9 ways to reduce manual pump operation
Discover the ways in which you can automate your pump.
“Wasted time is worse than wasted money” is how the quote goes, but in fact, wasted time IS wasted money for your business, as labour costs are one of the most expensive overheads in any company. Do your processes involve more time than necessary on the manual operation of your pumps? By freeing up your workers’ time for more value-adding tasks, you can also prevent pump damage, improve accuracy and reduce waste. Here are some more ways that you can automate your pump…
1. Pump timer
Sometimes you may wish the pump to start and run for specified periods of time before stopping. For example, a circulating application may need a fluid to be pumped for 10 minutes every 4 hours around a tank to prevent it from sitting still for too long and the ingredients separating. Fitting a timer would not only reduce the amount of time spent by someone walking to the pump and operating it, but it also eliminates the chance of someone forgetting and it not being done.
2. Batch meter
Pumps that are responsible for dosing or transferring a specific volume of fluid can be supplied with a batch meter that can turn the pump off once the amount is reached. This reduces reliance on the operator, and also ensures the amount is accurate and easily repeated. Batch meters are ideal for container filling applications and for adding a set amount of fluid/ingredient into a mixture.
3. Stroke counter
A stroke counter is similar in principle to a batch meter, but is specifically designed for air operated pumps. It counts the amount of times air is ejected by the pump and can turn it off once a specified number has been performed. By knowing how much fluid is transferred per stroke, you can use it for batching. However, if the viscosity of the fluid can differ, it will be inaccurate.
4. Level/float switches
Level switches can also control the pump start/stop cycle. When the fluid in a container has reached a certain level, the pump will turn on or off and continue until the sensor detects the other specified level. This is popular for tank emptying and filling and dewatering applications.
5. Dry run protection
If a pump is left to run with no fluid passing through it, then it can overheat, cause component seizure and damage to the seals and impellers. Pauses in your production line or operators forgetting to turn the pump off can result in dry running. Some pump designs such as AODD or peristaltic can dry run without damage, but if using a pump that doesn’t such as a centrifugal pump, then a dry run sensor can automatically turn the pump off when it is detected.
6. Leak sensor
The fitting of a leak sensor can turn a pump off upon detection of fluid leaking from the pump. These are particularly good practice for pumps handling high-cost product or hazardous fluids and chemicals that can be dangerous or flammable.
7. Variable speed drive
Where there are differing duty demands on the pump at different times, VSDs can help automate the speed of the motor to actual requirements rather than maximum capacity. They can be used to slow down or speed up the pump’s motor depending upon the pressure detected in the system.
8. Remote monitoring
These sophisticated systems have integrated data loggers that can monitor things like vibrations, pressure and motor current to ensure that issues can be spotted in advance without the need for manual inspection.
9. Remote control
Radio operated control pads enable pump start/stop or reverse operation to be carried out without physically going over to the pump. If a pump is operated multiple times per day, productivity can be drastically improved with this.
These are all great ways to automate your pump but it is rare that a pump will utilise them all. We advise you to think about what costs the most time or money in your process and from there decide which automation feature will be the best to solve that.
For more information get in contact with Castle Pumps.
Castle Pumps
- 01773 533 283
- sales@castlepumps.com
- https://www.castlepumps.com
- Office 1, Denby House Taylor Lane Loscoe Derbyshire DE75 7AB GB
About us
Castle Pumps Ltd are specialist suppliers of industrial pumps with over 10 years’ experience specifying pumping solutions to process engineers, operations managers and plant build consultants.
At Castle Pumps we understand that a pump that works isn’t necessarily the right pump. A pump that is pushed to it’s performance capabilities will result in more regular, costly maintenance, manual intervention from its operators, waste product and energy inefficiency. As a single source supplier of all of pumping technologies from centrifugal to air operated diaphragm to peristaltic to progressive cavity pump, we select the exact pump solution ideal for your application.
Whether you are looking to circulate water round a cooling system, dose ingredients on a production line, fill barrels of chemicals or transfer oil between tanks, contact Castle Pumps to deliver your process.
Where we supply to
UK Ireland, Europe, Africa, Asia, Australia, South America, North America
Industries we supply to
Energy and Power, Food and Beverage, Metals and Minerals, Paper and Pulp, Pharmaceutical Cosmetics Toiletries, Water and Wastewater
