Pump purchase return on funding may be measured in days
By Mike Libbey, Area Sales Manager CIRCOR and Bob Limper, Business Development Manager CIRCOR
A world producer of scented plastic garbage baggage was looking for an different 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 circulate charges required, whereas also reducing their costs and enhancing worker health. Yearly financial savings are so high that the return on investment for the pump system could be measured in days.
Seeking an alternative for costly pre-scented plastic pellets
A international producer of scented plastic rubbish luggage was in search of an various to the use of pre-scented plastic pellets, which required a dedicated silo for every of the 20 obtainable fragrances. The pellets are pneumatically conveyed to each silo from both tanker vehicles or rail vehicles and the producer was experiencing logistical issues related to preserving the silos filled. They also needed to carry high prices for maintaining the inventory of the pre-scented pellets.
In addition, the closely concentrated scents had been inflicting health issues for the workers who complained of headaches. To mitigate this problem, each extruder line was fitted with a vacuum exhaust hood to expel the fumes to the outdoors. On event, these emissions led to complaints from neighbors and citations from the United States Environmental Protection Agency.
The firm was seeking a way to make use of plain plastic pellets and apply scented oil directly to the plastic sheet instantly after the extrusion process to cut back costs, logistical challenges, and power use. They had tried to build such a system in-house but had struggled to attain accuracy and consistency on the low circulate rates they required. They determined to seek a pump-based solution that could instantly spray fragrance on the warm melted sheet plastic as a end result of the in-house resolution couldn’t meet rigorous quality control 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 producer attending the PackExpo show noticed a working demonstration of precision gear metering pumps made by Zenith and asked utility consultants if the pumps might be a match with their software. After collecting data on the application, an space supervisor for the pump producer with in depth expertise in dosing and blending techniques visited the plant to get a firsthand view of present operations and collect additional information.
Working with the pump manufacturer’s design group they developed a system solution using a Zenith B-9000 Series rotary constructive displacement pump specifically designed for single stream chemical responsibility applications. The pump options an accurate, repeatable, pulse free circulate in a compact design ideal for dosing additives similar to colours, flavors, and fragrances.
This sort of pump is defined as rotary as a outcome of the drive shaft is rotated as in comparability with different forms of pumps using a reciprocating movement and is also considered to be a optimistic displacement kind because the displaced volume is fixed and does not vary.
Pumping motion is achieved by filling the gear enamel areas and transporting the fluid around the outer diameter of the gears. When the gear tooth mesh, the fluid is displaced and compelled to the outlet side of the pump. The flow rate can solely be adjusted by rising or reducing the pace at which the shaft is rotated. The pump chosen presents precision grinding and lapping processes that lead to a precision metering instrument, producing precise, pulse-less, and repeatable fluid flow.
The pumps offer extraordinarily tight operating clearances to reduce fluid slip. Manufacturing tolerances on many components are to +/- 50 millionths of inch with floor finishes as smooth as four micro inches or higher. The pumps are provided with an AC “closed loop” motor speed controller to take care of 0.1 percent pump speed accuracy.
The Zenith 9000 collection pump is available in 11 sizes with capacities starting from .003 to 300 GPH. pressure gauge octa can be found in via hardened 440C series stainless-steel, specialty handled 316 stainless steel, and high quality tool steels similar to D2, M2, M4 and CPM-M4 to supply good corrosion and abrasion resistance.
The bag manufacturer chosen a model with a magnetic drive (mag-drive) sealing choice, which may get rid of shaft leakage of fluids, increasing plant security and lowering risky organic compound emissions. The use of a magnetic coupling also eliminates downtime due to mechanical seal failures and eliminates the necessity for buffer fluids.
New solution reduces costs and provides uniform perfume 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 adding the scent directly to the bags after leaving the extruder, the plastic bag producer not solely eliminated the necessity to have separate pellet silos for each scent, but additionally eradicated the necessity to vent the fumes that come from the pellets as they journey from the silos to the extruders.
The manufacturer bought the first system and after successful trials, ordered six further methods. Over the previous two years they’ve purchased greater than 30 systems, with plans to order extra. The producer is also excited about having Zenith conduct annual area calibrations of each system.
After two years of operation, the manufacturer estimates a yearly savings of roughly $480,000 per skid in operation. With 30 skids now running, the return on funding for every system purchase can be measured in weeks. To date, there have been no odor complaints because the buyer installed the Zenith systems