Pump buy return on funding could be measured in days
By Mike Libbey, Area Sales Manager CIRCOR and Bob Limper, Business Development Manager CIRCOR
A international producer of scented plastic rubbish luggage was on the lookout for an different to using pre-scented plastic pellets. A serendipitous encounter at a tradeshow led them to a precision gear metering pump resolution that gave them accuracy and consistency at the low move rates required, while additionally lowering their prices and bettering employee well being. Yearly financial savings are so high that the return on investment for the pump system can be measured in days.
Seeking an alternative for pricey pre-scented plastic pellets
A world producer of scented plastic garbage luggage was on the lookout for an alternative choice to using pre-scented plastic pellets, which required a devoted silo for every of the 20 obtainable fragrances. The pellets are pneumatically conveyed to each silo from both tanker vans or rail cars and the manufacturer was experiencing logistical points related to maintaining the silos stuffed. They additionally needed to carry excessive costs for maintaining the stock of the pre-scented pellets.
In addition, the heavily concentrated scents had been causing well being concerns for the workers who complained of complications. To mitigate this concern, every extruder line was fitted with a vacuum exhaust hood to expel the fumes to the outdoors. On occasion, these emissions led to complaints from neighbors and citations from the United States Environmental Protection Agency.
The firm was seeking a method to use plain plastic pellets and apply scented oil on to the plastic sheet immediately after the extrusion process to minimize back prices, logistical challenges, and energy use. They had tried to construct such a system in-house but had struggled to achieve accuracy and consistency on the low flow charges they required. They decided to hunt a pump-based resolution that would immediately spray perfume on the warm melted sheet plastic as a outcome of the in-house resolution couldn’t meet rigorous high quality management standards requiring the spray-on scent to exactly match that of pre-scented pellets.
Finding an answer on a tradeshow floor
Design engineers from the plastic bag manufacturer attending the PackExpo show observed a working demonstration of precision gear metering pumps made by Zenith and requested application experts if the pumps could be a fit with their utility. After accumulating info on the application, an space manager for the pump producer with intensive experience in dosing and blending methods visited the plant to get a firsthand view of present operations and collect extra info.
Working with the pump manufacturer’s design group they developed a system resolution utilizing a Zenith B-9000 Series rotary positive displacement pump particularly designed for single stream chemical obligation functions. The pump options an correct, repeatable, pulse free flow in a compact design best for dosing components corresponding to colours, flavors, and fragrances.
This kind of pump is defined as rotary because the drive shaft is rotated as compared to other kinds of pumps utilizing a reciprocating movement and can also be thought-about to be a optimistic displacement kind because the displaced quantity is constant and doesn’t differ.
Pumping action is achieved by filling the gear enamel spaces and transporting the fluid across the outer diameter of the gears. When the gear enamel mesh, the fluid is displaced and forced to the outlet facet of the pump. The move price can solely be adjusted by rising or decreasing the velocity at which the shaft is rotated. The pump selected provides precision grinding and lapping processes that lead to a precision metering instrument, producing exact, pulse-less, and repeatable fluid move.
The pumps supply extremely tight working clearances to attenuate fluid slip. Manufacturing tolerances on many elements are to +/- 50 millionths of inch with surface finishes as easy as 4 micro inches or better. The pumps are supplied with an AC “closed loop” motor pace controller to maintain 0.1 p.c pump pace accuracy.
The Zenith 9000 sequence pump is available in eleven sizes with capacities ranging from .003 to 300 GPH. Wetted parts can be found in through hardened 440C sequence stainless-steel, specialty treated 316 chrome steel, and high quality software steels such as D2, M2, M4 and CPM-M4 to offer good corrosion and abrasion resistance.
The bag manufacturer chosen a model with a magnetic drive (mag-drive) sealing option, which may remove shaft leakage of fluids, increasing plant safety and reducing risky natural compound emissions. The use of a magnetic coupling additionally eliminates downtime as a end result of mechanical seal failures and eliminates the necessity for buffer fluids.
New resolution reduces prices and provides uniform perfume distribution
The new Zenith pump system gave the scented bag producer a steady, pulse free course of, which ensures equal and uniform fragrance distribution. By adding the scent on to the luggage after leaving the extruder, the plastic bag manufacturer not solely eradicated the necessity to have separate pellet silos for every 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 manufacturer purchased the primary system and after profitable trials, ordered six extra methods. Over the previous two years they have bought more than 30 systems, with plans to order more. The manufacturer can be interested in having Zenith conduct annual subject calibrations of each system.
After two years of operation, the manufacturer estimates a yearly savings of approximately $480,000 per skid in operation. With เกวัดแรงดัน running, the return on investment for every system buy could be measured in weeks. To date, there have been no odor complaints since the buyer put in the Zenith methods