Paint and ink manufacturers improve efficiency

The ink industry is a multi-billion dollar industry that is experiencing many challenges today. Rising raw material and operational costs, fierce competition and other factors are forcing ink manufacturers to look for new opportunities for innovation, operational efficiencies and cost reductions. Tim Yakup, Product Specialist with Hurll Nu-Way, acquaints Australian manufacturers with new process pumping solutions for chemical transfer applications.

Evaluation

Tim Yakup evaluates manufacturers’ chemical transfer applications, and identifies opportunities to improve efficiencies, reduce pump maintenance costs and lower overall cost of ownership for the dozens of air operated double diaphragm pumps used in production. Recently, Mr Yakup presented to several Australian paint and ink manufacturers the Sotera Systems SP100 Air Operated Double Diaphragm (AODD) pump manufactured by Tuthill Corporation to achieve these goals.

Challenging fluids for process pumps

Water-based, solvent-based and UV-curable inks, along with other coatings, varnishes and adhesives, are often abrasive and exhibit a wide range of viscosities. These formulations can be extremely shear-sensitive as well. Subjecting them to the high shearing action of gear or centrifugal pumps can alter formulations and cause foaming, which adversely affects production efficiency and print quality. For these reasons and others, air-operated double diaphragm pumps have been the top choice for years.

Improving efficiencies and reducing costs

Paint and ink manufacturers use dozens of pumps in transferring chemicals to mix tanks to blend final ink formulations. Pumps that can reduce pulsation, consume less air, and require less maintenance will generate significant operational efficiencies.

Mr Yakup was quick to recognise the opportunities for his clients and offered to switch to the SP100 AODD pump to achieve these efficiencies and cost reductions.

Fluid compatibility

The SP100’s innovative design and available elastomers easily accommodate the wide range of fluids used in the inks business. Rugged pump body construction and an advanced ball check and seat design that yields 20 per cent more suction lift allow the SP100 to handle abrasive formulations and varying viscosities without a problem.

Reduction in pulsation

The SP100’s low pulsation and gentle, low-shear action help minimise in-system agitation that might otherwise negatively affect sensitive formulations, change viscosity and/or produce foaming. This is achieved by a patented, non-centring ceramic air valve for extremely fast trip-over. This drive system requires no external lubrication, will not ice internally and is volumetrically efficient, transferring virtually no heat to inks and vital fluids being pumped.

Less maintenance

Reduced maintenance is engineered into the SP100. Whereas most AODD pumps are held together with an inordinate number of fasteners around the perimeter of pump body, the SP100 uses patented QuikSeal ring technology. This innovative ring design eliminates these fasteners and ensures a 360-degree uniform seal.

This design greatly simplifies and speeds uproutine maintenance. Parts are easily and quickly replaced and the pump is back in service. It has the added benefit of minimising wear, increasing the life of the diaphragm and delivering reliable, consistent performance. The result is a dramatic 67 per cent reduction in maintenance time over most other AODD pumps on the market.

Improved efficiency

Compressed air energy costs are a major expense for ink manufacturers. In the industrial sector alone, compressed air systems account for an estimated $5 billion per year! The SP100 is designed to deliver 15 per cent more flow on 20 per cent less compressed air, resulting in impressive savings in compressed air costs over the life of the pump.

Overall performance 

What Mr Yakup recognised and presented to his clients is that the total cost of ownership of an AODD pump consists of the combination of the initial purchase price, maintenance time, parts costs, and the life expectancy of the pump.

Sotera Systems SP100 Air Operated Double Diaphragm Pumps are available from Hurll Nu-Way in 1/2” and 1” models in a variety of materials and elastomers to handle most chemical transfer operations in the inks and other process manufacturing applications. A 2” model will be available soon.

About Hurll Nu-Way

Hurll Nu-Way (HNW) has been serving the Australian industry for over a hundred years with over thirty years’ experience in supplying pumps, meters and mixers for high value fluids. Thanks to HNW’s technical expertise and extensive product and application knowledge, their customers are provided with the best possible solutions based on quality and value for money.

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