The Value of Applications Knowledge

Source: World Pumps

Industrial producers, such as paint and resin manufacturers or oil-and-gas refinery operators, are investing in advanced technologies that will help them to achieve their business goals. Smart SCADA systems can reduce downtime through proactive monitoring. Energy-efficient pump technology delivers operating-cost savings, hedges against energy-price fluctuations and helps companies to meet their environmental stewardship goals by reducing carbon emissions.

However, 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 specialized 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 that they don’t 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 knowledge, for support.

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

wilden

Wilden Original Series Air-Operated Double-Diaphragm (AODD) Pumps in operation at a ceramic plant in Spain.

wilden

A stainless-steel Wilden Advanced PX Series AODD Pump in use at the SABA B.V. glue- and adhesive-manufacturing facility in the Netherlands.

 

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 behaviour. 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. 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) opined that, “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 introduction of energy-efficiency policies and measures has been growing fast around the world. The increasing number of countries with an energy-efficiency law…signifies a strengthening and consolidation of the industrial commitment to energy efficiency.”

The report does also indicate, however, that “despite the significant advances, much more can and should be done to improve the efficiency of energy production and use.” This is extremely noteworthy for industrial manufacturers because, as the WEC also notes, “industrial electric motors and electric motor-driven systems consume almost half of the total electricity and account for 70% of the total (amount of) electricity consumed in the industry.” For many industrial companies, where energy is 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 their 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.

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 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% 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. Advances in technology that have been geared towards meeting the demands of a stricter regulatory environment will help industrial producers to navigate the compliance realm, but will be optimized only if they are applied with the appropriate applications expertise. In fact, the misapplication of a pump (e.g., incorrectly sizing the pump for its job) will likely lead to far greater energy consumption than can be saved from improvements in motor technology.

wilden

A Mouvex SLS Series Eccentric Disc Pump being used to transfer carbonated-beverage bases by the Coca-Cola Hellenic Bottling Company.

wilden

A Griswold 811 Series Centrifugal Pump in action during a Leased Asset Custody Transfer (LACT) operation in the Eagle Ford shale play in Texas.

Expectations for resource stewardship

A phrase that has gained in 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,' highlighted 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, 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 shouldn’t 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.” In short, to improve their CSR standing, more and more companies are investing additional time and resources toward incorporating new technologies, changing operating practices and even adjusting business strategies in order to better 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.

The solution

So how do industrial manufacturers address the challenges of price volatility, regulatory compliance and resource stewardship, and still successfully achieve their business goals? Many companies are turning to technology for assistance. In a February 2013 article titled, 'The Dawn of the Smart Factory,' IndustryWeek magazine detailed a looming manufacturing nirvana known as the 'Smart Factory.' This factory of the future will be “a paradise of efficiency where defect and downtime, waste and waiting are long-forgotten issues of a long-forgotten age.” The driving force behind this phenomenon would be plant managers and chief intelligence officers who work together to create a seamless blend of data and production that will “illuminate every turn of every machine, every cut of every blade, every move of every piece in its global dance to deliver.”

While the hyperbole in this article is heavy, the article’s basic premise was echoed in a 2015 study by Marketsand-Markets, a publisher of premium market-research reports. In its piece titled, 'Smart Factory Market by Technology, Component, Industry, and Geography – Global Forecast to 2022,' Markets and-Markets researchers found that the smart-factory market, in terms of value, is expected to reach $74.8 billion by 2022, with a compound annual growth rate (CAGR) of 10.4% between 2016 and 2022.

“The emergence of smart factories can be seen from the period of change toward cohesive control of the machineries, processes, and resources with local intelligence,” read the report. “The increasing focus on saving energy and improving process efficiency, along with the integration of engineering and manufacturing by the adoption of IoT (the ‘Internet of Things’) is expected to foster the growth of the smart-factory market.” While the smart-factory operating principles promise to be a boon for industrial manufacturers who implement them, they will raise the complexity of the operation, which poses its own set of unique challenges. In fact, according to strategic-management consulting firm A.T. Kearney’s 'How Much Does Complexity Really Cost?' survey of the top 30 companies in Germany, a reduction in operational complexity would boost earnings by more than €30 billion and increase earnings before interest and taxes (EBIT) by 3% to 5%.

The ultimate challenge for a manufacturer is to learn how new technologies can improve his or her operations and find the best, most efficient way to extract the benefits. This must be done while simultaneously not allowing the inherent complexities of these new systems to hinder or raise the cost of business processes. This is where the accumulation and deployment of applications expertise becomes immensely critical. In fact, Skip Giessing, President of DXP Enterprises’ Rotating Equipment Division, a company that has been supplying industrial pumps since 1908, sees no reason that the demand for and importance of applications expertise won’t continue to grow in coming years.

“I believe there will be an increased demand for outstanding supplier applications expertise as suppliers and manufacturers work together to tie technology to process-equipment networking, proactive health monitoring and reliability,” he said. “The huge customer spend reduction will come when all the key equipment within a manufacturing plant is interconnected and ‘talking with one another’ and adjusting to changes, etc. Customers will need to know and understand how changes affect equipment performance and reliability and how and what to do in order to maintain maximum productivity through reliable uptime and equipment efficiency.” So, what exactly is applications expertise? At its most basic level, it is specialized knowledge pertaining to the use of certain products in specific conditions. This knowledge can be used to create better business outcomes and, therefore, be the foundation for gaining a competitive advantage. As the complexity of the production system increases, the value that can be unlocked from applications expertise also increases. As the graphic illustrates (see Figure 1), the type of expert knowledge varies across the value chain, so there are ample opportunities for increased collaboration among pump manufacturers and distributors, and among distributors and end users, to strengthen expert knowledge and enhance value creation for all involved parties.

chart

Figure 1: Collaboration is key across the value chain.

Tools for managing costs

To better understand how applications expertise can help the operator realize the importance of improving equipment productivity, efficiency and effectiveness, ExxonMobil produced a Technical Help Desk Tip that spelled out the ways to improve what it called “Overall Equipment Effectiveness,” or OEE. OEE is measured as a ratio of a plant’s actual output compared to optimal output, using the equation: OEE = Availability x Performance x Quality, where:

• Availability represents how frequently a machine is available for its intended use, which can be affected by equipment failure, unplanned maintenance, material shortages and changeover times.

• Performance is a measure of speed loss, or the number of units a machine is rated to produce per hour versus the number of units it actually produces.

• Quality represents the amount of scrap material produced by a particular machine, with rejected materials, products that fall short of quality standards and any items that require rework all affecting overall quality.

The conclusion is that the operator “can realize significant efficiency gains by calculating OEE for particular pieces of equipment throughout the plant.” Doing this will also make it easier to identify where particular pieces of equipment are operating to expected standards and norms for efficiency and reliability, and makes the operator aware of the areas where operational improvement will result in the greatest recovery of efficiency.

Another useful tool for operators is the total life-cycle cost (LCC) model for pump technologies. Many factory managers consider only the upfront capital cost of a pumping system in their decision process, which can end up being a costly choice for their business in the long run. According to the Hydraulic Institute’s 'Pump Life Cycle Costs: A Guide to LCC Analysis for Pumping Systems' manual, which it developed in conjunction with Europump, “the single most important factor in minimizing a pumping system’s LCC is proper pumping system design.” Other design factors that impact the pumping system’s total LCC include pipe diameters, lengths, bends, elbows, fittings and valve types, which can increase friction loss. These factors include the correct sizing of the pump, as selecting a larger pump than necessary just ‘to be safe’ will result in the pump operating away from the best efficiency point and requiring more energy consumption; the use of throttling valves to control flow rather than pump speed; and application requirements such as flow rate head pressure and fluid viscosity. These are all areas where applications expertise can aid the designer and installer of the system. In fact, for this reason, many manufacturers look to third-party distributors, consultants or pump manufacturers for help in system design and pump selection.

Conclusion

Industrial manufacturers may feel that they are being bombarded when they are confronted with growing demands to confront and control energy-price volatility, meet the strict requirements of expanding regulatory-compliance legislation, and satisfy both the public and their customers who are ratcheting up expectations regarding improving environmental stewardship. While this can be daunting, it is also a significant, and necessary part of the cost of doing business in today’s manufacturing environment. Manufacturers must satisfy these demands while simultaneously running a profitable business. With that in mind, it’s becoming increasingly apparent that the manufacturers who will be successful in the future will be the ones who develop and utilize applications expertise, especially when selecting critical pumping technologies and systems.

To do this, industrial manufacturers and their channel partners (the distributors, consultants and engineering firms that work hand-in-hand with them) are committing to building applications expertise in their industries. This expertise, when thoughtfully applied to essential system challenges, can unlock significant value for the manufacturer and the end user alike. Therefore, companies that build superior applications expertise will create a significant competitive advantage in the market in the future.

www.wildenpump.com

www.psgdover.com

 

 


AODD Pumps a First Choice for Chemical Processors (Part 1 of 2)

Source: Modern Pumping Today

The circumstances that prompted Jim Wilden to develop the air-operated double-diaphragm (AODD) pumping principle six decades ago have taken on almost mythic status: a ruptured water pipe, a flooded workshop, and an exclamation from a coworker that “Slim” (Wilden’s nickname) could “make a million dollars” if he could invent a solution.

In the ensuing sixty-plus years, those words have proven to be prophetic as the AODD pump technology that was said to be “conceived out of necessity, born in the arms of innovation, and inspired by sheer will and determination” has become a go-to choice for operators in rough-and-tumble industries like mining and heavy construction who require a pump that can easily and reliably pump water, slurry, or any finely divided substance, such as cement, in diverse operating environments.

Click here to read the full story.


Wilden® Releases PS1 13 mm (½”) Original™ Clamped Metal Pump

PS1-AL-ClampedGrand Terrace, CA – August 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 availability of its PS1 Original™ 13 mm (½”) clamped metal AODD pump equipped with the energy-efficient Pro-Flo® SHIFT Air Distribution System (ADS). This new high performance pump features the reliability and energy savings of the Pro-Flo SHIFT ADS while its clamped configuration allows for easier maintenance, diaphragm replacement and cleaning.

The Wilden Pro-Flo SHIFT ADS incorporates a unique Air Control Spool that automatically restricts the amount of air going into the pump during the latter part of each stroke, which 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.

The footprint of the PS1 Original matches that of the Wilden PX1 Original, which enables direct replacement of a PX1 Original with no repiping necessary. With less components (no dial) and 7% more efficient than the PX1 Original, the backward capability of the PS1 Original makes it an easy, cost-effective way to enhance and upgrade existing pump performance. PS1 Original pumps are shear sensitive and intrinsically safe with self-priming and dry-run capabilities, and offer the longest mean time between repair (MTBR), superior anti-freezing and increased on/off reliability.

The Wilden PS1 Original has an aluminum center block and is available with an aluminum, stainless steel or alloy C wetted-path material. Meeting CE and ATEX requirements, the pump features maximum discharge pressures to 8.6 bar (125 psig), maximum flow rates to 60.2 lpm (15.9 gpm), and maximum suction lifts to 5.9 m (19.3’) dry and 9.8 m (32.2’) wet. Diaphragms are available in Buna-N, EPDM, Polyurethane, PTFE, Saniflex™, Viton® and Wil-Flex™. Additionally, PS1 Original pumps will be available for compliance with FDA CFR 21.177 and 1935/2004/EC standards.

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


Mastering the Art of Paint Production

Source: Paint & Coatings Industry

As it turns out, there is a definite ‘art’ to the manufacture of the arts and crafts paints that enables a child to finger paint a family portrait worthy of a place on the fridge door. One company that has moved to the head of the class in the production of school and hobby paints is Dutch company Havo.

Jaap Vos founded Havo in 1963 as a manufacturer of modelling materials for use in schools in the region. In the ensuing 53 years, Havo has grown to be a leading name in the production of creative materials – paints, clay, glues, drawing materials and other related accessories – for use in the educational and retail hobby market segments.

Today, Havo’s Creall paint brand is used by schools and hobby enthusiasts in 53 countries all over the world, with further expansion into the global retail marketplace ongoing.

“We do create a lot of products, and in paints we produce 4 million litres a year,” explains Jan Zwiers, managing director for Havo. “It’s very important that we have products that have good quality and reliability, so the equipment we use to make our products needs to be efficient and effective.”

Zwiers’ commitment to only producing creative products of the highest quality not only reflects well on the Havo name, but also helps ensure domestic tranquility because he is married to Annemieke Zwiers-Vos, who is also a managing director for the company and the daughter of Havo founder Jaap Vos.

Havo, producer of creative materials for use in the educational and retail hobby markets, was recommended to use Wilden’s Original and Advanced AODD pumps by pump distributor Holland Air Pumps

Searching for the perfect pump

Seeing hobby paints dispensed from a squeeze tube or bottle gives the impression that they must be easy to manufacture. In reality, though, there are many strict mixing, blending and transferring stages that must be successfully completed for every batch to guarantee that every colour, whether primary, secondary or tertiary, has the tint and look that is expected.

“Our products look ordinary and easy to handle, but at times it’s hard to produce or pump the paints because they can be hard to manage,” says Zwiers. “Because we are in a niche market, the machines we use to produce our paints may need to be modified to make them right for our purposes. That’s why we have high demands for our machines, and that’s why we need good machines.”

The man charged with the task of ensuring that every drop of Creall paint that leaves the manufacturing plant meets Havo’s high quality standards is technical manager Job Doppenberg.

“We work from 8am to 4.30pm every day, and if it’s busy, the plant keeps going until 9pm,” says Doppenberg. “My job is to guarantee that all the machines are running, and if they are not running well, I look for the solution.”

Keeping equipment running properly is often easier said than done because the raw materials that are used to produce Havo’s paints can have a long list of unique handling characteristics. This can be especially true at high-volume production rates, with Havo producing a total of 3.5 million tubes and bottles of paint annually, or nearly 10,000 a day.

“We pump the paint to one big tank, mix it with pigment, then fill the bottles that go to schools or retail outlets,” Doppenberg continues. “The paints we produce are abrasive, have high viscosity and can be a little bit sticky, with some paints more sticky than others. The viscosity of our paint is also very high, up to 30,000 kilopascals (kPa), which can have more handling problems than paint with a viscosity of 20,000 kPa. So, if we have a pump problem then the different lines can’t be filled and production stops.”

Over the years, Doppenberg and Havo had tried different pump technologies, most recently gear pumps, for the hypercritical blending, mixing and bottle-filling operations, but had begun to notice shortcomings in their operational ability that were hampering the production schedules.

“We have tried a lot of different pump technologies to pump our paint, pumps with seals, and very high-priced, expensive pumps, like gear pumps,” recalls Doppenberg. “We had a gear pump running for one year and it needed to be repaired, and it never pumped good again. We also had a piston pump on our high-pressure filter press that is used for cleaning the machines and it was breaking down. So, what do you do then? We started to look for another pump.”

wilden

Creall paint is used by schools and hobby enthusiasts in more than 53 countries worldwide

Solving the problem with air

To help with the problem, Doppenberg turned to Holland Air Pumps of Oirschot in the Netherlands, a distributor of air-powered pumps, and asked Gerrit Klaassen, Holland Air Pumps’ commercial director, if he could recommend any alternatives.

“We’ve been working with Holland Air Pumps for 15 to 16 years because the service is good. They have parts in stock and, if there is a problem, the people from Holland Air Pumps come here and explain what the solution is,” says Doppenberg.

“They also supply test pumps to show what the solution is, so I talked to Gerrit and he said we could test some air pumps that they had.”

Klaassen recommended Wilden air-operated double-diaphragm (AODD) pumps, a product brand of US company PSG, for which Holland Air Pumps is a distributor in the Netherlands and other European countries.

In particular, Klaassen suggested stainless-steel Wilden Original (clamped) and Advanced (bolted) AODD pumps, the 51mm PS8 and PS800 models, respectively.

“Since the viscosity of our paints is very high we needed AODD pumps with stainless-steel balls so that the ball would not get stuck in the paint when it was time to reseat in the valve,” explains Doppenberg.

“If the ball gets stuck in the paint, it stays up and the pump won’t pump. With the stainless-steel Wilden pumps, the balls have time to drop through the paint and reseat after pumping. It’s a nice pump, a very good pump.”

In addition to having the ability to handle high-viscosity liquids, the PS8 and PS800 pumps have a redesigned liquid path that reduces internal friction for maximised flow rates and pumping efficiency with leak-free product containment guaranteed.

Diaphragm options include Buna-N, EPDM, Geolast, Neoprene, polyurethane, PTFE (Teflon), Saniflex (Hytrel), Viton and Wil-Flex (Santoprene).

wilden

The production of hobby paints includes strict mixing, blending and transferring stages pressure

Additionally, the PS8 and PS800 pumps are fitted with Wilden’s revolutionary Pro-Flo SHIFT Air Distribution System (ADS). The design and operation of the Pro-Flo SHIFT provides up to 60% savings in air consumption when compared to competitive models, achieving lower operating costs and carbon footprint. This was another crucial consideration for Havo, which prides itself on being a ‘green’ company and powers its facility with solar energy while constantly monitoring electricity consumption.

Havo employs a total of 25 Wilden pumps in its production operation, all equipped with Wilden Equalizer SD series surge dampeners. This accessory minimises unwanted pressure fluctuations during liquid-transfer applications by providing a supplementary pumping action that virtually eliminates pressure variations that can create pulse in the liquid flow, with operational capability up to 8.6 bar (125 psi).

The SD series is available in aluminum, stainless steel, cast iron and polypropylene, depending on the pump model being used, and is also compatible with all of Wilden’s standard diaphragm options.

In the filter press that is used to clean the wastewater before it moves to the treatment plant, Havo is utilising an Advanced H800 high pressure AODD pump. The bolted configuration of the 51mm pump ensures total product containment with stainless steel and cast iron available for the wetted path, which has been redesigned to maximise output and efficiency. Diaphragm options include PTFE and Wil-Flex.

wilden

Original and Advanced AODD pumps are ideal for Havo because they can handle high-viscosity liquids

“When a long-time partner like Havo comes to us with a problem, we do our best to identify and recommend the right solution,” says Klaassen. “When Job approached me with the challenge he was facing in pumping highly viscous and sticky paint products, I knew the Wilden pumps would be the best solution.”

Pumps make life easier

By their nature, artists are perfectionists, and they feel that every painting is truly a work of art. That means that the companies that produce the paints they use must also strive to provide perfect products. Havo has been able to meet that standard for more than 50 years in part by partnering with equipment suppliers that recognise its unique production needs and are able to deliver the ideal solution.

“I need machines that I can trust to do the job, and we need partners that I can trust, that if I call them they can tell me what to do, and I get that from Holland Air Pumps,” says Doppenberg. “The Wilden pumps are very good at helping me do my job, and they make my job easier.”

www.wildenpump.com


Building Applications Knowledge Can Unlock Value in Pump Selection

Source: Pumps & Systems

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

By Nate Maguire, PSG

Last of Two Parts

Part 1 of this article (Pumps & Systems, June 2017) introduced a few challenges that those in the pump industry face. In terms of energy, manufacturers and industrial facilities of all types consistently face energy/price volatility. They are also looking for ways to deal with increased costs associated with regulatory compliance legislation. Finally, they are operating in a business climate that expects increased corporate social responsibility (CSR).

The Solution

So how do industrial manufacturers address the challenges of price volatility, regulatory compliance and resource stewardship, and still successfully achieve their business goals? Many companies are turning to technology for assistance.

In a February 2013 article titled, “The Dawn of the Smart Factory,” IndustryWeek magazine detailed a manufacturing utopia known as the “Smart Factory.” This factory of the future is hailed as “a paradise of efficiency where defect and downtime, waste and waiting are long- forgotten issues of a long-forgotten age.” The driving force behind this trend would be plant managers and chief intelligence officers working together to create a seamless blend of data and production to “illuminate every turn of every machine, every cut of every blade, every move of every piece in its global dance to deliver.”

While the hyperbole in this article is heavy, the basic premise was echoed in a 2015 study by MarketsandMarkets, a publisher of premium market-research reports.

In its piece titled, “Smart Factory Market by Technology, Component, Industry, and Geography – Global Forecast to 2022,” its researchers found that the smart-factory market, in terms of value, is expected to reach $74.8 billion by 2022, with a compound annual growth rate (CAGR) of 10.4 percent between 2016 and 2022.

view from the field

“The emergence of smart factories can be seen from the period of change toward cohesive control of the machineries, processes and resources with local intelligence,” read the report. “The increasing focus on saving energy and improving process efficiency, along with the integration of engineering and manufacturing through adoption of IoT (the ‘Internet of Things’) is expected to foster the growth of the smart-factory market.”

While the smart-factory operating principles promise to be a boon for industrial manufacturers who implement them, they will raise the complexity of the operation, which poses its own unique challenges. In fact, according to strategic-management consulting firm A.T. Kearney’s “How Much Does Complexity Really Cost?” survey of the top 30 companies in Germany, a reduction in operational complexity would boost earnings by more than €30 billion and increase earnings before interest and taxes (EBIT) by 3 to 5 percent.

A critical challenge for manufacturers is to embrace new technologies that help achieve the business outcomes that are desired while managing the inherent complexities of these new systems. This is where the accumulation and deployment of applications expertise becomes immensely critical.

In fact, Skip Giessing, president of DXP Enterprises’ Rotating Equipment Division, a company that has been supplying industrial pumps since 1908, sees no reason why demand for and importance of applications expertise won’t continue to grow in coming years. “I believe there will be an increased demand for outstanding supplier applications expertise as suppliers and manufacturers work together to tie technology to process-equipment networking, proactive health monitoring and reliability,” he said.

“The huge customer spend reduction will come when all the key equipment within a manufacturing plant is interconnected and ‘talking with one another’ and adjusting to changes, etc. Customers will need to know and understand how changes affect equipment performance and reliability and how and what to do in order to maintain maximum productivity through reliable uptime and equipment efficiency.”

So what exactly does “applications expertise” mean? At its most basic level, it is specialized knowledge of certain products in specific conditions. This knowledge can be used to create better business outcomes and, therefore, provide the foundation for gaining a competitive advantage.

As Figure 1 illustrates, this type of expert knowledge varies across the value chain, so there are ample opportunities for increased collaboration among pump manufacturers and distributors, and among distributors and end users, to strengthen expert knowledge and enhance value creation for all.

life cycle costs

Tools For Managing Costs

To better understand how applications expertise can help the operator realize the importance of improving equipment productivity, efficiency and effectiveness, ExxonMobil produced a Technical Help Desk Tip that spelled out ways to improve what it called “Overall Equipment Effectiveness,” or OEE. OEE is measured as a ratio of a plant’s actual output compared to optimal output, using equation 1, where:

  • Availability represents how frequently a machine is available for its intended use, which can be affected by equipment failure, unplanned maintenance, material shortages and changeover times.
  • Performance is a measure of speed loss, or the number of units a machine is rated to produce per hour versus the number of units it actually produces.
  • Quality represents the amount of scrap material produced by a particular machine, with rejected materials, products that fall short of quality standards and any items that require rework all affecting overall quality.

The conclusion in the article is that the pieces of equipment throughout the plant.” Doing this will also help identify when particular pieces of equipment are operating to expected standards and norms for efficiency and reliability – and makes the operator aware of areas where operational improvement will result in the greatest recovery of efficiency.

Value chain map

Another useful tool for operators is the total life-cycle cost (LCC) model for pump technologies. Many factory managers consider only the up-front capital cost of a pumping system in their decision-making process, which can end up being a costly choice in the long run. According to the Hydraulic Institute’s “Pump Life Cycle Costs: A Guide to LCC Analysis for Pumping Systems” manual, developed in conjunction with Europump, “the single most important factor in minimizing a pumping system’s LCC is proper pumping system design.” (See Sidebar: Determining Pump Life Cycle Costs)

Other design factors that impact the pumping system’s total LCC include:

  • Pipe diameters, lengths, bends, elbows, fittings and valve types, which can increase friction loss.
  • Correct sizing of the pump, wherein selecting a larger pump than necessary “to be safe” will result in the pump operating away from the best efficiency point (BEP) and requiring more energy consumption.
  • The use of throttling valves to control flow rather than pump speed.
  • Application requirements such as flow rate head pressure and fluid viscosity.

These are all areas where applications expertise can aid the designer and installer of the system. In fact, for this reason, many manufacturers look to third-party distributors, consultants or pump manufacturers for help in system design and pump selection.

Conclusion

Industrial manufacturers may think that they are being bombarded from all sides when they are confronted with growing demands to better confront and control energy-price volatility, meet the strict tenets of expanding regulatory-compliance legislation, and satisfy both the public and their customers, who are ratcheting up expectations regarding improving environmental stewardship. While these responsibilities can be daunting, they are also a significant—and necessary—part of doing business in today’s manufacturing environment.

Manufacturers must satisfy these demands while simultaneously running a profitable business. With that in mind, it’s becoming increasingly apparent that the manufacturers who will be successful in the future will be the ones who develop and use applications expertise, especially when selecting critical pumping technologies and systems.

To do this, industrial manufacturers and their channel partners–the distributors, consultants and engineering firms that work hand-in-hand with them–are committing to building applications expertise in their industries. This expertise, when thoughtfully applied to essential system challenges, can unlock significant value for the manufacturer and the end user alike.

Therefore, companies that build superior applications expertise will create a significant competitive advantage in the marketplace of the future.

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


Using AODD In Soda Production

World Pumps

Billions of gallons of soft drinks are consumed annually. But production quotas can be put under strain if the manufacturing process experiences inefficiencies or breakdowns. Therefore, soft-drink producers must employ the best systems and technology to meet these quotas.

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

wilden

Manufacturers of carbonated soft drinks, fruit juices, teas and energy drinks are constantly searching for the most reliable, safe and energy-efficient pump technology .

Though per-capita consumption of carbonated soft drinks 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, such as juice drinks and, more significantly, the energy drinks that have become extremely popular with millennials.

wilden

There are many important liquid-transfer points that require the use of the proper pumping technology.

The challenge

The global 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 flavourings 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 with their highly guarded, tried-and true formulas. There are also smaller operations that produce, for example, root beers and ginger ales on a much smaller scale, but still require the assistance of the canning and bottling company.

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:

wilden

The soft drink pumps have a seal-less design, dry-run capability and shear-sensitivity.

    • Common tap water is treated at the production facility so that any impurities that may affect the soft drink’s taste or colour 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, and gives the specific soft drink its colour, flavour 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 a pre-programmed weight, for example, 500 pounds (227 kg), is pumped into a tank before the pump turns off .
wilden

The pumps have been redesigned with a more efficient flow path that ensures desired flow rates are met.

  • 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 fl ash 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 fl ow 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) 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.

wilden

Wilden® Saniflo™ FDA Series AODD pumps provide soft-drink manufacturers with many construction materials.

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 fl ow rates, especially when handling higher-viscosity liquids like corn syrup, and they are unable to dead-head, which can lead to pump damage if a dry-run condition is encountered.

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 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 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 being pumped is a liquid.

The solution

The Wilden® Hygienic Series (HS) and Saniflo™ FDA AODD pumps, from Wilden Pump & Engineering, Grand Terrace, CA, USA, can pump a wide range of viscosities and shear-sensitive products, and can be used for corn syrups, phosphoric acids, concentrates and flavourings which play a major role in the production of soft drinks.

Wilden has also designed and developed diaphragm and air distribution system (ADS) technology:

wilden

The Pure-Fuse Diaphragm has an integrated stainless-steel core that uses no adhesives or nylon fabric.

  • Pure-Fuse diaphragms: This design combines food-grade plastics and elastomers with a stainless-steel core in a patented configuration that uses no adhesives or nylon fabric that can contaminate process fl uids in the event of a breech. The diaphragm features an unbroken fluid-contact surface with no product-trap areas. As a result, Pure-Fuse can reduce contamination risks. The elimination of the outer piston also reduces a common abrasion point, which could result in longer diaphragm life. Finally, the Pure-Fuse’s large internal piston and full-stroke shaft provide greater fluid-transfer displacement while 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.
wilden

The Pro-Flo® SHIFT Air Distribution System (ADS) hopes to reduce AODD pump air consumption by up to 60%.

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 keep 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 models from Wilden, are a wise choice for the many liquid-transfer points in soft-drink production and packaging. AODD pumps can help to guarantee that product quality is preserved, while also adding the benefit of lower operating and maintenance costs to the bottom line of the producer.

www.wildenpump.com
www.psgdover.com

Contact
Tom Zuckett, Regional Manager for Wilden® Pump & Engineering Co., LLC, and PSG®. Tel: (330) 923-2848
Email: Tom.Zuckett@psgdover.com.

Grant Gramlich is the Americas Market Manager Hygienic for PSG.
Tel: (714) 478-5893
Email: Grant.Gramlich@psgdover.com.


Wilden® Saniflo™ Hygienic™ Series Pumps & Pure-Fuse Diaphragms on Display at Drinktec 2017

Grand Terrace, CA – July 25, 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 exhibiting at Drinktec 2017. Drinktec – which will be held from September 11-15 in Munich, Germany – is the world’s largest leading trade fair for the beverage and liquid food industry, combining three exhibitions into one: Drinktec, SIMEI and Oil+Fats.

Wilden-HygienicExhibiting in booth B3-218, Wilden will be featuring its high-performing Saniflo™ Hygienic™ Series (HS) AODD pumps. 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. Furthermore, 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. Additionally, these pumps 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™) and Saniflex™ (Hytrel®). Wil-Flex and Saniflex diaphragms meet all FDA CFR 21.177, EHEDG and 3-A requirements. Additionally, Saniflex meets 1935/2004/EC 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).

To learn more about Drinktec 2017, please visit drinktec.com.

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® Launches New E-Commerce Store

Wilden becomes the first top tier commercial pump brand available through a self-directed e-commerce platform

Grand Terrace, CA – July 19, 2017Wilden®, part of PSG®, a Dover company and a worldwide leader in air-operated double-diaphragm (AODD) pump technology, is pleased to announce the launch of its new e-commerce store. Found at wildenstore.psgdover.com, the new online Wilden Store is the first self-directed platform of its kind for any pump brand in the industry.

wilden-online-store“Along with our channel partners, we are very proud to offer our customers a market leading e-commerce platform that meets the on-demand needs and buying habits of our customers,” said Michael Solso, Americas – Director of Business Development for Wilden and PSG.

The Wilden Store provides end users with an online, convenient shopping environment with best-in-class delivery. Not only can end users easily find appropriate and authentic spare parts and accessories for their Wilden pumps by using the Wilden Store, but they can also find comparable Wilden pumps based on competitor part numbers.

The new Wilden Store will also provide Wilden the flexibility to move quickly with new market demands and products since it utilizes a self-directed, customer-focused e-commerce environment while leveraging delivery through Wilden’s existing distribution network. This new e-commerce platform integrates a localized distributor network that will provide product, service and technical support once a customer purchases a Wilden product online. This ensures the products end users receive are authorized Wilden components.

“We pride ourselves on being at the forefront of our industry, constantly striving to be a company that is easy to do business with,” said Solso. “We recognize that many of our customers are looking for alternative channels to purchase pumps and parts online. The Wilden Store provides an easy-to-use platform designed for our customers to simply buy Wilden pumps and parts on-demand.”

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


AODD Pumps Can Put the “Pop” in Soda Production

Source: Drink Technology + Marketing

By TOM ZUCKETT & GRANT GRAMLICH

wilden

From the time raw materials - concentrates, corn syrup, flavorings, phosphoric acid, etc. - arrive at the soft-drink manufacturing and bottling plant to the point where finished products are put in bottles and cans, there are a large number of liquid-transfer operations that must be completed successfully. Manufacturers of carbonated soft drinks, fruit juices, teas and energy drinks are discovering that the most reliable, safe and energy-efficient technology for these operations are air-operated double-diaphragm (AODD) pumps, in many cases Saniflo™ Hygienic™ Series (HS) and FDA models from Wilden®.

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 US 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.

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, mouthfeel and, most importantly, taste.

wilden

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.

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-programmed 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.

wilden

Wilden® Saniflo™ Hygienic™ Series (HS) and FDA AODD Pumps offer a number of operatio-nal benefits that make them better suited for soft-drink production than centrifugal pumps, including seal-less design, dry-run capability, shear-sensitivity and higher energy efficiency.

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.

Centrifugal pumps also have mech-anical 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 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 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® Saniflo™ Hygienic™ Series (HS) and Saniflo™ FDA AODD Pumps 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.

wilden

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.

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 316L 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.

wilden

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 US Food & Drug Administration regulations for hygienic manufacturing.

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 combines food-grade plastics and elastomers with a stainless-steel core in a patented configuration that uses no adhesives or nylon fabric that can contaminate


Mastering the Art of Paint Production

Source: Asia Pacific Coatings Journal

Alberto Lerussi, Wilden and PSG, shows how Havo BV has reinforced its reputation as a world leading provider of arts & crafts paints by integrating Wilden AODD pumps into its production operations

As it turns out, there is a definite ‘art’ to the manufacture of the arts-and-crafts paints that enable a child to finger paint a family portrait worthy of an honoured place on the refrigerator door. One company that has moved to the head of the class in the production of school and hobby paints is Havo, BV, Ermelo, The Netherlands.

Havo was founded in 1963 by Jaap Vos in Bussum, The Netherlands, a suburb of Amsterdam, as a manufacturer of modelling materials for use in schools in the region. In the ensuing 53 years, which included relocation in 1971 to the nearby town of Ermelo, where production operations remain today, Havo has grown to be a leading name in the production of creative materials – paints, clay, glues, drawing materials and other related accessories – for use in the educational and retail hobby market segments. In fact, Havo’s Creall paint brand is used by schools and hobby enthusiasts in 53 countries all over the world, with further expansion into the global retail marketplace ongoing.

“We do create a lot of products, and in paints we produce 4M lit/yr (1.1M gal),” explained Jan Zwiers, Managing Director for Havo. “It’s very important that we have products that have good quality and reliability so the equipment we use to make our products needs to be efficient and effective.”

wilden

Zwiers’ commitment to only producing creative products of the highest quality not only reflects well on the Havo name, but also helps ensure domestic tranquility at home for him. That’s because he is married to Annemieke Zwiers-Vos, who is also a Managing Director for the company and happens to be the daughter of Havo founder Jaap Vos.

SEARCHING FOR THE PERFECT PUMP

Seeing hobby paints dispensed from a squeeze tube or bottle gives the impression that they must be easy to manufacture. In reality, though, there are many strict mixing, blending and transferring stages that must be successfully completed for every batch to guarantee that every colour, whether primary, secondary or tertiary, has the tint and look that is expected.

“Our products look ordinary and easy to handle, but at times it’s hard to produce or pump the paints because they can be hard to manage,” said Zwiers. “Because we are in a niche market, the machines we use to produce our paints may need to be modified to make them right for our purposes. That’s why we have high demands for our machines, and that’s why we need good machines.”

wilden

Havo’s Creall paint brand is used by schools and hobby enthusiasts in more than 53 countries all over the world

The man charged with the task of ensuring that every drop of Creall paint that leaves the manufacturing plant meets Havo’s high quality standards is Job Doppenberg, who is the facility’s Technical Manager.

“We work from 8am to 4:30pm every day and if it’s busy, the plant keeps going until 9pm,” said Doppenberg. “My job is to guarantee that all the machines are running and if they are not running well, I look for the solution.”

Keeping equipment running properly is often easier said than done as the raw materials that are used to produce Havo’s paints can have a long list of unique handling characteristics. This can be especially true at high-volume production rates, with Havo producing a total of 3.5M tubes and bottles of paint annually, or nearly 10,000 a day.

“We pump the paint to one big tank, mix it with pigment, then fill the bottles that go to schools or retail outlets,” Doppenberg continued. “The paints we produce are abrasive, have high viscosity and can be a little bit sticky, with some paints more sticky than others. The viscosity of our paint is also very high, up to 30,000 kilopascals (kPa), which can have more handling problems than paint with a viscosity of 20,000kPa. So, if we have a pump problem then the different lines can’t be filled and then production stops.”

wilden

The production of hobby paints includes many strict mixing, blending and transferring stages and the raw materials that are used to produce the paints can have a long list of unique handling characteristics

Over the years, Doppenberg and Havo had tried different pump technologies, most recently gear pumps, for the hypercritical blending, mixing and bottle-filling operations but had begun to notice shortcomings in their operational ability that were hampering Havo’s production schedules.

“We have tried a lot of different pump technologies to pump our paint, pumps with seals and very high-priced, expensive pumps, like gear pumps,” recalled Doppenberg. “We had a gear pump running for one year and it needed to be repaired, and it never pumped good again. We also had a piston pump on our high-pressure filter press that is used for cleaning the machines and it was breaking down. So, what do you do then? We started to look for another pump.”

SOLVING THE PROBLEM WITH AIR

For assistance, Doppenberg turned to Holland Air Pumps BV, Oirschot, The Netherlands, a distributor of air-powered pumps for use in many industrial applications. More specifically, he asked Gerrit Klaassen, Holland Air Pumps’ Commercial Director, if he could recommend any alternatives to the ill-performing gear pumps.

“We’ve been working with Holland Air Pumps for 15 to 16 years because the service is good, they have parts in stock and if there is a problem the people from Holland Air Pumps come here and explain what the solution is,” said Doppenberg.

wilden

Wilden Original and Advanced AODD pumps are the perfect solution for Havo thanks to their ability to handle high-viscosity liquids

“They also supply test pumps to show what the solution is, so I talked to Gerrit and he said we could test some air pumps that they had.”

Klaassen’s specific recommendation was air-operated double-diaphragm (AODD) pumps from Wilden, Grand Terrace, CA, USA, a product brand of PSG, Oakbrook Terrace, IL, USA, a Dover company, for which Holland Air Pumps is a distributor in The Netherlands and other European countries. More precisely, Klaassen suggested stainless-steel Wilden Original (Clamped) and Advanced (Bolted) AODD Pumps, the 51mm (2in) PS8 and PS800 models, respectively.

“Since the viscosity of our paints is very high we needed AODD pumps with stainless-steel balls so that the ball would not get stuck in the paint when it was time to reseat in the valve,” explained Doppenberg. “If the ball gets stuck in the paint, it stays up and the pump won’t pump. With the stainless-steel Wilden pumps the balls have time to drop through the paint and reseat after pumping. It’s a nice pump, a very good pump.”

In addition to having the ability to handle high-viscosity liquids, the PS8 and PS800 pumps have a redesigned liquid path that reduces internal friction for maximised flow rates and pumping efficiency with leak-free product containment guaranteed.

Diaphragm options include Buna-N, EPDM, Geolast, Neoprene, polyurethane, PTFE (Teflon), Saniflex (Hytrel), Viton and Wil-Flex (Santoprene). Additionally, the PS8 and PS800 pumps are outfitted with Wilden’s revolutionary Pro-Flo SHIFT Air Distribution System (ADS). The design and operation of the Pro-Flo SHIFT provides up to 60% savings in air consumption when compared to competitive models, which lowers operating costs and carbon footprint. This was another crucial consideration for Havo, which prides itself on being a ‘green’ company and even powers its facility with solar energy, while constantly monitoring electricity consumption.

wilden

Havo employs a total of 25 Wildenpumps in its production operation and all are equipped with Wilden Equalizer SD Series Surge Dampeners. This optional accessory minimizes unwanted pressure fluctuations during liquid-transfer applications

Havo employs a total of 25 Wilden pumps in its production operation that are all equipped with Wilden Equalizer SD Series Surge Dampeners. This accessory minimizes unwanted pressure fluctuations during liquid-transfer applications by providing a supplementary pumping action that virtually eliminates pressure variations that can create pulse in the liquid flow, with operational capability up to 8.6bar (125psi). The SD Series is available in aluminium, stainless steel, cast iron and polypropylene, depending on the pump model being used, and is also compatible with all of Wilden’s standard diaphragm options.

In the filter press that is used to clean the wastewater before it moves to the treatment plant, Havo is utilising an Advanced H800 High Pressure AODD Pump. The bolted configuration of the 51mm H800 pump ensures total product containment with stainless steel and cast iron available for the wetted path, which has been redesigned to maximise output and efficiency. Diaphragm options include PTFE and Wil-Flex.

“When a long-time partner like Havo comes to us with a problem, we do our best to identify and recommend the right solution,” said Klaassen. “When Job approached me with the challenge he was facing in pumping highly viscous and sticky paint products, I knew the Wilden pumps would be the best solution.”

wilden

In the filter press that is used to clean the various production machines, Havo utilises a Wilden Advanced High Pressure AODD Pump

CONCLUSION

By their nature, artists are perfectionists, and they feel that every painting is truly a work of art. That means that the companies that produce the paints they use must also strive to provide perfect products. Havo has been able to meet that standard for more than 50 years in part by partnering with equipment suppliers that recognise their unique production needs and being able to deliver the perfect solution. When underperforming pump technologies were threatening to compromise the quality of its products, along with the reliability and environmental sensibility of its production operations, Havo turned to Holland Air Pumps and Gerrit Klaassen, who were quick to advocate for Wilden AODD Pumps, and they have successfully met the needs of Havo’s highly critical paint-production operations.

“I need machines that I can trust to do the job, and we need partners that I can trust, that if I call them they can tell me what to do, and I get that from Holland Air Pumps,” said Doppenberg. “The Wilden pumps are very good at helping me do my job and they make my job easier.”

Author: Alberto Lerussi, EMEA - Dir of Sales - Diaphragm Equip for PSG
Tel: +33 139 11 5308
Email: alberto.lerussi@psgdover.com
Website: www.wildenpump.com; www.psgdover.com.