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Case Studies

Ceramic Sanitaryware Manufacturer

The Customer
A ceramic sanitaryware manufacturer with over 100 Diaphragm Pumps of which 53 are 2” Ported needed help

Sunday 8th November 2015

The Problems

  • Air consumption reaching maximum capacity for the compressors.
  • Electrical costs of running compressors at full capacity.
  • Pump failure rates due to 24/7 operation.
  • System downtime to replace pumps.
  • High wear due to abrasive nature of products.

The Solution

After extensive study of the applications the following recommendations were made.

  • Where possible increase the pumps from 2” to 3” ported.
  • Modify pipework to remove sharp bends and elbows allowing easier flow of material.
  • Install compressor control system to maximise efficiency of the current 4 existing compressors.
  • Instigate service exchange programme to ensure repaired pumps are always ready for use.

graph

The Result
The graph illustrates the actual results the client recorded during a trial. A 2” and then a 3” pump were mounted on the same application and regulated to the same flow capacity for a 1 week period.

  • By using 3” pumps, the air consumption dropped to 1/3 of a 2” pump, effectively running three pumps for the price of 1.
  • By modifying pipework, resistance was decreased meaning less pressure required to pump product, this meant pumps could be turned down saving huge amounts of air.
  • As a 3” pump displaces double the volume of a 2” pump, The reduced number of flexes and the lower liquid velocity extended maintenance intervals way beyond previous levels.
  • Utilising our service exchange program and test facility, no unnecessary spares were fitted, this reduced the parts costs per repair by over 50%
  • The client realised a £70k maintenance saving in the first year working with DPGOC.