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Editorial 

Artificial intelligence for industry 

Dear Readers, 

Artificial intelligence is a buzzword with distinct utopian overtones. Just about everyone has heard about ChatGPT, 

a program that can write texts of the same quality as a well educated person. Or about LamBDA, the computer that 

claims to have a consciousness and gives very human answers to questions. And who among us hasn’t seen a service 

robot? These are just three examples of a technology that is currently coming to the forefront in its first generation. 

Experience has shown that a better, stronger second generation of modern technologies quickly follows. Many 

renowned companies are already working on this. I am therefore confident that AI will establish itself in just a few 

years, just as the mobile phone and the Internet took hold and are now part of our daily routine. But what does that 

mean for our future? Soon, computers or robots will be able to do anything that is not directly creative, subject to 

changing requirements or mechanically complicated, and does not require strategic decisions linked to emotions to be 

made – even the production, assembly, monitoring and control of machines. On the other hand, AI can support the development 

of new products. Examples include circuit design, energy-optimised structures and social network effects. 

Is artificial intelligence a threat or an opportunity? But perhaps that isn’t the right question. Maybe I have to take a 

totally different approach: Central Europe is headed for a labour shortage crisis. According to the December 2022 edition 

of ZEIT magazine, the demand for workers is going to exceed the supply by up to 5 million people in 2035. Many 

jobs will be left without anyone to do them. So it would be better for us to reserve the challenging part of a job for ourselves, 

and to understand AI as a helpful technology that assists us in daily life. I would even go so far as to say that the 

country that makes this transition most effectively and quickly will have an advantage. This could mean faster, better 

product development or optimal system architectures. That being said, nobody really knows yet what areas are going 

to be affected. We should however assume that it will be of very high social and industrial relevance. Naturally one 

also has to consider the taxation of such services, the value of the work, working hours and the society that will subsequently 

establish itself. We will certainly have to reorganise ourselves and social factors must not be disregarded. 

Let’s take ChatGPT as an example. Using this program could streamline work processes in public or also industrial 

administration by having a few employees merely enter keywords, check the results that are produced, and then 

approve and send them out. Future workers, who are currently students, are already able to handle this. 

In an industrial application, for example, an AI system reports that a fault has been detected in a machine, indicating a 

damaged seal. The AI system could not only initiate the seal replacement but also order the new part. AI could propose 

how a circuit design can be improved, or assist with the programming of new software. AI is able to respond effectively, 

extremely quickly and rationally. Thus the first question we should ask is where using AI will be the most helpful. Have 

courage and seek advice. It’s worth your while. 

With best regards, 

Prof. Dr.-Ing. Eberhard Schlücker 

Prof. (ret.), advisor on hydrogen and energy issues 

PROCESS TECHNOLOGY & COMPONENTS 2023 

5

PROCESS TECHNOLOGY & COMPONENTS 

Editorial Advisory Board 

Editorial Advisory Board 2023 

Prof. Dr.-Ing. Eberhard Schlücker, Prof. (ret.), advisor on hydrogen and energy issues 

Head of the Editorial Advisory Board 

Prof. Dr.-Ing. Eberhard Schlücker was born in 1956 and studied mechanical engineering at the Heilbronn University of Applied 

Sciences and Chemical Engineering at the University of Erlangen-Nuremberg where he did his doctorate in 1993. His industrial 

activity comprised an apprenticeship as a mechanic, three years as a designing engineer, four years as head of the R&D department 

and five years as proxy in the Engineering division. From 2000-2022 he has been professor and has been holding 

the chair in “Process Machinery and System Engineering“ at the University of Erlangen-Nuremberg. His subject area included 

layout and operation of systems, machines and plants for chemistry, water, food and biotechnological engineering as well as 

practical management. His research focus is on the pulsation problem and system dynamics in plants, the optimization and simulation of pumps, 

compressors and systems, the high-pressure component and process technology, the application of ionic fluids, the energetic optimization of 

systems and the research of wear processes. In 2008 he was Vice Dean of the School of Engineering, is editor of journals, member of several committees 

and research associations, gives hydrogen seminars throughout Germany, and is a technical consultant for companies and lecturer in international 

training programs. 

Prof. Dr.-Ing. Andreas Brümmer, Head of Fluidics at Technical University Dortmund 

Prof. Dr.-Ing. Andreas Brümmer, born in 1963, studied aerospace engineering at the Technical University of Braunschweig 

where he received a doctorate at the Institute of Fluid Mechanics in the field of Flight of Birds. His industrial career started in 

1997 as Head of Department for Fluid Dynamics at Kötter Consulting Engineers KG. There, he gained first experiences in the 

physical analysis and elimination of flow-induced vibrations in industrial plants. In 2005, he became Technical Director of the 

company. Since 2066, he has been professor and Head of Fluidics at the Technical University of Dortmund. His research foci 

included the theoretical and experimental analysis of screw-type machines, both in compressor applications (e. g. refrigeration 

compressors and air compressors, vacuum pumps) and in expander applications (e. g. waste heat utilization). Furthermore, 

he researches the interaction between unsteady pipe flow and gas flow meters. From 2008 to 2011, he was Vice Dean and Dean of the Faculty 

of Mechanical Enginee ring and since 2012 he has been Senator at the Technical University of Dortmund. He is reviewer of several international 

journals, member of industrial advisory boards and scientific committees and scientific director of the VDI symposium “Screw-Type Machines”. 

Dipl.-Ing. (FH) Gerhart Hobusch, Project Engineer, KAESER KOMPRESSOREN SE, Coburg 

Gerhart Hobusch, born in 1964, studied mechanical engineering at the University of Applied Sciences in Schweinfurt, Northern 

Bavaria. He graduated with a degree in mechanical engineering and completed postgraduate studies with a degree in industrial 

engineering. He has been working as a project engineer at KAESER KOMPRESSOREN SE, Coburg, since 1989. His responsibilities 

include the planning of compressed air stations, the development of economical, energy-saving concepts for compressed 

air stations and the worldwide training of KAESER project engineers. As part of his job, he has worked on research projects 

such as the “Compressed Air Efficiency” campaign, the EnEffAH joint project, as well as FOREnergy and Green Factory Bavaria, 

and is active in the VDMA's compressed air technology department. The standard compliant implementation of volume flow 

and power measurements on compressors, also in connection with China Energy Label efficiency requirements, as well as compressed air quality 

measurements according to ISO standards are also part of his tasks. In addition to the specialist lectures on compressed air technology held 

over the years, he is participating in the development of the KAESER blended learning concept with the design of e-learning courses and the implementation 

of online training courses. 

Dipl.-Ing. (FH) Johann Vetter, Head of Integrated Management Systems, NETZSCH Pumps & Systems GmbH, Waldkraiburg 

Johann Vetter, born in 1966, studied mechanical engineering at the Technical Colleage of Regensburg. His diploma thesis 

dealt with the topic “Filters and filter materials“ in Environmental and Process Engineering. Prior to his studies, Mr. Vetter had 

completed an apprenticeship as machine fitter and thus created a practical basis for his later activities in the automotive industry, 

where he worked for 16 years as a quality engineer, development engineer, project manager and department manager 

for airbag systems. Mr. Vetter has shown outstanding achievements in the field of “gas generators“, where he has applied for 

several patents. Since 2013, Mr. Vetter has been responsible for special projects mainly for the oil and gas industry at NETZSCH 

Pumps & Systems, where he took over the position of Quality Manager after 3 years. Since October 2019 he has been responsible 

for the areas of integrated management systems and is also a member of the Management Board of NETZSCH Pumps & Systems. 

Dipl.-Ing. (FH) Sebastian Oberbeck, Manager Research & Development Backing Pumps, Pfeiffer Vacuum GmbH, Asslar 

Sebastian Oberbeck, born 1970, graduated at the University of Applied Sciences Mittelhessen in engineering and precision 

mechanics. His career startet as project engineer and later as project manager at the Fraunhofer Institute for Microsystems 

in Mainz developing mainly micro pumps, micro valves and microsystems (MEMS) in publically funded as well as in industry 

sponsored projects. From 1998 he was responsible for nano technically manufactured Pointprobe AFM sensors at Nanosensors 

GmbH in Wetzlar. In 1999 he became founding member and partner of the startup company CPC Cellular Chemistry 

Systems GmbH where he was responsible for developing micro chemical reaction systems in Laboratory and Pilot plant applications 

in the chemical and pharmaceutical industry. 2004 he took the product management responsibility for automotive 

drive shaft components of Daimler Chrysler and Getrag at tier 1 supplier Selzer Fertigungstechnik GmbH in Driedorf. Since 2009 he is employed 

at Pfeiffer Vacuum GmbH as R&D Manager for backing pumps and backing pump systems. 

6 PROCESS TECHNOLOGY & COMPONENTS 2023

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Contents 

Title 

100 % availability, 0 % problems 

AERZEN packages ensure reliable transport processes 

at A+S BioTec GmbH 

Availability and reliability have top priority at A+S BioTec GmbH. 

For this reason, the Saarland-based family business has exclusively 

used blowers and compressors from Aerzen for the pneumatic 

conveying of its raw materials and products for more than 

50 years. The packages provide absolutely oil- and absorption 

material-free air and guarantee a safe, reliable material flow. 

Service and support are also excellent in every respect. 

(starting on page 18) 

Contents 

Editorial 

Artificial intelligence for industry 5 

Leading article 

Artificial intelligence and the digitalisation of process components 10 

Hydrogen 

Anything but standard: Elastomer seal challenges in 

hydrogen applications 14 

Unafraid of hydrogen 16 

Cover story 

100 % availability, 0 % problems 18 

Pumps and Systems 

Diaphragm metering pumps 

Condition monitoring and prediction for 

diaphragm metering pumps 22 

Companies – Innovations – Products 

Pumps/Vacuum technology 49 

Index of Advertisers 64 

Impressum 64 

Trade fairs and events 

DIAM & DDM 66 

Compressors und Systems 

Energetic use of biogas 

Farm energy independence – for a crisis-proof future 68 

Screw compressors 

GEA compressor important component of new particle 

accelerator facility at GSI Helmholtzzentrum 

für Schwerionenforschung 72 

Compressed air supply 

Uninterrupted compressed air supply 

with added efficiency 74 

Compressed air technology 

Compressed air remote monitoring 

This is how it’s done – maintenance and service 4.0 76 

Components 

Sensors 

How to protect pumps from air and gas inclusions 79 

Valves 

Pure and affordable drinking water for a whole region 82 

Operation under high pressure 84 


Compressors/Compressed air/Components 86 

Technical Data Purchasing 91 

Intelligent pump technology 

Automatic adjustable pump makes life easier in WWTP 28 

Report – Industrial hose pumps 

Bredel industrial hose pumps convey corrosive media 

in flue gas purification 32 

Report – Downhole progressing cavity pumps 

60 % fewer production losses: Downhole 

progressing cavity pumps simplify replacment and reduce 

costs with special flush-by unit 35 

Report – Intelligent pumping solutions 

Energy savings potential with intelligent pumping solutions – 

how a beverage producer expects 430,000 € 

in energy savings per year 38 

Vacuum technology 

Vacuum-based leak testing methods 

Vacuum-based methods for testing the packaging 

of pharmaceutical products for leaks 40 

Reduction of production downtime 

7 ways to reduce production downtime 46 

8 

PROCESS TECHNOLOGY & COMPONENTS 2023

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Artificial intelligence and the digitalisation 

of process components 

Prof. Dr.-Ing. Eberhard Schlücker, Dominik Haspel 

Process components and process 

technology systems have moving 

fixtures and fittings. Substances 

pass through them, they are controlled 

electronically or electrically, 

moved electrically or with flow 

forces. They move liquids, gases 

and solids. As a result, forces are 

exerted on the component that, 

when measurable, also provide information 

about the condition or 

state. Thus the response to a controlling, 

driving or conveying action 

necessarily contains information 

about the device or machine. This 

may be visible directly in the current 

profile or indicated by vibrations. 

The latter tends to be the result of 

pulsing disturbances (all natural frequencies 

are excited) and intermittent 

events, which are usually typical 

for the type of damage. 

While the signals that are visible in 

load curves and control characteristics 

can be analysed relatively well in 

a chronological sequence, are easily 

and well recognised by computers 

and can be used for control purposes, 

vibration signals are somewhat more 

difficult to analyse and comprehend. 

At the same time however, they are 

the more interesting sources of information 

for (early) fault detection. 

They are the first indication we have 

of a fault, as soon as a mechanism 

develops a very small defect that 

can still be repaired in many cases, 

but the damage is not yet significant. 

Vibration measurements therefore 

support genuine early fault detection. 

That being said, how do we analyse 

and interpret vibrations correctly? 

A first step of such an analysis is 

to convert the data from the time domain 

to the frequency domain with 

the Fourier transform (FT). Measurements 

in practice consist only of values 

at discrete times of measurement. 

Consequently, a discrete 

Fourier transform is applied that determines 

amplitudes for discrete frequency 

values. However, these are 

always burdened with deviations 

due to the leakage effect or frequencies 

between two discrete frequency 

values. Individual aspects of the discrete 

transform can be improved with 

the application of various window 

functions (Figure 1). For example, 

the mathematical leakage effect can 

be reduced or the amplitude can be 

correctly described, but not both at 

once. In addition, measurements always 

contain a certain amount of additional 

noise, which is also found in 

the Fourier-transformed spectrum. 

AI-based approaches can be used 

here to identify these influences and 

correct for the resulting deviations. 

Vibration analysis 

As a rule, vibration patterns for early 

fault detection are based on structure-borne 

sound measurements. 

Structure-borne sound sensors are 

therefore required. Since their functioning 

is non-invasive, they can be 

easily installed anywhere. Measuring 

close to the sound source of the functional 

component being monitored is 

important here. 

Frequency images obtained from 

these measurement data using FT 

represent an intransparent mass 

of information for many, even experts. 

One often puzzles over which 

peak means what. However, a basic 

rule can help: The higher the amplitudes 

are overall, the greater the 

probability of damage. But to find 

out exactly what the damage is, or 

to identify initial signs of impending 

damage early on, one needs to go 

deeper and quickly encounters difficulties. 

Algorithms that process the 

data and provide additional information 

can be extremely helpful here. 

The four diagrams in Figure 2 

show what errors can occur even 

during measurement. On the left, 

Fig. 1: Transform results with different 

window functions. 

you see the signal sequence with a 

high sampling rate. Below that is the 

Fourier transform that, corresponding 

to the measurement signal, exhibits 

numerous frequency peaks 

and seems difficult to interpret. On 

the right, you see the same signal sequence 

with a lower sampling rate 

and a transform result consisting of 

only a few discrete frequencies. It differs 

considerably from the spectrum 

on the left. 

The second rule we can derive 

from this is that we need a high sampling 

frequency to correctly capture 

reality. A good recommendation for 

this is based on the natural frequencies 

of small components, indicating 

a sampling frequency of 20 KHz. 

To evaluate such signals, one 

now attempts to extract those peaks 

from the spectrum as a whole that 

belong to actually occurring frequencies 

in the measurement signal, and 

to exclude those caused by interfering 

factors due to the transform. 

The peaks extracted in this way and 

their corresponding amplitude value 

are then used to reconstruct the 

10 



Signal sequence 

Signal sequence 

Pressure [bar] 

Time [s] 

Frequency spectrum 

Time [s] 

Frequency spectrum 

Amplitude [bar] 

Amplitude [bar] 

Pressure [bar] 

Frequency [Hz] 

Frequency [Hz] 

Fig. 2: Signal sequences with different sampling rates and the corresponding Fourier transforms. 

unadulterated signal as accurately as 

possible.b Neural networks, for example, 

can be used to differentiate 

whether a large amplitude value corresponds 

to a peak or was caused by 

interfering factors. One can imagine a 

neural network as an extremely complex 

function with a very large number 

of variables. The input values for 

this function are the spectrum being 

evaluated, and the result is a statement 

whether there is a peak for 

each frequency of the spectrum. With 

the skilful construction of this “neural 

function”, it can be derived according 

to its individual variables. Assuming 

one now has training data (input 

values and the corresponding correct 

answers), these derivations can be 

used to determine how the individual 

variables have to be changed so 

that the result of the function corresponds 

as closely as possible to the 

correct answers. With a large volume 

of such training data, all variables can 

thus be optimised so that the total 

error of the function as a whole for 

the training set is as small a possible. 

With a sufficiently large and diverse 

training set, one can subsequently 

Fig. 3: Peak recognition by a neural network 


11


assume that the neural network can 

represent the underlying principles. 

It will therefore obtain corresponding 

good results for new, unknown input 

data as well. 

Results of such a neural network 

with corresponding training are 

shown in Figure 3. The Convolutional 

Neural Network (CNN) used in this 

case is composed of a series of mathematical 

convolutions. Here the individual 

entries in the respective convolution 

matrix are the variables to 

be optimised. With this construct, the 

same processing steps are applied 

at every position of the frequency 

spectrum. Hereby the principle that 

can be determined at a point in the 

spectrum from its surrounding values 

must be able to define whether 

this is a regular peak. Such peaks do 

not have to be “learned” separately 

for each frequency value, but are 

executed in the same way for every 

frequency. As a result, the network 

then supplies a value between 0 and 

1 for each frequency, reflecting how 

“certain” the network is that there is 

a real peak at the respective position. 

As a design parameter, one now still 

has to choose a suitable threshold 

at which one assumes that there is 

in fact a peak. Figure 3 presents an 

examination of the influence of this 

threshold. A signal of three vibrations 

(green markings) and additional 

white noise was examined for this 

purpose. Here the ratio of the vibration 

amplitude to the average noise 

intensity and the selected threshold 

were varied. The average noise intensity 

increases from no noise on the 

left to intense noise on the right. The 

required threshold for the positive 

identification of a peak (red markings) 

increases from top to bottom. 

One can see that increasing noise 

causes additional false positive identifications 

(see the right-hand column 

in particular). The number of false results 

can be reduced by choosing a 

higher threshold. However, note that 

setting the threshold too high can 

also cause false negative results (existing 

peaks are missed) (see the bottom 

row in particular). 

When a suitable threshold is selected, 

all real peaks can be identified 

and there are few false positive 

results, even with intense noise. 

Overall it was shown in this case that 

the detection of peaks using neural 

networks produced better results 

than comparable, conventional 

peak detection methods. Especially 

in cases with high noise levels, neural 

networks were able to produce 

signifi cantly better results. 

This example shows how AIbased 

algorithms can complement/ 

improve classic approaches or support 

manual evaluations with additional 

information in the evaluation of 

vibration spectrums. Such methods 

also have potential for subsequent 

evaluation steps. A neural network 

could provide comparable support in 

obtaining a more exact, undisturbed 

value for the respective amplitudes of 

the individual frequencies. 

In contrast to manual evaluation, 

algorithms can, for example, take into 

account the information from numerous 

different window functions at 

the same time. Additional application 

possibilities for AI-based methods 

can also be identified for the subsequent 

evaluation of the peaks that 

are found. For example, grouping 

multiple peaks into a basic vibration 

and their corresponding harmonics 

is a task one should be able 

to automate using machine learning. 

Overall, AI-based methods have 

great potential for the automation of 

evaluation steps that currently have 

to be performed manually as a rule. 

More elaborate evaluations, which 

are currently carried out manually in 

isolated cases only, will therefore be 

automated in the future and available 

for live monitoring. 

Consequently, increasingly small 

changes in the spectrum can be evaluated. 

Changes (and possible impending 

damage) can be detected earlier, 

and discerning between different 

changes (for example, different types 

of damage) can be improved. 


Prof. (ret.), advisor on hydrogen 

and energy issues and Dominik Haspel 

12 


14th – 15th June 2023 

/ Globana Trade Center Leipzig/ Schkeuditz 

Save 

the 

Date 

The largest national 

meeting for 

industrial valves & 

sealing technologies 

/ 08th – 09th November 2023 

/ Jahrhunderthalle Bochum 

DIAM-DDM.DE

Hydrogen 

Anything but standard: Elastomer seal 

challenges in hydrogen applications 

Dipl.-Ing. (FH) Michael Krüger 

Mobility, the energy sector and industry 

– there is tremendous potential 

for modern hydrogen technologies 

in many areas. Hydrogen is of 

central importance as a versatile 

energy carrier and offers new possibilities 

for production processes 

as a chemical raw material. Therefore, 

science and industry experts 

are conducting intensive research 

in the vast field of hydrogen technologies 

and continuously develop 

their practical applications. The optimal 

coordination of components is 

among the most important success 

factors here. In particular, the seals 

being used are of the greatest importance 

in terms of functionality. 

Countless projects in the mechanical 

engineering segment are therefore 

dedicated to this topic. A central difficulty 

at this juncture for both users 

and seal manufacturers is that hydrogen 

projects and their applications 

are rarely comparable to each other. 

This difficulty begins with the umbrella 

term “hydrogen applications”. It describes 

an extensive domain starting 

with H 2 

production and extending to 

transportation and distribution as well 

as the use and consumption of hydrogen. 

Many projects are still in the development 

phase, which means development 

teams are not making any 

project details public, protecting their 

development advantage for market 

strategy reasons. This in turn tends 

to produce individual solutions rather 

than standard applications. 

Choosing a suitable elastomer 

sealing material in the hydrogen environment 

is of vital importance. All 

operating parameters that occur in a 

real-world application must be taken 

into account. 

The following requirements for 

sealing materials (selection) have to 

be clarified: 

− Chemical resistance for all media 

that may come into contact with 

the seal (during operation, during 

assembly) 

− Temperature resistance (ambient 

temperature, operating temperature, 

also absolute short-term peak 

temperatures) 

− Pressure resistance, also in case of 

pronounced pressure fluctuations 

(resistance to explosive decompression 

where applicable) 

− Good physical properties (compressive 

deformation test, stress 

relaxation) 

− Low permeation (gas permeability) 

Hydrogen permeation 

Hydrogen permeation is an important 

selection criterion. Since the colourless 

and odourless H 2 

gas is highly 

inflammable and the production of 

molecular hydrogen is complicated 

and expensive, preventing volatilisation 

is essential for both safety and 

cost reasons. The H 2 

permeation coefficient 

varies considerably between 

the ASTM classes (elastomer material 

groups) and there are significant differences 

between the materials within 

an ASTM class as well. VMQ (silicone), 

for example, has a very poor 

permeation coefficient, EPDM has a 

much better one and FKM (fluororubber) 

has the best value in comparison. 

The temperature has a significant influence 

on the result as well. A value 

determined at 23 °C may, for example, 

exhibit a factor of +5 for EPDM 

Fig. 1: Test setup H 2 

permeation test (all photos © : COG 

materials and a factor of +3 to over 16 

for FKM at 80 °C. Tested materials are 

therefore clearly recommended in H 2 

applications. 

The field of application itself can 

also be an important selection criterion. 

Seals for natural gas containing 

hydrogen (in distribution/transport, 

for example) have to meet the 

requirements of the DVGW: 

− Gases according to DVGW worksheet 

G 260 (max. hydrogen content 

10 %) 

− DIN-DVGW certification of the sealing 

material according to DIN 

EN 549 and/or DIN EN 682 

− Typical operating temperature 

ranges: 

− DIN EN 549: -20 °C to +80 °C 

(class B2) 

− DIN EN 682: -15°C to +50°C 

(type GBL) 

− Typical pressure ranges: 

− Up to 5 bar (DIN EN 549) 

− Up to 100 bar (DIN EN 682) 

Fig. 2: Material exposure tests 


Hydrogen 

Fig. 3: Permeation test evaluation – “Vi 840” 

as high-quality FKM comparison material 

A comprehensive survey of the application 

process is essential for the selection 

of materials. 

Practical example – 

hydrogen electrolyser 

Permeability is not always the decisive 

selection criterion. A manufacturer of 

AEM (anion exchange membrane) 

electrolysers for hydrogen production 

experienced major problems with the 

elastomer seals. The chosen NBR material 

failed after a short time. The 

medium in the electrolyser was 5 % 

caustic potash solution (KOH) at max. 

65 °C. The seal manufacturer COG 

suggested a peroxide cross-linked 

EPDM as a suitable material. Surprisingly 

this too failed after approximately 

100 hours. Exposure tests in caustic 

potash solution (KOH 5 %) at 65 °C did 

not result in any significant material 

changes. It was therefore presumed 

that the material incompatibility was 

related to the materials used in the 

electrolyser itself. AEM electrolysis requires 

a catalyst and nickel was used 

in this case. Nickel is known to be 

“toxic” to rubber. Ethylene propylene 

diene monomers (EPDM) are terpolymers 

made of ethylene, propylene 

and diene. Dienes contain two carbon-carbon 

double bonds (C=C double 

bonds). Nickel attacks precisely 

those double bonds in diene and destroys 

the rubber. 

COG then proposed using an 

ethy lene propylene copolymer (EPM). 

This rubber does not contain diene 

and therefore has no double bonds 

in the polymer. Its resistance to caustic 

potash solution in the specified 

temperature range is very good. The 

chosen EPM O-ring exhibited no significant 

changes after being used for 

more than 6000 hours. 

This example shows that different 

and in part complex circumstances 

may play a significant role in the 

evalu ation of suitable sealing materials 

for hydrogen projects. 

H 2 

Sealing flagship project 

The independent manufacturer 

C. Otto Gehrckens (COG) has developed 

the new H 2 

Sealing series of 

sealing materials for hydrogen applications. 

The company has accumulated 

extensive experience in 

various hydrogen projects and developed 

sealing solutions for a wide 

range of customers. This has resulted 

in two high-performance materials 

covering a broad range of hydrogen 

applications: An FKM and an EPDM 

compound specifically designed for 

hydrogen applications. Both materials 

are the result of intensive development 

efforts by the seal manufacturer 

and have proven their optimal 

suitability for use in hydrogen technologies 

in external tests of their hydrogen 

permeability (gas permeability) 

by an independent laboratory. 

Fig. 4: COG H 2 

Sealing hydrogen seal series 

Measuring the hydrogen permeability 

using an increasing pressure method 

based on DIN 53380 takes centre 

stage in the extensive test series. 

The FKM material Vi 208 with a 

hardness of 80 Shore A developed by 

the seal experts passed the test convincingly 

with a very good hydrogen 

permeation coefficient of just 281 Ncm 3 

mally expected for FKM compounds. A 

high chemical resistance and a broad 

operating temperature range from -10 

to +200 °C complete the material profile. 

The newly developed EPDM AP 

208 also passed the H 2 

permeation 

test with very convincing values for 

an EPDM material (hydrogen permeation 

coefficient: 1317 Ncm 3 mm m -2 

day -1 bar -1 ). With a compression set of 

Hydrogen 

Unafraid of hydrogen 

Dipl.-Ing. Norbert Weimer 

The topic in this paper is the sealing 

of hydrogen using static flat gaskets 

made of fibrous materials (FA). Hydrogen 

is being hailed as the “oil of 

the future”, underlining how many 

designers and practitioners will 

have to become familiar with using 

it in their construction projects, 

plant designs, procurement scenarios 

and assembly activities. This 

includes determining how to seal 

components properly when working 

with hydrogen. The aim of this 

article is to raise awareness of this 

issue and provide information to enable 

proper decision-making for the 

material selection and the installation 

situation. 

One of the most common forms of 

sealing is static sealing, where the 

components to be sealed remain 

immobile in relation to each other. 

With these connections, considerable 

pressure is exerted on the sealing 

material installed between the 

flanges - the high-pressure seal. 

To seal properly, the material 

used must be adaptable and migrate 

into the roughness of the flange surface 

as well as compensate for its 

waviness. Conversely, despite the 

high forces involved, the material 

must remain intact - a typical technical 

compromise. 

Klinger has developed a manufacturing 

process to meet this compromise: 

The calendering process involves 

processing a mixture of fibres 

and fillers with elastomer as a binder 

into a sealing sheet on a hot roller by 

exerting enormous pressure. 

The result is a highly resilient 

seal, typically capable of withstanding 

loads of over 200 MPa (approx. 

2 tonnes per cm²) at room temperature, 

which has the smallest of pores 

and allows adaptation to the surface 

roughness by compressing the pores 

and the elastomer. 

Pressing together, e. g. via screws, 

prevents surface leakage and leakage 

through the sealing material - the 

higher the sealing force, the tighter 

the connection. 

Leakage requirements 

for gas supply 

The DIN-DVGW type test according 

to DIN 3535-6 of April 2019 specifies 

corresponding values. The specific 

Static gaskets - Soft gaskets 

Fig. 2: Sealing surface and seal 

leakage rate must be ≤ 0.1 mg/(s x m). 

For FA gasket materials, a gasket 

thickness of 2.0 mm, internal pressure 

of 40 bar and surface pressure 

of 32 MPa are assumed. The test gas 

is nitrogen. 

So far, we have been using fossil 

media such as natural gas (predominantly 

methane) and propane and 

butane as standards for our energy 

supply. For these gases, the tightness 

requirements are sufficient - but 

what about hydrogen? 

Does hydrogen differ from the 

usual fuel gases? 

Fig. 1: Flange with high-pressure seal (Photo © : KLINGER) 

Hydrogen gas has a low density and 

the atom has very low spatial expansion. 

In fact, it is the smallest atom in 


Hydrogen 

the periodic table of elements. This is 

why, in theory, it traverses the smallest 

channels with greater ease than 

larger atoms. The reality, however, is 

different, because hydrogen is only 

atomic when produced and immediately 

combines with the next hydrogen 

atom to form the hydrogen molecule 

H 2 

, which can be pictured in the 

shape of a dumbbell. Nevertheless, 

the fuel gases having proliferated to 

date, methane CH 4 

(the main component 

of natural gas), propane C 3 

H 8 

and butane C 4 

H 10 

are all clearly larger. 

Recent years have seen a growing 

shift in the use of helium (He) rather 

than nitrogen as the test gas for 

measuring any leakage from sealed 

joints. Accordingly, now we have the 

second-smallest atom in the periodic 

table of elements as our standard 

test gas, which is usable to detect 

the smallest leaks. Rather than being 

rigid, our gas particles move due 

to Brownian molecular motion. If we 

now compare the kinetic diameters 

of the relevant gas particles, we see 

that the helium atom and hydrogen 

molecule are comparable in size. 

In the table of kinetic diameters 

(www.arnold-chemie.de ) we see 

hydrogen H 2 

helium He 

and for methane CH 4 

3.8 Å 

where 1 Å = 0.1 nm 

2.3 – 2.9 Å 

2.6 – 2.7 Å 

And what we notice is that hydrogen, 

although “smaller” than methane, 

is on a par with our test gas helium, 

size-wise. Similarly, previous actual 

comparative measurements have 

shown that, despite differences in the 

quantities of hydrogen and helium 

leaking, they are of the same order of 

magnitude. 

One other thing to note about hydrogen 

is that it burns faster than natural 

gas, which explains the smaller 

distances between the burner nozzle 

and flame in gas burners. As a result, 

both the flame detection technology 

and the material selection of the 

burner nozzle and other parameters 

have to be adjusted. Furthermore, 

unlike other gases, hydrogen has a 

negative Joule-Thompson effect. But 

none of this is relevant in the context 

of tightness of connections. 

What practical experience 

do you have? 

Hydrogen has been a common raw 

material in the chemical industry for 

many years. According to the VCI, hydrogen 

is crucial here and forms the 

starting point of important chemical 

value chains. Already today, about 

12.5 billion cubic metres of hydrogen 

are used annually in Germany (according 

to vci.de). 

The town gas used in the past 

contained hydrogen up to around 

50 %. Hydrogen is not chemically aggressive 

and does not attack the usual 

fibre, graphite and PTFE sealing 

materials used. 

Ample proof of our strong familiarity 

with the medium and the fact 

we have long been successfully implementing 

corresponding sealing 

strategies. 

A look at the potential dangers 

of hydrogen 

As with all fuel gases, there is also a 

risk of unintentional combustion in 

the form of an explosion with hydrogen. 

And here, the explosion limits 

of the various fuel gases must be 

observed. The lower explosion limit 

(LEL) in air is 4 vol% for hydrogen and 

4.4 vol% for methane - which resembles 

the figures just mentioned. The 

upper explosion limits, however, at 

77 vol% H 2 

and 16.5 vol% CH 4 

are 

poles apart. 

Within CEN/TC 58 - Safety and 

control devices for Burners and appliances 

burning gaseous or liquid 

fuels - there is working group 15, 

which handles the subject of hydrogen 

and prepares information for international 

standardisation. Among 

other things, the “CEN/TC 58 WG 15 

evaluations 2022-04-14” presentation 

deals with a comparison of fuel 

gases methane, propane and butane 

with hydrogen and hydrogen/natural 

gas mixtures 20 % to 80 % with a view 

to gas installation equipment. Gas fixtures 

installed, like heating system 

burners, appliances and household 

devices, offer wide-ranging potential 

for future hydrogen applications. 

With all this in mind, the working 

group performed a hazard assessment, 

the scope of which included extensive 

calculations and initial measurements 

to get a clear picture. 

The danger from combustible 

gases is influenced not only by their 

leakage behaviour but also their 

ignit ability. So the working group assessed 

such influences and described 

them mathematically. Clearly, although 

the hazard potential of hydrogen 

exceeds that of natural gas 

(methane), it remains well below that 

of propane and butane. 

Conclusion 

1. We have positive experience with 

our well-known and high-quality 

fibre-based gaskets sealing materials 

from a history of safe sealing of hydrogen. 

2. Independent leakage measurements 

also show that we are within 

the usual ranges for fuel gases with 

hydrogen. 

3. And with the potential explosion 

hazard in mind, our experience with 

hydrogen underlines our progress 

within a familiar framework that 

has been safely controlled for many 

years. 

In sum, therefore, we see no need 

to fear hydrogen as a future carbon- 

free energy carrier. Contingent 

on appropriate design and having 

professionals in to install, hydrogen 

can be a safe means of achieving decarbonisation. 

The hydrogen age is 

on the horizon! 

The Author: Dipl.-Ing. Norbert Weimer, 

KLINGER GmbH, Idstein, Germany 


17

Cover story 

100 % availability, 0 % problems 

AERZEN packages ensure reliable transport processes 

at A+S BioTec GmbH 

Sebastian Meißler 

Availability and reliability have top 

priority at A+S BioTec GmbH. For 

this reason, the Saarland-based 

family business has exclusively used 

blowers and compressors from 

Aerzen for the pneumatic conveying 

of its raw materials and products for 

more than 50 years. The packages 

provide absolutely oil- and absorption 

material-free air and guarantee 

a safe, reliable material flow. Service 

and support are also excellent 

in every respect. 

Whether oat flakes, apricot kernels 

or bran: when it comes to the production, 

processing and refinement 

of raw materials for the food, cosmetics, 

technology and pharmaceutical 

industries, no one can ignore 

A+S BioTec GmbH. The family-owned 

company with headquarters in Völklingen, 

Saarland, specialises in grinding, 

drying, sieving, mixing, roasting 

and packaging and is one of the 

leading companies in this branch. 

The company also makes no compromises 

when it comes to blower technology 

and has relied on the robust 

and reliable packages from AERZEN 

for over 50 years. Approximately 40 

positive displacement blowers and 

two screw compressors guarantee 

maximum safety and availability in 

pneumatic conveying of powdery and 

small-grained materials. 

Development, production and 

finishing for large-scale industry 

A+S BioTec GmbH is part of the globally 

active Abel+Schäfer Group, which 

was founded as a milling company in 

1892. The company looks back on a 

long tradition, is characterised by innovations 

and is still family-owned 

today. In the meantime, the fifth generation 

has been steering the fortunes 

of the traditional company. 

Abel+Schäfer was one of the first 

Fig. 1: A+S BioTec GmbH at the Völklingen site is a specialist in the development, manufacture 

and refinement of raw materials and products (all photos © : AERZEN) 

manufacturers worldwide to launch 

baking premixes on the market in the 

middle of the 20 th century and has 

been successfully serving the growing 

demand ever since. Today, the 

group of companies produces at 14 

locations around the globe. 

In Völklingen, the focus is still on 

mill technology. The core areas here 

are on comminution as well as mixing 

and drying. The spectrum ranges 

from powdered raw materials to fermented 

or thermally treated to protein-enriched 

products. Of course, 

also in organic, kosher and halal as 

well as GMO- and allergen-free. In addition 

to its own products, the company 

makes its modern, flexible technology 

as well as its know-how and 

manpower available to contract customers 

as part of contract manufacturing 

services. 

Oil-free conveying air for transport 

from A to B 

From the delivery of the raw material 

to the finished end product, the 

materials go through several process 

steps and sometimes have to travel 

long distances for this. For example, 

the piping from the feed hopper on 

the ground floor extends over five 

Fig. 2: Via the silver pipe, the raw material is 

transported by AERZEN conveying air from 

the ground floor up to the fifth floor in the 

pre-silo for grinding 


Cover story 

“We produce 24 hours a day, five 

days a week. This is why we need 100 

per cent machine availability,” emphasises 

the Technical Manager at 

the Völklingen site. Reliability has top 

priority, and so has low downtime. 

“For this reason, we have been using 

blowers from Aerzen exclusively for 

more than 50 years. These machines 

are powerful, robust, need only little 

maintenance and are durable. It just 

fits nicely,” he says and adds: “What 

I particularly appreciate about the 

supplier is the availability of the employees. 

When the going gets tough, 

we have a contact person available 

at all times. A great product and a 

great team.” 

Fig. 3: In micronisation, the products are finely ground. Positive displacement blowers are 

used for the discharge (silver pipe) 

Positive displacement blowers are 

tough endurance runners 

Fig. 4: Via the bent silver pipe, the end product enters the pre-silo for bagging 

The proverbial reliability of the positive 

displacement blowers has its reason: 

All core components itself, from 

the package to the control system, 

are manufactured in-house. In doing 

so, the family business attaches great 

importance to quality and sustainability. 

Only high-quality materials are 

used for the production. The development, 

production, distribution, assembly 

and maintenance of the company’s 

products as well as the quality 

management system have been certified 

several times. In 1868, the familyowned 

company from Lower Saxony 

brought Europe’s first positive displacement 

blower onto the market. 

floors until it reaches the pre-silo for 

grinding under the roof. Even the 

transport after grinding to the bagging 

plant, where the filling into 25 kg 

bags or big bags takes place, is not 

exactly a stone’s throw. This is where 

the positive displacement blowers 

from the specialists in Aerzen come 

into play. The approximately 40 positive 

displacement blowers provide 

air which is absolutely free of oil 

and absorption material. With volume 

flows between 3 and 20 m³/min, 

a conveying speed of 25 to 30 m/s 

and a conveying pressure of 300 to 

500 mbar, they ensure efficient, gentle 

and reliable transport of the sensitive 

bulk materials. 

Fig. 5: The blower cellar houses the majority of the packages 


19

Cover story 

These stages and packages are now 

among the most successful compressors 

ever. 

First choice for generating pneumatic 

conveying air 

The positive displacement blowers 

are characterised by high efficiency, 

low maintenance costs, reduced lifecycle 

costs, compactness as well as 

easy handling. They are considered 

the first choice for generating pneumatic 

conveying air due to their high 

quality and reliability. These blowers 

achieve intake volume flows between 

30 and 15,000 m³/h with a control 

range of 25 % to 100 % and conveying 

pressures of up to 1 bar positive 

pressure or differential pressures of 

up to 1,000 mbar(g). The drive concept 

with belt drive enables optimum 

volume flow design, and subsequent 

power adjustments can also 

be implemented quickly and easily. 

A+S BioTec GmbH and its production 

facility use this flexibility in order to 

react in a fast and easy way to customers’ 

needs. 

The blower specialist is ISO 

22000 certified, guarantees oil-free 

operation according to ISO 8573-1, 

class 0 and trusts in silencers without 

absorption material. This means 

that the machines meet the highest 

food safety requirements and guarantee 

100 % product purity. The process 

air is guaranteed free of impurities 

such as oil, abrasion or insulation 

material. 

In addition to the 40 positive displacement 

blowers, the Saarland 

company also uses two VML screw 

compressors with start unloading 

device. The single stage packages 

can overcome a differential pressure 

Fig. 6: Two VML screw compressors are 

used to unload the trucks 

of 3,500 mbar and are thus the perfect 

choice for unloading the delivering 

silo vehicles high up into the silos. 

Annual maintenance guarantees 

optimum availability 

The supplier has been manufacturing 

quality products for over 150 

years and is today one of the world’s 

leading application specialists in the 

conveying and compression of gases. 

The high level of customer orientation 

is not only reflected in the product 

portfolio, but also in the range 

of services. Thanks to bespoke offers 

for every phase of the machines’ 

lives, the specialist supports its customers 

in the maintenance and servicing 

of their packages. Abel+Schäfer 

at the Völklingen site also likes to rely 

on the know-how of the service technicians 

and has all blowers and compressors 

inspected thoroughly once 

a year. The maintenance work in- 

cludes, among other things, changing 

the oil, changing the suction filter 

and replacing the components for the 

power transmission (V-belts, clamping 

bushes). The condition of the 

packages is also examined and possible 

need for repair is determined. 

“The maintenance contract is a great 

advantage for us. This allows us to 

concentrate on our core tasks and at 

the same time benefit from optimal 

availabili ty,” the Technical Manager 

makes clear and is pleased: “Since we 

have had the maintenance contract - 

that is, for about ten years - there has 

not been a single machine failure.” 

Relying on the proven 

A+S BioTec GmbH is at home in the 

food world, but also produces for the 

cosmetics and technology industries. 

And the tendency is increasing, because 

natural, plant-based materials 

- as they are exclusively processed in 

Völklingen - are in vogue. For example, 

specially processed flour is needed for 

glue production, crushed grain husks 

for plastic profiles or ground apricot 

kernels for face and body scrubs. 

New fields of application, new 

methods, new processes: The company 

adapts to the requirements of 

its customers. One thing, however, 

will not change in the near future: 

the blower technology for pneumatic 

conveying comes from the supplier 

from Aerzen, which is considered to 

be well supplied all around. 

The Author: Sebastian Meißler, 

Marketing, Communication & 

Branding Maschinenfabrik Aerzen 

GmbH, Aerzen, Germany 


Power Pumps for 

Top Performances 

URACA premium high pressure plunger pumps and 

units are the heart of modern plants in the industrial 

fields of chemical processes, petrochemical, metal 

producing and high pressure cleaning. 

URACA GmbH & Co. KG 

Sirchinger Str. 15 • 72574 Bad Urach 

info@uraca.de • www.uraca.com



Condition monitoring and prediction for 

diaphragm metering pumps 

Detect and avoid failures at an early stage 

Moritz Pastow 

Pump and plant availability are 

key factors for success in manufacturing 

companies. Production 

standstills mean sales losses. Due 

to more complex production systems 

and increasingly rigorous requirements 

for specific operator 

know-how, support from digital 

monitoring and analysis systems is 

necessary now in order to remain 

competitive in the future. 

1. Diaphragm metering pump 

trends in the process industry 

Pumps are often primary units in 

the process industry. Diaphragm 

metering pumps are particularly 

used in critical processes. The trouble-free 

and efficient operation of 

the installed pumps is crucial for a 

safe and profitable plant. 

The major driver of innovation 

in the process industry is digitalization 

– and it doesn’t stop at pumps. 

It is true that a diaphragm metering 

pump is initially a mechanical product 

and, with proper maintenance, 

it is also quite durable and troublefree. 

Nevertheless, continuous operational 

monitoring is necessary 

in order to detect process deviations 

and damage in time. In addition, 

the requirements for energy 

efficiency and safety are becoming 

more stringent. 

As a result, various trends are 

visible in numerous companies: 

Smart Factory 

The process industry is in the 

middle of a digital transformation. 

Factories are becoming increasingly 

networked and data exchange both 

within and between process chains 

is increasing. Since pumps are often 

operation-criti cal units but few have 

a digital moni toring system, there is 

neither data nor characteristic values 

for many processes. Many operators 

use their pump based on experience 

and follow cyclical or reactive 

maintenance strategies. 

System complexity 

The complexity of production systems 

is continuously increasing. 

This is related to the requirements 

for quality and process reliability, as 

well as to the general digitalization of 

many production facilities. 

Know-how 

The changes in the labor market also 

impact the day-to-day operations in 

the process industry. More and more 

experienced employees are retiring, 

turnover is rising and specific process 

and plant knowledge is declining. 

For this reason, many operators 

are increasingly turning to digital 

monitoring and support systems. 

Safety and environmental 

requirements 

The requirements for operational 

safety are increasing, and characteristic 

values that reflect the ecological 

footprint of production are taking 

on greater importance. The comprehensive 

environmental report has 

long been more than a marketing 

gimmick for companies. For investors, 

authorities and employees, it 

is an essential factor for evaluation, 

auditing or personal identification. 

Energy management 

The transformation in the energy 

sector directly affects the process industry. 

Pumps in the process industry 

often run 24/7 and are thus major 

consumers of energy. Optimizing 

their efficiency can have a significant 

impact on the energy efficiency of 

the entire plant. But here, too, evaluation 

requires characteristic values. 

2. Pump monitoring requirements 

Based on the trends in the process industry, 

various focal points can be derived 

for monitoring systems for diaphragm 

metering pumps. 

Condition monitoring and 

predication 

First of all, the operating states of the 

pump must be monitored and deviations 

from target values must be detected 

in good time. In the process, 

various parts of the pump must be 

monitored in a specific context: 

– Drive unit 

– Hydraulic system 

– Pump head 

– Valves 

System monitoring 

Within the plant, the pump can be 

used as a sensor for the complete 

system. With diagnostics collected 

in the pump, it is possible to derive 

statements about the system status: 

– Piping suction side 

– Piping pressure side 

– Pulsation 

– Flow rate 

– Fluid state 

Energy management and efficiency 

By measuring incoming energy 

and hydraulic power, it is not only 

possible to determine efficiency and 

CO 2 

balance, but also to diagnose material-related 

signs of wear. 

– Efficiency 

– CO 2 

balance 

– Load collectives 

3. Digital monitoring and operational 

support 

LEWA Smart Monitoring is a monitoring 

system consisting of sensors, 

a programmable logic controller 

(PLC), an industrial PC (IPC) and 




Fig. 1: Structure of LEWA Smart Monitoring 

data analysis for new and existing 

pumps. The system determines 

characteristic values and key performance 

indicators. There is no process 

control intervention or direct 

contact between the sensor system 

and the conveyed fluid. 

With parameter-based condition 

monitoring, operators detect 

and monitor their pumps proactively. 

They can also optimize the overall 

output and robustness of their 

pump and piping systems. This increases 

the efficiency of their entire 

production plant. 

Characteristic value determination 

is based on recording measured 

variables such as structure-borne 

noise, hydraulic pressure and trigger. 

To get results, 2,000 signals per 

pump head are processed per second. 

These signals are recorded by 

the connected PLC. 

The characteristic values and diagnoses 

are output and transmitted 

via various interfaces. The IPC has a 

web-based interface for making settings 

and visualizing the determined 

characteristic values and diagnoses. 

An OPC UA server is provided for 

transmission to a control center. 

In addition, characteristic values 

and diagnoses can be transmitted 

to the LEWA cloud and the customer 

portal via an Internet connection. 

Overview of diagnosis 

Fig. 2: Diagnoses with LEWA Smart Monitoring 

Hydraulic system: Diagnoses that 

are possible based on the analysis of 

the hydraulic operation of the pump 

Drive unit: Diagnoses that enable 

statements to be made about the action 

and condition of the pump unit 

Valves: Statements on the condition 

of valves on the suction and discharge 

sides of the pump 

Pump head: Diagnoses regarding the 

pump head and the diaphragm 

System: Diagnoses regarding the 

connected system, which consists of 

piping, pulsation dampers and MSR 

technology 

Table 1: Pump design 

5. Use case: Data-based failure 

prevention and root cause analysis 

As described above, the various requirements 

for a monitoring solution 

for diaphragm metering pumps can 

be summarized in the categories of 

condition monitoring and prediction, 

system monitoring and energy management 

& economy. 

In the following, various use cases 

are described based on the practical 

use of a Smart Monitoring System 

in a metering system. The characteristic 

values used to describe the use 

4. Smart Monitoring System 

performance 

The following diagram shows the possible 

diagnoses and characteristic 

values in the cross-section of a diaphragm 

metering pump. A distinction 

is made between five main areas for 

diagnostics. 

Bar force [N] 2000 

Stroke adjustment type 

Electric 

Stroke frequency max [min -1 ] 163 

Metering flow at pmax [l/h] 367 

Max. perm. working pressure [bar] 19.5 

Motor power [kW] 0.55 


23



Table 2: Operating fluid 

Fluid 

Aqueous 

Operating temperature [°C] 20 

Density [g/cm 3 ] 1.00 

cases are standardized. This means In the metering application, the deterioration 

of the valve condition due to 

that the set point is represented by 

the value 1 and the deviations refer 

to this value. In the following, we could already be measured at time t 1 

an increased structure-borne noise 

. 

will therefore speak of “standardized The operator receives a warning from 

characteristic values.” 

the Smart Monitoring System that 

the limit value has been exceeded. At 

6. Predictively measure valve wear this point, the valve wear has no influence 

on the performance of the 

In processes with abrasive fluids and plant, which is visible in the flow rate 

high pressures, the valves of diaphragm 

metering pumps are subject At time t 2 

(cf. Fig. 5). 

, the flow rate measurement 

also shows that the limit value 

to particularly high stress. Valve wear 

affects the sealing ability of the pump has been exceeded. The valve wear 

head during the stroke and thus the is now so advanced that it has a 

volumetric performance of the pump. nega tive effect on the performance 

For this reason, it is important for operators 

to monitor valve wear in or- 

Without valve monitoring, wear 

of the plant. 

der to schedule maintenance to avoid only becomes measurable when the 

unplanned shutdowns. It must also flow rate in the piping decreases (t 2 

). 

be ensured that the process quality is At this point, the process has already 

not impaired by valve wear. 

been disrupted and controlled main- 

Fig. 4: Comparison of worn valve set (l) and as-new valve set (r) 

tenance planning is no longer possible. 

With valve monitoring, signs 

of wear can be detected before they 

have a negative impact on the process 

(t 1 

). 

Viscosity [mPa·s] 1.04 

Plant diagram (P&ID) 

Fig. 3: Design of the pilot plant 

Fig. 5: Curve of structure-borne noise 

measurement (top) and flow rate (below) 

Identify worn valves 

With multi-head pumps in particular, 

it is difficult to detect wear. 

Both the damage pattern and the 

affected valve must be identified. 

The previous example showed how 

valve wear is detected before it 

has a nega tive effect on the performance 

of the plant. 

With the Smart Monitoring System, 

each valve in all pump heads 

can be analyzed individually, so that 

the cause of the fault can be determined 

precisely. Analyzing the individual 

pump heads shows that 

the structure-borne noise has increased 

in the second pump head (B) 

(Cf. Fig. 6). In this case, the Smart 

Monitoring System issues a plain text 

message about the valve wear that 

is occurring and also indicates which 

valve in which pump head is affected. 




Conclusion 

Valve monitoring not only enables 

valve wear to be measured before it 

affects plant operation. It also makes 

the exact localization of the affected 

valves possible. This creates the basis 

for targeted, condition-oriented and 

predictive maintenance. 

7. Prevent diaphragm ruptures 

Fig. 6: Structure-borne noise measurement 

across all pump heads 

Diaphragm ruptures are always critical 

for diaphragm metering pumps 

and lead to immediate process interruption. 

Since diaphragm ruptures 

can have various causes, prevention 

is difficult. While diaphragm ruptures 

due to foreign bodies in the fluid or 

wear cannot be predicted, hydraulically 

induced diaphragm ruptures are 

easy to identify in certain operating 

situations. 

The Smart Monitoring System 

determines the length of the “snifting 

phase” (leak supplement phase) 

for various diagnoses. In the sniffing 

phase, the hydraulic oil lost during 

the pressure phase due to internal 

leakage in the pump head is replenished. 

When the length of the sniffing 

phase (t 1 

) decreases, a condition develops 

that leads to diaphragm rupture 

(t 2 

) (Cf. Fig. 7). The system issues 

a warning when the sniffing phase 

can no longer be measured. In many 

cases, operators can see in good time 

when a hydraulically induced diaphragm 

rupture is imminent and can 

react accordingly. 

Fig. 7: Measurement of the sniffing phase 

at the pump head 

Conclusion 

Monitoring pump hydraulics enables 

undesirable conditions to be detected 

in good time and prevents hydraulically 

induced diaphragm ruptures. 

Monitoring makes controlled shutdown 

and maintenance possible. 

8. Avoid pulsations in the piping 

Piping and pulsation dampers are 

often subject to the inherent vibrations 

of the system, which can develop 

into pulsation shocks. These 

shocks not only endanger the process, 

but are also a safety risk. Monitoring 

the pump also simultaneously 

enables the vibration behavior of the 

peripher al systems to be monitored. 

Figure 8 shows a peak of the pressure-side 

pulsation in the piping, the 

“coupling pressure pulsation” (t 1 

). At 

the same time, the discharge pressure 

of the pump is constant during 

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25



the same period. This means that 

pulsation cannot be detected in the 

opera tor's process control system by 

measuring the flow rate. The Smart 

Monitoring System issues warning 

messages when the coupling pressure 

pulsation exceeds the limit values. 

This enables operators to see in 

good time when pulsation impacts 

occur in the piping, even if the process 

control system measures a constant 

flow rate. 

Fig. 8: Coupling pressure pulsation and discharge 

pressure in the same time period 

Conclusion 

Monitoring the piping enables pulsation 

shocks to be detected. The characteristic 

values are a reliable indicator 

of the condition of the piping 

system and can be used as the basis 

for optimizing pulsation dampers. 

9. Detecting and preventing drive 

unit damage in good time 

Drive unit damage in diaphragm metering 

pumps is rare, but usually the 

result of bearing wear. Active bearing 

monitoring in the drive unit using 

sensors is complex and costly. For this 

reason, indirect bearing monitoring is 

easier to implement and is a good basis 

for diagnostics and prediction. 

In this case, passive bearing monitoring 

means that the bearing itself 

is not monitored. Instead, the energy 

input into the pump is set in relation 

to its hydraulic power. If the ratio 

deteriorates, there is a loss of energy 

due to heat input into the system. 

This is usually a sign of unwanted friction 

due to bearing wear, which in 

this case is detected at an early stage. 

Subsequent damage due to damaged 

bearings can be prevented by timely 

shutdown and maintenance. 

Figure 9 shows the efficiency 

of the drive unit and the hydraulic 

power of the pump. It shows that the 

efficiency of the drive unit decreases 

while the hydraulic efficiency remains 

the same. This means that the 

pump requires more energy to provide 

the same hydraulic power. This 

indicates that there is a loss of energy 

Fig. 9: Drive unit efficiency and hydraulic 

efficiency 

in the system – usually due to frictional 

heat. The Smart Monitoring System 

informs operators with a warning 

that the relative efficiency has fallen 

below a limit value. This leaves time 

for a drive unit inspection before subsequent 

damage from a damaged 

bearing occurs, which can have farreaching 

consequences. 

Conclusion 

With the indirect monitoring of bearings 

via the energy balance, the Smart 

Monitoring System offers an efficient 

and reliable alternative to sensorbased 

bearing monitoring. 

10. Overall conclusion 

Smart Monitoring is a comprehensive 

condition monitoring and prediction 

system that process plants‘ operators 

can use to increase availability 

and operational safety. The system 

also makes a valuable contribution 

in other areas of application such as 

energy management and KPI-based 

production optimization. 




Fig. 10: Smart Factory Enablement 

Based on various practical examples, 

it was possible to prove that 

the Smart Monitoring System detects 

criti cal operating states before they 

affect plant operation. 

Investing in the system with its 

various possible applications will 

pay for itself over the life cycle of the 

plant, as operating costs, especially 

those for unplanned shutdowns, can 

be reduced. 

In the future, the Smart Monitoring 

System will provide the basis for 

introducing a Smart Factory concept 

with a focus on diaphragm pumps. In 

addition to pump monitoring, LEWA 

offers solutions for user training, asset 

management, spare part management, 

remote services and other 

services. The figure below visualizes 

services based on the analysis of operational 

data. 

The Author: Moritz Pastow, 

Program Manager Digital Services & 

Industrial IoT LEWA GmbH, 

Leonberg, Germany



Automatic adjustable pump makes 

life easier in WWTP 

Intelligent pump technology facilitates more sustainable 

operation at WWTP in Gelsenkirchen, Germany 

It's all a matter of adjustment: 

Municipal water supply is experiencing 

a smooth transition into the 

digital age and is becoming more 

sustainable. Intelligent pump technology 

from SEEPEX makes them 

fit for the future. One of the world’s 

leading specialists in progressive 

cavity pumps, pump systems and 

digital solutions was able to solve 

various technical challenges and 

help save time as well as energy in 

a municipal WWTP. The special feature 

of the pump is the digitally 

monitored, automated adjustment 

of the pumping elements. The SCT 

AutoAdjust increases the pump’s 

service life, leads to lower energy 

and resource consumption, increases 

operational reliability and process 

efficiency, and reduces maintenance 

requirements. 

sees “high savings potential in the 

more than 10,000 municipal WWTPs. 

These are responsible for an aver age 

of almost 20 percent of the electricity 

consumption of all municipal facilities.” 

Among the consumers with 

Saving energy, preserving resources, 

in short: sustainable behavior is 

on everyone’s mind. This applies, in 

particular, to the field of environmental 

technology. The German Federal 

Environment Agency, for example, 

Fig. 2: Installation of a BN35-6LAS with pump monitor at a plant. 

Fig. 1: SCT AutoAdjust - The progressive cavity pump with automatic stator clamping. 

Hydraulically adjustable and highly precise all at the touch of a button. 

high power consumption are “the 

continuously running pumps.” “With 

the automated progressive cavity 

pump, SEEPEX has been able to demonstrate, 

using the Gelsenkirchen 

WWTP as an example, that the investment 

in the new technology pays 

off both economically and for the 

climate,” says the Head of Product 

Mana gement, giving a positive summary 

after two years. 

Requirements placed on modern 

pump technology are getting more 

demanding in many places. The project 

at the WWTP in Gelsenkirchen 

demonstrates how the efficiency 

of conveying and processing highly 

abrasive sewage sludge can be fur- 




ther improved. The high viscosity of 

the sewage sludge and the highly 

abrasive dry matter content - in this 

case of around 3 to 4 percent at a 

flow rate of 5 to 7 m³/h and 2 to 6 bar 

back pressure - have an increasing 

effect on energy requirements and 

wear, making it a demanding conveying 

task. 

In the past, the pump’s performance 

decreased over time because 

the stator and rotor - as in many sewage 

treatment plants - are subject 

to high abrasive wear. At constant 

speed, wear becomes noticeable in 

a steadily accelerating decrease in 

flow rate. The reduced flow rate can 

be compensated for by increasing the 

speed. However, this leads to an increased 

energy demand of the pump 

and an exponential increase in the 

wear rate. In addition to increased 

operating costs, this leads to a shortened 

rotor and stator life, increased 

downtime, more resource requirements 

and higher costs for spare 

parts and maintenance. 

Perfect operating point at the 

push of a button 

As part of the municipal water management 

system, the WWTP in the 

north of the city is responsible for 

treating the wastewater of a population 

of more than 57,000 in this region. 

The pump manufacturer from 

Bottrop replaced its standard progressing 

cavity pump, previously 

used here in discontinuous operation, 

with state-of-the-art technology. 

Fig. 3: The flow rate per rotor revolution is scaled to the set point or optimal operating point. 

100 % stands for the optimal required operating point of the pump. The pump should run 

between 80 % and 100 % (green area) due to normal operating conditions. 

“The auto mated pump combines a 

new type of hydraulic adjustment unit 

with simultaneous digital moni toring 

and control, making it the world’s first 

progressive cavity pump that automatically 

(Auto) adjusts its operating 

point (Adjust) at the push of a button,” 

says the Head of Product Management, 

explaining the prin ciple. In 

this way, it can compensate for any 

wear that occurs and always operates 

at maximum efficiency at the 

optimum operating point. The new 

technology made it possible by using 

a smaller sized pump, including a less 

energy consuming drive than before, 

resulting in lower costs in terms of resources 

and energy. 

Real-time data at a glance 

The modern pump can be operated 

from the control room, on a tablet 

or smartphone. Long distances for 

control and maintenance are a thing 

of the past. The SCT AutoAdjust is 

equipped with an innovative hydraulic 

adjustment unit with associated 

sensor technology which, together 

with the digital connection of the 

pump (Pump Monitoring and Connected 

Services), enables automated 

adjustment of the stator clamping. 

The stator clamping is performancedetermining 

for the operation of the 

pump and can now always be optimally 

adjusted to the operating conditions. 

The digital connection is established 

via sensors, which record important 

parameters such as flow rate, 

pressure, rotor speed or temperature 

in real time and analyzes them in 

Connected Services using modern algorithms 

and artificial intelligence. In 

this way, the operating status of the 

pump can be monitored regardless 

of location. The wear caused by the 

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Fig. 4: The result of continuous innovation: SCT AutoAdjust - the world's most intelligent 

progressive cavity pump technology. 

highly abrasive medium is compensated 

for with the aid of the hydraulic 

adjustment unit by increasing the stator 

clamping. The optimum operating 

SCT extends the service life of the rotor and stator 

point is characterized here by a defined 

flow rate per rotor revolution. 

The initial results of the automated 

pump in Gelsenkirchen are promi sing 

The pump manufacturer from Bottrop has continuously optimized its Smart Conveying 

Technology (SCT) since 2008. The proven design principle: the Smart Stator consists 

of two halves, which makes maintenance very easy, without removing suction or discharge 

lines. An integrated re-tensioning device ensures that the clamping between 

the rotor and stator can be adjusted for optimum conveying if the flow rate is reduced, 

for example, due to wear. This significantly extends the service life of the rotor and 

stator, reduces the need for spare parts, and lowers the life cycle costs of pumps - 

while maximizing energy yield. 

Digital Solutions provide real-time information 

To ensure that the pump is always in top shape, SEEPEX uses its Digital Solutions in 

numerous applications. The digital solutions are in alignment with the requirements 

of the industrial era 4.0 in which intelligent and interconnected machines exchange 

information directly with each other in real time. In addition to Pump Monitoring and 

Connected Services, the supplier has developed other products that provide users 

with important data and derived information about operations. The added value for 

customers lies in tailored solutions, simpler processes and greater transparency. The 

focus here is on improved know-how about the performance of the pumps and lower 

maintenance costs thanks to optimized operation. 

In addition to remote monitoring via Connected Services, apps are also available for 

service and maintenance. These include a remote monitoring package, the Advanced 

Analytics package for process optimization, and tool interfaces for transferring data 

and operating parameters. The free maintenance app offers step-by-step instructions 

and 3-D animations. In a logbook, the maintenance history of the pump as well as the 

respective status is noted and the location is clearly displayed. Users can also track operating 

parameters such as speed, flow rate and current consumption in the logbook, 

so that they have all the necessary data at hand for optimal readjustment of the rotor/ 

stator clamping. The Service Point app supports uncomplicated spare parts procurement. 

Simply scan the QR code on the nameplate of the pump and various help functions 

and important data are available at the virtual Service Point. Suitable spare parts 

can be ordered easily. The operating instructions for the progressive cavity pump are 

also available for download and the experts offer their support directly by e-mail, 

phone or live chat via the app. 

after the first two years, as the Head 

of Product Management reports. 

“By automatically increasing the stator 

clamping, the pump escapes the 

downward spiral of exponentially progressing 

wear, including negative consequences 

such as shortened service 

life, frequent maintenance, including 

rotor and stator replacement, and increased 

resource requirements for 

spare parts and maintenance personnel. 

As a result, pumping efficiency 

has increased by 20 percent with a 

reduced pump size compared to the 

predecessor pump, which consumes 

less energy. Our innovation has 

demonstrated its great potential and 

advantages in the wear-intensive conveying 

of abrasive sewage sludge at 

the Gelsenkirchen WWTP. As part of 

the plant, it makes an important contribution 

to sustainable, reliable and 

efficient water management.” 

Water management benefits from 

innovative technology 

The more efficient use of resources 

on the one hand and the use of digital, 

intelligent technology on the 

other have long become a central issue 

in municipal environmental technology. 

For example, the German 

Association of Water, Wastewater 

and Waste (DWA) states in a position 

paper: “Digitalization affects all areas 

of water management, from planning 

tools and plant technology to staff 

training standards and use by the 

public. In this context, the automation 

and networking of water management 

plants, for example, has been 

standard practice for a long time. Extremely 

rapid advances in software, 

hardware and networking, however, 

continue to offer opportunities for 

improvement, especially in holistic 

approaches, benefiting the environment 

and people.” 

Seepex GmbH, Bottrop, Germany 


UNDER 

PRESSURE! 

Our new rotary lobe pumps with up to 

18 bar will handle almost anything 

• Pressures up to 18 bar 

• Higher efficiency due to flow-optimized, one-piece housing 

• Atmospheric protection of gear and pump chamber by AirGap 

• New sealing options to meet industry specific standards 

ATEX / TA-Luft / Cleaning according to CIP-SIP guidelines 

VOGELSANG – LEADING IN TECHNOLOGY 

vogelsang.info


Report 

Bredel industrial hose pumps convey 

corrosive media in flue gas purification 

Bredel hose pumps, a brand of 

Watson-Marlow Fluid Technology 

Solutions, offer a powerful and reliable 

solution for many pumping 

tasks in energy-from-waste plants. 

In the AVA Velsen waste treatment 

plant, the pumps were able to prove 

their suitability in the processing 

of corrosive and abrasive media in 

several process stages of flue gas 

purification. In the process, they 

offer longer service life and lower 

costs than the centrifugal and rotary 

lobe pumps previously used. 

The Zweckverband Entsorgungsverband 

Saar (EVS) is an association of all 

52 municipalities in the German state 

of Saarland. EVS is responsible for regional 

wastewater treatment and environmentally 

sound waste disposal 

throughout the state. The non-recyclable 

waste, especially a large part of 

the residual waste and commercial 

waste, is thermally recycled in the 

waste incineration plant AVA Velsen. 

In total, about 255,000 tonnes of 

residual waste are thermally recycled 

annually in AVA Velsen, generating 

about 150,000 MWh of electricity. 

This is achieved by optimised waste 

allocation and low-fault operation, 

based on the consistent use of modern 

and reliable technologies. 

Hose pumps in the flue gas 

cleaning system 

The flue gases produced during waste 

incineration are fed into a multi-stage 

flue gas cleaning system to remove 

pollutants. For flue gas scrubbing, 

the gas is first cooled in the so-called 

quench, by intensive spraying with 

water, which flushes out the first pollutants. 

The contaminated wash water 

(“quench water”) is later subjected 

to further treatment steps to precipitate 

and filter out more pollutants. 

Initially, several centrifugal pumps 

were used throughout the plant to 

transport the wash water. Since the 

wash water is very acidic (pH 0) and 

highly corrosive, these pumps repeatedly 

broke down: The mechanical 

seals of the centrifugal pumps 

proved to be especially susceptible to 

damage and had to be replaced frequently, 

reports the team leader of 

AVA Velsen GmbH responsible for the 

wastewater treatment and evaporation 

plant. In many cases, the damage 

even proved so serious that the 

entire pump head of the centrifugal 

pumps had to be replaced - with considerable 

costs for spare parts and 

downtime. 

Pumping without seals and valves 

AVA Velsen GmbH found a solution 

to these problems in the hose pumps 

from the supplier. These pumps require 

neither seals nor other additional 

equipment such as ball check 

valves, diaphragms, immersed rotors, 

stators or pistons, which can 

leak, clog or corrode and then have 

to be replaced at great expense. No 

moving pump components come into 

contact with the medium. 

The only spare part in the hose 

pumps is the precision-manufactured 

hose element. Depending on the application 

and purpose, it is available 

in a variety of different materials, including 

EPDM, which offers excellent 

resistance to aggressive chemicals 

and concentrated acids. 

A total of four centrifugal pumps 

in the wastewater treatment plant 

were replaced with industrial hose 

pumps. With great success: The service 

life of the EPDM hose elements 

enabled total costs to be reduced 

by more than 50 percent compared 

to the previously used centrifugal 

pumps. 

High reliability in the processing of 

limestone slurry 

Fig. 1: At AVA Velsen, about 255,000 tonnes of residual waste are thermally recycled 

per year and approx. 150,000 MWh of electricity are produced 

(all photos: Watson-Marlow Fluid Technology Solutions) 

The industrial peristaltic pumps have 

already been able to prove their suitability 

for difficult and demanding 

pumping applications in another application 

at AVA Velsen: During a subsequent 

process step, limestone slurry 

(“milk of lime”) is added to the wash 


Fig. 2: Industrial hose pump for pumping very 

acidic (pH value 0) and corrosive washing water. 

Since only the hose elements made of EPDM 

touch the aggressive medium, it offers a long 

service life. 

water in a treatment plant, thus enabling 

the sulphur dioxide to be filtered off in the 

form of gypsum. A rotary lobe pump was 

initially used to transport the limestone 

slurry. Due to the abrasive character and 

relatively high solids content of the limestone 

slurry, this pump proved to be very 

susceptible to breakdowns and caused 

high repair and downtime costs. The solution 

here was also a robust industrial 

Fig. 3: Pump to process lime slurry with a high 

solids content without any problems. 

Fig. 4: The direct-coupled design combines the 

reliability of the long-coupled design with the advantages 

of the compact close-coupled design. 

hose pump from the manufacturer. The 

pump now delivers the milk of lime with 

a high degree of reliability. The hose elements 

used achieve a service life of about 

nine months, reports the team leader. For 

safety reasons, however, the hose element 

is replaced every six months as part 

of planned maintenance. The costs for this 

are very low compared to the repair costs 

of the rotary lobe pump and moreover, the 

replacement of peristaltic hose elements 

can be carried out quickly and easily onsite. 

For these reasons, the hose pumps in 

various sizes are now also used in the AVA 

Velsen for pumping a saturated NaCl solution 

as well as filtrates. 

As the pumps are exposed to a corrosive 

atmosphere, the components have 

been made of stainless steel wherever possible. 

The pumps are also painted according 

to the C4 painting standard or are protected 

with a double layer of paint. More over, 

the pump manufacturer offers pumps 

with a paint-free, galvanically coated pump 

housing for aggressive atmospheres. 

Ideal solution for many applications in 

energy-from-waste plants 

At various application at AVA Velsen, the 

pumps are demonstrating the numerous 

advantages of peristaltic hose pumps for 

processing aggressive or abrasive pumped 

media: They offer a suction head of up to 

9.5 metres, are self-priming and offer good 

dry-running capabilities. Without internal 

seals or valves, no moving parts come 

into contact with the medium, and they 

impress with their high reliability and low 

maintenance requirements. 

Maximum reliability is also ensured by 

the manufacturers patented direct-coupling 

technology: it combines the reliability 

of the long-coupled design with the advantages 

of the compact close-coupled design: 

An innovative buffer zone protects the 

gearbox, bearings and pump head in case 

of leakage. Heavy-duty pump rotor bearings 

support the radial load, so the drive 

shaft transmits only the torque and speed 

needed for the specific application. 

Depending on the pump model and 

size, the hose pumps offer a high flow 

rate of up to 108,000 litres at a pressure 

of up to 16 bar and convey abrasive slurries, 

pastes and viscous media with up to 

80 percent solids content with 100 percent 

volumetric accuracy. 

Therefore, the supplier’s peristaltic 

pumps are the first choice for many applications 

in the environmental and energy 

industries. In these industries, they are 

used wherever corrosive, viscous, abrasive 

or other difficult-to-handle media 


Problem solver for 

process engineering 

and sewage technology 

www.eggerpumps.com 

Turo ® Vortex series T and TA 

Suitable for high solids concentrations 

and shear sensitive products in 

the chemical industry and for clogfree 

pumping of raw sewage with 

fibres and sludge. 

Iris ® Diaphragm Control Valve 

Highly precise and energy saving 

control of flow rate through concentric 

Iris ® diaphragms. For aeration airflow 

control in WWTP’s and for gases or 

liquids in industry. 

SWISS ENGINEERED 

PUMPS SINCE 1947 

Switzerland 

Emile Egger & Cie SA 

Route de Neuchâtel 36 

2088 Cressier NE 

Phone +41 (0)32 758 71 11 

Germany 

Emile Egger & Co. GmbH 

Wattstrasse 28 

68199 Mannheim 

Phone +49 (0)621 84 213-0


Report 

must be transferred safely. Applications 

include alkalis, acids, flocculants 

or other chemicals, process water 

and waste water, as well as slurries, 

brines or sludges, additives or dyes, 

plasticisers or solvents. Compared to 

other types of pumps, they often provide 

significant savings in total cost of 

ownership and a fast ROI of often less 

than twelve months. 

Interaction of pump and 

hose element 

Fig. 5: Pumps for pumping a saturated NaCl solution 

Fig. 6: Precision-machined hose elements are reinforced with multiple extruded layers of 

braided nylon. Thanks to precision grinding, they meet tight tolerances in wall thickness 

The heart of every industrial hose 

pump is the hose element. It is not 

only the single wearing part, but also 

the only component on the entire 

pump that comes into contact with 

the fluid. Only a perfect match of 

pump and hose element offers maximum 

reliability and performance: As 

one of few pump manufacturers, the 

supplier has its own production of 

high-performance hose elements - 

especially and exclusively for use with 

its own peristaltic pumps. 

Unlike many hoses from other 

manufacturers, the hose elements 

are precision-engineered. This means 

that only the highest quality rubber 

compounds are used, reinforced with 

several extruded layers of braided nylon, 

which ensure the automatic relaxing 

of the hose element and strong 

suction capabilities of the pump. As a 

result, the pump is self-priming and 

dry-running and can handle even high 

viscosity fluids with ease. Due to the 

extruded layers, the hose element offers 

higher strength and longer service 

life than hose elements with 

wrapped layers. The hose elements 

are ground to meet the tight tolerances 

in wall thickness thus providing 

maximum hose and pump life. 

Watson-Marlow GmbH 

Rommerskirchen, Germany 



Report 

60 % fewer production losses: Downhole 

progressing cavity pumps simplify replacment 

and reduce costs with special flush-by unit 

Pump service life is two to three times longer 

compared to previous models 

At one of Turkey’s largest and most 

productive oil fields, the BATMAN 

field in southeast Anatolia, different 

downhole progressing cavity 

pumps are used to pump a mixture 

of crude oil and water to the surface. 

To increase the service life of 

the pumps and to reduce the installation 

costs and the pump replacement 

time, the owners decided to 

test the use of insertable progressing 

cavity pumps. They chose the 

downhole variant of the proven 

progressing cavity pumps from 

the global manufacturer NETZSCH 

Pumpen & Systeme GmbH based in 

southern Germany. As all progressing 

cavity pumps, they use a special 

operating principle where a helical 

rotor rotates inside a fixed stator to 

form closed conveying chambers. 

These chambers continuously move 

the oil-and-water mixture to the delivery 

side with a consistent volumetric 

flow. While the efficiency of 

this system is between 40 and 70 % 

of the oil production maximum, the 

volumetric efficiency of a downhole 

progressing cavity pump reaches an 

impressive 75 to 95 % of the theoretically 

possible volume flow. Another 

essential advantage of the insertable 

pumps – three of which are 

now in use on the Turkish oil field – 

is that they are relatively easy to install 

directly in the conveying line. In 

addition, they can be replaced using 

a special flush-by unit without removing 

them from the pipe and uninstalling 

the well sensors. This significantly 

reduced the expenditures 

for workovers at the oil field, which 

minimised production losses by up 

to 60 per cent and significantly lowered 

costs. In addition to this, the 

Fig. 1: The Batı-Raman field in southeast Anatolia is one of the largest and most productive 

oil fields in Turkey. (Photo © : Adobe Stock/Inna) 

service life of the pumps is two to 

three times longer compared to the 

previously used conventional progressing 

cavity pumps. 

Various pump types from different 

manufacturers are used for pumping 

oil on the BATMAN field in Turkey, 

including NETZSCH standard downhole 

pumps. On this standard version, 

the stator is bolted to the tubing 

at the lowest point and, in a second 

step, the rotor is installed through 

the tubing together with the sucker 

rod. “To replace these pumps, however, 

they have to be removed together 

with the tubing in a complex 

process, which requires us to buy 

and use an expensive workover unit,” 

explains the Technical Support Engineer, 

Oil & Gas Upstream, NETZSCH 

Pumps and Systems Turkey. To lower 

rig costs and to shorten the pump 

replacement time, the owners therefore 

decided to use insertable down- 

Fig. 2: Different pump types from various 

manufacturers are in use on the oil field, 

including pumps type NTZ from NETZSCH 

Pumpen & Systeme GmbH. (Photos © 2-6: 

NETZSCH Pumpen & Systeme GmbH) 


35


Report 

hole progressing cavity pumps from 

the supplier. These pumps feature a 

very small outer diameter. 

Reliable pumping of 

multi-phase media 

Just like conventional progressing 

cavity pumps from the Bavarian supplier, 

these pumps are also based on 

a rotor that rotates in a geometrically 

adapted fixed stator in an oscillating 

motion. The precise geometry pairing 

produces conveying chambers during 

the rotation and the medium is gently 

transported in these chambers from 

the intake side to the delivery side. 

The chambers are closed, which not 

only prevents backflow but also ensures 

movement of the medium with 

stable volume and pressure so that 

no shear forces and hardly any pulsation 

occur. This is crucial because 

oil-and-water mixtures otherwise produce 

emulsification effects. These effects 

would make the subsequent 

separation of the mixtures at the surface 

much more difficult. This risk also 

exists for the medium that is pumped 

on the BATMAN field, because it consists 

of 25 % water and 75 % oil. 

The volumetric efficiency of the 

downhole progressing cavity pumps 

is between 75 and 95 % of the theoretically 

possible volume flow. While 

conventional pumping systems soon 

reach their limitations in the case of 

fluctuating consistencies, resulting 

in pumping interruptions, pressure 

loss, and material damage, the consistency 

and viscosity of the medium 

are irrelevant with this displacement 

technology. The pumps are therefore 

particularly suitable for difficult 

multi-phase media and can transport 

even highly viscous oils to the 

surface with over 50,000 mPas. The 

pumped volume is determined by 

the pump size and the speed of the 

unit, meaning it can be controlled 

with great precision. Another key feature 

of the downhole models based 

on the progressing cavity pump is the 

high level of flexibility with respect to 

the flow rate – it can be between 0.5 

and 475 m³/d. For the medium on the 

BATMAN field, which is pumped at 

60 °C with a pressure of 15 bar, the 

flow rate is 4.77 m³/d. 

Fig. 3: Like all progressing cavity pumps, they feature a special pumping principle where a 

helical rotor rotates in a fixed stator to form closed conveying chambers. These chambers 

move the oil-water mixture to the delivery side in a continuous, consistent volumetric flow. 

Fig. 4: These insertable progressing cavity pumps were developed with the main objective of 

minimising the costs for installing the pumps in the well. Pictured: equipment for securing 

the downhole pump in the tubing. 

Fig. 5: The first two models of this NETZSCH downhole pump, which is much easier to replace, 

were installed on the Turkish oil field. 


Fig. 6: Subsequent replacement or 

maintenance of the pump can be carried 

out with a special flush-by unit: 

The pump can be replaced with a rod 

pulling unit which is much less expensive 

than a workover unit. 

Installation directly in 

the tubing and replacement 

with rod pulling unit 

or the locking system. The installation 

is completed by lowering 

the pump until it reaches the 

nipple or the locking system once 

again and then securing it there 

with a friction anchor and an 

axial lock. Another advantage is 

that subsequent replacement or 

maintenance of the pump can be 

carried out with a special flush-by 

unit. The pump can be replaced 

with a rod pulling system which is 

much less expensive than a complex 

workover unit with special 

hydraulic tongs for bolting the 

tubing. Overall, this procedure 

can significantly reduce costs because 

the pump with the sucker 

rod can be removed through the 

tubing. The tubing, any well sensors, 

and the sensor cable do not 

have to be removed. This minimises 

the time required for the 

workover and reduces production 

losses by up to 60 %. 

The longer service life 

of the pumps 

World Class. 

The pumps used at the Anatolian 

oil field have other special 

features as well: They are insertable 

progressing cavity pumps 

designed with the main focus 

on minimising the costs for installation 

of the pumps in the 

well. The key feature of these 

pumps is therefore the installation 

through the tubing string. 

That means that the pump is not 

connected to the tubing, but installed 

directly inside it. The procedure 

is as follows: The pump 

is first lowered into the tubing 

string until the installation clamp 

reaches the wellhead and is then 

held by means of the pump rod. 

The installation clamp can then 

be removed and the sucker rod 

can be installed. The pump is 

subsequently lowered down to 

nipple N11 or the pump locking 

system N12 – one of these systems 

will have already been installed 

in the well beforehand. 

The engineers can then check the 

position of the pump by pulling 

the rod string upwards and releasing 

the pump from the nipple 

The first two models of these 

much easier-to-replace downhole 

pumps installed in the 

Turkish oilfield were so successful 

that a third model followed 

in the year after. “The purchaser 

is very satis fied with the result 

of this project because it 

not only reduced the plant costs 

but also increased the service 

life of the pumps,” summarises 

the Technical Support Engineer. 

“It is two to three times as 

long as the service life of conventional 

progressing cavity 

pumps from NETZSCH that are 

not installed inside the tubing.” 

The Bavarian pump manu- 

facturer also regards this as a 

highly successful project because 

this was the first time that insertable 

downhole progressing cavity 

pumps were used in Turkey. 

NETZSCH Pumpen & Systeme GmbH 

Waldkraiburg, Germany 

LEWA ecoflow ® – the gamechanging 

metering pump series. 

Chemical, pharma or energy industry, vacuum, 

high pressure or other applications: Each purpose 

demands its own metering solution. LEWA 

ecoflow series for diaphragm and packed plunger 

pumps combines various drive unit sizes with 

different pump heads. 

Customers rely on more than 70 years 

expertise in process industry concentrated 

in LEWA ecoflow series. 

More information: 

www.lewa.com/ecoflow


Report 

Energy savings potential with intelligent 

pumping solutions – how a 

beverage producer expects 430,000 € 

in energy savings per year 

Energy crisis, 1.5 degree target, CO 2 

savings, science-based targets, water 

scarcity... these are all topics 

that we are currently encountering 

again and again. Turning down the 

heating, taking shorter showers and 

not leaving electrical appliances on 

standby are familiar recommendations 

for private households. But 

what are the possibilities for industry? 

How can water and energy consumption 

in the manufacturing sector 

be reduced? 

Many industrial applications like temperature 

control, water treatment 

and wash & clean are energy-intensive 

and consume a lot of water. And 

pumps always play a part. But at the 

same time, these areas offer relatively 

simple and quick ways on how to 

realise savings. Let’s take energy savings 

as an example, upgrading the 

current pump installation can pay 

for itself quite quickly due to the increased 

energy costs. How process 

optimisation can be realised in an 

existing plant is shown in the following 

example. The soft drink manufacturer 

Britvic is expecting ener gy savings of 

more than 430,000 € per year by investing 

in new pressure boosting 

equipment. 

Fig. 1: The four booster sets with CR pumps 

The situation 

Water is essential to Britvic’s production 

processes and used widely 

throughout its value chain. An element 

of this includes the heating and cooling 

of water at its factory in Rugby, UK. 

The pump manufacturer 

Grundfos performed an Energy 

Check Advanced on site to measure 

the actual energy use in the system. 

This is not simply a ‘nameplate’ check 

of efficiency; sensors are placed in 

Fig. 2: The Energy Check is a pump survey by the customer or a member of the pump 

supplier’s staff with subsequent analysis/calculation by the supplier 

the system to get the live data from 

the existing setup, helping operators 

find potential energy savings in 

their pumps. The proven and validated 

measurements help the soft drink 

manufacturer support its ‘Healthier 

People, Healthier Planet’ strategy and 

the focus on energy and carbon emissions 

reduction. 

The solution 

To help achieve these twin goals, the 

recommended solution was a full 

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The booster sets installed 

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The outcome 

For each 

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the perfect 

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Fig. 4: “We are very happy to have 

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facility’s production lines, to allow 

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Vacuum-based methods for testing 

the packaging of pharmaceutical products 

for leaks 

Secure packaging of pharmaceutical products 

The quality and effectiveness of 

medicines depends to a significant 

extent on their proper packaging: 

Sterile products and medicines that 

are sensitive to moisture or oxygen 

must remain extremely well sealed 

throughout their entire shelf life to 

protect them from biological contamination 

and the ingress of water 

and oxygen. Otherwise, there may 

be serious consequences. 

The most important barrier for ensuring 

sufficient integrity of pharmaceutical 

products and for protecting 

them against harmful external influences 

is the so-called primary packaging. 

The most common types of 

primary packaging include plastic or 

glass bottles, vials and syringes, but 

also IV bags and blister packs. 

(1) Product development and 

process validation 

In the first part of the life cycle, the 

requirements for the primary packaging 

and the container closure system 

are defined. The goal is to define 

the minimum requirements for 

sealing. This includes testing using 

sensitive test methods such as helium 

leak detection. In the case of particularly 

sensitive products, such as 

sterile medicines, the so-called MALL 

(Maximum Allowable Leakage Limit) 

is checked, for example, which is defined 

in USP as < 0.2 μm de- 

Fig. 2: Microbial ingress failure rate as a function of leak size in µm and mbar•l/s. [1] 

ate various widely used methods. The fect size or < 6*10 -6 mbar • l/s. This 

directive divides the product life cycle defect size was determined in a study 

into three parts, each of which places by Kirsch, in which the microbial ingress 

failure rate was measured for 

different demands on the leak testing 

systems: 

various defect sizes. From a defect 

Fig. 1: Selection of common primary packaging used for pharmaceuticals. 

Necessity of leak detection 

The primary packaging must be subjected 

to leak tests at various times 

throughout the life cycle of the pharmaceutical 

product. The United 

States Pharmacopeia (USP), which is 

the government body responsible for 

standards and directives in the pharmaceutical 

industry in the USA, introduced 

a new directive in 2016: USP 

. This describes methods and 

procedures for the leak testing of 

pharmaceutical packaging and gives 

the user guidelines on how to evalu- 

size 0.2 μm onward, no microbial ingress 

can be detected. By means of 

a helium leak test, this value has also 

been quantitively determined with a 

gas flow measured in mbar*l/s. [1] 

(2) Product manufacturing 

The second step involves regular testing 

and monitoring of the quality of 

the chosen packaging during the production 

process. Here, random inspections 

are often performed, but 

also 100-percent checking of the containers. 

Since sterility has already 

been demonstrated during product 




development, the chosen methods 

prioritize faster testing times rather 

than higher sensitivity. 

(3) Assessment of the 

commercial shelf life 

Integrity tests are then carried out on 

a sufficient number of samples during 

various periods throughout the 

entire shelf life of the products. The 

objective here is to ensure that the integrity 

of the packaging is maintained 

even if the product is stored for long 

periods. 

Different test methods 

The high risk involved with leaks in 

pharmaceutical container closure integrity 

(CCI) testing has resulted in a 

strictly regulated environment. The 

FDA (USA) and the EMA (Europe), for 

example, are two of the key authorities. 

These bodies have published directives 

that stipulate reliable, physical 

measurements to ensure proper 

CCI. In practice, however, these directives 

are rather broad and give 

no concrete recommendations. Often, 

the official regulations fail to give 

detailed instructions on how the CCI 

tests should be carried out. 

USP was introduced in 

order to provide more clarity in this 

respect. This directive concentrates 

on sterile and critical pharmaceutical 

products and therefore does not 

attempt to describe all possible test 

methods. It does, however, provide a 

good overview and basic guidelines 

for the evaluation of various different 

methods. 

The test methods are divided into 

so-called probabilistic and deterministic 

test methods, whereby the latter 

are generally recommended. By 

way of example, we take a closer 

look, here, at the blue dye test as a 

proba bilistic method, and the three 

va cuum test methods as deterministic 

test methods. 

a) Probabilistic test methods 

A probabilistic leak testing procedure 

is based on a series of sequential 

and/or simultaneous events, each 

of which is associated with uncertainties. 

These methods are therefore inherently 

stochastic, since the results 

are randomly affected by probability 

distributions. To compensate for 

this uncertainty as much as possible, 

larger random sample sizes and strict 

monitoring of the test conditions are 

necessary. 

The blue dye test is a probabilistic 

test method. This test involves 

submerging the test packaging into 

a methylene blue solution. The dye 

bath is placed in a temporary vacuum 

chamber, from which some of 

the air is evacuated in the first stage 

of the test. After a predefined evacuation 

time, the chamber is returned 

to atmospheric pressure, or is pressurized. 

Finally, after a defined resting 

period, the packaging is taken 

out of the bath and then cleaned and 

visu ally inspected to see whether or 

not the blue liquid has penetrated 

the packaging. 

b) Deterministic test methods 

In contrast to probabilistic test 

methods, deterministic test methods 

are based on phenomena that follow 

a predictable chain of events. This is 

because the leaks are measured via a 

Table 1: Probabilistic and deterministic methods according to USP [2] 

Probabilistic 

Series of sequential and/or 

simultaneous events 

Random result based on the 

probability distribution 

Subjective and qualitative results 

Primarily destructive 

Sample preparation required; 

high risk of error 

Deterministic 

Predictable chain of events 

Measured physical or chemical 

end point 

Objective and quantitative results 

Non-destructive 

Usually no sample preparation 

required, therefore low risk of 

preparation errors 

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41



physical or chemical end point, which 

can be easily checked and monitored. 

In the vacuum test methods, for example, 

the gas flow through an open 

leakage channel is measured as a 

specific differential pressure is applied, 

and the results are then evaluated. 

Below, three of the deterministic vacuum 

test methods are described in 

more detail: 

Mass extraction technology 

With mass extraction technology, the 

packaging specimen is placed in a volume-optimized 

vacuum chamber. A 

mass extraction sensor, which measures 

the gas flow, is installed between 

the vacuum reservoir of the test device 

and the vacuum chamber (see 

Figure 3). 

pressure of < 1•10 -02 mbar. In the sensor, 

a plasma is ignited with the gas 

that escapes through defects in the 

specimen, and the gas-specific light 

emission is intercepted by an optical 

spectrometer. Information about the 

integrity of the packaging is then provided 

based on the intensity of the 

light emission. This test method is selective 

for different gases and does 

not necessarily require the use of a 

volume-optimized chamber, which 

means that several test specimens 

can be tested simultaneously. 

that the test packaging must have 

previously been filled with helium. 

The helium-filled test specimens are 

placed in a vacuum chamber, as with 

the other methods. The escaping gas 

is ionized in the detector by a heating 

filament, and is deflected by the magnetic 

field along different curves depending 

on the mass. 

The incoming ion current is processed 

by the electronics in the device 

and displayed as a leakage rate 

signal. The helium selectivity ensures 

high sensitivity. 

Fig. 4: Illustration showing the operating principle of O.E.S. 

Fig. 3: Operating principle of mass extraction 

technology 

The first step involves evacuating the 

entire device and the chamber to a 

pressure of around 1 mbar. The differential 

pressure between chamber and 

the inside of the packaging now allows 

gas to escape through any prevailing 

leaks and to flow toward the vacuum 

reservoir. The sensor installed in 

the flow path measures the gas flow 

quantitively and provides information 

on the integrity of the test specimen. 

With mass extraction technology, the 

test specimen does not need to contain 

a specific type of test gas. 

Helium mass spectrometry 

The helium leakage test is the most 

sensitive of the deterministic test 

methods. The sensor used here is a 

magnetic sector mass spectrometer, 

which is set up selectively for helium 

atoms with a mass of 4. This means 

Study comparing different defects 

In addition to the aforementioned 

study by Kirsch, there is a further 

study, by Burrel et al, that compares 

the sensitivity of the blue dye test 

and the microbial ingress method. 

Optical emission spectroscopy 

No special test gas is required for the 

optical emission spectroscopy (O.E.S.) 

procedure either. The gas mixture 

present in the head room inside the 

packaging specimen is used – usually 

ambient air or nitrogen. A multigas 

sensor is used to detect gases 

that escape from a leaking specimen. 

This method involves placing the 

test specimen into a vacuum chamber 

and evacuating the chamber to a 

Fig. 5: Structure of a helium mass spectrometer 




The test vials used in the study were 

prepared with 3-cm-long capillary defects. 

The widely accepted sensitivity 

limit of a defect size of 20 µm for the 

blue dye test is based on the results 

of this study. [3] 

Fig. 6: Percentage of specimens showing blue dye ingress as a function of leak size in µm. [3] 

Table 2: Specimen preparation for the comparative study 

Preparation of 

positive control 

samples 

Composition 

of vials 

20 ml vials prepared 

with micro-pipettes 

With reference 

to Kirsch 

20 ml vials prepared 

with capillaries (3 cm 

long) 

With reference 

to Burrel 

Head room 

Liquid 

Defects 

helium, the O.E.S., and the mass extraction 

methods, and the measured 

values were recorded. Then, the vials 

were subjected to the blue dye 

test. The vials were submerged in the 

blue dye for 60 minutes at a relative 

ø: 0.1/0.2/0.4/1/2/5/10 µm 

30 specimens for each diameter 

30 negative control specimens 

(adhesive on the defect) 

ø: 2/5/10/15/18/30/40 µm 

30 specimens for each diameter 

30 negative control specimens 

(adhesive on the defect) 

Gas mixture: 

20 % helium 

80 % nitrogen 

6 ml WFI 

(water for injection) 

The defects are in the area of 

the head room – they have no 

contact with the liquid. 

vacuum pressure of -370 mbar. The 

specimens were then brought to atmospheric 

pressure and cleaned before 

being visually inspected by three 

technicians, in order to obtain the 

most objective results possible. The 

diagrams in Figure 7 and Figure 8 

summarize the results of the study. 

With a measured detection limit 

of 20 µm for the capillaries and 5 µm 

for the micro-pipettes, the blue dye 

test is found to have the lowest sensitivity. 

The most sensitive method, 

even with a helium concentration of 

just 20 %, was found to be the helium 

mass spectrometry method with approximately 

4 µm for the capillaries 

and 0.1 µm for the micro-pipettes. If 

a helium concentration of 100 % is 

assumed, then even the 2 µm capillaries 

are measurable. Both the O.E.S. 

method, with a detection limit of 

~ 7 µm for the capillaries and ~ 0.6 µm 

for the micro-pipettes, and the mass 

extraction method, with 15 µm for the 

capillaries and ~ 1-2 µm for the micropipettes, 

lie somewhere between the 

other two methods. It must be noted, 

however, that the O.E.S. method is 

quicker and more sensitive for both 

types of defect. 

Pros and cons of the 

different test methods 

There are other factors, in addition 

to sensitivity, that may be taken into 

account when deciding whether to 

switch from the blue dye test to a 

vacuum-based test method. A few of 

these factors are shown in Table 3. 

To allow a comparison of the sensitivity 

of the three deterministic vacuum 

methods with the known studies 

and, above all, with the blue dye test, 

a comparative study of different defects 

was carried out. Here, the defect 

types from the Kirsch study as well 

as those from the Burrel study were 

used. The types of specimen are explained 

in Table 2. 

The gas composition makes it 

possible to use all three deterministic 

methods. The vials were filled with the 

gas mixture before they were sealed. 

The tests were carried out sequentially 

and non-destructively with the 

Fig. 7: Study results for micro-pipettes 


43



Fig. 8: Study results for capillaries 

30 minutes at atmospheric pressure). 

The time required for testing depends 

on the type of packaging. In practical 

applications, significantly shorter test 

durations are usually chosen for the 

blue dye test, which further reduces 

the sensitivity. The test duration for 

vacuum-based methods is significantly 

shorter, even taking into account 

that several specimens can be 

tested at once with the blue dye test. 

Furthermore, the evaluation time for 

the blue dye test is longer. 

With regard to the latest directives, 

the great advantage of the 

vacuum-based test methods is that 

all three deterministic test methods 

meet the criteria of USP . Both 

Table 3: Parameters used to compare vacuum-based test methods with the blue dye test 

Parameter Helium (20 %) O.E.S. Mass Extraction Blue dye test 

Sensitivity 

– Capillaries 

– Micro-pipettes 

4 µm 

0.1 µm 

~ 7 µm 

~ 0.6 µm 

~ 15 µm 

~ 1-2 µm 

20 µm 

5 µm 

Test duration < 20 seconds 25 seconds 75 seconds Batch dependent 

Deterministic Yes Yes Yes No 

Non-destructive 

Simple set-up 

(Yes) 

only for open packaging 

No 

Helium as a test gas 

is challenging to handle. 

Yes Yes No 

Yes Yes Yes 

Can be automated No Yes Yes No 

As shown in the comparative study, 

the vacuum-based test methods are 

significantly more sensitive than the 

blue dye test. This is a plus point, 

since the test requirements for primary 

packaging of pharmaceutical 

products have become increasingly 

stringent in recent years. It must 

also be noted, here, that the sensitivity 

results for the blue dye test were 

achieved based on a lengthy test duration 

(60 minutes under vacuum and 

the mass extraction method and helium 

mass spectrometry method 

are explicitly listed as deterministic 

methods in this directive. 

Also, the vacuum-based test 

methods are non-destructive, which 




means that the specimens can be 

used again, e. g. for additional tests 

at a later date. Only the helium test is 

limited insofar as it can only be used 

for open packaging or packaging that 

has already been filled with helium. 

Although helium is the most sensitive 

method, this limitation means that it 

is not usually possible to use the test 

during production. Also, setting up 

a system for helium testing is more 

challenging compared to the other 

methods, since helium as a test gas is 

not easy to handle. 

Only the O.E.S. and mass extraction 

methods can be expediently 

automated in order to increase 

the throughput of tested packaging 

units during production. With these 

methods, throughput can be increased 

relatively easily and cost-effectively 

by introducing automated 

loading and unloading, for example. 

The O.E.S. method can also be used 

to test several vials in one chamber, 

which can significantly increase the 

throughput at little extra cost. 

The use of vacuum-based test 

methods is subject to the additional 

basic restriction that the primary 

packaging must be able to withstand 

a differential pressure of approximately 

1 bar. This can be mitigated 

by using volume-optimized vacuum 

chambers that have been prepared 

for special use, but the method is still 

limited, to non-porous primary packaging/packaging 

types in general. 

Summary 

The steadily increasing demands 

placed on the integrity of packaging 

for pharmaceutical products are 

leading to a shift toward different CCI 

leak testing methods. Directives such 

as USP promote a move away 

from probabilistic test methods such 

as the blue dye test, which has been 

well established for decades, and toward 

deterministic test methods, 

which also include the vacuum-based 

test methods (helium mass spectrometry, 

optical emission spectroscopy, 

and mass extraction). 

The comparative study shows 

that a significantly lower detection 

limit can be achieved with vacuumbased 

test methods than with the 

conventional blue dye test. The first 

step for users to take when switching 

to one of the deterministic test 

methods is to carry out a series of 

tests to determine the detection limit 

currently achieved with their blue dye 

test. Users should also be clear about 

the critical detection limit that needs 

to be achieved in regular testing, for 

example during production. This may 

already narrow down the range of 

possible new test methods. 

The area of application must also 

be determined. Helium mass spectrometry, 

for example, is the most 

sensitive test method, but the difficulties 

of handling helium make it more 

suitable for use in R&D, or in the development 

and validation of packaging. 

Where in-process testing during 

production is required, the blue dye 

test can best be replaced by the O.E.S. 

or mass extraction test method. 

List of sources 

[1] L. E. Kirsch: PDA J Pharm Sci Technol 

54,4, 2000, p. 305-314 

[2] United States Pharmacopeia: 

Package Integrity Testing in 

the Product Life Cycle – Test Method 

Selection and Validation. 

[3] L. S. Burrell: PDA J Pharm Sci Technol 

54 (2000) 6,449-455 

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7 ways to reduce production downtime 

Production downtime is one of the 

biggest risks in the manufacturing 

industry. From equipment failures 

to shortages of raw materials, any 

production downtime can result in 

major losses in revenue and market 

share. 

There are two types of downtime: 

planned and unplanned. 

Planned downtime is a scheduled 

shutdown of manufacturing equipment 

or processes to perform maintenance, 

inspections, repairs, upgrades 

or manufacturing setups. It is 

essential to plan downtime for maintenance 

to keep the equipment in 

its optimum condition and to avoid 

unplanned downtime. Although 

planned downtime interrupts the 

manufacturing process, you are still 

in control of productivity processes. 

Thus, preventing production downtime 

is key to ensuring productivity. 

Follow our seven tips to reduce 

machine downtime in your production 

line. 

1. Develop a system for quickly 

identifying and resolving production 

issues 

The system should gather and analyze 

data that gives insight into the 

equipment’s total maintenance requirements. 

Interpretation of the 

data can help your teams resolve 

production issues by carrying out 

preventive maintenance. The implementation 

of such a system allows 

factories cut down on time lost due to 

production issues and prevent costly 

unplanned downtime by alerting employees 

of possible upcoming equipment 

failures. 

2. Use predictive analytics to 

identify potential problems before 

they occur 

Predictive analytics detect patterns 

in real-time machine data that could 

lead to the onset of a problem. Data 

analytics can inform you weeks in 

advance about which parts of a machine 

are likely to fail. This allows you 

to plan your maintenance schedules 

and order spare parts in advance, 

effectively reducing downtime and 

lessening the likelihood of issues reoccurring. 

3. Implement a preventive maintenance 

program 

Preventive maintenance programs are 

one of the most effective ways to minimize 

unplanned machine downtime. 

You can routinely collect valuable 

information about your equipment for 

Unplanned downtime occurs when 

there is an unexpected shutdown or 

failure of the manufacturing equipment 

or process. It causes foodstuffs 

to spoil if they are not packaged, as 

well as expensive delays in production 

and delivery schedules. Additionally, 

when operations are unstable, it 

is more difficult to adhere to environmental 

regulations and comply with 

sustainability measures. This could 

result in an increase of environmental 

incidents. 

a systematic maintenance approach. 

With the right targeted maintenance, 

you can react to predicted equipment 

failures or accidents before they occur. 

By reducing the possibility of unexpected 

downtime, your staff can focus 

on more profitable tasks. 

4. Create a system for dealing with 

glitches and problems as they arise 

Having a system that tracks and monitors 

glitches as they arise allows you 

to identify the root cause of an issue 

in your production line. This will en- 




downtime in your manufacturing 

process. If operators know how to 

use equipment correctly, they are 

less likely to halt production and can 

respond faster in emergency situations. 

Proper training also prevents 

unplanned downtime caused by human 

error and decreases the risk of 

workplace accidents. 

able you to understand how production 

failures occur and how to prevent 

them from happening again. 

This reduces unplanned machine 

downtime while increasing manufacturing 

efficiency. 

5. Automate as many processes as 

possible to reduce human error 

Reduce downtime and make your 

production process more efficient 

by automating repetitive and tedious 

tasks that are prone to human error. 

This will give your staff more time to 

focus on profitable tasks and develop 

their skill sets, which will translate 

into higher profits for your company 

and show your workforce that they 

are your most valuable resource. 

6. Train operators on how to 

properly operate equipment 

Training operators to properly use 

equipment can significantly reduce 

7. Use intelligent IoT solutions 

Are six tips too many? Then use tip 7 

for an all-in-one solution! Intelligent 

IoT solutions help reduce downtime 

by providing you with a system that 

quickly identifies and resolves production 

issues (tip 1). It tracks and 

monitors your equipment and process 

with predictive analytics, enabling 

you to create a maintenance 

schedule and order the necessary 

spare parts ahead of time (tip 2). Sensors 

and data analytics enable IoT 

to continuously track and monitor 

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are two types of downtime: planned 

and unplanned. 

Planned downtime is a scheduled 

shutdown of manufacturing equipment 

to perform maintenance, inspections, 

repairs and upgrades. 

Unplanned downtime is an unexpected 

shutdown or failure of your 

manufacturing equipment or process. 

ment preventive maintenance (tip 3) 

and predict potential issues as they 

arise (tip 4), effectively lessening the 

frequency of planned or unplanned 

downtime. IoT also enables the automation 

of tasks, shortening the time 

it takes to complete them and ultimately 

boosting productivity and reducing 

human errors (tip 5). Thanks 

to its user-friendly tools, it is easy to 

learn how to operate IoT. Your workforce 

will be able to use it properly in 

no time (tip 6). 

Would you like to optimize your process 

by installing an IoT system? 

Busch also provides you with preventive 

maintenance by automatically 

dispatching a service specialist based 

on the analysis of the collected data 

when needed. 

FAQs 

What is production downtime? 

Downtime is the time during which a 

production process is stopped. There 

How do you calculate production 

downtime? 

Use the following equation to calculate 

production downtime costs: 

Downtime % = (amount of downtime/ 

planned operating time) * 100 

What is the average production 

downtime? 

Manufacturers lose an average of 

800 hours per year, or more than 15 

hours per week, of production time 

due to equipment downtime. 

Let's consider a common scenario for 

a parmesan cheese factory: 

A parmesan cheese block weighs an 

average of 42 kg. The estimated price 

is 9 Euro per kilo, amounting to one 

parmesan block having a total value 

of 378 Euro. Three cheese blocks can 

be produced per minute, resulting in 

68,040 Euro per hour. 

If the parmesan factory experienced 

15 hours of unplanned downtime 

caused by equipment failure in one 

week, they would lose 1,020,600 Euro. 

Busch Vacuum Solutions 

Maulburg, Germany 


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120 m³/h at a pressure of 10 to a maximum of 18 bar. The free ball passage 

is 40 mm. The high-pressure performance and temperature limit 

of 200 °C along with its seal versatility make the EP series suitable for 

application areas in which companies previously used primarily screw, 

gear and progressive cavity pumps. These are usually larger and have 

difficulty maintaining the conveyance volume when the viscosity of the 

medium changes. The new areas of application include the oil and gas 

sector, tank farms, the petrochemical industry and the production of 

paints and varnishes, paper, glue and sugar. 

For greater operational reliability and temperature resistance, 

Vogelsang has also equipped the EP series with an AirGap. This air gap 

atmospherically separates the gearbox and the pump chamber, ensuring 

that in the event of a leak, liquid will drain off to the outside rather 

than entering the gearbox. At the same time, the AirGap protects the 

gearbox when conveying hot media. If required, integrated sensors in 

all chambers provide information about the current operating status. 

VY series: the all-rounder with high efficiency 

With the VY series, Vogelsang has further developed its VX series, 

opening up new fields of application for its proven pump technology. 

Thanks to its highly versatile sealing, the VY series is an all-rounder for 

demanding applications such as the chemical industry or the paper 

and textile sectors. The VY pumps’ performance spectrum ranges from 

1 m³/h to 120 m³/h at a maximum pressure of 10 bar. Integrated sensors 

provide all important information about the pump’s operating status. 

The VY series is also available with axial and radial wear protection 

for media with abrasive components. 

Fig. 2: The double-acting mechanical seal CoX-Cartridge is designed for use at high 

temperatures and pressures. 

Fig.1: The Vogelsang Automatic Supply Unit (ASU) is compact and increases the 

service life of a seal by up to 100 percent. 

Wide range of seals for even more flexibility 

Depending on the industry-specific standards and requirements, a variety 

of different sealing systems can be used in the housings of the 

new pump series. In addition to the Vogelsang Quality Cartridge, a 

completely pre-assembled mechanical seal in a cartridge design, additional 

special mechanical seals are available for the EP and VY series. 

Vogelsang has developed the double-acting, TA-Luft compliant mechanical 

seal CoX-Cartridge together with leading manufacturers. The 

company consequently offers the right solution for various fields of 

application, such as for use in the oil and gas industry or in the chemical 

sectors. If required, the new pump series can also be equipped with 

robust mechanical seals according to API 682. 


49



Service-friendly assembly and cleaning 

For a high degree of service-friendliness, both pump series feature 

a quick connection in addition to a variety of seals. This allows pipelines 

to be connected to pumps in a matter of minutes, thus minimising 

time, effort and costs for installation and conversion. Maintaining 

the pumps is also quick and easy. Via a quick service cover, wear parts 

can be replaced quickly without removing the pump from the pipeline. 

The design of the new housings, which minimizes dead space, also allows 

for easy cleaning. 

bpsense – intelligent monitoring of 

unregulated pumps 

bpsense integrates unregulated pumps into automated processes 

– Comprehensive energy monitoring 

– Continuous condition monitoring 

– Predictive maintenance 

New framework concept: even easier maintenance and service 

To protect the pump casings of the EP series from abrasive or aggressive 

media, the interiors can be fitted with radial casing protection 

plates. The innovative framework concept makes it possible to loosen 

the screw connection from the outside. It is based on an intelligent fastening 

system consisting of four modules that are screwed together 

from the outside. This way, the radial protection plates are optimally 

positioned and can be changed very easily for servicing. For maintenance 

or service purposes, the user only has to remove the covers and 

take out the modules. This straightforward handling greatly simplifies 

access and reduces downtimes during maintenance or servicing, which 

also saves time and money. 

Fig. 1: BRINKMANN PUMPS has developed the pump monitor bpsense, a fully integrated 

monitoring system for unregulated pumps (Photos © : Brinkmann Pumpen) 

Fig. 3: The innovative framework concept makes it possible to loosen the screw 

connection from the outside. 

With the pump control bplogic and the variable frequency drive (VFD) 

bpdrive, the portfolio of BRINKMANN PUMPS includes important products 

to digitize existing system environments. Now the Sauerlandbased 

manufacturer of intelligent pump solutions and innovative systems 

is taking the next step: The bpsense pump monitoring system 

provides a smart entry into the world of digital pumps. In practice, this 

Innovative seal supply system in miniature format 

In addition to the two-pump series, the innovative Automatic Supply 

Unit (ASU) seal supply system is also suitable for use in demanding industrial 

environments. The ASU is significantly smaller than conventional 

seal supply systems and can be easily installed even in tight installation 

spaces. The patented system is much less expensive than 

currently available options while extending the service life of seals by 

up to 100 percent. To maintain the barrier pressure, the ASU consists 

of a reciprocating piston pump that adds barrier fluid to the seal with 

each revolution. This keeps the overpressure at either 2.0 or 4.3 bar. 

Vogelsang GmbH & Co. KG 

Holthöge 10-14 

49632 Essen (Oldenburg), Germany 

Tel +49 (5434) 83-0 

Fax +49 (5434) 83-10 

germany@vogelsang.info 

www.vogelsang.info 

Fig. 2: The Team Digital for more efficiency: bpsense perfectly complements the 

digital portfolio of BRINKMANN PUMPS 




means: bpsense integrates unregulated pumps into automated processes 

and takes companies a big step further in their efforts to meet 

Industry 4.0 conditions. The integration of unregulated pumps into the 

digital landscape ensures complete transparency of the fluid system. 

bpsense – Entry into the digital world of pumps 

Digital. Integrated. Simple. This is the short formula for entering 

the digital pump world of BRINKMANN PUMPS. Thanks to the intelligent 

onboard sensor technology, bpsense enables the continuous 

monitoring of unregulated pumps. The simultaneous evaluation of 

acceleration, vibration, sound and temperature sensor signals makes 

it possible to detect the status of unregulated pumps in real time. Furthermore, 

extensive analysis functionality allows plant operators to enhance 

the system availability. bpsense is already prepared for wear 

detection of centrifugal pumps, which is a feature that is currently developed. 

Among the most important benefits of the digital pump monitoring 

system is that bpsense significantly helps to increase production 

quality through the traceability of production steps and continuous 

process monitoring. 

bpsense – seamless integration into digital system landscapes 

The pump monitor integrates into digital architectures – even as part 

of a retrofit of existing pumps. bpsense is IIoT-capable (Industrial Internet 

of Things) and enables the monitoring of complex systems by integrating 

unregulated pumps. In addition to optimal process monitoring, 

bpsense enables the entry into predictive maintenance – one of the 

key elements of Industry 4.0. bpsense impresses with good scalability. 

It can be used both as a stand-alone solution and in an online network, 

for example when combined with Brinkmann Pumps’ bplogic or a comparable 

pump controller. An NFC (Near Field Communication) connection 

allows the display of basic data such as energy consumption or 

operating hours even when the device is removed from the system or 

operating in off-grid environments. All you need is a smartphone and 

a standard NFC app, meaning, no cables or special tools are required. 

bpsense – Monitoring without additional wiring effort 

The bpsense pump monitor can be easily integrated into existing system 

landscapes. Optionally, the connection can be made via fieldbus 

or a data gateway such as bplogic. Two analog inputs on the bpsense 

provide all the prerequisites for the integration of additional sensors. 

In addition, there is an IEPE input for connecting external vibration sensors 

and an analog output for external actuators. bpsense fits into the 

terminal box of the pump drive and uses the existing power supply of 

the pump system. Additional wiring or batteries are not required to 

mount the pump monitoring system. 

BRINKMANN PUMPEN 

K.H. Brinkmann GmbH & Co. KG 

Friedrichstr. 2 

58791 Werdohl, Germany 

Tel + 49 (2392) 5006-0 

Fax + 49 (2392) 5006-180 

kontakt@brinkmannpumps.de 

www.brinkmannpumps.de 

We tackle the 

challenges of the 

future – with our 

intelligent vacuum 

solutions. 

www.buschvacuum.com



Vertical inline twin-screw pumps in block design 

The universal pump solution 

for space problems 

In many companies, lack of space is a major problem. However, relocating 

production to another location is usually not an alternative. 

So, another solution must be found. It is often difficult do replace a 

positive displacement pump in a narrow room or to integrate it into 

a new plant if the available installation space is limited. While some 

models can be arranged vertically, this usually requires a near wall 

or side support frame for vertical mounting. The versatile HYGHSPIN 

and CHEMSPIN inline twin-screw pumps offer new approaches that effectively 

solve these problems. Thanks to special block design, these 

pumps allow free vertical installation in space without lateral structures 

for horizontally running pipelines. 

Fig. 2: The models of the CHEMSPIN and HYGHSPIN series are also available in 

vertical version 

The HYGHSPIN and CHEMSPIN pumps have a wide speed range. The 

pumping is almost pulsation-free. The low mass inertia of the rotors and 

an imbalance-free design also contribute to the smooth running. 

Not only for space reasons, but also because of the high viscosity 

and volume flow ranges, these twin-screw pumps can effectively replace 

other pump types. Thus, HYGHSPIN and CHEMSPIN pumps can also be 

used for CIP and SIP processes without an additional bypass. Furthermore, 

the pumps are characterized by a low risk of cavitation even when 

pumping viscous media. The pumps are available in five sizes each. 

Hygienic HYGHSPIN twin-screw pumps are used in the beverage and 

food industry, for cosmetics and pharmaceutical products, and animal 

feed. Examples of applications for CHEMSPIN pumps are adhesives, underbody 

protection, paints, lacquers, cleaning agents as well as tank 

farms. Manufacturing is carried out exclusively in Germany. 

Fig. 1: Vertical inline twin-screw pumps in block design 

The block design is a construction characteristic of the north German 

pump manufacturer Jung Process Systems, which has been building 

hygienic stainless steel pumps according to this principle since 2009. 

The pump and the motor shaft are positioned by geometry therefore 

cannot shift. Problems caused by unaligned or strained couplings are 

avoided. The twin-screw pumps in block design can thus be mounted 

vertically on the front cover free-standing like multi-stage centrifugal 

pumps. 

The modules are very compact and can be easily integrated into 

existing plants. When installed vertically, the footprint of a HYGHSPIN 

or CHEMSPIN twin-screw pump is reduced up to 70% compared to 

other pumps types. The pumps are self-emptying via the lower connection 

on the front cover. The main difference to the well-known horizontal 

pumps is the front cover especially designed for vertical installation. 

This makes it possible to retrofit existing pumps if changes in the 

plant require this. 

Jung Process Systems GmbH 

Auweg 8 

25495 Kummerfeld, Germany 

Tel +49 (4101) 80409-0 

Fax +49 (4101) 80409-142 

info@jung-process-systems.de 

www.jung-process-systems.de 

Polymer metering capabilities 

advanced with the 

new Qdos 60 PU pump 

With an expanding market worldwide for advanced polymer dosing 

systems, the introduction of the Qdos 60 PU peristaltic pump from 

Watson-Marlow Fluid Technology Solutions (WMFTS) is a timely addition 

to the company’s range. It means operators can now deploy efficient, 

safe, and reliable polymer metering at any water or wastewater 

treatment plant. 




Polymers are used mostly in coagulation and dewatering applications 

in the sludge treatment process. Dewatering sludge minimises sludge 

bulk, which can reduce the cost associated with storage and disposal 

by up to 75 per cent. 

There are strong regulatory drivers globally for efficient sludge 

dewatering. In 2023, sludge treatment will be included under the UK 

Government's environmental permitting system to encourage use of 

sludge as a beneficial resource. 

Accurate and reliable metering of polymers in the sludge dewatering 

process is essential to ensure it is managed properly. 

The Qdos 60 PU offers precise and repeatable flows for many hard 

to handle fluids, including viscous flows and aliphatic hydrocarbons, at 

linear flow rates of up to 60 l/h and pressures of up to 5 bar. The pump 

provides excellent compatibility for complex polymers such as polyacrylamide 

(PAM) and other flocculants and coagulants used in wastewater 

treatment. 

Peristaltic pumps have notable advantages over diaphragm pumps in 

PAM metering applications, including enhanced accuracy and reliability. 

There is no need for diaphragms, valves, or seals that risk clogging. 

The highly innovative design of Qdos pumps means the only part 

of the pump that ever requires replacing is the patented ReNu pumphead. 

The ReNu pumphead offers repeatable, accurate flow rates, 

and lasts longer for tough applications in the field. It takes less than 

a minute to replace the ReNu pumphead - a new pumphead is a new 

peristaltic pump, ready to serve again. 

Adeel Hassan, product manager at WMFTS said, “The new Qdos 

ReNu PU pumphead has extended the range of applications of our 

Qdos series. These versatile pumps can be used for accurate and safe 

dosing of liquids up to 120l/h and 7 bar pressure in various applications 

across a range of sectors. They are available in different sizes and 

control options depending on requirements.” 

WMFTS expects market scope to grow significantly, particularly 

with the pump’s integral leak detection and chemical containment 

capability, which reduces operators' exposure to chemicals during 

maintenance. 

Customers in the food and beverage industry can also benefit from 

the Qdos 60 PU pump as it is also compatible with fats, oils, and grease, 

and is Food and Drug Administration (FDA) and European Commission 

(EC) 1935/2004 certified. 

Watson-Marlow Limited 

Bickland Water Road, Falmouth 

Cornwall, TR11 4RU, United Kingdom 

Tel +44 (1326) 370370 

info@wmfts.com 

www.wmfts.com 

New PROFINET-enabled pumps from 

Watson-Marlow enable seamless 

integration of fluid delivery up to 

enterprise-level 

– 530, 630 and 730 pumps are now PROFINET-enabled 

– Industrial Ethernet provides real time process information for 

enhanced productivity 

– Network dosing and dispensing features avoid network lags 

– Reduce system cost and complexity by using the pump as a gateway 

to sensor data 

Photos © : Watson-Marlow Fluid Technology Solutions 

Leveraging decades of engineering expertise and research and 

development experience at WMFTS, the Qdos 60 PU is optimised for 

low-shear, gentle pumping to protect polymer chains and maintain 

product integrity. As with the Qdos 20 PU, it uses an aliphatic hydrocarbon-resistant 

tubing material, enhancing chemical compatibility in 

peristaltic pumps. 

Watson-Marlow Fluid Technology Solutions (WMFTS) is extending its industrial 

Ethernet control offer by making PROFINET available on its 530, 

630 and 730 series of cased peristaltic pumps. This additional communication 

capability allows customers to access fast, accurate performance 

data and seamless connectivity with modern PLC control systems and 

the Internet of Things (IoT) using either EtherNet/IP and PROFINET ® . 

Industry’s transition to digitalisation is emanating from the need 

to improve process performance, reduce operating costs and minimise 

downtime. With Watson-Marlow’s extended range of PROFINETenabled 

process pumps for digital network control, users no longer 

need digital gateways, adaptors or expensive PLC interface cards. Instead, 

by using the pump as a gateway to sensor data, it is possible to 

reduce system cost and complexity. 


53



ultra-high-pressure pumps. A high vertical range of manufacture at 

the headquarter in Germany guarantees the required quality and lifetime 

at the highest level. The high-pressure plunger pumps are used in 

many different high-pressure applications all over the world and have 

proven themselves for decades in manufacturing, production and 

cleaning processes. 

In order to continue maintaining such a high level of quality and 

sustainability, the expansion of state-of-the-art drive systems is being 

intensified and optimization of the pumps is being ensured by 

reducing internal friction losses and minimizing damaged spaces. Depending 

on the operating conditions and flow rate, the machines are 

individually adapted so that long-term economic success is achieved. 

Photo © : Watson-Marlow Fluid Technology Solutions 

These pumps include network dispensing functions, allowing users to 

create dispensing and dosing recipes which can be controlled and adjusted 

remotely or through the pump HMI. This capability ensures accurate 

and repeatable dosing and filling for optimal process performance. 

The pumps feature a direct interface to third-party pressure and 

flow sensors. This extended, smart communication capability enables 

users to read information across their network via the pump. It is 

also possible to set local control limits, offering a simple, cost-effective 

way to safeguard process integrity through independent performance 

monitoring. 

Watson-Marlow’s 530, 630 and 730 Industrial Ethernet pump 

range is fully compatible with advanced distributed control systems 

and leading brands of PLC, including Rockwell Automation, Emerson 

(Delta-V), Siemens and Beckhoff. Furthermore, the pumps support a 

broad range of sensor technologies such as Krohne, Pendotech, Sonotec 

and Em-tec for single-use biopharma as well as Parker Hannifin and 

Balluff for process industries. 




Tel +44 (1326) 370370 


www.wmfts.com 

Energy-efficient high-pressure pumps 

Full power, full efficiency 

Especially in the field of energy and power efficiency URACA pumps 

can score with very high efficiencies. The flow rates of the pumps can 

be controlled independently of the pressure. Another advantage is an 

almost constant high efficiency over the entire delivery range. Also unbeatable 

is the product quality, which reflects the efficient use of resources. 

URACA pumps are known for their durability and can be used 

as continuous runners for decades. URACA has been building highly 

efficient positive displacement pumps “Made in Germany” for over 

125 years and is one of the world's pioneers in the field of high and 

Also in the field of drinking water URACA contributes to an environmentally 

conscious use of water and energy. Especially in higher regions 

it is a special challenge for municipal and private suppliers to install 

energy-efficient pumping stations. 

By using the special drinking water URACA plunger pumps, this 

task is optimally mastered both ecologically and economically. The 

high-pressure pumps achieve a very high efficiency in direct comparison 

to centrifugal pumps. This applies over the entire speed range of 

the pump, which also includes partial load operation. The significantly 

better efficiency - compared to other types of pumps - not only notice- 




The pump manufacturer established its head office in Ottobrunn in 

March 2008. More than 800 square metres of production and warehouse 

space along with office space of 800 square metres support further 

growth, ensuring that special customer requests can be met over 

the long term. Eccentric screw pumps are designed and produced at a 

second site in Upper Bavaria. 

Personal and technical consulting by the employees, the greatest 

possible flexibility throughout the enterprise and direct contact with 

customers helped establish the company’s good reputation in the drum 

pump segment. The company’s owners have set the goal of maintaining 

close personal connections with their customers through numerous 

trade fair presentations. Flexibility thanks to the clear company structure 

is proven in particular regarding delivery times and special requests. 

Sales partners in Germany, Europe and around the world complement 

this concept and guarantee optimal customer support. 

Two of the proven pump types are presented here: 

ably lowers operating costs, but also considerably reduces CO 2 

emissions. 

The following applies: The greater the height or pressure differences, 

the higher the energy-related savings. In addition to their low 

energy requirements, the pumps are also characterized by very favourable 

maintenance and service costs, which also significantly reduce the 

cost of maintaining the high-pressure pump. Economically short payback 

times can be achieved even for small differences in height. The 

pumps are used, for example, in the Alps and low mountain ranges 

such as the Swabian Alb. 

JP-810 double diaphragm pump 

Functionality 

The double diaphragm pump works with compressed air and starts 

automatically. A pneumatic drive at the heart of the pump alternately 

pulls and pushes the left and right diaphragms. Balls in the pump serve 

as a non-return valve, directing the flow direction from the pressure input 

side to the pressure output side. 


Sirchinger Str. 15 

72574 Bad Urach, Germany 

Tel +49 (7125) 133-0 

Fax +49 (7125) 133-202 

info@uraca.de 

www.uraca.de 

Flexible pumps to handle 

challenging media 

bpsense 

Jessberger, a family business based in Ottobrunn near Munich, not 

only develops pumps and applications for its customers but also builds 

them to customer specifications. 

The company manufactures drum pumps, manual hand pumps and 

eccentric screw pumps. Compressed air operated diaphragm pumps, 

rotary pumps and other industrial pumps complete the portfolio. 

Jessberger works closely with customers to find the right pump for any 

medium. Typical fields of application for Jessberger pumps include 

chemical applications, food, wastewater and agriculture (for drums, 

IBCs and also inline) 

The company has a wealth of pump technology experience thanks 

to long-term employees and the business owners. Even though 

JESSBERGER has only existed as a company name in the drum pump 

segment since the beginning of 2003, the supplier has established itself 

quickly as a true alternative. Setting new standards in terms of 

price combined with the highest quality was the goal, with impressive 

results. 

DIGITAL. INTEGRATED. EASY. 

The intelligent pump monitoring for 

uncontrolled pumps. Also retrofittable. 

■ Comprehensive energy monitoring 

■ Continuous condition monitoring 

■ Predictive maintenance 

BRINKMANN PUMPEN | K.H. Brinkmann GmbH & Co. KG 

T +49 2392 5006-0 | sales@brinkmannpumps.de | www.brinkmannpumps.de



The JP-810 is self-priming and, with the selection of suitable conductive 

materials and the pneumatic drive, can be used in explosion-prone 

areas. It is suitable for ATEX zone 2 or 1 depending on the chosen materials. 

Particles or pieces of fruit can also be conveyed thanks to gentle 

pumping, depending on the pump size. A major advantage of this 

pump is that it can also run dry in addition to being self-priming. 

The robust and handy double diaphragm pump is designed 

specifi cally for the customer’s medium. All components with media 

contact can be carried out in various materials. Aside from the food 

industry, these pumps have therefore been established in the chemicals 

sector for many years as well. The JP-810 pumps have a pump capacity 

of 8 –1050 l/min. 

the operating panel after each stroke. The pump stops automatically 

after a configured number of strokes or just counts the strokes (no action), 

depending on the configuration. 

A hose reel is mounted on the carriage so the customer does not 

have to search for the compressed air hose. This application is possible 

with smaller or larger pumps as well. The smallest volume is 18 ml, the 

largest is 9750 ml per stroke. 

Sample application 2 

Customers have a choice of various connections (flanged, NPT thread, 

BSP or Triclamp). A CIP-compatible pump for food applications can 

be realised as well. To prevent the (sometimes) unwanted vibration 

in the line, a damper can be installed as a sensible accessory in the 

pressure line or screwed directly onto the pump. Precise operation 

of these pumps can be guaranteed with optional stroke counters. 

The pumps are suitable for viscosities up to 55,000 mPas. JP-810 diaphragm 

pumps are easy to disassemble and just about all parts can be 

replaced quickly. 

A customer has an aggressive liquid medium with smaller particles. 

However, a suction pipe similar to the Jessberger drum pumps is 

needed, rather than a suction hose. 

Sample application 1 

A customer wants a portable pump for the flexible conveying of chemicals. 

The pump needs to be air operated, with an adjustable volume. 

The solution 

Jessberger configures a JP-810 double diaphragm pump for the customer. 

All materials are tailored to the chemicals in question. A damper 

is permanently mounted on the pump to prevent pulsation of the 

medium. Installed on a carriage, it can now be moved from site to site. 

The volume is precisely adjustable per stroke using a handheld 

panel. The pump used in this application conveys 700 ml per stroke. To 

count the strokes, a pneumatic signal is transmitted from the pump to 




The solution 

A JP-810 with a threaded bottom suction opening is provided for the 

customer. This permits the installation of a fixed suction pipe that is 

screwed to the pump, which then sits on the tap hole. The pump can 

convey small particles of 2–12 mm, depending on the pump size. 

Leakage detection is implemented here so the customer knows 

immediately if a diaphragm breaks, even before medium leaks out 

of the pump. 

This leakage detection is optional and screwed directly into the 

pump’s air-side pressure section. It monitors the pressure chamber on 

the air side and emits a signal when moisture enters. 

The drum pump 

The drum pump is one of Jessberger’s best-known products. It always 

comprises two components, a motor and a pump unit. The pump unit 

consists of a pipe with a rotor or impeller, which pushes the medium 

up towards the discharge. Pump units are configured according to the 

conveying medium. The pump units can be made of PP, PVDF, stainless 

steel or aluminium. A suitable motor (electric or pneumatic) is manually 

screwed onto the pump according to the required delivery volume. 

No tools are needed. Motors are available up to IP classification 55 

and for ATEX applications. Typical fields of application include emptying 

IBCs or drums in the chemicals industry and food sector. 

Aside from ease of operation, an advantage of the drum pump is that 

it can be combined with a nozzle and, depending on the medium, also 

with a meter or even volume pre-selection. 

Jessberger employees are happy to help you in case of questions 

and to support your projects. Many pumps in different versions are 

available directly from stock or at short notice. Please visit our website 

for monthly offers. 

Jessberger is celebrating its 20 th anniversary this year. Inflation and 

crises notwithstanding, the company has once again decided not to 

raise prices in 2023 for its own production programme. 

JESSBERGER GmbH 

Jägerweg 5-7 

85521 Ottobrunn, Germany 

Tel +49 (89) 6666 33-400 

Fax +49 (89) 6666 33-411 

info@jesspumpen.de 

www.jesspumpen.de 

THINK BIG – Exhaust gas cleaning 

for large engines 

Users of diesel vehicles are familiar with “AdBlue”. The pollutants produced 

during combustion are usually effectively removed directly in 

the engine, the exhaust gas drives the turbocharger and then passes 

through the oxidation catalytic converter. Now AdBlue - a mixture of 

synthetic urea and water - is added. Through a chemical reaction, the 

SCR catalytic converter then converts the nitrogen oxides into water 

and nitrogen. With the introduction of the EURO 6 emissions standard 

in 2015, the use of AdBlue in new cars has become mandatory - 

commercial vehicle owners and drivers have been obliged to do so for 

much longer. 

Jessberger supplies a comprehensive range of accessories for its products. 

Hoses and nozzles are offered to customers as a rule in addition 

to the pump units and motors. Please note that the pump units always 

have to be positioned vertically in the drum or tank. Suitable adapters 

are offered. Liquids up to 1000 mPas can be conveyed with this solution. 

Jessberger also offers a version of this pump that allows the drum 

to be completely emptied. 

Industrial and large engines, such as those on ships, are now also subject 

to increasingly stringent emission guidelines. Engine manufacturers 

are therefore forced to significantly reduce emissions of both soot 

particles and nitrogen oxides. 

The reduction of nitrogen oxide emissions can be achieved on the 

one hand through lower-pollution combustion, i. e. an internal engine 

solution, and on the other hand through exhaust gas post-treatment 

with an SCR catalytic converter (SCR: selective catalytic reduction). Often, 

a combination is used - first lower-pollution combustion, then SCR. 

The chemical reaction at the SCR catalytic converter is selective, i.e. 

the nitrogen oxides (NO, NO 2 

) are reduced preferentially, while undesirable 

side reactions such as the oxidation of sulphur dioxide to sulphur 

trioxide are largely suppressed. 

The reaction requires ammonia (NH 3 

), which is mixed into the exhaust 

gas. When urea is used, it must first be decomposed in a thermolysis 

and subsequent hydrolysis reaction in order to release the ammonia 

necessary for the SCR reaction. 

The dimensions of industrial and large engines make the use of 

dosing systems possible and necessary. The dosing system from sera 

is used in exhaust gas post-treatment. The urea solution is dosed from 

a day tank with a sera dosing pump. The urea is finely atomised by 

means of a nozzle lance. The urea quantity required for optimum pollutant 

reduction is specified via a control system by means of a control 

signal of the iSTEP series metering pump. 


57



In depth filtration, diatomaceous earth, due to its fine structure, is 

washed up with water on cellulose cloths, thus forming a filter cake 

that holds back the yeast particles. To prevent this layer from sticking 

together, diatomaceous earth continues to be dosed in during filtration, 

thus building up new filter layers. Accurate dosing under increasing 

counterpressure is therefore crucial to ensure that the beer does 

not undergo any negative changes in taste. 

A large German private brewery has therefore switched to hose 

pumps with the support of AxFlow. A peristaltic metering pump of the 

brand realAx is now used for the addition of diatomaceous earth. In 

this application, the hose pump delivers at a rate of 125 l/h and a pressure 

of 2.5 bar. The realAx ISI 22 model in use operates with roller compression. 

In this process, the hose is compressed by the movement of 

the rollers and the filter medium in the hose is gently conveyed. Rollers 

generate significantly less friction on the hose than shoes. As a result, 

the hose wears slower and needs to be replaced less frequently. In 

addition, a drive with lower power consumption is sufficient, so that 

energy costs are saved during operation. 

The dosing of the urea is monitored with pressure and volume flow 

sensors. Since optimal atomisation and evaporation of the aqueous 

urea solution is crucial for the process, the nozzle lance is also supplied 

with compressed air. The compressed air cools the nozzle lance. Furthermore, 

the compressed air is used to flush the urea line via a bypass 

function between the compressed air and the urea line, so that blockages 

caused by crystallising urea are avoided. 

In this way, sera products ensure clean air by post-treatment of exhaust 

gases from industrial and large engines. 

sera GmbH 

sera-Str. 1 

34376 Immenhausen, Germany 

Tel. +49 (5673) 999-0 

Fax +49 (5673) 999-01 

info@sera-web.com 

www.sera-web.com 

Beer filtration with improved results 

thanks to the right pump technology 

In breweries, diatomaceous earth is often used to filter the beer. Its 

fine-pored structure absorbs the suspended particles from the beer, 

resulting in a clear product. In diatomaceous earth filtration, it is therefore 

essential that the particles are pumped gently and that the porous 

surface of the diatomaceous earth is preserved. AxFlow has used hose 

pumps in many breweries here, most recently in a large German private 

brewery. 

After the new beer has been given its taste 'finishing touches' in the 

maturation cellar, the turbid matter must be filtered off in the case of 

clear beer varieties. This filtration removes residual yeast cells and other 

turbidity from the beer. Depth filtration and screen or surface filtration 

are common processes in this case, using both feed and discharge 

pumps for diatomaceous earth. 

Composed mainly of the constituents of fossil algae, diatomaceous 

earth is an excellent filter medium. Optimized filtration improves the 

appearance, shelf life and saleability of the beer. 

realAx ISI 22 roller hose pump in a large German private brewery 

As part of the installation, AxFlow service engineers assisted with the 

initial cleaning of the hose pump and system. In a first step, the pump 

was cleaned with diluted caustic solution in a second step with an acid 

mixture and then rinsed. 

As a valveless technology, hose pumps stand out for their troublefree 

operation. Despite the highly abrasive properties of diatomaceous 

earth, hose pumps operate reliably and require less maintenance than 

comparable pump technologies. At the same time, realAx brand hose 




pumps with high-strength hoses have strong resetting forces and thus 

excellent suction performance. The food-grade hoses, made of natural 

rubber, are reinforced with multiple layers of nylon fabric. They are 

manufactured with precision surfaces so that there is even less friction, 

resulting in a high efficiency and long durability. 

The brewmaster is very satisfied with the filtration result. Gentle 

conveying with roller hose pumps preserves the surface structure of 

the diatomaceous earth and results in a safe product that is attractive 

to the end customer. 

AxFlow GmbH 

Theodorstraße 105 

40472 Düsseldorf, Germany 

Tel +49 (211) 23806-0 

Fax +49 (211) 23806-20 

info@axflow.de 

www.axflow.de 

Wide-range Speed Control for Diaphragm Metering Pumps 

Energy efficient in accordance with 

class IE5+: Compact permanent magnet 

synchronous motor extends control 

range and reduces total cost of 

ownership 

In many applications, metering ingredients in the pharmaceutical or 

food industry for example, pumps are required that not only can be 

precisely controlled in terms of flow rate and dosing time, but also 

convey the ingredients particularly gently. To enable the proven pump 

units of the ecodos series from LEWA GmbH to fulfill this demanding 

task with even more flexibility and energy efficiency in the future, the 

manufacturer is expanding the portfolio to include a new form of widerange 

speed control. Alongside asynchronous motors and servomotors, 

permanent magnet synchronous motors, or PMSMs for short, are 

also used now. They are characterized by high energy efficiency and a 

control range greater than 1:200. This significantly expands the range 

of applications. 

Fig. 1: LEWA ecodos LED3 with PMSM (Photo © : LEWA GmbH) 

be dispensed with and the required flow rate can be realized by speed 

control only. The PMSM also has a constant torque, from engine 

speed 0 rpm (standstill) up to the rated speed of the motor. This ensures 

particularly smooth and gentle system start-up, since each process 

can be started with a pump capacity of 1 percent instead of the 

usual 10 percent. 

The diaphragm metering pumps in the LEWA ecodos series are particularly 

well suited for applications in the food or pharmaceutical industries. 

All materials in contact with the fluids used in the pump units 

meet the FDA and USP Class VI requirements, and the EU directives for 

the food industry. In the hygienic version, for example, the pump head 

is made of PP or electropolished stainless steel with a surface roughness 

< 0.5 µm. This facilitates cleaning of the surfaces in contact with 

the product. 

Wide-range speed control with permanent magnet synchronous 

motor extends the range of applications 

Unlike the asynchronous motor, the rotor of this drive consists of 

permanent magnets and rotates synchronously, i.e. without loaddependent 

slip. Among other things, it features an extreme control 

range, which often makes the use of multiple pumps for different flow 

rates unnecessary. Particularly in the case of multiple pumps, an additional 

manual stroke adjustment or electric stroke adjustment can 

Fig. 2: In contrast to the ASMs shown, the constant torque of the PMSM enables 

continuous operation at low speeds. Oversizing for the required pump starting 

torque has become unnecessary due to the high overload capability of the PMSM. 

(Source: LEWA GmbH) 

It also features a high short-term overload capacity, which enables 

a drive design without oversizing for the starting torque. As a result, 

smaller, more cost-efficient sizes can be realized than with classic 

drives. Like the asynchronous motor, the PMSM can be controlled via 

a standard frequency converter, so users can rely on common parts. 

The compact drive can be easily cleaned due to its fanless design and 

offers high IP protection. If required an additional conversion process 


59



– called nsd tupH – can be applied to the aluminum body for FDA requirements. 

This makes the surface extremely resistant and even easier 

to clean – ideal for applications with stringent hygienic requirements, 

such as aroma metering in the food industry or additive dosing 

in the pharmaceutical industry. 

LEWA GmbH 

Ulmer Str. 10 

71229 Leonberg, Germany 

Tel +49 (7152) 14-0 

www.lewa.de 

From the outside the KAMAT unit looks like an ordinary 20-foot-long 

container with soundproofing on the inside but it is filled with hightech. 

The compact format allows it to be transported and operated 

mobile, just like any ordinary container. A powerful Scania engine, an 

industrial engine with eight cylinders arranged in a V-shape, an automated 

ZF Traxon transmission and a high-performance pump work in 

a perfect triad here. 

New pump concept at KAMAT: 

Perfect triad of industrial engine, 

automated transmission and KAMAT 

high-performance pump 

In cooperation with Scania from Sweden KAMAT has developed a technically 

complete new mobile high-pressure pump unit. The made in 

Witten container unit represents a never seen unity of a Scania industrial 

V8 diesel engine, the automated Traxon-gearbox by ZF and our 

tried and true high-pressure plunger pumps. The innovation of the 

high-pressure pump unit lies in the interaction and communication of 

all of these three outstanding components. 

A central control unit steers all three components instead of the usual 

three separate controls. The control with three separate controls usually 

led to an inefficient operation at non optimal rpm. This led to a reduction 

in longevity of all parts of the high-pressure pump unit while 

also reducing the energy efficiency of the entire application. 

The well tested and intelligent V8 Scania with its 450 kW of KAMAT’s 

supplier ScanDiesel, the ZF gearbox as well as the KAMAT pumps are 

now controlled by a singular fully automated control unit. All the user 

has to do is to enter the wanted working pressure into the main control 

panel. After that, the fully automated control unit recognizes which 

water tools are being used and adjusts all three components to work at 

optimal efficiency for the pressure and flow rate needed. This doesn’t 

just increase the longevity of any component but also reduces fuel consumption 

and therefore costs of running drastically. 

Fig. 2: The turnkey unit viewed from the outside: A normal 20-foot container but 

with a perfect interior. 

The mission of this unique development is to change the way mobile 

units are operated. It is delivered key-ready and can be operated with 

very little knowledge needed. It reduces the chances of operator error 

induces inefficiencies to minimum and therefore achieves to date unseen 

efficiencies. “With our new system, we replicate what only experienced 

operators have been able to do so far, for everyone” explains 

KAMAT general manager Dipl. Ing. Jan Sprakel, who came up with the 

idea for the development, always striving for improvement. 

The unit is now set up in a way that it recognizes all kind of tools 

without any need for manual input. Therefore, long working task with 

multiple different tools can be done without the time-consuming 

breaks needed for adjustment of the parameters. “From now on, the 

user only has to enter the wanted working pressure and from there 

on the control unit takes over and adjusts everything as needed.” Jan 

Sprakel summarizes the advantages of the new designed high-pressure 

pump unit. 

The design of the new high-pressure unit is mainly aimed at industrial 

service providers. It is not unusual to accumulate above 10 hours 

of runtime a day for a unit like this when it comes to industrial cleaning 

of tanks for example. In this environment, the sustainability of the 

drive plays an important role. Therefore, the new unit can drastically 

reduce the running cost and increase the maximum runtime of each 

of the components. The fuel efficiency being important in two different 

ways, firstly the cost of running and secondary reducing the time it 

takes to finish a task. Every litre and minute that a unit safes is money 

for the entrepreneur. 

Fig. 1: The new pump concept: the perfect triad of industrial engine, automated 

transmission and KAMAT high-performance pump 

KAMAT GmbH & Co. KG 

Salinger Feld 10 

58454 Witten, Germany 

Tel +49 (2302) 89 030 

info@KAMAT.de 

www.KAMAT.de/en/ 




Green light for green pumps – KAMAT 

receives order for pilot project testing 

H 2 

-pressure tanks 

The year 2023 starts with an unusual and green order at KAMAT which 

we received at the end of 2022: Within a project of the federal ministry 

for digital affairs and transport, trying to decrease pollution caused by 

traffic, KAMAT is delivering two high-pressure pump units to be used in 

pressure testing systems for hydraulic pressure tests on H 2 

gas tanks. 

chokes, sensors and controls) is to precisely hit and control the desired 

pressure. 

Due to the design of the KAMAT pump, upper pressures of up 

to 1350 bar can be achieved in this setup. This raises the question 

of how exactly the pumps can be pressure-controlled. A suitable solution 

was designed with the engineering department, including the 

necessary valve, control and automation technology. All of the parts 

needed are designed and manufactured in-house at KAMAT – All 

from one provider. 

Last year the company Industrieanlagenbetriebsgesellschaft mbH with 

headquarters in Ottobrunn (IABG) reached out to us with a contract 

within the pilot project commissioned by the ministry for the pressure 

testing of hydrogen tanks. The IABG is building a hydraulic testing 

unit for hydrogen tanks that are to be used in various vehicles. This 

includes the technology for the filling of such tanks. IABG asked us to 

check whether KAMAT’s high-pressure units could meet the requirements 

needed for the project. Sales director Fabian Hoff didn’t hesitate 

for long. He was confident that KAMAT could meet the requirements. 

Straightaway he started talks with the head of the project. He requested 

more information to create the best possible technical solution for 

the application. 

Fig. 2: Suitable for the unit for the pilot project in the field of H 2 

gas tank testing: 

KAMAT high-pressure pump of type K50018A-3G 

About the pilot project using high-pressure pumps for pressure 

testing units of H 2 

gas tanks 

KAMAT’s client is a member of a consortium of companies. The companies 

specialize in hydrogen tanks, filling of tanks, testing and commercial 

vehicles. This consortium is supported by the Ministry of Digital 

Affairs and Traffic with 25 million Euro for a period of three years 

that started 2020. The consortium’s aim is to provide a market ready 

solution for hydrogen driven vehicles, applications and filling technology 

by 2025. 

Fig. 1: KAMAT receives green light for pilot project testing H 2 

-pressure tanks 

The task: Impinging tanks with a minimum volume of 600 l with cyclic 

pressure using water as media. According to the IABG, there are only 

very limited test options for tanks of this size class, which is why IABG 

cannot fall back on existing systems and they therefore weren’t sure 

for the feasibility of the project. “The customer, before starting talks 

with us, had talked to other companies about possible solutions. But 

all of them were limited by volume due to the use of pressure transducers. 

The tanks that are to be tested in this project needed a lot 

more volume than others were able to work with, that is where we 

came in to play with our high-pressure plunger pumps. Because our 

high-pressure pumps are basically also suitable for volumes well over 

600 l”, says a delighted Fabian Hoff. 

At any rate, a key function our units have to fulfil is both to run 

1-10 full cycles per minute and to be able to release that pressure after 

ramping it up. Accordingly, that means that our pumps have to be 

operated in intervals or with swelling loads. Another unique challenge 

when strength testing for pump systems (including valves, regulating 

Fig. 3: KAMAT control throttle 3000 bar: New product from KAMAT for use in the 

area of pressure vessel testing 


61



IABG, a leading testing expert, is taking on the part of tanks and filling 

of the tanks. IABG is now developing a testing mechanism to ensure 

safety when using CRYOGAS tanks and the filling of them. The task 

of developing emission free transport and traffic will lead to steep increase 

in their high-pressure filling and testing capacity at IABGs headquarters 

in Dresden and Lichtenau (Paderborn). Exactly that is where 

KAMAT comes into play as a supplier for knowledge in high-pressure 

technology and pumping units. 

KAMAT’s delivery scope for use in the field of hydraulic leak, pressure, 

and burst testing: 

– Unit (drive 630 kW) including the necessary valve technology, control 

throttle and control technology for cycling tests on hydrogen tanks – 

K55032A2-5G-E630B 

– Unit including the necessary valve technology and control technology 

for bursting hydrogen tanks (small mobile unit with high efficiency) 

– K108A-3-E15B 

– Cycling test with max. upper pressure peak value of 1500 bar, unit 

design 1500 bar 

– Burst test with a maximum achievable static pressure of 2200 bar 


Salinger Feld 10 

58454 Witten, Germany 

Tel +49 (2302) 89 030 

info@KAMAT.de 

www.KAMAT.de/en/ 

Reliable filter press feeding with 

ABEL hydraulic diaphragm pumps – 

optimized due to use of 

the monitoring system SPA 

The customer 

Our customer, the company SOLVALOR in Rouen (France), specializes 

in recycling and recovery of soils – for the most part excavated soils in 

civil engineering and mainly coming from Paris. Today, the company is 

market leader in the recovery and recycling of soils. 

Fig. 1: Application of the ABEL HM-pumps for filter press feeding at the French 

company SOLVALOR 

Optimal support through the ABEL Smart Pump Assistant 

The daily deployment and monitoring of the two ABEL HM pumps is 

supported at the company SOLVALOR by the monitoring system Smart 

Pump Assistant (SPA). 

With this SPA, ABEL offers remote assistance. Immediate anomalies 

are detected based on the data and appropriate corrective action 

is suggested. 

Furthermore, our customer receives a monthly performance report, 

which documents the daily use as well as the condition of their 

pump-/ filtration process. “The performance report allows us to optimize 

production scheduling as well as maintenance planning.”, so 

Maxime Jolly, Industrial Director, SOLVALOR. 

On special request, now, the customer can also access the theoretically 

calculated throughput capacity which saves them costly flowmeters. 

Thus, information on the state of their ABEL pumps is constantly 

available to the ABEL customer. 

By means of the Smart Pump Assistant detailed operational parameters 

like temperature and pressures can be visualized. If parameters 

are exceeded, the customer receives an alert. 

The implementation of the knowledge gained through the ABEL 

Smart Pump Assistant results in the customer saving significant quantities 

of time, costs and energy in the production process while at the 

same time accelerating the productivity throughout the company. 

Figure 2 below shows that the ABEL pumps have managed 46 filter 

press cycles in 5 production days without any standstill. 

On the whole, the company SOLVALOR is very satisfied with the 

performance of the ABEL pumps as well as the ABEL services. 

The plant 

In spring 2021, two ABEL hydraulic diaphragm pumps were put into operation 

at the plant of this French customer. These diaphragm pumps 

of the type HMD-G-80-1000 are used for filter press feeding at a level 

of 80 m³/h and 12 bar. 

Fig. 2: “The ABEL pumps have allowed me to increase the productivity dramatically 

and to transfer more slurry, because – compared with the prior technology – 

I can manage more filtration cycles in the same time. Also, it doesn’t matter any 

longer what kind of slurry I transfer – the ABEL pump will get the job done!”, says 

Maxime Jolly, Industrial Director, SOLVALOR. 




Fig. 3: Filter press at SOLVALOR 

The ABEL piston diaphragm pump is an important component in filter 

press feeding. Among the advantages of ABEL pumps compared with 

other types of pumps are: 

– High wear resistance 

– Robustness and durability 

– Very long service intervals 

– Low energy requirements 

– Reduction of operating costs 

The ABEL piston diaphragm pumps fulfil the requirements of filter 

press feeding in various ways. 

Equipped with an analogue pressure transducer and a frequency 

converter, the initial flow rate, the break-point and the minimum flow 

rate can be set easily. It is particularly important that these components 

can be varied if required, which is crucial for some applications. 

Compared with other feeding pumps, whose feed rate – due to 

the design – is dependent on the counterpressure, the flexibility of the 

ABEL pumps provides a real added value – particularly so when the 

customer needs filtration times to be as short as possible and a high 

solids content. 

The ABEL hydraulic diaphragm pumps are extremely energy-efficient 

and durable and they have a high efficiency rate when used as 

filter press feed pumps. 

Due to their robust design, the ABEL piston diaphragm pumps are 

also employed in other industrial areas throughout the world for the 

transport of difficult media. ABEL pumps are used, for example, in 

mining for dewatering mines and in the water and sewage industry 

as transport pumps. Furthermore, many customers in a wide range of 

industrial sectors use the ABEL pumps for spray dryer feed and rotary 

kiln charging. 

ABEL GmbH 

Abel-Twiete 1 

21514 Büchen, Germany 

Tel +49 (4155) 818-0 

Fax +49 (4155) 818-499 

abel-mail@idexcorp.com 

www.abelpumps.com 

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63


Index of Advertisers 

Index of Advertisers 

Aerzener Maschinenfabrik GmbH 

Cover page 

KLAUS UNION GmbH & Co. KG page 47 

AxFlow GmbH page 29 

BAUER KOMPRESSOREN GmbH page 81 

BOGE KOMPRESSOREN Otto Boge GmbH & Co. KG page 71 

BRINKMANN PUMPEN 

K.H. Brinkmann GmbH & Co. KG page 55 

Busch Dienste GmbH page 51 

C. Otto Gehrckens GmbH & Co. KG page 69 

Emile Egger & Cie SA page 33 

GRUNDFOS GMBH page 7 

Hammelmann GmbH page 9 


3. Cover page 

Kaeser Kompressoren SE 

Insert 

KAMAT GmbH & Co. KG page 27 

KLINGER GmbH page 41 

LEWA GmbH page 37 

MT – Messe & Event GmbH page 13 


4. Cover page 

Pfeiffer Vacuum GmbH page 73 

Pumpenfabrik Wangen GmbH page 39 

SEEPEX GmbH 

2. Cover page 

URACA GmbH & Co. KG page 21 

Vogelsang GmbH & Co. KG page 31 

Watson-Marlow GmbH page 45 

WOMA GmbH page 25 

Zwick Armaturen GmbH page 67 

Your media contact 

D-A-CH 

Thomas Mlynarik 

Tel.: +49 (0) 911 2018 165 

Mobile: +49 (0) 151 5481 8181 

mlynarik@harnisch.com 

INTERNATIONAL 


Gabriele Fahlbusch 

Tel.: +49 (0) 911 2018 275 

fahlbusch@harnisch.com 

Impressum 

Publisher 

Dr. Harnisch Verlags GmbH in cooperation 

with the Editorial Advisory Board under the 

management of Prof. Dr.-Ing. Eberhard Schlücker 

© 

2023, Dr. Harnisch Verlags GmbH 

Errors excepted 

Reprinting and photomechanical 

reproduction,even in extract form, is 

only possible with the written consent 

of the publisher 

Editor 

Silke Watkins 

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Responsible for content 


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Editorial Advisory Board 2023 

Prof. Dr.-Ing. Eberhard Schlücker, 

Prof. (ret.), advisor on hydrogen 

and energy issues 

Prof. Dr.-Ing. Andreas Brümmer, 

TU Dortmund 

Dipl.-Ing. (FH) Gerhart Hobusch, 

KAESER KOMPRESSOREN SE 

Dipl.-Ing. (FH) Johann Vetter, 


Dipl.-Ing. (FH) Sebastian Oberbeck, 

Pfeiffer Vacuum GmbH 

Suppliers source 

Matti Schneider 

Technical Director 

Armin König 

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D-97821 Marktheidenfeld 

ISSN 2364-723X 


GREEN EFFICIENT TECHNOLOGIES 

The independent media platform for 

energy supply, efficiency enhancement and 

alternative energy sources and storage 

Sustainable opportunities in process 

technology 

Circular economy in the industrial 

production process 

Topics H 2 

, Synthetic Fuels, Water, 

Solar & Photovoltaics, Wind Power, 

Bioenergy, Geothermal Energy, Battery 

Technology, System Integration and 

other alternative options 

Dr. Harnisch Verlags GmbH · Eschenstr. 25 · 90441 Nuremberg · Tel.: +49 (0) 911 - 2018 0 · info@harnisch.com · www.harnisch.com

Trade fairs and events 

DIAM & DDM 

DIAM & DDM 2023 - Double pack 

for the 10 th anniversary 

A special year is coming for all DIAM 

& DDM interested parties. In addition 

to the double pack this year, 

the trade fair for industrial valves 

& sealing technology celebrates its 

10 th anniversary. The DIAM & DDM 

will kick off the anniversary year on 

June 14 th and 15 th 2023 in Leipzig/ 

Schkeuditz. This is already the third 

time that the national meeting takes 

place in the Central German Chemistry 

Triangle. On the grounds of the 

Globana Trade Center, all conditions 

for an uncomplicated trade fair presence 

are in place. You will find an optimal 

connection by the airport and 

motorway, the hotel right next to the 

exhibition hall as well as a comfortable 

parking situation. 

The Bochum edition of the DIAM & 

DDM will be on agenda in the autumn 

of this year, exactly on November 

the 8 th and 9 th . Since the beginning 

in 2013, it will be held for the 6 th time 

in the Jahrhunderthalle Bochum. In 

October 2021, the DIAM & DDM returned 

to the face-to-face event 

during the ongoing pandemic. More 

than 1.600 visitors came to Bochum. 

The consequence of this consistently 

very successful event was a high rebooking 

rate of exhibitors. Since the 

start of the fair, this was the highest 

percentage rebooking rate. 

Exactly 10 years ago, the premiere 

took place with 90 exhibitors in 

the Jahrhunderthalle Bochum. At that 

time, the event was still under the 

sole DIAM flag and developed steadily 

from time to time, before the DDM – 

the trade fair for sealing technology 

was added for the first time in 2017. 

This is how the trade fair for industrial 

valves & sealing technology 

was created. Since the beginning, the 

organiser has been in close cooperation 

with its exhibitors. Many exhibitors 

use the term “family reunion”. 

The initiator of the DIAM & DDM – 

Malte Theuerkauf – takes a stand on 

this: “It is precisely this term “family 

reunion” that makes it all. The entire 

team is looking forward to our two 

trade fairs in this special year for all 

of us. Personally, I am thrilled with 

the popularity of the DIAM, which was 

launched in 2013. There were more 

and more exhibitors, the DDM joined 

the DIAM in 2017 and the exhibition 

concept has established itself. It fills 

me with pride how the DIAM & DDM 

has matured into the familiar and national 

industry meeting for industrial 

valves & sealing technology. For this 

I would like to thank all exhibitors, 

partners, visitors and employees. 

With two of our own events and our 

10th anniversary, for which we have 

some surprises, there is every reason 

to be excited about the DIAM & DDM 

anniversary events. 

With the following voucher code, interested 

parties can register free of 

charge at www.tickets.diam-ddm.de. 

The voucher code is valid for both locations. 

Voucher code: PUK-23 

The dates 

GLOBANA Trade Center 

Leipzig/Schkeuditz 

14-15 June 2023 

Jahrhunderthalle Bochum 

08-09 November 2023 

Opening hours: 

1 st day of the fair from 09–17 h 

2 nd day of the fair from 09–16 h 

The DIAM & DDM team is looking forward 

to your visit! 

www.diam-ddm.de 


WWW.ZWICK-ARMATUREN.DE 

TRI-SHARK 

100 % CONTROL VALVE 

100 % TIGHT* 

*acc. to DIN EN 12266-1

Compressos and Systems 


Farm energy independence – 

for a crisis-proof future 

Helei Ammura 

Natural gas has been in short supply 

since the start of Russia’s war against 

Ukraine. The energy supply has been 

a leading topic in Germany over the 

past year. Germany does however 

have a very large pool of biomass. 

Around 9,600 biogas plants (as of 

August 2022) are producing more 

than 5,600 megawatts of electricity 

in Germany right now. At the latest 

since 1 January 2021, the operators of 

biogas production plants have been 

forced to reconsider their operations. 

Funding under the Renewable Energies 

Act (EEG) for renewable energy 

plants, which have been subsidised 

for the last 20 years, has ended. The 

good news: Notwithstanding the end 

of funding, an economically viable 

solution is available to operators by 

converting to an intelligent own use 

concept. This is particularly beneficial 

for operators in the current situation. 

Using biogas to produce biomethane 

as an energy carrier makes a significant 

contribution to sustainable development, 

especially in rural areas. 

It considerably improves the security 

of the energy supply. 

Biogas processing is the first step in 

using biogas as biomethane. It primarily 

involves separating the accompanying 

carbon dioxide gas and other 

components from the raw biogas 

using various technical processes. 

The resulting biomethane is chemically 

equivalent to natural gas. It can 

be fed into the natural gas network 

and thus used just like natural gas. 

Biomethane made from biogas is a 

renewable energy source. It is an important 

part of the energy transformation 

and can be readily used anywhere 

that natural gas is consumed. 

Plants that produce biogas and 

process this into biomethane have 

increasingly established themselves 

in recent years. Martin Schulze 

therefore implemented the concept 

described above in his farming 

operation in 2022. BAUER 

KOMPRESSOREN supplied the filling 

station technology required for 

the project. Mr Schulze was willing 

to discuss several points and explain 

them in more detail from the perspective 

of a farming operation: 

Mr Schulze, what exactly prompted 

you to process biogas produced on 

your farm when EEG funding ended? 

I believe we need to explore new fuel 

supply sources, regardless of compensation 

for electricity produced 

from biogas under the EEG or in the 

market. Using biomethane in agriculture 

became possible with the advent 

of biomethane-fuelled tractors. A degree 

of energy supply independence 

also played a role. 

To what extent was this compatible 

with your farming concept? 

Since we have our own biogas plant, 

the only questions that remained after 

the methane-fuelled tractor from 

New Holland became available was 

how to produce our own fuel-quality 

biogas and get it into the tank. I 

studied a do-it-yourself gas purification 

solution for a few months because 

small processing plants are not 

available in the market. Then I was offered 

a pilot plant by chance. Now I 

have my own biomethane supply on 

the farm along with the compressor 

system and filling station. 

Biomethane fuelling solutions – 

economical for the future 

As a premium manufacturer and natural 

gas compression pioneer with 

more than 40 years of global experience, 

BAUER KOMPRESSOREN has 

the required state-of-the-art technology 

in the form of tailor-made, 

turnkey fuelling systems from one 

source. The sustainability-oriented, 

ISO 14001 certified company puts 

great emphasis on actively working 

towards reaching climate protection 

and energy transformation 

targets. Thus the company firmly 

Fig. 1: CTA120 (B800, fast fill post) 


Compressors and Systems 


supports the continued operation 

of existing renewable energy 

plants for bio methane production. 

Its fuelling systems are 

generally designed to be used 

with biome thane as well as conventional 

natural gas. As a rule, 

they consist of a high or medium-pressure 

compressor system 

that is tailor-made for fuelling, a 

gas drying and filtering system, 

an appropriate storage solution 

and the fuel dispenser. The practical, 

modular design of the system 

supports fast, straightforward 

installation and integration 

into existing infrastructures. 

System versions with a low, 

moderate or high daily output are 

available, tailored to the respective 

demand. This is illustrated by 

the following example of farmer 

Martin Schulze’s concept: 

Martin Schulze work yard 

filling station – a compact, 

energy-independent and 

highly economical solution 

The small, compact module 

consists of a compressor with 

a flow rate of 11-51 Nm 3 /h or 

7.9-36.7 kg/h, an intake pressure 

of 0.05-4 bar (gauge) and a discharge 

pressure of 250-300 bar. 

In continuous operation, the daily 

delivery rate of the compressor 

unit is 190-880 kg in 24 hours. 

The system has integrated filter 

and final drying cartridges installed 

on the high pressure side. 

These clean the compressed gas 

and remove residual moisture. 

The high-pressure gas reservoir 

is comprised of individual 

Fig. 2: B3360 storage module 

Fig. 3: Fast fill/slow fill post filling station 

high-pressure cylinders mounted 

on one frame. The standard 

capacity is up to 42 high-pressure 

storage cylinders, with a filling 

volume of 80 litres per storage 

module. Capacities of 265 m 3 

to 1105 m 3 of geometric gas filling 

volume at 300 bar can thus 

be realised. 

A “fill post” is used as the fuel 

dispenser since public fuelling 

is not provided. This model was 

developed especially for simple, 

temperature-compensated and 

low-cost fuelling. The fuel dispenser 

series is frequently used 

for natural gas filling stations in 

work yards that are not staffed. 

Depending on the filling 

capa city, fuel volume and compressor 

model, fuelling times of 

around 5 minutes are obtained 

with the “fast fill post” version 

used here. The Munich-based 

manufacturer offers the “slow fill 

post” version without the integrated 

storage module for applications 

where the fuelling time is 

less important. Here vehicles are 

fuelled directly from the compressor. 

For technical reasons, 

fuelling times vary considerably 

in this case. Overnight vehicle 

fuelling is an ideal application 

scenario. 

Using a fuel dispenser is required 

by law for the operation 

of public filling stations. Fuel 

payment at the dispenser, without 

staff, can be realised with 

a customer activated terminal. 

The dispenser can also be realised 

with a calibratable flow meter 

(display of the delivered fuel 

volume in kg or m³) and a display 

panel that shows the specific gas 

price and the total price in the desired 

currency. 

Core competence – 

economical and comprehensive 

project development 

First the project engineers select 

the best site for the filling station 

according to the customer’s 

speci fications and in close coordination 

with them. Special attention 

is paid to exact compliance 

with legal regulations. By 

mini mising explosion protection 

zones and tailoring the size 

of the filling station, the Munichbased 

supplier is able to find 

an optimal installation solution, 

even when the available space 

presents a challenge. Installation 

comprises the complete pipe- 

work for the system according to 

the applicable directives. This includes 

all pressure lines from the 

compressor to the reservoir and 

from there to the filling station 

and dispenser. An inspection by 

an approved regulatory authority 

such as TÜV follows. The project 

team manages and coordinates 

the necessary scheduling with 

the companies and authorities 

that are involved. 

Service technicians install the 

electrical wiring for the compressor 

system and the filling station/ 

dispenser according to the approved 

plans. The operator only 

has to provide a high-voltage 

connection. After installation, the 

compressor system is started up 

for the first time and inspected 

again in detail. 

End-to-end project organisation 

is handled by the supplier. 

This includes the installation 

and putting into operation 

of the compressor/storage unit 

and fuel dispenser technology 

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Compressos and Systems 


as well as detailed scheduling. As a 

rule, the system can be put into operation 

within a few days. The installation 

is inspected by an expert after it 

has been completed on site. This acceptance 

at the installation location is 

also performed by a service team in 

cooperation with the respective regulatory 

authority. Comprehensive service 

includes detailed instruction for 

authorised personnel of the customer 

in the system technology and electrical 

equipment. This ensures that 

the operator is able to handle basic 

settings and simple maintenance independently. 

Continuous monitoring of the 

compressor system with 24-hour and 

after-sales service is offered on request. 

Changes to settings and adjustments 

can then be made around the 

clock, online over the Internet or using 

a mobile device. Status messages including 

operating hours and gas volume 

sales can be delivered by SMS 

or e-mail, along with maintenance requests 

or fault messages. 

Biomethane supply with BAUER 

Aside from filling stations, the compressor 

manufacturer from Munich 

has developed special compressor 

systems for biomethane production 

based on its expertise acquired 

over many years and successfully established 

them in the market. They 

are used among other things for 

the seasonal compensation of transport 

fluctuations and network overloads: 

When a low-pressure line is 

overloaded, for instance by an increase 

in the biomethane supply, 

the excess biomethane-natural gas 

mixture can be supplied to a highergrade 

network. Existing buffer volumes 

in high-pressure transmission 

networks are more effectively utilised 

as a result. Biomethane is supplied 

to a natural gas network in various 

network types with pressure ratings 

from PN10 to a maximum of PN100. 

Climate-neutral mobility for the 

hydrogen future 

Based on its sustainability-oriented 

philosophy, the company stands for 

climate-friendly mobility concepts 

without compromise. The manufacturer 

as a technology leader in mechanical 

engineering and a member 

of Zentrum Wasserstoff.Bayern 

(H2.B) therefore consistently supports 

the broad establishment of this 

future energy carrier with a recently 

launched development offensive for 

H 2 

filling station systems. 

Sources 

FGS brochure 

https://www.bmel.de/DE/themen/ 

html#:~:text=Derzeit%20erzeu 

gen%20in%20Deutschland%20 

etwa,Prozent%20des%20 

landwirtschaft/bioeokonomienachwachsende-rohstoffe/biogas. 

deutschen%20Stromverbrauchs%20ab. 

The Author: 

Helai Ammura, 

Sales and Project Engineer 

Fuel Gas Systems, 

BAUER KOMPRESSOREN, 

Munich, Germany 


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GEA compressor important component of 

new particle accelerator facility at GSI 

Helmholtzzentrum für Schwerionenforschung 

GEA Grasso screw compressors for 

the compression of helium gas are 

playing a crucial role in one of the 

world’s largest construction projects 

for cutting-edge international research. 

The compressors are part of 

the FAIR (Facility for Antiproton and 

Ion Research) particle accelerator 

facility for cooling superconducting 

magnets. 

Powerful compressors - driving 

force in the cooling process 

The order placed with GEA by the 

project partner Enerproject S.A. includes 

compressors type XH, GEA's 

largest compressors, XE compressors 

and XC compressors, all belonging 

to GEA's proven LT series. The 

GEA compressors are the driving 

force of the process to liquefy the 

helium and thus cool the superconducting 

magnets. The entire refrigeration 

system will have a cooling capacity 

of 15 kW at about -269°C. 

The ions are accelerated with 

high electric fields. Magnets are 

used to direct and bundle them. 

The ions can be accelerated to a 

maximum speed of around 90 percent 

of the speed of light, i.e. almost 

270,000 km/s. Researchers from all 

over the world use the accelerated 

ions at GSI for experiments in a variety 

of research fields, from particle, 

nuclear and atomic physics to plasma 

physics, materials research, biophysics 

and tumor therapy. 

Together with its partners such 

as Enerproject S.A. and Linde 

Kryotechnik AG, both from Switzerland, 

the compressor manufacturer’s 

team faced major challenges - and 

mastered them. To cool the magnets, 

it is not possible to use ammonia 

or any other refrigerant to 

reach the required temperature. 

This is only possible with helium, the 

“coldest” element on earth. The normal 

boiling point of helium is 4.2 K, 

which corresponds to about -269 °C. 

The entire plant contains 12.5 tons 

of helium. The project manager and 

key account for gas compressors 

(DACH), explains: “Helium is an expensive 

and extremely rare chemical 

element that cannot be produced artificially. 

Therefore, the loss and contamination 

of helium must be minimized 

in order to reduce costs for 

the customer. For this reason, the installation 

of a second O-ring seal for 

the low-pressure compressors, as 

well as a leak test (sniff test) with helium 

were necessary.” 

For the evaluation phase, the supplier 

was able to recruit an expert for 

the team: a specialist for screw compressors 

and with a cryo technical 

background due to his research 

time at the Technical University of 

Dresden. He provided valuable technical 

advice to the various parties 

involved in the project phase and is 

keen to promote the use of the supplier’s 

screw compressors for helium 

and hydrogen applications. 

Reference for future projects 

The FAIR project is an important reference 

for the compressor manufacturer 

for further future projects 

in the application of helium in refrigeration 

for such low temperatures 

as for the FAIR ring accelerator. Another 

challenge was to coordinate 

this long-term project in close cooperation 

with all parties involved 

so that the compressors could be 

de livered on time. For example, leak 

testing by the ILK Institut für Luftund 

Kältetechnik Dresden had to 

be organized after completion and 

prior to shipment. According to current 

planning, the helium compressor 

plant is scheduled to be commissioned 

in 2024 and the first jet 

in 2025. 

With this project, GEA demonstrated 

its competencies not only 

Major challenges mastered 

The photo shows the GEA XH compressors before delivery. (Photo: GEA) 




in ammonia as a natural refrigerant, 

but also in the compression 

of gases such as the noble 

gas of helium. The company is 

confident that it will be able to 

meet further requests for similar 

helium plants. 

GEA, Düsseldorf, Germany 

FAIR mega construction project 

The FAIR particle accelerator facility in Darmstadt is one of the world's largest construction projects for cutting-edge 

international research. Among other things, an underground accelerator ring tunnel 1,100 meters long, laboratories 

and other operational and utility buildings are being built on an area of around 150,000 square meters. The transfer 

building is the most complex building in the facility. It is the central hub of the facility beamline. The 1,100-meter tunnel 

for the SIS100 particle accelerator will also be up to 17 meters underground. Adjacent to the accelerator tunnel itself 

will be a supply tunnel that will house, among other things, lines for electricity and liquid helium, space for power 

supply equipment and facilities for controlling ion beam quality. 

An integrated construction schedule was developed for the multinational, highly complex mega-construction project, 

closely coordinating civil engineering, accelerator development and construction, and scientific experiments. Construction 

began in the summer of 2017. 

Facts and figures on construction: 

2 million m 3 of earth 

...will be moved - as much as for 5,000 single-family homes 

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...will be used – as much as 8 times the size of the Frankfurt soccer stadium 

65.000 t steel 

...are used – the equivalent of nine Eiffel Towers 

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73


Report 

GER4TECH relies on BOGE 

Uninterrupted compressed air supply 

with added efficiency 

From simple sheet metal parts to 

complex assemblies and entire 

machine parts, GER4TECH GmbH 

in Redlham (Austria) offers a 

broad wide range of metalworking 

services. The company also has substantial 

expertise in developing customer-driven 

solutions for automated 

manufacturing processes. 

It depends on compressed air 

in almost all of its production 

areas, which is where compressed 

air expert BOGE comes in – ensuring 

an efficient and reliable supply to 

the company thanks to three of its 

screw compressors. But that’s not 

all – the supplier has also helped the 

company achieve excellent system 

availability levels of over 95 per cent 

and a significant increase in efficiency 

thanks to consistent recirculation 

of waste heat. 

a broad range of services in the laser 

cutting and bending to machining 

(turning, milling) and welding sectors. 

In addition to metalworking with the 

latest technology, it also provides 

customised automation projects and 

currently employs 75 members of 

staff in its metal and mechatronics 

departments. The family-owned company 

requires compressed air for 

numerous metalwork processes: as 

pneumatic actuator for the laser cutting 

machines, for the break forming 

presses and sheet metal warehouse, 

to cool the cutting machines and to 

run the welding robots. 

Constant compressed air for 

three-shift operations 

“Nothing would run at all in our company 

without compressed air,” explains 

GER4TECH GmbH’s Mana - 

ging Director. “We already had a 

Founded in 2012, the company 

moved from its initial production facilities 

in 2019 after construction finished 

on the GER4TECH Metall & 

Mechatronik Center in Redlham (Austria). 

Over a total surface area of 

9,600 sq. metres, the company offers 

Fig. 2: The company offers a broad range of services in the laser cutting and bending to 

machining (turning, milling) and welding sectors. 

Fig. 1: GER4TECH GmbH left its original production facilities in 2019 after completing construction 

of the GER4TECH Metall & Mechatronik Center with 9,600 sq. metres of production 

space in Redlham. (All photos: GER4TECH) 

BOGE compressor at our previous 

location that also reliably provided 

compressed air, so we completely 

equipped our new facilities with the 

supplier’s devices”. This machinery 

was actually integrated into the building 

during the construction phase. 

The compressor room (which was designed 

specifically for the plant) was 

constructed once all the devices had 

been installed. The company operates 

two oil-lubricated screw compressors 

with a performance of 

55 kW to cover the base load, while 

two refrigerant compressed air dryers 

provide a constant pressure dew 

point at each operating stage. In addition, 

a compressor with refrigerant 



Report 

covered by the heat recovery from 

the compressor, with the winter seeing 

additional support from the company’s 

wood chip and gas heating 

system. The compressed air expert 

took responsibility for the entire interface 

management in order to implement 

these energy saving measures 

and help GER4TECH achieve 

maximum efficiency. 

Fig. 3: The family-owned company requires compressed air for numerous metalwork processes: 

as pneumatic actuator for the laser cutting machines, for the break forming presses 

and sheet metal warehouse, to cool the cutting machines and to run the welding robots. 

Excellent service and 

maximum availability 

dryer covers the reduced demand 

over the weekends. The operating 

pressure is 7.5 bar at a free air delivery 

of between 2.25 and 9.8 m³/min. 

All the compressors are frequencycontrolled 

and guarantee a constant 

compressed air supply throughout 

all three shifts every day. An oil-water 

separator purifies the condensate 

and reduces the residual oil content 

to under 10 ppm. 

Flexibility and efficiency 

The compressors from the Bielefeld 

supplier with tried and tested airends 

and high-quality components ensure 

maximum efficiency, with SLF 

devices offering the highest standards. 

On one hand, the fully designed 

in-house airend permits high free air 

delivery combined with a low power 

demand and the highly developed 

oil separation system with horizontal 

receiver results in optimum efficiency 

yield. The direct drive and frequency 

control complete the highly 

flexible system that can adapt to the 

actual demand. The clear layout of 

the functional areas ensures fast and 

simple maintenance. The ingenious 

construction concept, high-grade 

components and flexible fields of application 

make the screw compressors 

particularly reliable and longlasting. 

As a belt-driven compressor 

with integrated frequency regulation, 

the C 25 F screw compressor also 

adapts the volumetric flow rate to the 

actual demand, meaning the energy 

consumption falls as the compressed 

air demand drops. Idling is also minimised 

which, especially in the metalworking 

sector with its wildly fluctuating 

compressed air demand, is a 

huge advantage. Soft starts and stops 

conserve the material and prolong 

the service life of the device. And, in 

addition, thanks to its compact, integrated 

construction, pressure losses 

are kept to a minimum. 

“We really value maximum reliability 

and high system availability, 

which for compressors from the supplier 

reaches an impressive 95 per 

cent,” tells the Managing Director. 

“If we should ever need any repairs, 

we know we can count on 24/7 support, 

too”. Certified technicians are 

available around the clock for any 

questions and technical assistance. 

On top of that, the Austrian company 

also benefits from high spare part 

availability from the compressed air 

specialist. Regular maintenance using 

original spare parts guarantee continued 

high system efficiency and a 

five-year warranty on all replacement 

parts round off the service package. 

“We’re extremely happy with the 

quality of the compressed air and the 

reliable operation of the systems”, 

concludes the Managing Director. “In 

addition to the technology itself, we 

appreciate the extremely extensive 

customer-focused service. We feel 

very well supported and prepared for 

whatever the future might hold”. 

Making use of excess heat 

Fig. 4: In the compressor room (specially 

designed by BOGE), the company operates 

two SLF 75-3 oil-lubricated screw compressors 

with a performance of 55 kW, two 

powerful refrigerant compressed air dryers 

and a C 25 F compressor with refrigerant 

dryer. 

GER4TECH’s total hot water demand 

is 15,000 litres split across three 

buffer tanks. Heat produced by the 

compressors is transferred into one 

of these tanks where it is used to 

heat process and hot water, meaning 

approx. 70 per cent of the heat energy 

used in the compressor can be 

recovered. During the summer, the 

entire hot water demand can be 

BOGE KOMPRESSOREN, 

Bielefeld, Germany 


75




This is how it’s done – 

maintenance and service 4.0 

Dipl. Betriebswirtin Daniela Koehler, Dipl.-Ing. (FH) Gerhart Hobusch 

Milchwerke Oberfranken West eG 

has been a leading international 

manufacturer of fine cheese 

speciali ties for many years now 

and its products are becoming ever 

more popular around the world. 

Production, which has been constantly 

growing for years, requires 

a reliable source of premium-quality 

compressed air around the clock, 

seven days a week. This state-of-theart 

company has been using remote 

monitoring for some time now, 

which is a service package that not 

only ensures smooth compressed 

air supply, but also makes costs 

fully predictable at a fixed price over 

multiple-year terms. 

The delivered milk – separated according 

to type – is purified, pasteurised, 

cooled and subsequently stored 

in tanks. From there, it passes into the 

production stage. Prior to processing, 

the milk is heated and enriched with 

cheese-specific cultures, depending 

on the intended type of cheese being 

manufactured. Only then does 

the actual cheesemaking process begin. 

Once complete, 60 different varieties 

leave the company, including 

hard cheese, soft cheese, mozzarella 

and ready meals such as baked and 

grilled cheese products. 70 percent of 

the cheese stays in Germany and customers 

include all major retail chains; 

the rest is exported throughout the 

world, from China to Canada. 

As in many industrial production 

facilities, compressed air is essential 

for almost every application 

Milchwerke Oberfranken processes 

500 million litres of milk annually 

to make its cheese – that’s around 

1.35 million litres of milk per day! 

Production runs around the clock in 

three shifts, seven days a week, under 

stringent food-industry quality 

standards. Accordingly, the compressed 

air supply must also be of a 

suitably high quality. 

Fig. 2: Milk, curds and whey are stored in huge tanks. 

Fig. 1: Fresh milk being delivered. 

throughout the plant and plays an 

integral role in product manufacture 

from start to finish. The valves that 

direct the liquid products and concentrates 

from the milk intake to the 

pipeline transport are controlled by 

compressed air, as are the cleaning 

systems. The cheese presses, as well 

as the feeders and ejectors for the 

cheese-forming towers, in which the 

raw cheese is shaped into manageable 

blocks, also operate using compressed 

air, as do the cheese cutters 

and packaging machines. The airconditioning 

for the cheese-maturing 

rooms is even supported by compressed 

air. 

A total of four stations, comprising 

compressors and blowers, is cur- 




Fig. 3: A wide variety of cheeses are made 

from the curd. 

compressors, but also the treatment 

components such as dryers, filters, 

air-main charging system and condensate 

treatment equipment. Upon 

initial commissioning, the entire system 

is digitally recorded and the local 

conditions analysed in order to 

gain an overall picture of the operation. 

The Sigma Air Manager “learns” 

the behaviour of the compressed air 

system, including the reaction times 

of the individual components, and 

uses this “knowledge” in the event of 

fluctuating consumption to adjust the 

compressed air supply to the most 

energy-efficient operation possible, 

based on past experience and the 

measured values available. Here, the 

master controller is also guided by 

the required pressure – i. e. the network 

pressure actually required by 

the customer at the air station outlet. 

The controller endeavours to maintain 

this pressure as low as possible, 

whilst at the same time ensuring that 

it does not drop below the minimum 

permissible value. 

If remote monitoring is used, the 

controller simultaneously transmits 

operating, service and energy performance 

data from the compressed 

air system to the service provider’s 

data centre. In this instance, the dairy 

plant works in close partnership with 

Kaeser Kompressoren. The service 

provider’s data centre contains a 

“digi tal twin” of the customer air station, 

which identically mirrors the actual 

station and, thanks to data transfer, 

is constantly updated in real time, 

rently responsible for ensuring reliable 

operation of the dairy-production 

facility in Upper Franconia. Compressed 

air is used for everything 

from delivery right through to the industrial 

wastewater treatment plant. 

Unsurprisingly, a highly reliable and 

economical supply of dry, technically 

oil-free compressed air is essential, 

with even higher-quality sterile 

air being required in the maturing 

rooms. Due to the high and constantly 

growing demand, the systems almost 

always run at high load. The 

stations were kept in peak condition 

by the compressed air systems provider 

for a long time on the basis of a 

classic maintenance contract. In 2021 

however, the dairy plant decided to 

switch to the very latest maintenance 

concept: remote monitoring. 

This was possible because the 

dairy plant’s compressed air station 

was already centrally controlled by 

an advanced master compressed air 

management system. Such a system 

is an optimal prerequisite to enable 

users to benefit from all of the advantages 

that Industrie 4.0 services 

have to offer. This master controller 

constantly monitors and evaluates 

compressed air generation and 

always selects the most efficient solution 

for the respective needs of the 

business in everyday operation. It 

achieves this by collating and analysing 

all operating data from the components 

in the system; not only the 

Fig. 4: Certain cheeses are automatically turned during the maturing process. 

Fig. 5: Two of the four compressed air stations at Milchwerke Oberfranken. 

Blowers on the left, compressors on the right. 


77



Fig. 6: Data are transmitted to the service provider via the advanced master controller 

(Sigma Air Manager). The service technician performs demand-optimised maintenance. 

monitored and analysed for any further 

requirements. Data transmission 

is encrypted in real time via a 

proprietary network that is specially 

developed for this purpose. Access 

to the operator’s network is therefore 

not required to perform this task. 

The service package offers many 

advantages. With a classic maintenance 

contract, service technicians 

are scheduled to make visits and perform 

certain checks at fixed intervals. 

With remote monitoring, thanks to direct 

insight into station performance 

data, maintenance is performed on 

a system-specific basis according to 

actual system status. Maintenance 

is therefore needs-based and takes 

place only when actually necessary. 

This is where the provider’s expertise 

comes into play to facilitate predictive 

maintenance. Through the availability 

of the compressed air system’s 

process data and the resulting analysis, 

it is possible to determine the ideal 

time to implement maintenance 

work. Consequently, necessary service 

measures are recognised early 

on and can be carried out in a timely 

manner as required. This not only reduces 

downtime and increases energy 

efficiency, but also saves time and 

money. This combination of remote 

diagnostics and needs-based, preventative 

maintenance ensures maximum 

dependability for the operator’s 

compressed air supply. 

Maintenance costs can also be 

significantly reduced. With a classic 

Fig. 7: If a station is being serviced, the relevant 

compressors can be bridged externally 

using a portable compressor. 

maintenance contract, the operator 

bears all of the costs incurred, even 

if a major repair is needed. With the 

remote monitoring model, the operator 

pays a fixed service rate per 

year based on the actual volume of 

compressed air generated. All costs 

for maintenance and any repairs, regardless 

of the amount, are borne by 

the service provider. The service rate 

is fixed for five years, so that the operator 

knows exactly what to expect 

and is able to plan precisely, regardless 

of potential market price increases 

or actual repair costs. 

In addition to these maintenancerelated 

aspects, remote monitoring 

also provides further benefits for 

compressed air station operators. 

Since data are transmitted live and 

constantly monitored and analysed, 

the key figures generated will quickly 

show if a business’ compressed air 

demand should change. The smart 

service package includes monitoring 

of key figures such as service costs, 

reserve levels and specific package 

input power. When an operation 

grows, so too does its compressed 

air consumption. When this happens, 

it may be that the existing air station 

soon reaches the limit of its capacity, 

whereby the back-up compressors installed 

for reserve must be operated 

constantly. Or indeed the reverse 

may be the case; e. g. due to a change 

in production processes, a company’s 

compressed air consumption actually 

drops. Constant data monitoring 

identifies such developments early 

on, giving the operator the opportunity 

to verify the need for any expansion 

or investment plans they may 

have in good time. 

Furthermore, remote monitoring 

makes energy and life-cycle management 

possible throughout the air station’s 

entire service life. Up-to-date 

key energy management figures from 

a single source provide the basis for 

energy management in accordance 

with ISO 50001. 

In contrast to so-called “Contracting”, 

where the service provider 

makes the air system available and 

the user only purchases the compressed 

air that is used, with this service 

package the operator continues 

to be the owner of the compressed 

air station. After almost a year, the 

dairy plant is highly satisfied with the 

new service model. Based on past experience, 

the company is more than 

confident that it made the right decision 

in terms of economy, reliability 

and safety. 

The Authors: 

Dipl. Betriebswirtin Daniela Koehler, 

Press Officer, 

Dipl.-Ing. (FH) Gerhart Hobusch, 

Lead Project Engineer, 

both Kaeser Kompressoren, 

Coburg, Germany 



Sensors 

How to protect pumps 

from air and gas inclusions 

New sensor technology for intelligent gas bubble 

detection prevents pumps from running dry 

Julian Budde 

When pumps fail, production stops, 

cooling systems are interrupted, 

and machines must be stopped. 

That is why effective pump protection 

is a crucial task for both plant 

engineers and technicians. It is particularly 

important to detect unwanted 

gas inclusions in fluid media 

at an early stage. This is remedied 

with a novel sensor technology detecting 

gas bubbles before they 

damage pumps. 

Fig. 1: By detecting gas bubbles in the supply pipe, the sensor protects pumps from running 

dry. (Photo: Baumer) 

Pumps are a key component to ensure 

consistent process flow where 

fluids are involved. They can be found 

virtually everywhere and are used to 

keep industrial processes moving forward, 

heat homes, and supply machines 

with lubricant. To ensure a 

process runs smoothly, pumps must 

be prevented from running dry and 

any cavitation must be identified, as 

both can lead to damage or failure. 

Dry running describes the situation 

that occurs when gas bubbles get 

into a pump and cannot be released. 

This means that there is too little or no 

fluid in the pump housing. One reason 

for this may be the improper commissioning 

of systems with, for example, 

an empty tank or closed suction pipe. 

Another may be the improper installation 

of pumps – if plant engineers do 

not pay sufficient attention to differences 

in height, this can lead to pump 

suction problems in the future. 

Possible damage caused by 

dry running 

So, what happens when pumps run 

dry? Depending on how quickly gas is 

detected in the pipes and on the volume 

of the gas inclusions, the effects 

may be more or less severe. At best, 

components are temporarily overloaded; 

in the worst-case scenario, 

the pump is destroyed. Dry running 

can cause, among other things, the 

following pump damage: 

– Considerable overheating of 

the bearings 

– Leakage due to destroyed sealing 

– Loss of performance, pressure 

loss, increased noise levels 

– Stiffness 

– Increased energy consumption and 

labor-intensive maintenance work 

– Complete destruction of the pump 

Bubble formation by cavitation 

Cavitation in fluid occurs when bubbles 

form on fast-moving objects or 

in constricted areas and dissipate 

again abruptly. This often occurs on 

ship propellers and in pumps and can 

cause considerable damage, or worst 

case, total failure. How does cavitation 

occur and why does it damage 

pumps? The reason behind cavitation 

is explained by Bernoulli’s principle 

stating that the faster a fluid moves, 

the lower its static pressure will be. 

When it comes to the fast-moving 

parts of a pump, the static pressure 

can even drop below the evaporation 

pressure of the fluid. If the static 

pressure falls below this threshold, 

gas bubbles form on these parts. As 

soon as the ambient pressure rises 

again as the flow continues, the gas 

bubbles implode loudly and cause vibrations. 

These implosions are characterized 

by high pressures which 

can damage or destroy the impeller 

and pump housing through pitting if 

they are not stopped in time. Cavitation 

does not only occur in pumps, 

but also in constricted areas of the 

supply pipes. This can also result in 

gas bubbles which damage the pump 

interior. 


79


Sensors 

How does gas get into pumps? 

There are various causes behind gas 

inclusions in systems. The most common 

reasons include: 

– Leakages 

– Leakages due to the manufacturing 

process (for example, when stirring 

and mixing ingredients and components) 

– Valves 

– Outgassing of media 

– Air pockets in the medium 

– Cavitation 

The more complex the system, the 

greater the likelihood of gas getting 

into pipes and pumps. Given the 

damage often associated with downtime 

and high maintenance costs, it 

would be ideal to detect gas in the 

system at an early stage. Reliable gas 

bubble detection provides the following 

benefits: 

Novel sensor detects even the 

smallest of gas bubbles 

To ensure effective pump protection, 

gas bubbles must be reliably detected 

before they enter the pump interior. 

No sensor was able to do this to 

date. The Baumer analysis sensor now 

closes this gap, which reliably detects 

even the smallest gas bubbles and air 

bubbles in the medium. Thanks to the 

smart sensor principle, it will immediately 

report any individually adjustable 

limit for gas inclusions being exceeded. 

The sensor measuring principle is 

dc-value based detection (dc = dielectric 

constant) of air and gas bubbles in 

fluids with a minimum conductivity of 

dc > 1.5. Thanks to sophisticated algorithms, 

the sensor will recognize very 

precisely any presence of gas and fluid 

in the flow. It measures independently 

of the medium, providing maximum 

flexibility. The “Gas bubbles in the medium” 

signal can be used to shut down 

the pump or report an alarm warning. 

The analysis sensor has its origins 

in the food industry. For years, 

dairy company Sachsenmilch GmbH 

was unable to completely empty the 

delivery containers containing an expensive 

fruit concentrate for the production 

of fruit yogurt. The problem 

was that if the yogurt manufacturer 

wanted to use nearly all the fruit concentrate, 

it ran the risk of gas pene- 

– Increased service life of pumps 

– Less maintenance and downtime 

– Increased system availability 

– Process safety 

– Higher product quality 

– System effectiveness and process 

efficiency 

– Cost reduction 

– Food safety in hygienic applications 

How have plant operators protected 

their pumps from harmful gas bubbles 

to date? In closed systems not 

allowing for visual inspection, operators 

can only guess at the presence 

of gas bubbles. Pump protection is 

therefore mostly based on acoustic 

monitoring – in other words, when 

an attentive technician hears something 

unusual. Given that machines 

suddenly generate much more noise 

when there is gas in the pumps, this is 

usually quite easy to detect. 

A sensor solution for detecting 

empty pipes has also been available 

for several years. A limit level sensor, 

which is embedded in the pipe 

from above, checks whether the pipe 

is filled with fluid or not. This method 

is primarily intended to provide the 

start-up signal for the pump as soon 

as it no longer draws gas, but only the 

fluid medium. 

Fig. 2: The Baumer analysis sensor reliably detects even the smallest gas and air bubbles. 

(Photo: Baumer) 

Fig. 3: Destructive gas bubbles have caused minor cavitation damage on this centrifugal 

pump. (Photo: stock.adobe.com 



Sensors 

trating the system which then had to 

be exhausted at great expense. For 

this reason, the company always left a 

safety reserve of the expensive ingredient 

in the container when changing 

containers. Working together 

with Sachsenmilch GmbH, Baumer 

developed the solution, which is ideal 

for protecting pumps. At the dairy 

company, the analysis sensor detects 

air and gas bubbles in the pipe system, 

pinpointing the imminent emptiness 

of the container and defining 

the best point in time for exchanging 

containers. 

The benefits for Sachsenmilch 

GmbH can be quantified precisely. 

By completely emptying the transport 

containers, the dairy company 

can use up to 8 kilograms more fruit 

concentrate per product type and 

production line than before. What’s 

more, the company can produce up 

to an extra 10000 cups of yogurt. 

This is because the sensor prevents 

the 15-minute downtimes that used 

to be required for cleaning and reconditioning 

the system when the 

container was empty. 

Ideal for the food industry and 

heating/cooling systems 

Wherever fluids are moved in closed 

systems, the analysis sensor can protect 

pumps from air and gas: in industrial 

applications, food production, 

building technology, or water 

supply. More target applications include 

monitoring cooling circuits and 

dry run prevention, process monitoring 

and ensuring process safety in 

terms of pump protection. The application 

is particularly beneficial for the 

food industry and in heating/cooling 

systems. In heating systems, a similar 

phenomenon happens right at home. 

When there is air in the system, 

household radiators do not properly 

heat up and energy is wasted. This 

is even more true for industrial heating 

and cooling systems. Gas bubble 

detection therefore ensures both resource-efficient 

operation and system 

effectiveness. Process safety and 

pump service life are increased, while 

the maintenance effort is reduced. 

In industrial applications, functioning 

pumps are all the more important 

because downstream processes can 

also be jeopardized if a failure occurs. 

In food production, unwanted gas 

bubbles in the system are particularly 

problematic because they can endanger 

not only the pumps but also food 

safety. This is because contact with 

air or gas during processing, filling, 

or packaging can have a direct impact 

on the quality of the food produced. 

In this scenario, early gas detection 

can reduce waste and increase system 

efficiency. 

The analysis sensor is particularly 

suited to protecting centrifugal 

pumps, gear pumps, and piston 

pumps. 

The Author: Julian Budde, 

Product Manager, Baumer GmbH, 

Friedberg, Germany 

THE NEW BM SERIES - COMPACT, 

ECONOMICAL AND POWERFUL 

LEGENDARY BAUER PERFORMANCE AND 

RELIABILITY IN THE MEDIUM-PRESSURE 

SEGMENT 

› Air-cooled medium-pressure compressors for 

the compression of air 

› Reliable and robust machines based on our 

decades of experience 

› Lightweight and compact with a small installation 

footprint 

› Outstanding performance and longevity, even 

at high ambient temperatures 

› Suitable for heavy-duty operating conditions 

bauer-kompressoren.com 

› 30 bis 110 bar 

› 620 bis 7200 l/min 

› 11 bis 132 kW 

NEW


Valves 

Pure and affordable drinking water 

for a whole region 

Sliding gate valves are optimising Belgium’s largest facility 

for RO water purification 

Veolia Water Technologies has built 

an ultra-modern plant to produce 

drinking water in Ostend, Belgium. 

In a multi-stage filtration process, 

the local water supplier is now producing 

drinking water of excellent 

quality – far above the statutory 

requirements. At critical points of 

the process – during reverse osmosis, 

filtration with activated carbon 

and remineralisation of the water 

– sliding gate valves made by 

Schubert & Salzer Control Systems 

are responsible for regulating pressure 

and flow rate. 

The water supplier, FARYS, produces 

drinking water for the city of Ostend 

and its surrounding area from 

the brackish water in the Bruges- 

Ostend Canal. In the current development 

stage of the waterworks built 

by Veolia Water Technologies, up to 

1,200 cubic metres of drinking water 

per hour can be fed directly into the 

pipe network. The plant constructed 

by the leading specialist for water 

Fig. 1: One DN125 and one DN50 sliding 

gate valve are used in each of the twelve 

reverse osmosis units. (Photo © : Schubert & 

Salzer Control Systems) 

Fig. 2: In reverse osmosis, microcontaminants 

down to particle sizes of 0.1 nanometres 

are filtered out of the water. The 

fine-pored, semi-permeable filter layers are 

rolled up in pressure tubes. 

treatment is the largest Belgian drinking 

water production facility using 

RO technology and the production 

speed is among the fastest in the 

world. It is also unique that the installation 

can be used very flexibly within 

a variety of canal water qualities and 

that the entire process is done within 

consider ably reduced energy costs. 

The project manager of Veolia 

Water Technologies Belgium, describes 

the process as follows: “The 

canal water is treated in eight stages. 

First, in coarse, fine and microfiltration, 

all suspended particles, microbiological 

substances and pathogenic 

microorganisms are removed. During 

the subsequent reverse osmosis, 

fine-pored, semipermeable membranes 

filter microcontaminants up 

to particle sizes of 0.1 nanometre as 

well as minerals and salts.” Only water 

molecules remain. This water is 

sent through activated carbon filters 

and after injection with carbon 

dioxide, remineralised with limestone. 

Finally, the water is disinfected 

with UV light and then chlorinated. 

The result – drinking water of the 

highest quality – is fed into the pipe 

network via buffer storage tanks. 

“The operator of the waterworks 

wanted a facility that works cost- 

effectively. Maximum energy efficiency 

was required everywhere – even at 

the control valves”, explains the International 

Sales Manager at Schubert & 

Salzer Control Systems. “Equally, reverse 

osmosis and the subsequent 

process stages are demanding applications. 

There are special requirements 

here in terms of the control 

accuracy and reaction speed of the 

valves used.” 

Sliding gate valves provide effective 

protection against damage 

“During the reverse osmosis process, 

precise and fast pressure regulation 

is very important”, emphasises the 

Fig. 3: Sliding gate valves from Schubert & 

Salzer with a nominal size of 150 millimetres 

control the pressure at the outlet of the 

total of 12 reverse osmosis units. Striking: 

the compact dimensions of the valve and 

electropneumatic actuator. 



Valves 

Fig. 4: The precise flow control of the sliding gate valves ensures that each of the 

eight activated carbon filters (pictured here) and 13 remineralisation tanks are 

evenly utilised. 

Veolia engineer. “The highly sensitive 

filtration layers are rolled 

up in pressure pipes. Pressure 

shocks and excessive flow quantities 

have to be reliably prevented. 

Even the slightest overshoots 

in the control process could damage 

the expensive membranes. 

That is why we use one DN125 

and one DN50 sliding gate valve 

in each of the twelve reverse osmosis 

units. They ensure the exact 

regulation of the high process 

pressures that are ne cessary to 

compensate for the osmotic pressure 

of the brackish water and 

keep the reverse osmosis going. 

The decisive factor for the 

high precision and extremely 

short response time of the sliding 

gate valves is their special design 

principle. The sliding gate technology 

controls the flow rate in 

milliseconds, by two slotted sealing 

discs arranged vertically to 

the direction of flow moving on 

top of each other. The pneumatic 

actuator only has to overcome 

the sliding friction between the 

two discs. This means that the 

required actuating force is up to 

90 per cent less than on other 

types of valves. The actuators can 

be dimensioned consider ably 

smaller and the need for control 

air can be reduced. Simultaneously, 

the short strokes of only a 

few millimetres and the reduced 

kinetic masses of the throttle element 

protect the actuator and 

the spindle seal. 

Material and energy efficiency 

help overall cost-effectiveness 

The special design principle of 

the sliding gate valves has a double 

positive effect on the weight 

and dimensions. On the one 

hand, the valves are smaller and 

lighter due to the intermediate 

flange design and the smaller actuators. 

On the other hand, the 

significantly better flow properties 

due to the particularly high 

KVS values also allow the use 

of smaller nominal sizes, which 

makes these valves even more 

compact and lighter than common 

alternative solutions. Hence 

the 45 sliding gate valves in the 

plant weigh just 1,100 kilograms 

altogether. Seat valves in comparison 

would weigh in at around 

5 tonnes. This difference is considerable 

and, due to the savings 

on resources and CO 2 

, has positive 

effects over the valve’s entire 

life cycle – from manufacture to 

transport through to its operation 

in the plant. The maintenance 

and hence the operating 

costs are also reduced because 

of the more compact dimensions 

and low weight. 

The long service lives of the 

sliding gate valves were also a decisive 

point. These result, among 

other things, from the fact that 

they neutralise the damaging effects 

of cavitation. In alternative 

globe valves, imploding cavitation 

bubbles often cause cost-intensive 

wear due to erosion. Due 

to the special design of the sliding 

gate valves without flow deflection, 

the cavitation bubbles 

implode clearly behind the valve 

in the pipeline. This can easily be 

designed so that no damaging effect 

arises from the cavitation. 

Fig. 5: Size comparison between a normal seat valve and a sliding gate valve. In 

the example, the nominal size of both valves is identical. 

For this purpose, it is sufficient to 

run the pipe straight for a short 

distance after the valve. The control 

valves remain more or less 

untouched even in case of water 

shocks. The force of any water 

shock occurring in the pipework 

is not transferred to the actuator 

for the sliding gate valves, meaning 

that this cannot be damaged 

by pressure spikes. 

Even utilisation due to 

high-precision positioners 

“Before the treated water is fed 

into the region’s pipe network, 

we use DN150 sliding gate valves 

during the activated carbon filtration 

and remineralisation with 

limestone and CO 2 

”, adds the Project 

Manager. Here too, the supplier’s 

high-precision positioners, 

combined with the sliding gate 

valves, guarantee extremely accurate 

flow control, such that 

the eight activated carbon filters 

and 13 remineralisation tanks 

are evenly utilised. In this application, 

a linear flow characteristic 

curve proves to be particularly 

suitable for the regulation of the 

flow quantities to keep the process 

stable. 

Reliable, regional water supply 

guaranteed 

With an average output of 24,000 

cubic metres per day, the plant 

makes an important contribution 

to the reliable and cost-effective 

supply of drinking water to the 

people in the Ostend region. 

Periods of water shortage – as 

Belgium has experienced in the 

past summers and which will become 

even more frequent due to 

climate change - will be avoided in 

the future. For this reason, FARYS 

is already planning a second similar 

plant in Nieuwpoort. 

Schubert & Salzer 

Control Systems GmbH, 

Ingolstadt, Germany 


83


Valves 

Operation under high pressure 

Specially adapted automatic basket strainer 

for pressures up to 1,160 psi (80 bar) 

Ulrich Latz 

In a hydroelectric power plant of the 

Swiss energy company Kraftwerke 

Oberhasli AG, specially modified 

Eaton automatic basket strainers 

minimize the wear on the hydraulic 

control valves caused by glaciers 

and suspended solids. They are designed 

for water pressures of up to 

1,160 psi (80 bar) and filter out particles 

with a fineness of 25 μm. 

the runoff into the reservoir and collect 

there together with other suspended 

matter brought in by rainfall. 

These 25 to 200 micron particles pose 

a problem for the huge turbines in 

the KWO power plants, as they cause 

heavy wear of the slide valves. These 

valves use the pressure of the water to 

control the ball valves which, in turn, 

control the intake to the turbines. Due 

sis, but now they are no longer available 

on the market. In order to reduce 

or, ideally, eliminate costly and 

time-consuming repairs, the hydroelectric 

power plant operator was interested 

in finding a new solution. 

“The installation of larger settling 

tanks was not an option,” continues 

the manager. “At water pressures of 

870 psi (60 bar), 1,160 psi (80 bar) or 

even more than 1,450 psi (100 bar), 

very large and complex tanks would 

be needed. But that would not be feasible 

for economic and environmental 

reasons, and for lack of space. Converting 

to oil hydraulics was likewise 

not feasible for the same reasons.” 

Therefore, KWO decided to install 

filter systems directly upstream of 

the control valves and turned to BT- 

Hydraulik, a leading company in the 

field of hydraulic drive technology. 

The experts from the Bernebased 

company advised KWO to use 

an auto matic basket strainer. Conventional 

filters clog up over time and 

Grimselsee in Switzerland (Photo © : gettyimages/Francesco Meroni) 

The Kraftwerke Oberhasli AG power 

plant (KWO) can generate energy 

on demand at any time using water 

dammed in the Grimselsee, 1909 meters 

above sea level. The Swiss energy 

company makes an important contribution 

to generating electricity and 

stabilizing the grid in Switzerland and 

Europe from its hydroelectric power 

plants in the Grimsel area. In addition, 

reservoirs act as natural batteries 

in which energy can be stored in 

the form of water and later used to 

generate electricity. However, the use 

of natural glacial runoff and rainwater 

poses a problem-suspended matter. 

The glacier is continuously eroding 

very fine stone particles from the 

mountains. These solids, derived from 

glacial abrasion, are transported by 

to the water’s drop height of 670 meters, 

very high pressures occur in the 

valves and their supply lines. 

Heavy wear on hydraulic 

control valves 

Sand settling tanks are in place upstream, 

which prevent the entry 

of coarse particles into the control 

valves, however they have demonstrated 

only limited success. “Until 

now, the valves had to be cleaned and 

repaired by the KWO every three to 

four months,” explains the Sales and 

Technical Manager at BT-Hydraulik 

AG, which was commissioned by KWO 

to find a solution to the problem. In 

the past, the valves even had to be 

completely replaced on a regular ba- 

Fig. 1: This strainer is designed for continuous, 

uninterrupted removal of entrained 

solids from liquids in pipeline systems. 

Model 2596 strainers are available in different 

sizes from DN50 to DN900 (standard 

pressure ratings PN10/PN16), with automatic 

backwash and a broad selection of 

screen options. (Photo © : Eaton) 



Valves 

need to be serviced and replaced at 

regular intervals. An automatically 

self-cleaning filter is the more economical 

solution. The problem is that 

standard backwash filters are not designed 

for the high pressures in a hydroelectric 

power plant. BT-Hydraulik, 

together with Eaton, continued 

to work on refining the strainer. This 

motor-driven strainer provides continuous 

removal of solids from fluids 

in pipework systems - though only 

within a standard pressure range up 

to a maximum of 232 psi (16 bar). 

However, the supplier provides customization 

of this filter system to 

serve customer-specific applications. 

Modified automatic basket 

strainer withstands pressures up 

to 1,160 psi (80 bar) 

A version of the automatic basket 

strainer was developed for KWO 

that is designed for pressures of up 

to 1,160 psi (80 bar). However, a variety 

of measures were required to 

make this possible: First of all, in order 

to withstand the high pressures, 

Eaton modified the entire housing 

by increasing the wall thickness and 

making the cover considerably sturdier. 

In addition, the flushing arm 

drive shaft was sealed with a quadruple 

mechanical seal. A particularly 

challenging problem was to find 

a filter element that offers the highest 

possible filter fineness that could 

also withstand the high pressures 

and was backwashable. A reinforced 

version of the DuraWedge ® filter elements 

proved the solution: Made of 

V-shaped stainless steel wire profiles, 

even the standard version is capable 

of being used in demanding applications. 

After being further reinforced, 

they now can withstand the high pressures 

in the hydroelectric power plant, 

filtering out a large part of the suspended 

matter due to a filter fineness 

of 25 μm. The system had to be ad- 

Fig. 2: With flow rates of up to 35.000 GPM (7.950 l/min), a broad selection of screen 

options and automatic backwashing, this strainer is designed for continuous, uninterrupted 

removal of entrained solids from liquids in pipeline systems. (Photo © : Eaton) 

ditionally adjusted so that the screen 

baskets would not be deformed in the 

backwash phase. A pressure reduction 

of 870 psi (60 bar) to the ambient 

pressure would have been problematic 

despite the reinforcement. 

The high-pressure basket strainers 

used in KWO’s hydroelectric power 

plant – so far there are four – have 

also been adapted to the operating 

parameters used there. The connector 

size for two of the filters is 

2 inches and for the other two is 

3 inches, with a flow rate of between 

53 and 106 gallons per minute (200 

and 400 liters per minute). How ever, 

the design of the high-pressure strainer 

basket developed jointly by Eaton 

and BT-Hydraulik can also be adapted 

to other parameters – in line with 

whatever the application requires. The 

backwash is triggered by a control – in 

KWO’s case, whenever the differential 

pressure reaches 11.6 psi (0.8 bar). Alternatively, 

control using predetermined 

time intervals or permanent 

backwashing would also be feasible. 

Wear and repair costs significantly 

reduced 

Even though the test phase of the 

new filter system is scheduled to run 

for several years, initial results are 

already clear. “The results are very 

good,” says KWO. “So far we have 

had no outages and the system perfectly 

meets our needs in terms of 

maintaining and cleaning the baskets.” 

Especially compared to the 

turbine lines where the sliding gate 

valves have not yet been retrofitted, 

it is clear that wear and tear has been 

significantly reduced – the amount of 

maintenance required and the associated 

costs have been minimized by 

the high-pressure automatic basket 

strainer. 

The Author: Ulrich Latz 

Global Product Manager, 

Industrial Filtration, 

Eaton Technologies GmbH, 

Nettersheim, Germany 


85

Compressors/Compressed air/Components 


No things by half with actubar ® ! 

Every pneumatic actuator in the actubar ® series is now equipped 

with the additional pneumatic interface of the bar-vacotrol ® system 

as standard. The openings of the pneumatic air duct as a direct connection 

between actuator and control unit are closed with a blow-outproof 

and reusable screw. When retrofitting control units from the 

bar-vacotrol ® series, only the screw plug is unscrewed from the actuator 

housing to open the direct connection. The control unit can be 

mounted directly and put into operation. 

bar-vacotrol ® as an integrated air duct realises an increased level in 

the reduction of interfaces between actuator and control unit and is 

predestined for an optimal realisation according to VDI/ VDE 3847-2. 

The suitably developed generation of control components makes external 

piping unnecessary, is easily accessible and logical to operate. 

This applies to the bar-positrol ® and bar-positurn2 positioners as well 

as to the bar-posiswitch ® and bar-valve&switch ® limit switch boxes. 

Thus, devices with internal as well as external solenoid valves can be 

selected for more flexibility in adapting to the installation situation and 

environment. 

In the 4 largest actubar ® actuators of the 18 available sizes, the solenoid 

valve interface can be flexibly adjusted to ¼" or ½" air flow with 

additional mounting plates, which also achieves better adaptation to 

existing process conditions. 

bar pneumatische Steuerungssysteme GmbH 

Auf der Hohl 1 

53547 Dattenberg, Germany 

Tel +49 (2644) 96070 

Fax +49 (2644) 960735 

bar-info@wattswater.com 

www.bar-gmbh.de 

BOGE at the 2023 Hanover Trade Fair 

Increasing efficiency of 

compressed air systems with 

digital transformation 

Smart compressed air management in the age of Industry 4.0 – at the 

Hanover Trade Fair, BOGE will show how compressed air systems can 

easily be analysed and optimised using BOGE connect. The smart service 

tool has been expanded with additional connection options and is 

therefore even more versatile. Trade fair visitors can find out for themselves, 

thanks to the C 14 PM screw compressor on display. 

A constant overview of all operating data – BOGE connect records, 

monitors and visualises all important parameters, thus significantly 

simplifying administrative work. All relevant data is saved in a digital 

machine file. Continuous monitoring allows conclusions to be drawn 

regarding the device’s status at all times. Anomalies can be detected 

and malfunctions fixed early, thanks to data analysis. BOGE connect 

will provide timely automatic reminders of upcoming maintenance 

or servicing. Data can be retrieved in real-time from anywhere and is 

available on all mobile end devices. 

Clean business: Pipe-free connection with bar-vacotrol ® . 

Advantages 

Emissions due to leakage are minimized by eliminating susceptible 

pneumatic fittings and the small number of robust sealing points. There 

is no dead volume in lines. Process operation is less susceptible to faults 

and less sensitive to vibrations. External influences lead to damage 

and failures much less frequently. This results in longer running times 

and higher availability for the systems. When changing components, 

the modular system makes adjustments to pipelines super fluous. The 

changeover process of components can be easily integrated into the 

workflows and assembly times are considerably reduced. 

New connection options 

Thanks to numerous interfaces, even older models and products from 

other brands as well as various components can be connected. The re- 

NAMUR+ 

In addition, a new adapter plate has been developed with which the 

NAMUR interface can be an extension to the Namur+ connection. Solenoid 

valves with NAMUR+ interface can be screwed onto the free flange 

surface of the adapter plate. Connections for supply compressed air, 

control air and venting are easily accessible from the side. Assembly or 

replacement is possible without having to tighten and seal the pneumatic 

fittings. 

At the Hanover Trade Fair, BOGE will show how compressed air systems can be 

easily analysed and optimised with BOGE connect. (Photo © : BOGE) 




vised version features new interface modules 2.0 for the connection of 

compressors and loose as well as built-in accessories. Additional Modbus 

TCP components can be connected using the 5-way switch with 

four free Ethernet ports. Overall, BOGE connect, in the bigger switch 

cabinet version, now offers more space for modules and therefore optimised 

connection options. Visitors to Hannover Trade Fair can test 

the comprehensive functions of the advanced service tool using the example 

of the C 14 PM screw compressor. The compact compressor is 

equipped with a permanent motor and, even by itself, delivers incredible 

performance, combined with a very low noise level. However, with 

BOGE connect, performance can be increased again. Seamless reporting 

across the entire life cycle ensures low operating costs, maximum 

planning reliability and maximum efficiency. The service tool, as an industrial 

IoT platform, paves the way for future smart services such as 

predictive maintenance. 

At Hanover Trade Fair, BOGE experts will report on current trends 

in technology and support at Booth D27 in Hall 7 from 17 th to 21 st April. 

Fig. 1: High pressure test bench up to 1500 bar 

BOGE Kompressoren 

Otto Boge GmbH & Co. KG 

Otto-Boge-Str. 1-7 

33739 Bielefeld, Germany 

Tel +49 (5206) 601-0 

Fax +49 (5206) 601-200 

info@boge.com 

www.boge.com 

Hydrogen on the rise – from small 

projects to large-scale plants 

Fig. 2: High pressure safety valves for technical gases up to 1500 bar 

Hydrogen has long since become our focus. Initially, we supplied fittings 

for small projects, but now we also supply large plants. 

The initial situation is clear: a way is needed to make electricity from 

renewable sources storable. The technology required for this ranges 

from electrolysis to pure hydrogen and oxygen to the production of 

ammonia and synthetic hydrocarbon compounds produced with PtX 

processes. Fittings are needed for all these processes. 

Well prepared 

We are well prepared and have qualified our product range for use 

with the medium hydrogen. This ranges from specific material testing 

to the fulfilment of special standards for seals. Especially for the application 

for storing high-pressure hydrogen, we have significantly expanded 

the possibilities in production with new test benches. 

As a manufacturer of safety valves, pressure reducing valves and 

overflow valves, Goetze products are used in almost all areas of the 

hydrogen value chain - from generation via electrolysis or other thermal 

processes and via storage at high pressures or cryogenic liquefied 

up to the point-of-use at the end user. We regulate the pressure before 

electrolysis, secure the feedwater pump circuit and ultimately the 

tanks for storing the hydrogen against impermissible overpressure. 

Employees already trained 

The hydrogen industry needs suitable fittings, for which certain materials 

are to be used. We focus in particular on stainless steels with a higher 

nickel content, for example, to prevent hydrogen embrittlement. For 

seals, compliance with certain standards is important. The very small 

H 2 

molecule can accumulate in sealing materials, penetrate them and 

destroy them from the inside. The seal must therefore be manufactured 

and specially tested with this in mind. 

We do not see the use of hydrogen as a challenge, but rather the way 

to get there, in order to have it widely available as quickly as possible. Internally, 

we are looking at proven designs that we can improve and optimise 

for hydrogen applications and realise with high-quality, tested materials. 

Our employees have already been trained on this topic. 

Valves get bigger 

As a company, we are globally positioned, but we see a focus in Europe, 

due to the lack of gas from Russia. 

Like the markets, the hydrogen projects are also growing. While 

pressures of up to 350 bar were common in the past, the valves are 

now required for significantly higher pressures, e. g. protection against 

overpressure in vehicle refuelling systems for 700 bar. Here, our Goetze 

valves protect the system components at up to 960 bar. We could 

go even higher. An end? Not in sight... 

Goetze KG Armaturen 

Robert-Mayer-Str. 21 

71636 Ludwigsburg, Germany 

Tel +49 (7141) 488 946-0 

Fax +49 (7141) 488 9488 

info@goetze-armaturen.de 

www.goetze-group.com 


87



Compact performers – BAUER’s new 

BM Medium Pressure Series NB 

The new BM Series from BAUER KOMPRESSOREN is the perfect combination 

of performance and compact design. With free air delivery 

from 620 to 7200 l/min and power rating from 11 to 132 kW, these aircooled 

directly coupled systems serve an enormously broad range of 

applications. 

They deliver pressures of up to 40 bar for the two-stage models, and 

100 bar for the three-stage models. A suite of optional features is available 

including compressor control unit, pressure and temperature 

monitoring system for all compressor stages, and air and gas purification 

systems. This allows bespoke configurations to be tailored to customers’ 

individual needs. 

Like all BAUER systems, the BM series is synonymous with ultimate 

ruggedness and reliability in even the toughest environments, making 

these compressors the ideal choice for difficult application scenarios. 

And their extra-low operating costs, with minimum oil consumption 

and long maintenance cycles, are particularly attractive to compressor 

operators. 

The BM Series’ extensive features and capabilities open up a virtually 

unlimited range of applications for their users. With compact footprint, 

low centre of gravity and ability to operate at extreme angles up 

to 30°, they are perfect for marine and offshore scenarios. DNV approval 

is naturally possible. 

BAUER KOMPRESSOREN GmbH 

Stäblistr. 8 

81477 München, Germany 

Tel +49 (89)78049-0 

Fax +49 (89)78049-167 

industrie@bauer-kompressoren.de 

www.bauer-kompressoren.de 

It's time to shake hands again... 

After the last “virtual” edition of Hannover Messe, the event will once 

again take place in presence in one of the most prestigious Exhibition 

Centers in Europe. Some of the most important players in the compressed 

air technology sector will meet again to take stock of the situation 

on market developments and future prospects. 

With this in mind, Logika Control will be on stage with new products 

and even more “smart” applications. What better opportunity to concretely 

show the potential and reliability of LogiTronik series electronic 

controllers, whose continuous evolution allows to fully meet the requirements 

of the most important compressor manufacturers (OEM) 

and to facilitate the valuable work of Service Centers. 

In addition to all standard functions of electronic controllers 

and control units for monitoring compressed air production plants, 

LogiTronik range is set up as an appropriate tool for reducing energy 

consumption. Developed to ensure maximum machine performance 

and plant efficiency, they now also have a consumption detector that 

provides reliable data on actual energy usage. 

Logika Control enters the App Stores 

Next edition of Hannover Messe will be the springboard for LogikAir, 

the new App developed by R&D Department of Logika Control, which 

allows to have the full of LogikaCloud system at your smartphone. A 

multi-purpose tool that supports users with all the essential functions 

for monitoring and managing air compressors and that let devices to 

be interconnected in complete comfort and safety. 

LogikAir is also able to autonomously set up the maintenance calendar 

(Predictive Maintainance) according to the operation parameters 

of the machines and the relative wear level. Thanks to the integration 

with Android and iOS navigation systems, LogikAir sets the optimal 

route to reach the plant to be maintained. 

LogikAir will soon be available on Apple Store and on Google Play 

Store: a new milestone for Logika Control which reconfirms its leading 

role in the sector. 

Logika Control Srl 

Via Garibaldi, 83A 

20834 Nova Milanese (MB), Italy 

Tel +39 (362) 3700-1 

Fax +39 (362) 3700-30 

info@logikacontrol.it 

www.logikacontrol.it 




ChemBall - A revolution in PFA-lined 

ball valves 

The PFA-lined ball valve ChemBall is the new flagship of the Swiss company 

ChemValve-Schmid AG. The TrueFloat ® technology, developed 

in-house and patented worldwide, is revolutionary and strict on-site 

production ensures that this ball valve always bears the hallmark 

“Swiss Made”. 

ChemValve-Schmid AG, based in Welschenrohr, Solothurn is synonymous 

with insourcing instead of outsourcing. The independently 

owned company is a leading European manufacturer of PTFE-lined 

butterfly valves. Continuous research and development is the driving 

force behind the company and its production, the most recent example 

being the ChemBall. 

Maiden voyage of the flagship 

The first prototypes of the ChemBall were delivered to a European textile 

fibre manufacturer in October 2020 in a unique venture. After a 

two-year test phase, the product specification was successfully completed. 

Today, the ChemBall is also on sale throughout North America 

and Asia. 

PFA-lined ball valve ChemBall 

The PFA-lined ball valve ChemBall is based on the TrueFloat ® technology 

developed and patented in-house. Specifically, this means that a 

single-piece PFA jacket encloses the floating ball stem, which is able to 

move within itself. The ball is suspended by means of a metal-to-metal 

connection, which eliminates wear. The result is maximum tightness 

combined with an extended service life. The valve can be used in temperatures 

ranging from -20° C to 200° C. Whereas development and 

production initially focused in particular on the chlor-alkali industry, 

the further-developed ChemBall is ideal for use with all types of aggressive 

media. 

The ball valve is currently available in the EN sizes DN 25, 40, 50, 

80, 100 and 150 and in the ASME nominal diameters 1″, 1-1/2″, 2″, 3″, 

4″ and 6″. In the first half of 2023, the product range will be expanded 

to include the nominal diameters DN 15, 20, 32 and 65. 

Swiss-made for shorter paths to success 

ChemValve-Schmid AG has outstanding expertise in PFA manufacturing. 

Dedicated PFA-injection-moulding machines have been specially 

developed for the production of these unique valves. Both metal and 

PTFE valves, such as the ChemBall, are developed, produced, tested 

and prepared for shipping in Dünnernstrasse 540, Welschenrohr, 

Switzer land. “We are a down-to-earth team, the decision-making process 

is short, and people find it easy to talk to us” says the managing director, 

Christoph Schmid. Despite a high workload, it only takes a short 

space of time from the quotation stage to production. The standard 

delivery time is four weeks. Every PFA ball valve and every PTFE butterfly 

valve from ChemValve-Schmid AG is given a unique “valve ID” so 

that it can still be clearly identified years later. Every product test and 

certificate is fully traceable. 

Join the Valve Revolution! Now! 

The declared objective of ChemValve-Schmid AG is to increase its presence 

in the German market. “As a medium-sized Swiss company that 

develops and produces valves itself, we are on the lookout for trade 

partners as well as end users. We welcome every contact” says Managing 

Director Christoph Schmid. He has been on board for around 17 

years now, but the flagship, the ChemBall, is new. 

ChemValve-Schmid AG 

Dünnernstr. 540 

4716 Welschenrohr, Switzerland 

Tel +41 (32) 639 5010 

sales@chemvalve-schmid.com 

www.chemvalve-schmid.com 

New BioPure braided hose assemblies 

offer a total solution for bulk fluid 

transfer in critical bioprocess fluid 

transfer applications 

Watson-Marlow Fluid Technology Solutions (WMFTS) has launched 

BioPure Braided Hose assemblies as an end-to-end solution for companies 

requiring fitting, hose, assembly and testing. 

Providing a safe, reliable and repeatable method of high-pressure fluid 

transfer, braided silicone hose assemblies combine BioPure platinumcured 

silicone hose fitted with biopharmaceutical grade stainless steel 

tri-clamp connections. 

Biopharmaceutical and pharmaceutical companies can reduce 

supply chain risk and ensure quality control with the WMFTS total offering 

of hose assemblies designed for bulk fluid transfer and repeat 

use by autoclave sterilisation. With testing and assembly centres in the 

United States and the United Kingdom, the hose assemblies meet USP 

Class VI standards with 316 Stainless Fittings and an SF4 surface finish. 

Mark Lovallo, Product Manager – Fluid Path – WMFTS, said: 

“Watson-Marlow is one of the only suppliers that produces biopharmaceutical 

grade silicone hose and machines stainless hygienic fittings 

in-house. With decades of experience in silicone extrusion, CNC 

machining and hose assembly and testing, Watson-Marlow provides 

a unique opportunity for end-users to minimise supply chain risk and 

source silicone hose assemblies from a trusted supplier.” 


89



Photo © : Watson-Marlow Fluid Technology Solutions 

The hose assemblies are made to custom lengths and come with a permanently 

crimped stainless steel triclamp style fitting. All hose assemblies 

are pressure tested to check and confirm hose integrity. 

The SAUER Orkan series is suitable for the compression of many gases 

and a variety of applications. The first standard types of the series are 

two high-pressure air compressors with a final pressure of up to 350 and 

500 barg respectively, a high-pressure helium compressor with a final 

pressure of up to 350 barg, and a high-pressure nitrogen booster with 

a final pressure of up to 350 barg and an inlet pressure of 4 to 8 barg. 

Next to developing completely new compressor platforms Compressors 

focuses on the enhancement and expansion of existing compressor 

series. The air-cooled series SAUER Hurricane is a good example 

for that. The new nitrogen boosters SAUER Hurricane WP4366LH 

B3-8 and WP4399LH B3-8 provide a final pressure of up to 350 barg 

and an inlet pressure of 3 to 8 barg. They are specially designed for the 

compression of nitrogen and are based on the robust platform of the 

series, that has proven itself under toughest operating conditions for 

years. The new launches complement Sauer Compressors’ portfolio of 

gas compressors, also including oil-free, dry-running and hermetically 

gas-tight types of the HAUG product line, which will be exhibited at the 

fair as well. 




Tel +44 (1326) 370370 


www.wmfts.com 

Sauer Compressors presents new 

gas compressors 

Sauer Compressors traditionally invests in new compressor concepts, 

and this way constantly expands its product portfolio. At this year’s 

Hannover Messe/Compressed Air & Vacuum the company introduces 

several new types of gas compressors. The first standard types of the 

SAUER Orkan series will celebrate their premieres. Furthermore, expansions 

of the trusted SAUER Hurricane series will be shown. (Hannover 

Messe, 17 - 21 April, Hall 4, stand D07) 

Sauer Compressors developed the new gas compressors in close cooperation 

with partners and customers to ensure that they are perfectly 

designed for current and upcoming requirements of the gas industry. 

Fig. 2: The SAUER Hurricane series is already the 3 rd generation of air-cooled 

SAUER high-pressure compressors for industry and is located directly below the 

new SAUER Orkan series in the performance range. (Photo © : Sauer Compressors) 

One-stop-shop for complete compressor systems 

Sauer Compressors furthermore constantly expands its selection of 

accessories for high-pressure applications, like refrigerant dryers, adsorption 

dryers, and gas cylinder bundles. The self-developed, intelligent 

compressor control system Sauer ecc 4.0 is one of those. The 

compressor manufacturer from the north of Germany provides the 

industry with individually designed complete solutions. The portfolio 

ranges from compressor systems on base frames over complete systems 

compiling high-pressure compressors including gas processing, 

storage, and distribution to complex ATEX compliant hydrogen plants 

for the space industry. 

Second fair presence regarding hydrogen 

Sauer Compressors will also be present with a stand at Hydrogen + 

Fuel Cells Europe. At this occasion the company will show its newest 

solutions for the hydrogen industry from the product lines SAUER and 

HAUG. (Hall 13, stand D43/1) 

Fig. 1: The high-pressure compressors of the SAUER Orkan series are suitable for 

many gases and applications. (Photo © : Sauer Compressors) 

J.P. Sauer & Sohn 

Maschinenbau GmbH 

Brauner Berg 15 

24159 Kiel, Germany 

Tel +49 (431) 3940-0 

Fax +49 (431) 3940-24 

info@sauercompressors.de 

www.sauercompressors.com 



2023 

Water Wastewater Environmental Technology 

Energy Oil Gas Hydrogen 

Automotive 

Shipbuilding Heavy Industry 

Chemistry Pharmaceutics Biotechnology 

Food and Beverage Industry 

ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 



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Technical Data Purchasing >>> 

Independent magazine for Pumps, Compressors and Process Components 

91

Pumps 

Range of applications/Applications 

Manufacturers/Suppliers 

Agricultural technology 

Automobile industry 

Beverage industry 

Biochemistry 

Breweries 

Building services engineering 

Chemical industry 

Construction industry 

Cosmetics industry 

Dairy farming 

Dosing technology 

Drainage 

Electrical industry/Information industry 

Emptying 

Energy industry 

Environmental engineering 

Filling technology 

Fire extinguishing/foaming agent dosing technlogy 

Food technology and bioprocess engineering 

Fountains/Sprinkler systems/Irrigation 

Gas drying 

Gas scrubber 

Geothermics 

Groundwater technology/Wells 

Heat transfer systems 

Heating and house technology 

High-pressure cleaning and descaling 

Atlas Copco Gas and Process 

Schlehenweg 15, 50999 Köln/Germany 

Phone: +49 (0)2236 9650 0 

E-mail: atlascopco.energas@de.atlascopco.com 

Website: www.atlascopco-gap.com 

AxFlow GmbH 

Theodorstr. 105, 40472 Düsseldorf/Germany 

Tel +49 (0)211 238060 

E-mail: info@axflow.de 

Website: www.axflow.de 

BRINKMANN PUMPEN, K.H. Brinkmann GmbH & Co. KG 

Friedrichstr. 2, 58791 Werdohl/Germany 

Phone: +49 (0)2392 5006-0, Fax: +49 (0)2392 5006-180 

E-mail: sales@brinkmannpumps.de 

Website: www.brinkmannpumps.de 


Route de Neuchâtel 36, 2088 Cressier NE/Switzerland 

Phone: +41 32 758 71 11 

E-mail: info@eggerpumps.com 

Website: www.eggerpumps.com 

GRUNDFOS GmbH 

Schlüterstr. 33, 40699 Erkrath/Germany 

Phone: +49 (0)211 92969-0, Fax: +49 (0)211 92969-3799 

E-mail: infoservice@grundfos.de 

Website: www.grundfos.com/de 


Carl-Zeiss-Str. 6-8, 59302 Oelde/Germany 

Phone: +49 (0)2522 76-0, Fax: +49 (0)2522 76-140 

E-mail: mail@hammelmann.de 

Website: www.hammelmann.de 


Jägerweg 5-7, 85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 

E-mail: info@jesspumpen.de 

Website: www.jesspumpen.de 


Salinger Feld 10, 58454 Witten-Annen/Germany 

Phone: +49 (0)2302 8903-0, Fax: +49 (0)2302 801917 

E-mail: info@KAMAT.de 

Website: www.KAMAT.de 

KLAUS UNION GmbH & Co. KG 

POB 101349, 44713 Bochum/Germany 

Phone: +49 (0)234 4595-0, Fax: +49 (0)234 4595-7000 

E-mail: info@klaus-union.com 

Website: www.klaus-union.com 

Leistritz Pumpen GmbH 

Markgrafenstraße 36-39, 90459 Nürnberg/Germany 

Phone: +49 (911) 4306- 9650, Fax: +49 (911) 4306-439 

E-mail: pumps@leistritz.com 

Website: pumps.leistritz.com 

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92

High-temperature engineering 

Horticulture 

Industrial technology 

Injection 

Laboratory technology 

Machine and plant engineering 

Metallurgical plants and Rolling mills 

Mineral oil industry 

Mining, pit and quarry 

Multiphase fluids 

Nuclear and reactor technology 

Odorizers 

Offshore installations 

Oil hydraulics and presses 

Oil production technology 

Osmosis technology 

Paper and pulp industry 

Petrochemical industry 

Pharmaceutical industry 

Pipeline 

Power plant technology 

Precision mechanics and optical industry 

Pressure rise 

Pressure test 

Process engineering 

Process technology 

Public services 

Refrigeration and air conditioning technology 

Seawater desalination 

Sewage technology/Canalisation 

Ship technology/Shipyard 

Steel industry 

Sterile technology 

Swimming pool technology 

Tank systems 

Technical universities 

Textile industry 

Tunnel construction 

Vehicle construction/Aircraft construction 

Viscose and adhesives 

Wastewater treatment plants 

Waterjet cutting 

Water supply/Water technology 

Water treatment 

Woodworking and wood processing 

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93

Pumps 






Biochemistry 

Breweries 

Building services engineering 



Cosmetics industry 

Dairy farming 

Dosing technology 

Drainage 


Emptying 


Environmental engineering 


Fire extinguishing/foaming agent dosing technology 

Food technology and bioprocess engineering 

Fountains/Sprinkler systems/Irrigation 

Gas drying 

Gas scrubber 

Geothermics 

Groundwater technology/Wells 

Heat transfer systems 

Heating and house technology 

High-pressure cleaning and descaling 

LEWA GmbH 

Ulmer Str. 10, 71229 Leonberg/Germany 

Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 

Website: www.lewa.com 

• • • • • • • • 


Geretsrieder Str. 1, 84478 Waldkraiburg/Germany 

Phone: +49 (0)8638 63-0 

E-mail: info.nps@netzsch.com 

Website: www.pumps-systems.netzsch.com 

Pumpenfabrik Wangen GmbH 

Simoniusstr. 17, 88239 Wangen im Allgäu/Germany 

Phone: +49 (0)7522 997-0, Fax: +49 (0)7522 997-199 

E-mail: mail@wangen.com 

Website: www.wangen.com 

SEEPEX GmbH 

Scharnhölzstr. 344, 46240 Bottrop/Germany 

Phone: +49 (0)2041 996-0 

E-mail: info@seepex.com 

Website: www.seepex.com 


Sirchinger Str. 15, 72574 Bad Urach/Germany 

Phone: +49 (0)7125 133-0, Fax: +49 (0)7125 133-202 

E-mail: info@uraca.de 

Website: www.uraca.de 


Holthoege 10-14, 49632 Essen (Oldenburg)/Germany 

Phone: +49 (0)5434 83-0, Fax: +49 (0)5434 83-10 

E-mail: contact@vogelsang.info 

Website: www.vogelsang.info 


Bickland Water Road, Falmouth Cornwall, TR11 4RU, United Kingdom 

Tel +44 (1326) 370 370 

E-mail: info@wmfts.com 

Website: www.wmfts.com 

WOMA GmbH I Kärcher Group 

Werthauser Str. 77-79, 47226 Duisburg/Germany 

Phone: +49 (0)2065 304-0, Fax: +49 (0)2065 304-200 

E-mail: info@woma.kaercher.com 

Website: www.woma-group.com 

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94

High-temperature engineering 

Horticulture 

Industrial technology 

Injection 


Machine and plant engineering 




Multiphase fluids 

Nuclear and reactor technology 

Odorizers 


Oil hydraulics and presses 

Oil production technology 

Osmosis technology 




Pipeline 

Power plant technology 


Pressure rise 

Pressure test 

Process engineering 

Process technology 


Refrigeration and air conditioning technology 

Seawater desalination 




Sterile technology 

Swimming pool technology 

Tank systems 



Tunnel construction 


Viscose and adhesives 


Waterjet cutting 

Water supply/Water technology 

Water treatment 


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95

Pumps 

Type of pumps 


Centrifugal pumps 

Axial flow pumps 

Block pumps 

Channel impeller pumps 

Inline pumps 

Mixed flow pumps 

Pitot tube pumps 

Propeller pumps 

Radial flow pumps 

Side channel pumps 

Standardized pumps 

Vortex pumps 

Rotary positive displacement pumps 

Eccentric screw pumps 

Gear pumps 

Peristaltic pumps 

Rotary lobe pumps 

Screw pumps 

Vane pumps 

Oscillating displacement pumps 

Disposable design 

Hose diaphragm piston pumps 

Hydraulic diaphragm pumps 

Mechanical diaphragm pumps 

Piston/Plunger pumps 



Phone: +49 (0)2236 9650 0 



AxFlow GmbH 


Tel +49 (0)211 238060 





Phone: +49 (0)2392 5006-0, Fax: +49 (0)2392 5006-180 





Phone: +41 32 758 71 11 



GRUNDFOS GmbH 


Phone: +49 (0)211 92969-0, Fax: +49 (0)211 92969-3799 


Website: www.grundfos.de 



Phone: +49 (0)2522 76-0, Fax: +49 (0)2522 76-140 





Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 





Phone: +49 (0)2302 8903-0, Fax: +49 (0)2302 801917 





Phone: +49 (0)234 4595-0, Fax: +49 (0)234 4595-7000 





Phone: +49 (911) 4306- 9650, Fax: +49 (911) 4306-439 



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96

Drive concept Design features Conveyed media Services 

Canned motor 

Combustion engine 

Hydraulic drive 

Linear motor 

Magnetic rotor 

Pneumatic drive 

Stepper motor 

Submersible motor 

Three-phase asynchronous motor 

Abrasion resistant 

Hermetically/Leakage-free 

High-temperature applications 

Hygienic design 

Nickel-based materials 

Plastic/Plastic lining 

Rubberized 

Self-priming 

Special materials 

Stainless steels 

Suction aid (Priming aid) 

Biomaterials/Foodstuffs 

Boiler feed water 

Brackish water 

Chemicals/Acids/Alkaline solutions 

Concrete/Mortar/Cement 

Condensate 

Coolant 

Faeces/Liquid manure 

Fish 

Fuel 

Heating oil 

Oils/Greases/Lubricants 

Water/Waste water 

Installation and commissioning 

Maintenance, service and repair 

Status and demand analysis 

Support and project engineering 

Training and instruction 

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97

Pumps 

Type of pumps 




Block pumps 


Inline pumps 







Vortex pumps 



Gear pumps 



Screw pumps 

Vane pumps 







LEWA GmbH 


Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 

Website: www.lewa.de 

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Phone: +49 (0)8638 63-0 





Phone: +49 (0)7522 997-0, Fax: +49 (0)7522 997-199 



SEEPEX GmbH 


Phone: +49 (0)2041 996-0 



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Phone: +49 (0)7125 133-0, Fax: +49 (0)7125 133-202 



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Phone: +49 (0)5434 83-0, Fax: +49 (0)5434 83-10 





Tel +44 (1326) 370 370 



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Phone: +49 (0)2065 304-0, Fax: +49 (0)2065 304-200 



• • 

98

Drive concept Design features Conveyed media Services 

Canned motor 

Combustion engine 

Hydraulic drive 

Linear motor 

Magnetic rotor 

Pneumatic drive 

Stepper motor 

Submersible motor 

Three-phase asynchronous motor 

Abrasion resistant 

Hermetically/Leakage-free 

High-temperature applications 

Hygienic design 

Nickel-based materials 

Plastic/Plastic lining 

Rubberized 

Self-priming 

Special materials 

Stainless steels 

Suction aid (Priming aid) 

Biomaterials/Foodstuffs 

Boiler feed water 

Brackish water 

Chemicals/Acids/Alkaline solutions 

Concrete/Mortar/Cement 

Condensate 

Coolant 

Faeces/Liquid manure 

Fish 

Fuel 

Heating oil 

Oils/Greases/Lubricants 

Water/Waste water 






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99

Pumps 

Matrix Power ratings 

Head p [MPa] 

(1 MPa = 10 bar = 

100 mWS) 

< 0,5 < 2,0 < 6,3 < 25,0 > 25,0 

Capacity Q [m3 / h] 

< 1 A F K P V 

< 10 B G L R W 

< 100 C H M S X 

< 500 D I N T Y 

> 500 E J O U Z 




Block pumps 


Inline pumps 







Phone: +49 (0)2236 9650 0 



API 610 

centrifugal 

pumps 

AxFlow GmbH 


Tel +49 (0)211 238060 



A, B, C, 

F, G, H, 

K, L, M 



Phone: +49 (0)2392 5006-0, Fax: +49 (0)2392 5006-180 



A, B, C, 

D, F, G, 

H 

A, B, C, 

D 



Phone: +41 32 758 71 11 



D, E A to O A to O D, E 

GRUNDFOS GmbH 


Phone: +49 (0)211 92969-0, Fax: +49 (0)211 92969-3799 


Website: www.grundfos.de 

0.25 - 630 

kW 

11 - 700 

kW 

0.25 - 200 

kW 

1.1 - 11 

kW 

0.12 - 630 

kW 

11 - 700 

kW 

0.25 - 630 

kW 



Phone: +49 (0)2522 76-0, Fax: +49 (0)2522 76-140 





Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 



A, B, C A, B, C 



Phone: +49 (0)2302 8903-0, Fax: +49 (0)2302 801917 





Phone: +49 (0)234 4595-0, Fax: +49 (0)234 4595-7000 



C, D, E B, C, G, H C, D, E A, B, C, 

D, E, G, 

H, I, J, L, 

M, N, S 



Phone: +49 (911) 4306- 9650, Fax: +49 (911) 4306-439 



100



Vortex pumps 



Gear pumps 



Screw pumps 

Vane pumps 







A, B, C, 

D, F, G, 

H, I, K, 

L, M 

A, B, C, 

D, F, G, 

H, I 

A, B, C, 

F, G, H 

A, B, C, 

D, F, G 

A, B, C, 

D, F, G, 

H, I 

A, B, C, 

F, G, H, 

K, L, M, 

P, R, 

V, W 

A, B, C, 

F, G, H, 

K, L, M, 

P, R, 

V, W 

A, B, C, 

F, G, H, 

K, L, M, 

P, R 

A to J 

0.25 - 630 

kW 

0.25 - 75 

kW 

1.5 - 90 

kW 

0.09 - 2.2 

kW 

0.09 - 1.1 

kW 

0.09 - 2.2 

kW 

on request 

A, B, F, 

G 

A, B, C, 

F, G 

A, B, F, G A, B, C, F, 

G, H 

K, L, M, 

N, P, R, 

S, T, V, 

W, X, Y 

A, B, C, 

F, G,H, 

L, M 

B, C, D, 

G, H, I 

C, D, E, 

H, I, J, 

M, N, O, 

S, T, U 

A-V 

and 

E-Z 

101

Pumps 

Matrix Power ratings 

Head p [MPa] 

(1 MPa = 10 bar = 

100 mWS) 

< 0,5 < 2,0 < 6,3 < 25,0 > 25,0 

Capacity Q [m3 / h] 

< 1 A F K P V 

< 10 B G L R W 

< 100 C H M S X 

< 500 D I N T Y 

> 500 E J O U Z 




Block pumps 


Inline pumps 





LEWA GmbH 


Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 




Phone: +49 (0)8638 63-0 





Phone: +49 (0)7522 997-0, Fax: +49 (0)7522 997-199 



SEEPEX GmbH 


Phone: +49 (0)2041 996-0 





Phone: +49 (0)7125 133-0, Fax: +49 (0)7125 133-202 





Phone: +49 (0)5434 83-0, Fax: +49 (0)5434 83-10 





Tel +44 (1326) 370 370 





Phone: +49 (0)2065 304-0, Fax: +49 (0)2065 304-200 



102



Vortex pumps 



Gear pumps 



Screw pumps 

Vane pumps 







A, B, C, 

F, G, H, 

K, L, M, 

P, R, S, 

V, W, X 

A, B, F, 

G 

A, B, C, D, 

F, G, H, I, 

K, L, M,N, 

P, R, S, T, 

V, W, X, Y 

Up to 

1.000 

m 3 /h 

up to 

240 bar 

Up to 

21 m 3 /h 

up to 

10 bar 

Up to 

1.000 

m 3 /h 

up to 

10 bar 

Up to 

3.000 

m 3 /h 

up to 

160 bar 

A, B, C, D, 

F, G, H, 

K, L, M 

A, B, C, 

D, F, G, 

H, I 

on 

request 

K, L, M, 

N, O, P, 

R, S, T, 

U, V, W, 

X, Y 

K, L, M, 

N, P, R, 

S, T, V, 

W, X, 

K, L, M, 

N, O, P, 

R, S, T, 

U, V, W, 

X, Y 

U 

U 

A, B, C A, B, C, 

D, F, G, 

H, I 

K, L, M, 

N, P, R, 

S, V, 

W, X 

103






Beam conducting systems 


Biotechnology 

Ceramic industry 


Clamping devices 

Coating 

Conveying/Materials handling 

Distillation in the fine vacuum range 

Distillation in the low vacuum range 

Distilling 

Dry freezing 

Drying technology 


Electronics 

Electron microscopy 

Energy technology 


Food preservation and packing 

Foodstuffs, drinks and tobacco industry 

Foundry technology 

Heat treatment 

Hoisting 



Reherweg 28, 31855 Aerzen/Germany 

Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 

E-mail: info@aerzener.de 

Website: www.aerzener.de 


Schauinslandstr. 1, 79689 Maulburg/Germany 

Phone: +49 (0)7622-681-0, Fax: +49 (0)7622-5484 

E-mail: sales@busch.de 

Website: www.buschvacuum.com 


POB 2143, 96410 Coburg/Germany 

Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 

E-mail: produktinfo@kaeser.com 

Website: www.kaeser.com 


Berliner Str. 43, 35614 Asslar/Germany 

Phone: +49 (0)6441-802-0, Fax: +49 (0)6441-802-1202 

E-mail: info@pfeiffer-vacuum.de 

Website: www.pfeiffer-vacuum.com 

• • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • 

104

Vacuum accessories 

Laser technology 

Leak detection 

Low-pressure plasma treatment 

Materials technology 

Mechanical engineering 

Medical technology 

Metal finishing 

Packaging technology 



Plastics industry 

Printing and paper industry 

Refrigeration/Air conditioning technology 

Research institutions 

Space simulation technology 

Space travel 

Spectrometry/Spectroscopy 

Sputtering 


Suction/Exhausting 


Thin layer technology 

Universities 

Vaporising 

Vapour sterilisation 

Ventilating 

Accessories, other 

Analysis devices 

Ball valves 

Chambers 

Cold traps 

Component parts 


Condensers 

Container 

Custom-made devices 

Filters 

Flange components (flanges, seals, cables) 

Leak detectors 

Measurement devices 

Separators/Traps 

Service 

Sound enclosures 

Special components 

Valves 

• • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

105


Vacuum pumps and systems 


Claw-type vacuum pumps 

Cryo-vacuum pumps 

Diaphragm vacuum pumps 

Diffusion vacuum pumps 

Fuel jet vacuum pumps 

Gas ring vacuum pumps (Side channel blower) 

Getter pumps 

Liquid ring vacuum pumps 

Pressure vacuum pumps 

Reciprocating vacuum pumps 

Roots vacuum pumps 

Rotary piston vacuum pumps 

Rotary vane vacuum pumps, dry-running 

Rotary vane vacuum pumps, fluisealed 

Screw vacuum pumps (Helicoidal gear vacuum pumps) 

Scroll vacuum pumps 

Slide vane rotary vacuum pumps 

Steam ejectors 

Turbomolecular vacuum pumps 

Vacuum systems 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 





Phone: +49 (0)7622-681-0, Fax: +49 (0)7622-5484 





Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 





Phone: +49 (0)6441-802-0, Fax: +49 (0)6441-802-1202 



• 

• • • • • • • • • • • • • 

• • 

• • • • • • • 

106

Vacuum pumping stations 

Services 

Diffusion pumping stations 

Roots vacuum pumping stations with dry-running backing pump 

Roots vacuum pumping stations with fluisealed backing pump 

Special pumping stations chemical applications 

Special pumping stations customer-specific designs 

Special pumping stations helium leak detection 

Special pumping stations HV and UHV design 

Turbomolecular pumping stations with dry-running backing pump 

Turbomolecular pumping stations with fluisealed backing pump 






• • • • • • • • • • • • • 

• • • 

• • • • • • • • • • • • • 

107


Power Ratings 

Key for pressure range 

Coarse vacuum 1000 mbar – 1 mbar A 

Fine vacuum 1 mbar – 10 -3 mbar B 

High vacuum 10 -3 mbar – 10 -7 mbar C 

Ultra-high vacuum < 10 -7 mbar D 


Claw-type vacuum pumps 

Cryo-vacuum pumps 

Diaphragm vacuum pumps 

Diffusion vacuum pumps 

Fuel jet vacuum pumps 

Gas ring vacuum pumps (Side channel blower) 

Getter pumps 

Liquid ring vacuum pumps 

Pressure vacuum pumps 

Reciprocating vacuum pumps 

Roots vacuum pumps 

Rotary piston vacuum pumps 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 



A, B, C 



Phone: +49 (0)7622-681-0, Fax: +49 (0)7622-5484 





Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 





Phone: +49 (0)6441-802-0, Fax: +49 (0)6441-802-1202 



A C A A A A,B 

A, B A, B, C 

A 

108

Rotary vane vacuum pumps, dry-running 

Rotary vane vacuum pumps, fluisealed 

Screw vacuum pumps (Helicoidal gear vacuum pumps) 

Scroll vacuum pumps 

Slide vane rotary vacuum pumps 

Steam ejectors 

Turbomolecular vacuum pumps 

Vacuum systems 

Diffusion pumping stations 

Roots vacuum pumping stations with dry-running backing pump 

Roots vacuum pumping stations with fluisealed backing pump 

Special pumping stations chemical applications 

Special pumping stations customer-specific designs 

Special pumping stations helium leak detection 

Special pumping stations HV and UHV design 

Turbomolecular pumping stations with dry-running backing pump 

Turbomolecular pumping stations with fluisealed backing pump 

Chambers 


Leak detectors 

Measurement devices 

A A, B A, B A, B A, B C on request 

on request 

on request 

on request 

on request 

on request 

on request 

on request 

on request 

A 

A, B A, B A, B C, D A, B, C, 

D 

A, B, C A, B, C A, B A, B, C, 

D 

A, B, C, 

D 

C, D C, D C, D on request 

on request 

A, B, C, 

D 

A, B, C, 

D 

109

Compressors 





Biogas 

Biotechnology 

Blast-furnace blowers 

Blasting technology 

Brewery technology 

Bulk transport 


Cleaning (blowing out) 

Coke oven technology 

Compensating air 

Compressed air tools 


Control air 

Conveying air 

Drying 



Fertiliser industry 


Foodstuffs, drinks and tobacco industry 

Foundries 

Garage equipment/Tool drive 

Garage technology 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 





Phone: +49 (0)2236 9650 0 




Stäblistr. 8, 81477 München/Germany 

Phone: +49 (0)89 78049-0, Fax: +49 (0)89 78049-167 

E-mail: industrie@bauer-kompressoren.de 

Website: www.bauer-kompressoren.de 

BOGE KOMPRESSOREN Otto Boge GmbH & Co. KG 

Otto-Boge-Straße 1-7, 33739 Bielefeld/Germany 

Phone: +49 (0)5206 601-0, Fax +49 (0)5206 601-200 

E-mail: info@boge.com 

Website: www.boge.com 



Phone: +49 (0)7622-681-0, Fax: +49 (0)7622-5484 





Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 



• • • • • • • • • • • • • • • • • • • • 

• • • • 

• • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • 

• • • • • 

• • • • • • • • • • • • • • • • • • • 

110

Gas compressor helium 

Gas compressor nitrogen 

Gas transport 

General factory air 

Harbour basins 

Heat recovery 


Lifting/Clamping 

Machinery and plant engineering 

Manual operation 

Medical technology 




Natural gas industry 


Oil field 

Oil firing blowers 

Packaging (exclusive foodstuffs) 

Paint coating units 

Paint spraying technology 



Petrol stations 


Pneumatic delivery blowers 

Powder coating 


Printing industry 


Refinery 

Sand blasting 



Silo technology 

Starting of motors/Engines 

Switchgears 



Trade 


Ventilation of instruments 


Wind tunnel 


• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

111

Compressors 

Type of compressors 


Axial compressors 

Booster, dry-running 

Booster, fluilubricated 

Breathing air compressors 

Construction compressors 

Dental compressors 

Diaphragm compressors 

Gas compressors 

Liquid ring compressors 

Piston compressors, dry-running 

Piston compressors, fluilubricated 

Portable screw compressors, fluicooled 

Portable screw compressors, fluifree compression 

Roots compressors 

Rotary gear compressor 

Rotary piston blowers 

Rotary vane compressors 

Rotary vane compressors, dry-running 

Rotary vane compressors, fluilubricated 

Screw compressors, dry-running 

Screw compressors, fluilubricated 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 



• • • • • • • • 



Phone: +49 (0)2236 9650 0 





Phone: +49 (0)89 78049-0, Fax: +49 (0)89 78049-167 



• • • • • 



Phone: +49 (0)5206 601-0, Fax +49 (0)5206 601-200 





Phone: +49 (0)7622-681-0, Fax: +49 (0)7622-5484 





Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 



• • • • • • 

• • • • • • • • • • 

112

Conveyed media 

Services 


Side channel compressors 

Small and very small compressors 

Turbo chargers 

Turbo compressors, axial 

Turbo compressors, radial 

Turbo compressors, radial/axial 

Acetylene 

Ammonia 

Breathing air 

Carbonic acid 

Chloric gas 

Compressed air 

Ethylene 

Gases, other 

Helium 

Hydrogen 

Natural gas 

Nitrogen 

Oxygen 

Synthesis gas 

Vapour 






• • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • 

• • • • • • • • 

• • • • • • • • • • 

• • • • • • • • • • 

113

Compressors 

Power Ratings 

Key for volume flow and pressure 

Volume V 

m 

[ ] 

3 

min 

 

Pressure [in bar] 0–0,2 0,2–5 5–20 20–100 > 100 

0 – 2 A B C D E 

2 – 10 F G H I J 

10 – 25 K L M N O 

25 – 50 P Q R S T 

> 50 U V W X Y 


Axial compressors 



Breathing air compressors 

Construction compressors 

Dental compressors 


Gas compressors 

Liquid ring compressors 



Portable screw compressors, fluicooled 



Phone: +49 (0)5154-81-0 

Fax: +49 (0)5154-81-9191 



E, J, O, 

T 



Phone: +49 (0)2236 9650 0 





Phone: +49 (0)89 78049-0 

Fax: +49 (0)89 78049-167 



25-500 

bar 

1,1-315 

kW 

Motorpower 

25-500 

bar 

1,1-315 

kW 

Motorpower 

25-500 

bar 

1,1-315 

kW 

Motorpower 

25-500 

bar 

1,1-315 

kW 

Motorpower 



Phone: +49 (0)5206 601-0 

Fax +49 (0)5206 601-200 



5.5 

up to 

11 kW 

5.5 

up to 

18.5 kW 

0.75 

up to 

30 kW 

0.75 

up to 

30 kW 

5.5 

up to 

18.5 kW 

0.75 

up to 

11 kW 

0.65 

up to 

18.5 kW 



Phone: +49 (0)7622-681-0 

Fax: +49 (0)7622-5484 



B, C 



Phone: +49 (0)9561-640-0 

Fax: +49 (0)9561-640-130 



G, H, L, 

M, Q, R 

G, H, I, 

L, M, N 

F, G F, G, K, 

L, P, Q 

G, H, I, 

L, M, N 

114

Portable screw compressors, fluifree compression 

Roots compressors 


Rotary piston blowers 

Rotary vane compressors 






Side channel compressors 

Small and very small compressors 

Turbo chargers 

Turbo compressors, axial 

Turbo compressors, radial 

Turbo compressors, radial/axial 

B, C, D, 

E 

B, C, D, 

E 

B, C, D, 

E, G, H, 

I, J, M, 

N, O 

G, H, I, 

J, L, M, 

N, O, T 

900 kW Air up to 

30 MW, 

500,000 

m 3 /h; 

PP/PE: 

10 MW, 

65,000 

m 3 /h 

up to 

35 MW, 

208 bar, 

500,000 

m 3 /h 

on 

request 

on 

request 

45 

up to 

355 kW 

2.2 

up to 

315 kW 

4 up to 

30 kW 

0.65 

up to 

1.5 kW 

150 + 

220 kW 

A, B, C, 

D 

B, C A, B, C, 

D 

B B B, C 

on B, C, D, 

request E 

B, C, D, 

E 

H, I G, H, I, 

L, M, N 

D, E 

115

Compressed air technology 

Compressed air production 

Compressed air treatment 







Roots compressors/Rotary piston blowers 







Turbo compressors 

Adsorber (hydrocarbon) 

Adsorption dryer 

Combination dryer (Refrigeration/adsorption dryer) 

Compressed air filter 

Condensation drain and treatment 

Emulsion separator 

Maintenance unit 

Membrane dryer 

Nitrogen generators 

Oil-water separator 

Pressure maintaining systems 

Pressure vessels 

Refrigeration dryer 

Water separator 



Phone: +49 (0)5154 81-0, Fax: +49 (0)5154 81-9191 





Phone: +49 (0)89 78049-0, Fax: +49 (0)89 78049-167 





Phone: +49 (0)5206 601-0, Fax +49 (0)5206 601-200 





Phone: +49 (0)9561 640-0, Fax: +49 (0)9561 640-130 



• • • • • • • • • • • 

• • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • 

116

Pressure 

distribution 

Compressed air tools Other Services 

Connection technology 

Hoses 

Pipes/Pipe systems 

Valves 

Workshop equipment 

Clamping/Nailing/Riveting 

Drilling/Screwing 

Grinding/Polishing/Brushing 

Hammering/Chiselling 

Milling/Thread 

Painting/Spraying 

Planing/Filing 

Sandblasting/Purging 

Sawing/Cutting/Separating 

Other Compressed air tools 

Controllers and management systems 

Heat exchangers and aftercoolers 

Heat recovery systems 

Measurement devices (volume flow, pressure, dew point) 

Residual oil content measurement 

Suction filters 






• • • • • • • • 

• • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • 

117


Range of applications 



Biotechnology 

Chemical and process technology 

Containers and tanks 

Conveyor technology 

District heating 

Fluid technology 

Food and beverage industry 

Gas distribution 

Marine and sea engineering 

Pharmaceutical industry and cosmetics 

Pipeline systems and offshore technology 

Power plant technology and energy supply 

Refrigeration and cryo technology 

Solids 

Water production, supply and sewage 

Other industrial applications 

AxFlow GmbH 


Tel +49 (0)211 238060 



C. Otto Gehrckens GmbH & Co. KG 

Gehrstücken 9, 25421 Pinneberg/Germany 

Phone: +49 (0)4101 5002-0, Fax: +49 (0)4101 5002-83 

E-mail: info@cog.de 

Website: www.cog.de 



Phone: +41 32 758 71 11 




Robert-Mayer-Str. 21, 71636 Ludwigsburg/Germany 

Phone: +49 (0)7141 48894-60, Fax: +49 (0)7141 48894-88 

E-mail: info@goetze-armaturen.de 

Website: www.goetze-group.com 


Jaegerweg 5, 85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 





Phone: +49 (0)234 4595-0, Fax: +49 (0)234 4595-7000 



• • • • • • • • • • • • • • • • 

• • • 

• • • • 

• • • • • • • • • • • • • • • • 

• • • • • • • • 

KLINGER GmbH 

RicharKlinger-Str. 37, 65510 Idstein/Germany 

Phone: +49 (0)6126 4016-0, Fax: +49 (0)6126 4016-11 

E-mail: mail@klinger.de 

Website: www.klinger.de 



Phone: +49 (911) 4306- 9650, Fax: +49 (911) 4306-439 



LEWA GmbH 


Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 


• • • • • • • 

• • • • • • • • • 

118

Industrial valves 

Valves 

Automatic valves 

Check valves, lift type 

Heavy duty valves 

Outlet valves for vessels 

Plastic valves 

Regulators and control valves 

Shut-off valves 

Special valves 

Stainless steel valves 

Angle seat valves 

Bellow-type valves 


Compressed air valves 

Control valves 

Cryogenic valves 

Diaphragm valves 

Drain and vent valves 

Float valves 

Hydraulic valves 

Magnetic valves 

Monoflange valves 

Multiway valves 

Needle valves 

Pinch valves 

Piston valves 

Pressure control valves 

Pressure reducing valves 

Safety valves 

Sampling valves 



Steam valves 

Other valves 

• 

• • • 

• • • • • • • 

• • • • • • • • • • • • • 

119


Range of applications 



Biotechnology 

Chemical and process technology 

Containers and tanks 

Conveyor technology 

District heating 

Fluid technology 

Food and beverage industry 

Gas distribution 

Marine and sea engineering 

Pharmaceutical industry and cosmetics 

Pipeline systems and offshore technology 

Power plant technology and energy supply 

Refrigeration and cryo technology 

Solids 

Water production, supply and sewage 

Other industrial applications 



Phone: +49 (0)6441 802-0, Fax: +49 (0)6441 802-1202 



• • • • • • • • • • • • • • 



Tel +44 (1326) 370 370 



Zwick Armaturen GmbH 

Egerstr. 1 & 25, 58256 Ennepetal/Germany 

Phone: +49 (0)2333 9856-5, Fax: +49 (0)2333 9856-6 

E-mail: info@zwick-gmbh.de, 

Website: www.zwick-armaturen.de 

• • • • • • • • 

120

Industrial valves 

Valves 

Automatic valves 


Heavy duty valves 

Outlet valves for vessels 

Plastic valves 

Regulators and control valves 



Stainless steel valves 

Angle seat valves 

Bellow-type valves 


Compressed air valves 

Control valves 

Cryogenic valves 

Diaphragm valves 

Drain and vent valves 

Float valves 

Hydraulic valves 

Magnetic valves 

Monoflange valves 

Multiway valves 

Needle valves 

Pinch valves 

Piston valves 

Pressure control valves 

Pressure reducing valves 

Safety valves 

Sampling valves 



Steam valves 

Other valves 

• • • • • • • • • • • 

• • • 

• • • • • • 

121


Components and assemblies 

Butterfly/Gate valves 


Compensators 

Condensate separators 

Couplings 

Filters 

Gear drives 

Pipelines and hoses 

Pipe fittings 


Seals and seals systems, dynamic 

Seals and seals systems, static 

Separators 

Sight glasses 

Other accessories 

Backflow flaps 

Butterfly control valves 

Butterfly valves, shut-off 

Check valves, swing type 

Gate valves, shut-off 

Knife-gate valves 

Slide valves 

C. Otto Gehrckens GmbH & Co. KG 

Gehrstücken 9, 25421 Pinneberg/Germany 

Phone: +49 (0)4101 5002-0, Fax: +49 (0)4101 5002-83 

E-mail: info@cog.de 

Website: www.cog.de 

• • 



Phone: +41 32 758 71 11 




Robert-Mayer-Str. 21, 71636 Ludwigsburg/Germany 

Phone: +49 (0)7141 48894-60, Fax: +49 (0)7141 48894-88 

E-mail: info@goetze-armaturen.de 

Website: www.goetze-group.com 


Jaegerweg 5, 85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 





Phone: +49 (0)234 4595-0, Fax: +49 (0)234 4595-7000 



KLINGER GmbH 

RicharKlinger-Str. 37, 65510 Idstein/Germany 

Phone: +49 (0)6126 4016-0, Fax: +49 (0)6126 4016-11 

E-mail: mail@klinger.de 

Website: www.klinger.de 

• • • • 

• 



Phone: +49 (911) 4306- 9650, Fax: +49 (911) 4306-439 



LEWA GmbH 


Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 




Phone: +49 (0)6441 802-0, Fax: +49 (0)6441 802-1202 



• • • • • • • • • • • • 

122

Ball and plug valves Actuators and positioners Measuring-Control technology/Sensors Other 

Ball valves 

Cylindrical plug valves 

Floor drain ball valves 

Multiway ball valves 

Plug valves 

Sampling ball valves 

Actuator accessories 

Actuators 

Control actuators 

Electrical actuators 

Electropneumatically and electrohydraulically positioners 

Hydraulic actuators 

Manual actuators 

Pneumatic actuators 

Underwater actuators 

Other actuators 

Analysis 

Condition monitoring 

Electronic monitoring and control 

Fill level 

Flow 

Function monitoring 

Gas leakage 

Humidity 

Pressure 

Residual oil vapour 

Temperature 

Commissioning 

Planning/Engineering 

Services/Maintenance 

Training/Instruction 

• 

• • • 

• • • 

• • • • 

• • • • • • • • • • • • • • 

123


Components and assemblies 

Butterfly/Gate valves 


Compensators 

Condensate separators 

Couplings 

Filters 

Gear drives 

Pipelines and hoses 

Pipe fittings 


Seals and seals systems, dynamic 

Seals and seals systems, static 

Separators 

Sight glasses 

Other accessories 

Backflow flaps 

Butterfly control valves 

Butterfly valves, shut-off 

Check valves, swing type 

Gate valves, shut-off 

Knife-gate valves 

Slide valves 



Tel +44 (1326) 370 370 



• 

Zwick Armaturen GmbH 

Egerstr. 1 & 25, 58256 Ennepetal/Germany 

Phone: +49 (0)2333 9856-5, Fax: +49 (0)2333 9856-6 

E-mail: info@zwick-gmbh.de, 

Website: www.zwick-armaturen.de 

• • • 

124

Ball and plug valves Actuators and positioners Measuring-Control technology/Sensors Other 

Ball valves 

Cylindrical plug valves 

Floor drain ball valves 

Multiway ball valves 

Plug valves 

Sampling ball valves 

Actuator accessories 

Actuators 

Control actuators 

Electrical actuators 

Electropneumatically and electrohydraulically positioners 

Hydraulic actuators 

Manual actuators 

Pneumatic actuators 

Underwater actuators 

Other actuators 

Analysis 

Condition monitoring 

Electronic monitoring and control 

Fill level 

Flow 

Function monitoring 

Gas leakage 

Humidity 

Pressure 

Residual oil vapour 

Temperature 

Commissioning 

Planning/Engineering 

Services/Maintenance 

Training/Instruction 

• 

125

Brand name register 

ABEL GmbH 

Abel-Twiete 1 

21514 Büchen/Germany 

Phone: +49 (0)4155 818-0 

Fax: +49 (0)4155 818-499 

E-mail: abel-mail@idexcorp.com 

Website: www.abelpumps.com 

ABEL EM - Electromechanical membrane pumps 

ABEL CM - Compact membrane pumps 

ABEL HM - Hydraulic membrane pumps 

ABEL HMT - Hydraulic membrane pumps Triplex<br /

PuK - Process Technology & Components 2023

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