®, a Dover company, and manufactured in Grand Terrace, CA.

Marketing Contact:
Christine Anderson, Marketing Communications Manager
PSG®
909-422-1774 or Christine.Anderson@psgdover.com

Media Contact: 
Darren Wight, VP Media & Publicity
DeanHouston (agency for PSG)
513-280-0047 or dwight@deanhouston.com


Wilden® Releases Chem-Fuse Diaphragms for Industrial Applications

New diaphragms provide benefits of traditional IPDs without sacrificing performance

soda-production-4Grand Terrace, CA – April 26, 2017Wilden®, part of PSG®, a Dover company and a worldwide leader in air-operated double-diaphragm (AODD) pump technology, is pleased to announce the release of its new Chem-Fuse diaphragms specifically designed for industrial applications. Incorporating the core patented technology of the Wilden integral piston Pure-Fuse diaphragm, the new Chem-Fuse diaphragm is the ideal solution for critical industrial application issues without sacrificing performance.

Wilden Chem-Fuse diaphragm technology eliminates the potential leak point at the outer piston as well as outer piston abrasion. This is crucial for industrial applications that pump abrasive or dangerous fluids. The diaphragm design also offers easy cleanability for faster changeovers between products. These features allow Chem-Fuse diaphragms to greatly enhance your pump through increased productivity, reliability and safety without impacting performance.

An additional benefit of Chem-Fuse diaphragms compared to other reduced-stroke integral piston diaphragms (IPDs) is the use of a large integral piston and full-stroke shaft that provides greater efficiency. This design allows Chem-Fuse diaphragms to provide up to 100% increased flow and suction lift compared to other diaphragms.

Wilden Chem-Fuse diaphragms are available in 25 mm (1”), 38 mm (1-1/2”), 51 mm (2”) and 76 mm (3”) sizes with a temperature range from -40°C to 107°C (-40°F to 225°F). These diaphragms are constructed of Wil-Flex™ material that offers excellent flex life, high abrasion resistance and outstanding durability, even when handling acids, caustics and other aggressive fluids. Chem-Fuse diaphragms are available for Wilden Pro-Flo® SHIFT bolted-metal and plastic models.

For more information about Wilden, please visit wildenpump.com. Wilden is a product brand within PSG, a Dover company. For more information on PSG, please visit psgdover.com.

About Wilden Pump and Engineering:
Jim Wilden revolutionized the pumping industry when he invented the air-operated double-diaphragm (AODD) pump in 1955. Since then, Wilden AODD umps have proven to be trustworthy solutions to pumping applications in a wide variety of industries. Wilden pumps are part of PSG®, a Dover company, and manufactured in Grand Terrace, CA.

Marketing Contact:
Christine Anderson, Marketing Communications Manager
PSG®
909-422-1774 or Christine.Anderson@psgdover.com

Media Contact: 
Darren Wight, VP Media & Publicity
DeanHouston (agency for PSG)
513-280-0047 or dwight@deanhouston.com


Irrigating Fruit Caps: A Clean and Green Solution

The Grapevine

By John Wallace

When Rodney Strong Vineyards built its new 10,500-square-foot fermentation facility in Healdsburg, CA, USA to accommodate premium grapes from their Cooley Ranch Vineyard, each detail was precisely planned. All equipment was carefully engineered or researched before purchase to assure the most efficient operations and optimum product handling possible. Among the critical components required were pumps for the important “pumping over” function of irrigating the fruit cap at the top of the fermentation tank.

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Rodney Strong’s new 10,500-square-foot state-of-the-art cellar in Healdsburg, CA, USA, utilizes 51 stainless-steel 6,000-gallon fermentation tanks to accommodate premium grapes from their Cooley Ranch Vineyard.

To evaluate available pump technologies and manufacturers, Rodney Strong conducted exhaustive research and testing. As a result, optimum pump and diaphragm technologies were successfully identified and implemented, yielding a balance of energy efficiency, reduced maintenance, ease of use, cleanability, reliability and gentle handling the product for optimum fermentation.

Building a State-of-the-Art Cellar

Nestled in rugged northwestern Sonoma County, CA, the remote 200-acre Cooley Ranch Vineyard produces high-Bordeaux Varietals in its volcanic soils. To best accommodate the prized harvests from this property, Rodney Strong built a new state-of-the-art cellar with 51 stainless-steel 6,000-gallon fermentation tanks. From the onset of the project, highly specialized equipment was specified to ensure that the fermentation process would follow their precise standards and maximize energy and labor efficiency.

Square tanks were constructed to maximize floor space utilization compared to traditional circular tanks. Cutting-edge electronic controllers were installed on all tanks to automatically and precisely control product temperature and auxiliary support equipment operation throughout the fermentation process.

Challenges in Irrigating the Cap

An important requirement during the fermentation process is managing the fruit cap that forms at the top of the tank in order to prevent hardening. Known as “pumping over,” the operation requires the pump to draw juice from just above the seed layer near the bottom of the fermentation tank and pump it to the tank top. At Rodney Strong, the juice is sent through a flinger device and an oxygen-inducing nozzle that spread the juice to completely cover the cap and keep it wet. Juice is pumped for 20-minute periods up to three times per day.

Like many wineries, Rodney Strong has primarily utilized centrifugal pumps for this purpose in the past. However, experience has shown that centrifugal pumps tend to grind and break up any grape seeds that are sucked in by the pump and become part of the flow. The ground seeds introduce a high quantity of tannins into the wine, which adversely affects product quality. Because of this pump draw-back, Rodney Strong sought to examine alternative pump technologies that would reduce – or even eliminate - grinding the seeds.

Testing Various Pump Solutions

Manuel Villanueva, Rodney Strong Cellar Master, played a key role in selecting the optimum pump technology for irrigating the cap. “We had strict requirements that the pump provide gentle product handling, energy efficiency, ease of cleaning and operational reliability,” said Villanueva. “Our challenge was to identify the best technology available to meet those goals.”

For assistance, Rodney Strong turned to Pumping Solutions, Inc. in Hayward, CA, USA, a leading pump and process equipment supplier that has a long history working with the wine industry. Based on Rodney Strong’s requirements, Pumping Solutions Sales Engineers Pat Mooney and Ben Touzinsky suggested the air-operated double-diaphragm (AODD) pump. “The first issue we addressed was product handling, and we suggested the AODD pump as the natural solution because of its excellent sheer sensitivity,” said Mooney. “The AODD pump’s gentle product handling circulates the liquid for the pumping over process without damaging the juice.”

AODD pumps also offer a durability and flexibility not available in centrifugal or progressive cavity pumps. “Additional reasons why we proposed AODD pumps is that they have the ability to run dry with no damage, deadhead without problems and allow easy liquid flow-rate adjustment by simply changing the air flow,” explained Touzinsky. “They are also easy to install and operate.”

Because of Rodney Strong’s high standards and long-standing commitment to quality, the next step was to conduct extensive tests on AODD, centrifugal and progressive cavity pumps to determine which type would best meet their qualifications.

Villanueva oversaw the pump comparison tests. “Based on our tests, we concluded that AODD pumps are the superior pump for the overall quality of the juice in the fermentation process,” said Villanueva. “The AODD pump was clearly the best in helping to extract the juices as well as control the desired tannins and color from each grape varietal that we put in. Based on those results, we decided to utilize AODD pumps.”

In addition, they found that AODD pumps provided the reliability needed for their operations. “With AODD pumps, we know that when we set the air pressure, it will maintain the required flow consistently,” explained Villanueva. “These pumps are extremely efficient and reliable in pumping the product through.”

Wilden Wins Energy-Efficiency Tests

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Founded in 1959, Rodney Strong has earned a reputation for critically acclaimed Single Vineyard and Reserve wines, stand out Estate releases and best-in-class Sonoma County varietal wines as evidenced by being named Wine Enthusiast’s American Vineyards of the Year in 2013.

Once Rodney Strong decided to standardize on AODD pumps, the next step was to evaluate pumps from different manufacturers for performance, quality, energy efficiency and ease of maintenance. Of particular importance was pump air consumption. “We were utilizing a smaller air compressor, so our goal was to find an energy-efficient pump that could be driven by our current equipment,” said Justin Seidenfeld, Rodney Strong Winemaker. “Our staff worked with Pat Mooney to conduct extensive pump research comparing specifications, features and performance.”

A critical segment of the evaluation process took Villanueva and Rodney Strong Maintenance Technician Richard Ivaldi to Grand Terrace, CA, USA, where Mooney arranged for them to conduct performance tests and examine the quality of each manufacturer’s AODD pump side-by-side at the headquarters of Wilden®, part of PSG®, a Dover Company, based in Oakbrook Terrace, IL, USA.

After conducting a battery of closely monitored performance tests, Rodney Strong concluded that Wilden Saniflo™ FDA pumps equipped with the Pro-Flo® SHIFT Air Distribution System (ADS) are far more energy efficient than other brands. Villanueva explained, “We tested different pumps from different manufacturers so we could evaluate the performance and air consumption of each at the same air pressure. While they all will pump juice, the Wilden efficiency was an obvious benefit. Our tests showed that Wilden pumps equipped with the Pro-Flo SHIFT ADS require less air consumption (reduced SCFM) to provide the same liquid flow as pumps from other manufacturers, giving us much greater efficiency and energy savings. This was a key factor in selecting Wilden.”

Reduced air consumption is realized by using the patent-pending Wilden Pro-Flo SHIFT ADS, which incorporates a unique air control spool that automatically restricts the amount of air going into the pump during the latter part of each stroke. This eliminates over-filling of the air chamber and results in reduced energy consumption. By optimizing air consumption, the Pro-Flo SHIFT lowers energy and operating costs, achieving up to 60% savings over competitive AODD pump technologies.

Easy Cleanability of Wilden Pumps and Diaphragms

Sanitary practices are critical in all winemaking operations, and pumps that move wine are required to comply with FDA CFR 21.177 standards. Wilden Saniflo FDA pumps feature 316 stainless steel wetted parts with an Ra 1.3 μm (51.2 μin) interior polish that fully meet FDA standards.

“In addition to meeting FDA standards, cleanability was a very important factor to consider in our evaluation process for efficiency and labor savings,” said Villanueva. “In comparing designs, we found that Wilden Saniflo FDA pumps provided superior cleanability. They utilize tri-clamps for extremely quick disassembly and assembly to save labor in the sanitization process. In addition, the overall pump design makes cleaning easy. We know that good sanitization processes help ensure you produce a good wine, and that’s part of maintaining our high quality.”

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Wilden® PS8 Saniflo™ FDA pumps equipped with the Pro-Flo® SHIFT Air Distribution System (ADS) and Full-Stroke Integral Piston Diaphragm (FSIPD) provide maximum cleanability and energy savings for cap irrigation at Rodney Strong Vineyards.

As an additional cleanability factor, Mooney suggested utilization of the unique, patented Wilden Full-Stroke Integral Piston Diaphragm (FSIPD). “We showed them the new Wilden Wil-Flex™ Sanitary FSIPD made of Santoprene™ that encapsulates the outer piston completely. This totally eliminates the cracks and crevices inherent with traditional diaphragms where the bacteria can hide.”

“The Wilden one-piece diaphragm makes it significantly easier for the pump to be cleaned at the end of the season when we’re done with our cap management,” said Seidenfeld. “Sanitation is key in our operations to ensure the highest quality product, and Wilden is the only pump manufacturer that offers this type of innovative diaphragm that is perfect for this type of application.”

Rodney Strong also found the Wilden FSIPD is more efficient than conventional diaphragms. Its full-stroke design provides increased displacement per stroke resulting in higher productivity for enhanced flow rates and 115% greater suction lift. This operational efficiency allows for fewer strokes for the same performance, which reduces energy consumption and extends diaphragm life.

Successful First Season

Rodney Strong tested the new cellar during the 2015 season, which included utilizing the Wilden PS8 Saniflo FDA pumps for pumping over and was extremely pleased with their performance. Villanueva commented, “The performance, the high-quality parts, the expert assembly compared to the competition made me very comfortable in the decision to go with Wilden pumps, and we are very pleased with the results.” In fact, Rodney Strong Vineyards are so pleased with the initial order of 16 pumps, Rodney Strong has ordered an additional 43 pumps to complete the cellar.

About the Author:

John Wallace is Western Regional Manager – Industrial Sales for Wilden® and PSG®. He can be reached at John.Wallace@psgdover.com. Wilden is the global leader in air-operated double-diaphragm (AODD) pumps from PSG, a Dover company. Headquartered in Oakbrook Terrace, IL, USA, PSG is comprised of several of the world’s leading pump brands, including Abaque®, Almatec®, Blackmer®, Ebsray®, Griswold™, EnviroGear®, Mouvex®, Neptune™, Quattroflow™, RedScrew™ and Wilden®.

For more information on Wilden or PSG, please go to www.wildenpump.com or www.psgdover.com

About Rodney Strong Vineyards

Founded in 1959 by Sonoma County wine pioneer Rodney D. Strong as the 13th bonded Vineyards in the county, Rodney Strong Vineyards is dedicated to crafting world-class wines that capture the essence of Sonoma County. Rodney Strong sustainably farms 13 estate vineyards and produces wines from Sonoma County’s finest appellations– Alexander Valley, Russian River Valley, Chalk Hill and Sonoma Coast. Purchased by the Klein family, a fourth generation California farming family, in 1989, Rodney Strong has earned the reputation for critically acclaimed Single Vineyard and Reserve wines, standout Estate releases and best-in-class Sonoma County varietal wines as evidenced by being named Wine Enthusiast’s American Vineyards of the Year in 2013. Rodney Strong Vineyards is located at 11455 Old Redwood Highway, Healdsburg, Sonoma County, CA, USA.

About Pumping Solutions

Pumping Solutions was founded in 1995 and is a leading supplier of pumps and process equipment in the western United States. With locations in Washington, California, Arizona and representation in Northern Mexico, Pumping Solutions supplies and services top brands of pumps and process equipment for a wide range of industries, including wineries. Pumping Solutions can be reached at 800-603-0399 or sales@apumpstore.com.

For more information about Pumping Solutions, go to www.apumpstore.com


Optimizing Air Usage In AODD Pumps

Processing magazine

Next-generation ADS can reduce air consumption for improved efficiency and reduced operating costs

By Erik Solfelt, Wilden Pump & Engineering Co. LLC

Successful industrial operations are often measure success many ways — such as operational equipment efficiency, productivity and safety, to name a few. Almost always, they can be grouped into one of three categories:

  • Maintaining low operating costs
  • Ensuring happy customers
  • Providing a safe environment for employees
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Advanced ADS technology can reduce the operating costs for AODD pumps in a number of industries, including chemical processing, food and beverage, oil and gas, pharmaceuticals and mining.

Happy customers and safe employees are typically easy to identify and measure. However, operating costs often have hidden components that are not so easy to quantify.

In the industrial sector, some significant operational costs — whether in the chemical processing, food and beverage, oil and gas, pharmaceutical or mining industries — are the ones incurred for the purchase, operation and maintenance of pumps used during different production and transfer processes.

One hidden component from the operating-cost perspective is the electricity used by pump systems, which, per a Hydraulic Institute study, account for nearly 20 percent of the world’s electricity demand. Assuming 7 cents per kilowatt/hour, that equates to approximately $294 billion to operate pump systems. Therefore, energy consumption can make up close to 90 percent of the total life-cycle costs of owning and operating a pump.

Approximately 30 to 50 percent of the energy consumed by pump systems can be saved through equipment or control-system upgrades. Considering all the usage estimates, simple arithmetic reveals that up to $147 billion of electricity costs will be charged to the industrial companies or the energy provider.

Since pump systems are ever-present in industrial manufacturing facilities and are crucial to the operation of many production applications, they are also ripe for operational improvements that can decrease energy consumption, resulting in lower operating costs for the facility manager and a more environmentally friendly carbon footprint.

This article shows how recent improvements in air-operated double-diaphragm (AODD) pump technology are helping industries reduce air consumption, which delivers many significant benefits for the operator and the environment.

The Challenge
The two main challenges for industrial manufacturers with fluid-transfer operations are the fact that all pumping systems, no matter the technology deployed, can be operationally improved in some way so that they are more efficient and cost-effective to operate. Second, speaking specifically of AODD pumps, hidden electricity costs related to air consumption may be difficult to measure because those costs can be included in the expenses needed to operate other equipment in the plant.

Upon its invention more than six decades ago, AODD pump technology became sought-after technology in the industrial and manufacturing sectors. AODD pumps are often ideal solutions for many applications because of their simple design, which allows the displacement of a regulated amount of fluid from one of its two liquid chambers upon the completion of each pumping stroke. AODD pumps also feature only a few wetted parts that are dynamic: their two diaphragms, which are connected by a common shaft, the two inlet valve balls and the two outlet valve balls.

Driving the diaphragms with compressed air instead of the shaft balances the load on the diaphragm, which removes mechanical stress from the operation and extends diaphragm life. This also allows the valve balls to open and close on the valve seats that direct liquid flow. This uncomplicated design and operation allows the operator to find the correct pressures and flows to optimize the AODD pump’s operation, making AODD pumps ideal for use with different liquid types, from crude oil and paints to cooking sauces and shampoos.

An AODD pump’s design, though, could leave its operation susceptible to higher rates (and corresponding costs) of compressed air usage. Namely, the earliest air distribution systems (ADSs), which are the AODD pump’s motor, would, at the completion of each stroke, produce a moment in which a small but still notable amount of compressed air would “overfill” the air chamber without any corresponding displacement of fluid. Think of this overfilling as similar to hitting the gas pedal in a vehicle while driving over a patch of ice: the wheels may spin, but the vehicle does not move forward, ultimately wasting gas or energy.

Knowing this, the search began to develop an ADS that could reduce the rate of air consumption related to the product flow rate while minimizing the overall amount of wasted air that does not enhance the product yield during the pumping cycle. If realized, this type ADS would positively impact an operation’s bottom line with improved production rates and reduced compressed-air consumption. While some notable enhancements to ADS performance had occurred, the troubling problem of wasted air continued at the end of each pumping cycle.

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The incorporation of an innovative air control spool into the design of the Pro-Flo® SHIFT ADS is what gives it the ability to arrest air loss at the conclusion of each pumping stroke, which helps make the Pro-Flo SHIFT up to 60% more efficient than competitive ADS technologies.

The Solution
In 2013, a solution to this industry challenge was developed with a new ADS. Its operation presented an entirely new way of looking at how AODD pumps operate and consume air.

To combat the inefficient use of air, it restricts air flow into the air chamber near the end of each pump stroke so that only enough air is introduced to keep the pumping process going. This is accomplished through the incorporation of an air-control spool that automatically meters the air to prevent overfilling with no reduction in product yield rates. The result is reduced air consumption while maximum operational efficiency and flow rates are maintained. This means that, in many cases, the new ADS can reduce air consumption by 60 percent when compared to the operation of competitive technologies while retaining desired flow rates.

In addition, the automatic efficiency gains of the system eliminate the need for the operator to manually dial in the efficiency or control it with an electrical system. This creates an improved efficiency point in AODD pump operation with no loss of flow rate. This ADS also delivers maintenance advantages because it minimizes wear and tear on the diaphragms during operation through the optimization of every pump stroke.

Additional benefits of the optimized ADS include:

  • Reduced total cost of ownership
  • Faster setup time
  • Ease of maintenance
  • Drop-in configuration capability
  • Ability to be retrofitted into certain existing AODD pumps
  • Ability to be used in harsh operating environments
  • No electricity required
  • Completely submersible
  • Environmental sensitivity

This ADS’s ability to reduce and optimize air usage and maintain or even improve flow rates, can save the plant operator the cost of purchasing new pump equipment or compressed-air systems. The simplest way to increase a plant’s production capacity may be to replace the ADS in the existing AODD pumps with the most current ADS technology rather than buying new or additional pumping units.

Conclusion
For industrial operations, built-in costs of doing business (CODBs) will always exist. To mitigate these costs, recognizing what the CODBs are and finding ways to streamline them to create a more profitable business are important. While those industries and facilities that rely on AODD pumps for their production and product-transfer operations are taking advantage of reliable, efficient and environmentally friendly pumping technology, they can only realize the ultimate benefits of that technology if they optimize their air usage.

The next-generation ADS effectively eliminates the problem of wasted air during the pump’s operation, resulting in optimized operating costs and a healthier bottom line for the facility operator.

Controlled Comparisons

To create real-world conditions to measure the effectiveness of ADS technologies industry-wide, a controlled, objective head-to-head test was arranged comparing the industry’s top AODD pumps with traditional, electronically controlled and mechanically actuated ADSs. Common conditions of service that are seen in the field were replicated in the laboratory. This simulated application required that each pump produce a flow of 320 liters per minute (L/min) (85 gallons per minute — gpm) against a head pressure of 2.1 bar (30 psi). To achieve a fair comparison between these competing pumps, each pump was operated at the inlet air pressure needed to meet the common condition of service. Air-consumption data was then recorded.

optimizing-air-chart-1

The data gathered in the objective AODD test revealed that Pump D (with the next-generation ADS) performed better than the competition in all three key points of measurement with the lowest air consumption in standard cubic feet per minute (SCFM), the lowest strokes per minute and the highest volume of fluid pumped per SCFM. Pump D averaged an overall 30 percent reduction in air consumption compared to Pumps A, B and C. It also managed the largest reduction in air consumption among the four pumps while managing the best overall volume of fluid moved per stroke, requiring the lowest strokes per minute.

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Erik Solfelt is the Diaphragm Pump product manager for Wilden Pump & Engineering Co. LLC, a manufacturer of AODD pumps. He may be reached at erik.solfelt@psgdover.com or 909-422-1741. Wilden is a product brand of PSG, a Dover company. PSG is comprised of several pump brands, including Abaque, Almatec, Blackmer, Ebsray, EnviroGear, Griswold, Mouvex, Neptune, Quattroflow, RedScrew and Wilden.

To view the video documenting the laboratory pump demonstration of the Wilden Pro-Flo SHIFT versus other ADS systems, visit profloshift.com/proof.

Wilden Pump & Engineering Co. LLC
www.wildenpump.com


Wilden® High-Performance Saniflo™ Hygienic™ Series AODD Pumps On Display at INTERPHEX 2017

Grand Terrace, CA – February 16, 2017Wilden®, part of PSG®, a Dover company and a worldwide leader in air-operated double-diaphragm (AODD) pump technology, is pleased to announce that it will be featuring its highly versatile Saniflo™ Hygienic™ Series (HS) AODD pumps in Booth 2253 at INTERPHEX 2017. Taking place from March 21-23 in New York, NY, USA, the INTERPHEX event brings together a wide variety of leaders from the pharmaceutical and biotech industries.

Wilden_Saniflo_HSWilden Saniflo HS AODD pumps are designed to meet and exceed the strictest international regulatory guidelines for hygienic and pharmaceutical process applications. Saniflo HS pumps feature excellent product containment and a straight flow-through design that contributes to performance and enables clean-in-place (CIP) capability, critical to hygienic-process success. Saniflo HS pumps also offer self-priming, dry-run and deadhead capabilities, and are ideal for handling shear-sensitive products such as cell structures and delicate polymers.

Wilden Saniflo HS pumps feature pharmaceutical-grade elastomers and are available in 316L stainless steel, polished to required RA standards. Thanks to these features, as well as clean-in-place (CIP) capability, Wilden Saniflo HS pumps are one of the few North American made AODD pumps that are validated by both 3-A in the area of CIP and EHEDG cleaning protocol. Saniflo HS pumps also exceed all CE, ATEX, USP Class VI, 1935/2004/EC and FDA CFR 21.177 requirements.

Wilden Saniflo HS pumps are available in four sizes from 25 mm (1”) to 76 mm (3”) and feature flow rates from 144 lpm to 874 lpm (38 gpm and 231 gpm). These pumps are available with the Pro-Flo® SHIFT Air Distribution System (ADS) for outstanding energy efficiency. Diaphragm options include the Wilden Pure-Fuse diaphragm with a one-piece design that eliminates product-trap areas between the out piston and diaphragm that can harbor bacteria.

For more information about Wilden, please visit wildenpump.com. Wilden is a product brand within PSG, a Dover company. For more information on PSG, please visit psgdover.com.

About Wilden Pump and Engineering:
Jim Wilden revolutionized the pumping industry when he invented the air-operated double-diaphragm (AODD) pump in 1955. Since then, Wilden AODD pumps have proven to be trustworthy solutions to pumping applications in a wide variety of industries. Wilden pumps are part of PSG®, a Dover company, and manufactured in Grand Terrace, CA.

Marketing Contact:
Christine Anderson, Marketing Communications Manager
PSG®
909-422-1774 or Christine.Anderson@psgdover.com

Media Contact: 
Darren Wight, VP Media & Publicity
DeanHouston (agency for PSG)
513-280-0047 or dwight@deanhouston.com


Wilden® Advanced™ FIT AODD Pumps Now Available in Ductile Iron

Grand Terrace, CA – January 31, 2017Wilden®, part of PSG®, a Dover company and a worldwide leader in air-operated double-diaphragm (AODD) pump technology, is pleased to announce the release of ductile iron versions of its Advanced™ FIT AODD pump. Specifically designed to be direct replacements for existing pump installations, Wilden Advanced FIT pumps feature bolted product containment, easier maintenance and more efficient operations.

Wilden-FIT-Ductile-IronProviding increased performance with no repiping necessary, Advanced FIT pumps precisely “FIT” bolt-to-bolt and pipe-to-pipe in existing fluid-handling piping systems that utilize competitor pumps or Wilden Original™ or Advanced pump models. Wilden Advanced FIT pumps feature superior flow rates and easier installation compared to other brands. They have been engineered to be an easy, cost-effective way to enhance and upgrade existing pump performance with superior bolted product containment.

In addition, Wilden Advanced FIT pumps come equipped with the revolutionary FIT wetted path that minimizes the number of fasteners and allows for single socket reassembly for faster, easier maintenance. These pumps also come equipped with the extremely energy-efficient Pro-Flo® SHIFT Air Distribution System (ADS). This innovative ADS provides up to 60% reduction in air consumption compared to competitive AODD pump technologies.

Wilden Advanced FIT pumps are offered in sizes from 38 mm (1-1/2”) to 76 mm (3”), and are available with a wide variety of elastomer options for even the most severe applications.

For more information about Wilden, please visit wildenpump.com. Wilden is a product brand within PSG, a Dover company. For more information on PSG, please visit psgdover.com.

About Wilden Pump and Engineering:
Jim Wilden revolutionized the pumping industry when he invented the air-operated double-diaphragm (AODD) pump in 1955. Since then, Wilden AODD pumps have proven to be trustworthy solutions to pumping applications in a wide variety of industries. Wilden pumps are part of PSG®, a Dover company, and manufactured in Grand Terrace, CA.

Marketing Contact:
Christine Anderson, Marketing Communications Manager
PSG®
909-422-1774 or Christine.Anderson@psgdover.com

Media Contact:
Darren Wight, VP Media & Publicity
DeanHouston (agency for PSG)
513-280-0047 or dwight@deanhouston.com