Pump purchase return on investment can be measured in days
By Mike Libbey, Area Sales Manager CIRCOR and Bob Limper, Business Development Manager CIRCOR
A international manufacturer of scented plastic rubbish bags was in search of an various to using pre-scented plastic pellets. A serendipitous encounter at a tradeshow led them to a precision gear metering pump solution that gave them accuracy and consistency at the low move charges required, whereas also decreasing their prices and bettering employee health. Yearly financial savings are so excessive that the return on investment for the pump system could be measured in days.
Seeking an alternative for expensive pre-scented plastic pellets
A international producer of scented plastic rubbish bags was on the lookout for an different to using pre-scented plastic pellets, which required a dedicated silo for each of the 20 obtainable fragrances. The pellets are pneumatically conveyed to every silo from either tanker trucks or rail automobiles and the manufacturer was experiencing logistical issues associated with preserving the silos filled. They also had to carry high prices for maintaining the stock of the pre-scented pellets.
In addition, the heavily concentrated scents had been inflicting well being considerations for the employees who complained of complications. To mitigate this problem, every extruder line was fitted with a vacuum exhaust hood to expel the fumes to the outside. On occasion, these emissions led to complaints from neighbors and citations from the United States Environmental Protection Agency.
The company was looking for a method to make use of plain plastic pellets and apply scented oil on to the plastic sheet instantly after the extrusion process to minimize back prices, logistical challenges, and power use. They had tried to construct such a system in-house however had struggled to realize accuracy and consistency on the low circulate rates they required. They decided to hunt a pump-based resolution that would immediately spray fragrance on the warm melted sheet plastic as a result of the in-house solution couldn’t meet rigorous quality management requirements requiring the spray-on scent to precisely match that of pre-scented pellets.
Finding a solution on a tradeshow floor
Design engineers from the plastic bag producer attending the PackExpo present noticed a working demonstration of precision gear metering pumps made by Zenith and requested software consultants if the pumps might be a fit with their utility. After ร้านซ่อมเครื่องวัดความดันomron on the application, an space supervisor for the pump manufacturer with extensive expertise in dosing and blending techniques visited the plant to get a firsthand view of current operations and gather extra info.
Working with the pump manufacturer’s design group they developed a system solution utilizing a Zenith B-9000 Series rotary positive displacement pump particularly designed for single stream chemical obligation purposes. The pump options an accurate, repeatable, pulse free circulate in a compact design perfect for dosing components corresponding to colours, flavors, and fragrances.
This sort of pump is defined as rotary as a end result of the drive shaft is rotated as in comparability with different forms of pumps utilizing a reciprocating movement and can also be thought-about to be a positive displacement sort because the displaced quantity is constant and does not vary.
Pumping motion is achieved by filling the gear teeth spaces and transporting the fluid around the outer diameter of the gears. When the gear teeth mesh, the fluid is displaced and compelled to the outlet side of the pump. The circulate fee can only be adjusted by rising or reducing the velocity at which the shaft is rotated. The pump chosen presents precision grinding and lapping processes that result in a precision metering instrument, producing precise, pulse-less, and repeatable fluid flow.
The pumps provide extraordinarily tight working clearances to minimize fluid slip. Manufacturing tolerances on many parts are to +/- 50 millionths of inch with surface finishes as easy as four micro inches or higher. The pumps are provided with an AC “closed loop” motor pace controller to maintain zero.1 p.c pump speed accuracy.
The Zenith 9000 sequence pump is on the market in 11 sizes with capacities ranging from .003 to 300 GPH. Wetted components can be found in through hardened 440C series stainless-steel, specialty handled 316 stainless steel, and prime quality device steels similar to D2, M2, M4 and CPM-M4 to offer good corrosion and abrasion resistance.
The bag producer selected a model with a magnetic drive (mag-drive) sealing possibility, which might remove shaft leakage of fluids, increasing plant safety and reducing risky organic compound emissions. The use of a magnetic coupling additionally eliminates downtime due to mechanical seal failures and eliminates the necessity for buffer fluids.
New answer reduces costs and offers uniform fragrance distribution
The new Zenith pump system gave the scented bag producer a steady, pulse free course of, which guarantees equal and uniform fragrance distribution. By including the scent on to the bags after leaving the extruder, the plastic bag producer not only eliminated the need to have separate pellet silos for each scent, but in addition eradicated the want to vent the fumes that come from the pellets as they journey from the silos to the extruders.
The producer purchased the primary system and after successful trials, ordered six further techniques. Over the previous two years they’ve bought greater than 30 techniques, with plans to order extra. The producer can additionally be thinking about having Zenith conduct annual field calibrations of each system.
After two years of operation, the manufacturer estimates a yearly financial savings of approximately $480,000 per skid in operation. With 30 skids now running, the return on investment for each system purchase could be measured in weeks. To date, there have been no odor complaints for the reason that customer put in the Zenith methods
Pump purchase return on investment can be measured in days