PuK - Process Technology & Components 2024

INSPIRING SUSTAINABLE CONNECTIONS 

+ 

Special Show 

HYDROGEN 

10 - 14 June 2024 

Frankfurt am Main, Germany 

#ACHEMA24 

World Forum and Leading Show 

for the Process Industries 

ACHEMA is the global hotspot for industry 

experts, decision-makers and solution 

providers. Experience unseen technology, 

collaborate cross-industry and connect 

yourself worldwide to make an impact. 

Are you ready? Join now!

Sustainable energy savings 

with heat recovery 

When using rotary screw compressors, boosters and blowers, a considerable portion of the energy generated is lost as heat. However, this doesn’t have 

to be the case: Thanks to innovative heat recovery systems from KAESER KOMPRESSOREN, this heat can be recovered and put to effective use. 

Heat recovery – The right decision 

Energy efficiency: You can significantly reduce your energy costs by recovering recyclable heat. The recovered 

heat can be used to heat spaces, to heat water, or to support industrial processes. You are therefore able to use your 

energy twice and save money at the same time. 

Sustainability: By utilising the recyclable heat from your compressed air supply, you significantly reduce CO2 emissions. 

Heat recovery actively contributes to climate protection and helps your company operate more sustainably. 

Durability: A lower compressor operating temperature means a longer service life. Heat recovery therefore not only 

saves money but also protects your investment. 

Flexibility: Heat recovery systems from KAESER can be adapted to almost any compressor. Whether you already 

have an existing system or wish to install a new one, our innovative technology can be integrated seamlessly. 

Funding opportunities: Government subsidy programmes are available to support energy-efficiency measures. 

Find out about potential funding opportunities and start benefiting today. 

www.kaeser.com

Approx. 5 % Approx. 15 % Approx. 76 % 

Heat dissipation 

from the drive motor 

Heat energy 

recoverable through 

compressed air cooling 

Heat energy 

recoverable through 

fluid cooling 

100 % Approx. 96 % 

Total electrical power 

consumption 

Usable heat 

Approx. 2 % Approx. 2 % Approx. 4 % 

Non-usable heat 

Heat dissipated by the 

compressor into the 

ambient surroundings 

Heat remaining in the 

compressed air 

Heat recovery systems – 

Flexible for every need 

Hot air for space heating: Air-cooled rotary screw compressors, boosters and blowers from KAESER are ideal as 

complete systems to aid heat recovery for space heating and other hot air applications. Direct use of recyclable heat 

via an exhaust air ducting system enables up to 96 % of the total energy input to be recovered and reused. 

Hot water production: KAESER offers heat recovery systems with special heat exchangers for applications requiring 

hot water. Depending on the design, these systems can generate hot water up to 70°C for use as process, service and 

tap water. The indirect use of recyclable heat via heat exchanger systems can utilise up to 76 % of the electrical power 

provided to the compressed air supply. 

This is where heat recovery counts: 

● Feed into central heating systems 

● Hot water for sanitary equipment 

● Drying and sterilisation processes 

● Utility water for the food and beverage industry 

● Service water for the textile industry 

● Process water for the manufacturing industry 

Would you like to learn more about our innovative heat recovery systems? 

Then follow the QR code. 

P-119ED.19/24

Editorial 

Total Cost of Ownership (TCO) 

Dear Readers, 

Up to now, TCO is a term that has primarily been used by manufacturers to define what users of leased products must pay 

the manufacturer per unit of time. I am now expanding the scope of this definition to include the entire technical industry, 

whether rented or purchased. TCO is the total cost (all costs arising) of ownership of a product, including depreciation, 

energy costs, maintenance and repair costs, personnel and spare parts costs, and the necessary peripheral costs such as 

administration and infrastructure. 

But why am I writing about this topic? The countries of Central Europe, and Germany in particular, are undergoing demographic 

change, with baby boomers retiring and younger generations unable to fill the resulting gaps in the labour market. 

Another point concerns the energy supply and the available raw materials. All of which underlines why we, in Europe, 

should be seeking out solutions to boost energy efficiency and remain economically significant without large reserves of 

raw materials. 

Well, it's actually quite simple. We need to improve and streamline everything and make it cheaper, from technology, to 

our energy and resource supply, to administration. In other words, reduce the TCO according to my new definition - and 

preferably with the help of AI. 

If we want to sell our products going forward, they will have to be highly energy efficient with an extended service life, given 

that our competitors can offer existing technology more cheaply. We should feed the raw materials we have back into processes 

and develop processes for them. This suggests a consistent circular economy and using materials more intentionally 

at the same time. Regardless of the personnel costs, this means: Reducing costs while achieving high quality. Whatever 

AI can do to help us, it should: Write letters, analyse data and issue control commands in normal processes. Staff should be 

deployed where control, creativity and sophisticated expertise are required. This could help underpin our future. 

So we’ve selected the articles in this issue to highlight efficiencies in a range of areas and show you how you - too - 

can further streamline your company and products to remain competitive going forward. 

Kind regards, 

Prof. Dr.-Ing. Eberhard Schlücker 

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

PROCESS TECHNOLOGY & COMPONENTS 2024 

5

PROCESS TECHNOLOGY & COMPONENTS 

Editorial Advisory Board 

Editorial Advisory Board 2024 

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 

Andreas Brümmer, born in 1963, studied aerospace engineering at the Technical University of Braunschweig, where he completed 

his doctorate in the field of bird flight at the Institute of Fluid Mechanics. He began his industrial career in 1997 as head 

of the fluid dynamics at the company KÖTTER Consulting Engineers KG. Here he gained experience in the physical analysis and 

elimination of flow-induced vibrations in industrial plants. In 2005, he took over the technical management of the company. 

Since 2006, he has been Professor and Head of the Fluid Technology Department at TU Dortmund University. His research 

focuses on the theoretical and experimental analysis of screw machines both in compressor applications (e.g. refrigeration and 

air compressors, vacuum pumps) and in expander applications (e.g. waste heat utilisation). He also researches pulsating flows 

in the environment of positive displacement machines and centrifugal pumps. He was Vice Dean and Dean of the Faculty of Mechanical Engineering 

from 2008 to 2011 and Senator at TU Dortmund University from 2012 to 2014. He is a reviewer for various international journals, serves on industrial 

advisory boards and scientific committees and is the scientific director of the International Conference on Screw Machines (ICSM), which 

has been held regularly at TU Dortmund University since 1984. 

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. 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. He is currently also the project manager responsible for sustainability at the NETZSCH Group. 

Dipl.-Ing. (FH) Sebastian Oberbeck, Global Energy Manager, 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. From 2009 to 2019, he was 

responsible for development and basic research for backing pumps and systems at Pfeiffer Vacuum GmbH. From 2020 to 2022, he was responsible 

for setting up and managing the Silicon Valley Innovation Center in San Jose, California for Pfeiffer Vacuum North America and took over the 

role of Global Energy Manager at Pfeiffer Vacuum at the beginning of 2023. 

6 PROCESS TECHNOLOGY & COMPONENTS 2024

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Contents 

Title 

SEEPEX optimizes sewage sludge transport in 

the Ruhr region 

Pump monitoringand process expertise for 

sewage treatment plants 

The pump manufacturer Seepex installed its monitoring 

solution in one of the largest wastewater companies in Germany 

– the Ruhrverband – to optimize the transport of sewage sludge. 

The permanent, live monitoring of all parameters during pump 

operation optimizes performance, increases energy efficiency 

and brings a high degree of reliability and predictability to 

maintenance processes. (starting on page 14) 

Contents 

Editorial 

Total Cost of Ownership (TCO) 5 

Leading article 

Efficiency and quality 10 

Cover story 

SEEPEX optimizes sewage sludge transport in the Ruhr region 14 

Pumps and Systems 

High-efficiency pumps 

The best control 18 

Diaphragm metering pumps 

Diaphragm metering pumps prove their worth 

for critical mixing tasks in industrial oligonucleotide production 20 

Progressing cavity pumps 

Battery production in Europe drives pump manufacturers 

to new innovations 26 

Conical progressive cavity pump for demanding 

applications in the industrial and wastewater sectors 38 

Smart factory 

The intelligent path to the Smart Factory: 

How “pain points” become future-proof 

use cases thanks to the cloud 30 

Peristaltic pumps 

“Peristaltic pumps are an economical solution“ 33 

Screw pumps 

Advancing fluid conveyance beyond conventional boundaries 40 

Vacuum technology 

Vacuum systems 

Tracking the Big Bang 42 

Index of Advertisers 52 

Impressum 52 

Companies – Innovations – Products 

Pumps/Vacuum technology 56 

Trade fairs and events 

IFAT Munich 2024 70 

IVS - INDUSTRIAL VALVE SUMMIT 2024 72 

ACHEMA 2024 74 

FILTECH 2024 76 

VALVE WORLD EXPO 2024 77 

DIAM & DDM 2025 78 

Compressors und Systems 

Machine room ventilation 

So that the packages do not run out of air 80 

Biogas backfeed 

Biogas Backfeed in Leoben 86 

Sustainability 

Sustainability on the rise 88 

Heat recovery 

Save money and benefit the environment 90 

Components 

Plant documentation 

Getting started is easier than you think 93 

Frequency converter 

Multilevel technology: What it can do and what it enables 96 

Total cost of ownership 

Energy saving support 100 

Gaskets 

The complete, worry-free package for drinking water 

gaskets with KTW-BWGL conformity 102 

OT security 

OT security must be planned from the outset 104 

Sensors 

Sensors measure axle temperature: 

JUMO continues the success story of the TGV 106 

Drives 

Modern pioneer with a long tradition 108 

Seals 

New sealing options for CIP/SIP processes 110 


Compressors/Compressed air/Components 112 

Technical Data Purchasing 117 

Screw spindle vacuum pumps 

Potential of surface structures for the 

reduction of vacuum gap flows 46 

Repair vs. replace 

When to repair vs. replace your vacuum pump: A guide 53 

8 

PROCESS TECHNOLOGY & COMPONENTS 2024

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Efficiency and quality 


Electricity is going to be our preferred 

form of energy in the future 

since it directly or indirectly 

replaces fossil fuels in everything 

from electric cars to homes and the 

chemical industry. CO 2 

and hydrogen 

are the magic bullets for indirect 

replacement. 

Hydrogen is universal in application 

and produced using electricity, 

while CO 2 

is harmful to our climate 

but will be an important raw material 

in the future. However, this means 

that we will need five to eight times 

more electricity or 10 to 16 times 

more electricity from wind and solar 

than today. This would only be possible 

if photovoltaic and wind power 

plants become far more efficient. 

Otherwise we will not have enough 

room, and resistance from the population 

is often encountered as well. 

We therefore have to import energy. 

Ammonia is no doubt the best 

option since its hydrogen content is 

high (110 Kg/m 3 ) and it only requires 

positive pressure of about 10 bar 

for transportation. The technology 

for recovering the hydrogen is available 

and relatively efficient. Australia 

is promising $1.50 per kilogram of 

hydrogen and the price is currently 

$2.00. Presumably this will be stored 

in ammonia. It will however cost 

more than that by the time it gets to 

us. Investments need to be made in 

production abroad, the construction 

of cargo ships, transportation, port 

receiving systems and the pending 

development of distribution structures 

in Europe. Since ammonia is 

toxic, one cannot expect to pump it 

through pipelines or to use it in municipal 

structures. Gas distribution 

networks in Germany are therefore 

being converted to hydrogen. Hydrogen 

currently costs € 4.55/kg in Germany. 

According to a publication of 

the Wuppertal Institute, hydrogen 

can be produced at lower cost in 

Germany compared to importing it 

in the form of ammonia. This is true 

in particular when the required electricity 

is produced domestically using 

photovoltaics (currently approx. 

8.5 cents/KWh, thus € 2.83/kg). We 

should therefore produce as much 

hydrogen as possible and sensible in 

Europe. This should allow us to meet 

our energy needs in conjunction 

with imports. However, we still have 

a long way to go and may experience 

occasional electricity shortages until 

we get there. There is at least some 

doubt whether energy imports will 

always proceed smoothly due to political 

changes. We should therefore 

turn this threat into an opportunity 

by developing products that are better 

than anything comparable in the 

world. Efficiency in all facets and durability 

are the keys to success. We 

need to build machinery and equipment 

that outperform all others in 

terms of efficiency and service life. 

In the examination of process 

technology, heat suggests itself as 

the focal point for assessing the efficiency 

of machinery (pumps, compressors 

etc.), equipment, electricity, 

materials and overhead. 

Heat energy and heating 

equipment 

Heat is a physical state that we need 

for technical applications and in our 

private life. Unfortunately, heat cannot 

be transported – or only in mobile, 

extremely well insulated heat 

storage vessels (costly). Heat should 

therefore be consumed where it is 

produced and one should always 

strive to maintain it at a high energy 

level where it is used. This means 

that heat dissipation losses should be 

minimised by good insulation or that 

waste heat should be utilised as far 

as possible. Heat flows can also be 

upgraded through compression, vapour 

recompression or heat pumps, 

thereby raising them to higher temperatures. 

In process technology, this means 

using heat cascades or heat upgrading 

methods, for example: 

1) The cold heat flow cools the warm 

flow, the warm flow cools the hot 

flow, and so forth! The hot flow 

can either be transformed back 

into electricity using a Carnot battery 

or the residual heat can be 

used for heating and returned to 

upgrading. 

2) If a flow of warm water is available 

that cannot be used any more, this 

could be provided to neighbours 

for heating or upgraded to reach 

a level that makes it usable again 

(for example, reheating from this 

level or, in case of gases or steam, 

compression or vapour recompression). 

3) If a hot flow is available that cannot 

be used any more, it should 

be stored in a mobile heat storage 

vessel or transformed into electricity 

using a Carnot battery 

4) When heating as well as cooling 

are required, both can be produced 

using a heat pump or the 

heat can be used for cooling generation, 

producing a warmer flow. 

Pumps and compressors 

The choice of a pump depends on 

the type of process used to produce 

a certain product. A rotary pump is 

the best choice when this meets the 

project requirements since it is costeffective 

and robust. However, its efficiency 

factor is poor in case of low 

flow rates or large control ranges. 

This raises the question of costs. The 

costs for a conveying task with a pressure 

increase of 10 bar, a flow rate 

of 10 m 3 /h and an efficiency factor of 

10 % are €19,352 when an electricity 

price of 0.285 cents/KWh is assumed 

10 



Fig. 1: Conveying costs per year (8800 hours) for different pump efficiency factors, sample 

calculation for water at 10 m 3 per hour and 10 bar pressure increase. 

(published industry price). With an efficiency 

factor of 80 %, the costs decrease 

by 88 % to just € 2,418. 

You can easily determine the 

costs for different conveying tasks 

in the table to the right by multiplying. 

For example, the costs double 

when the pressure difference increases 

to 20 bar. The same applies 

for the delivery rate and electricity 

costs. Also note that the motor has to 

be matched to the respective conveying 

task. The motor of a pump with 

a 20 % efficiency factor is about four 

times larger compared to a pump 

with an efficiency factor of 80 %. 

Better efficiency factors for rotary 

pumps can however also be obtained 

through strategic control and regulation 

measures. [Hieninger] 

The efficiency factor of displacement 

pumps is better on average up 

to mid-range delivery rates. Such machines 

are rarely offered beyond that, 

even though they are clearly preferable 

for conveying highly viscous substances, 

higher pressures, or when a 

high dosing accuracy is required. Oscillating 

pumps achieve the highest 

dosing accuracy, often with the highest 

efficiency factor, at up to +- 0.5 %. 

Unfortunately, oscillating pumps 

have the largest footprint as a rule 

and also produce the greatest pulsation. 

Pulsation dampers can usually 

reduce this to a residual pulsation 

of about 1–3 %. This is classified 

as harmless, which is surely incorrect 

since oscillations and pressure 

surges as well as cavitation cause 

wear on pumps and other system elements. 

Choosing the right pump in 

terms of sustainability and service life 

is therefore a key task. 

A pressure surge passes through 

a system at the speed of sound 

(1480 m/s in water) and acts in all directions 

in pipes. It has a lot of force 

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Pressure: 

Flow rate: 

50 – 4000 bar 

0,1 – 200 m³/h 

HAMPRO® HIGH-PRESSURE 

PROCESS TECHNOLOGY 

Hammelmann GmbH 

Carl-Zeiss-Straße 6-8 

D-59302 Oelde 

+49 (0) 25 22 / 76 - 0 

pp@hammelmann.de 

www.hammelmann-process.com


and frequently attacks sensors, expands 

pipes or deforms surfaces. 

This often leads to small relative 

movements between components 

that can degrade the structure. All 

other pumps including rotary pumps 

also cause pulsation, which can even 

be severe under some conditions but 

is usually tolerated. To improve the 

durability of pumps, we need to optimise 

the damping of oscillations and 

surges, and of course prevent cavitation. 

Since such dampers unfortunately 

do not exist yet, this is an engineering 

challenge. 

leading engineering challenges for 

compressors. Leakages may also occur 

depending on the type of gas. 

This is more of an issue the smaller 

the gas molecules are. Hydrogen, for 

example, is being discussed a great 

deal today. Its lubrication properties 

are extremely poor and it gets 

warmer, not colder, when the pressure 

is relieved at the start of the intake 

stroke. A liquid seal is highly suitable 

here but does of course require 

gas purification on the pressure side. 

In view of the energy loss through 

heat and leakage close to a factor of 

Fig. 2: Compression types of compressors: d1 isothermal; d2 polytropic, adiabatic with efficient 

cooling; d3 adiabatic or isentropic; d4 polytropic with additional heat input, e. g. from 

seal friction. 

The efficiency factor of compressors 

is highly dependent on cooling during 

the entire compression process. 

When seal friction occurs in addition, 

this results in polytropic compression 

in which the gas is additionally 

heated beyond compression heating. 

The hotter the gas, the more energy 

is needed for conveying. Heating 

of the gas during intake into the 

working chamber with hot walls is 

also problematic since it reduces the 

intake volume. Compared to isothermal 

compression in which the working 

chamber is cooled, ideally using 

a liquid, polytropic compression consumes 

at least twice the energy. Selecting 

appropriate cooling or perfectly 

separating coolant droplets 

of the internal coolant are thus the 

two, gas purification on the pressure 

side should be amortised quickly. 

The energy demand for a target pressure 

also increases the lower the actual 

intake pressure is. Therefore, 

the pressure loss on the intake side 

should be minimised as far as possible. 

The same applies for the seal 

friction. The area below the curves 

and lines in Figure 2 represents the 

required compression energy. 

The efficiency factor of compressors 

depends on the following aspects: 

1) A lack of effective cooling results in 

adiabatic compression. When relatively 

high seal friction on the piston 

is added, we have polytropic 

compression. The consumption of 

energy is 150 % higher compared 

to isothermal compression. The 

hotter the gas at the end of conveying, 

the more conveying energy. 

2) Gas heating during intake is also 

problematic; compression heating 

results in hot working chamber 

walls. The incoming gas is heated 

and expands during intake. This 

considerably reduces the intake 

volume. 

3) Every piston compressor in the 

classic design has a dead space. 

This is the remaining space at upper 

dead centre, which first has 

to be depressurised on the intake 

stroke before the intake as such 

can begin. When conveying hydrogen, 

it also heats up when the 

pressure is relieved. 

4) The intake with pressure loss 

means that the actual intake pressure 

is lower than the static intake 

pressure. While the difference is 

small as a rule, it nevertheless has 

a negative effect since compression 

starting at a lower pressure 

consumes the most energy per 

compression stroke. 

5) A pressure loss also occurs on the 

pressure side. However, it occurs 

in the upper pressure range and is 

therefore the smallest loss in this 

list. 

6) Leakage on the piston: Depending 

on the gas type and its lubricating 

properties, the seal suffers 

considerable wear and thus also 

an appreciable leakage flow. Both 

are particularly high for hydrogen 

since it does not lubricate. A lot if 

research is therefore being done in 

this area as well. 

7) With poorly lubricating gases 

(such as hydrogen), sliding movements 

of the compressor valves 

can be expected to occur during 

valve closing, from the initial contact 

until the final limit of travel is 

reached, which can cause wear. 

The functionally best solution is a 

liquid piston or a layer of liquid over 

the metallic piston (piston works upward). 

This can reduce the dead space 

to zero. Leakage is also zero due to 

the barrier effect of the liquid and the 

piston seal is lubricated, which can 

12 



extend the maintenance intervals. A 

nearly isothermal compression can 

be achieved with the proper layout. 

Cooling with a liquid means that 

droplets are produced so that filter 

technology is required on the pressure 

side. Considering that the loss 

of energy through heat and leakage 

is in the range of more than a factor 

of two compared to isothermal 

compression and the drive motor 

has twice the output, meaning its approximate 

cost is at least 50 % more, 

gas purification on the pressure side 

should be amortised quickly and may 

in fact be less costly than one year of 

wasted energy and leakage. 

Chemical and biological 

production facilities 

The smaller the system with the same 

material flow, the lower the friction 

pressure loss. This should be taken 

into account in system planning. Some 

tests have already been conducted in 

this direction, but they stalled at the 

standardisation stage and a breakthrough 

was not achieved. We may 

have to rethink plant engineering and 

construction. One example that was 

intensively discussed are rails around 

a chemical plant, on which tank cars 

are moved e. g. from A to B etc. in order 

to be filled or emptied, transporting 

materials and goods. This would 

definitely open up new opportunities 

since there would no longer be tanks 

inside the plant. At most, there would 

be reactors if these could not be relocated 

to a rail car as well. In this case 

the plant would be reduced to pipework 

only. Physical separation could 

also be realised, permitting function 

pools with storage in moveable tanks. 

The number of pipe elbows would 

definitely be reduced as well. For 

those that cannot be eliminated, recent 

developments cut the additional 

loss in pipe elbows almost in half. 

When the plant as such consists only 

of pipework, cross-section changes 

that deplete energy are hardly needed 

and the length of the pipework 

could be reduced. In addition, many 

systems need to be pressurised and 

the pressure is usually discharged 

without being utilised. 

Energy recovery using expansion 

machines could be amortised relatively 

quickly. 

General rules: 

1) Since friction always consumes energy, 

optimal lubrication and materials 

with sliding properties or 

pressure lubrication are important. 

2) A noisy machine consumes more 

energy than a machine that runs 

quietly. Noise can also be indicative 

of wear. 

3) Heat distortion due to uneven thermal 

expansion can lead to damage 

caused by wear or loud machine 

noises. When a machine becomes 

louder after starting up, this can be 

an indicator of such effects. 

4) Vibrations in a pipe section can be 

indicative of small pressure surges 

or oscillations that energetically 

match the resonance frequency 

of the pipe section. This indicates 

oscillations in the system and increases 

the probability of damage. 

5) Cavitation is loud when bubbles 

implode on the walls and usually 

quiet when the bubbles implode in 

the fluid space. The latter is generally 

not harmful. However, cavitation 

that is barely audible but can 

nevertheless cause damage also 

occurs. Experience and learning 

processes are required here. 

Literature 

[Hieninger] Energy Efficiency (2021) 

14:23 https://doi.org/10.1007/s12053- 

021-09932-5 

The Author: 


Prof. (ret.), advisor on hydrogen 

and energy issues 

We put the filling 

into the strudel! 

MORE! 

Hygienic WANGEN PUMPS pump 

medium-specifically, gently and reliably.

Cover story 

Pump monitoring and process expertise for 

sewage treatment plants 

SEEPEX optimizes sewage sludge transport 

in the Ruhr region 

Every river needs clean water. 

Treated wastewater from approximately 

two million people feeds the 

river that gives its name to Germany’s 

largest urban area, the Ruhr. 

For the Ruhrverband, digital monitoring 

solutions from the internationally 

renowned specialist SEEPEX 

ensure that the sludge treatment 

process remains under control. 

After a successful test phase of the 

pump monitoring system, Ruhrverband 

is convinced that permanent 

live monitoring of important parameters 

during pump operation 

improves performance, increases 

energy efficiency and brings high reliability 

and predictability to maintenance 

processes. 

Fig. 1: Ruhrverband, one of Germany’s largest waste water operators, treats the wastewater 

of approx. 2.2 million people in the Ruhr area every day. (Source: Ruhrverband, Essen Kupferdreh 

sewage treatment plant) 

Ruhrverband and SEEPEX have a 

long-standing partnership in the field 

of sewage sludge conveying. The 

Bottrop-based company’s powerful 

progressive cavity pumps transport 

viscous sludge over long distances to 

treatment plants. In two wastewater 

treatment plants in the city of Essen, 

pump monitoring solutions optimize 

processes on a permanent basis. 

Since 2021, the pump monitoring system 

has been recording sensor data 

for analysis. The goal is to optimize 

the operating performance of the installed 

pumps and reduce their maintenance 

requirements. The technology 

has proven to be successful and is 

now in permanent use. 

A challenging process over 

long distances 

Both partners faced the special challenge 

of long pumping distances of 

up to eight kilometers as well as with 

varying quantities and changing viscosity 

of the pumped medium. The 

result is a demanding and, in some 

cases, complex process with a great 

Fig. 2: Seepex installed digital monitoring solutions at two sewage treatment plants in the 

south of Essen, thereby optimizing sewage sludge transport. (Source: Seepex) 

deal of potential for optimization. The 

customer hoped that pump monitoring 

would provide suggestions for improvements 

in terms of operating parameters, 

operating times and energy 

consumption by analyzing pump operation 

and process conditions over 

a long period. Critical pressure conditions 

and wear were also areas of 

focus. Consequently, the pump monitoring 

system recorded pump data 

such as flow, pressure, vibration and 


Cover story 

temperature. This allowed the system 

to monitor components and process 

conditions in real-time. 

The one-year pilot project involved 

two pumps conveying primary 

sludge from different locations 

for further treatment. One NS 70-24 

pump transports the primary sludge 

from the Essen-Kupferdreh WWTP 

over a distance of eight kilometers 

to the sludge treatment facility. The 

other BN 130-12 progressive cavity 

pump transports the sludge from the 

Essen-South WWTP over a distance of 

six kilometers. The task was to match 

both conveying methods to the capacity 

of the sludge treatment facility. 

Problem detection and 

root-cause analysis 

In February 2021, SEEPEX installed 

its pump monitoring units at the two 

sites. The scope of supply included 

the pump monitoring hardware, a 

customized sensor package, as well 

as the communication infrastructure 

and Connected Services for collecting, 

monitoring and analyzing the 

data. “SEEPEX supported Ruhrverband 

with monthly reports, presentation 

of findings and recommendations 

for action based on algorithms 

and our expert knowledge,” says the 

Product Manager of Digital Solutions 

at SEEPEX. 

Early in the analysis, SEEPEX experts 

were able to uncover previously unknown 

problems and determine the 

underlying causes. For example, discharge 

pressures were high and 

sometimes outside the pump’s specifications. 

The experts quickly determined 

that resonant frequencies 

overstressed the mechanical components, 

which was causing loosened 

screw fittings and a broken tie rod. 

Pump monitoring made the condition 

of the rotor and stator transparent 

as the test phase progressed. 

SEEPEX was able to determine the 

ideal time for their replacement with 

one month’s notice. This way, the customer 

was able to plan the maintenance 

work ahead of time and avoid 

process interruptions. On the other 

hand, the water association was able 

to fully utilize the wearing parts without 

jeopardizing process reliability. 

Further adjustments increased the 

service life of the rotor and stator by 

more than 50 %, which translates into 

annual savings of more than € 6,000 

per pump. 

25 % less power to operate 

By determining three key factors influencing 

energy consumption, the 

team of the pump manufacturer was 

able to identify potential energy cost 

savings of more than 25 % and ultimately 

recommend actions to improve 

energy efficiency. Ruhrverband 

implemented process control adjustments 

in close coordination with 

SEEPEX. Overall, Ruhrverband was 

impressed with the detailed energy 

analysis of its pumps. The monitoring 

system provides a clear overview 

of energy consumption and specific 

energy costs per cubic meter of 

pumped sludge. From now on, continuous 

pump monitoring will ensure 

optimal process conditions and consistently 

low energy consumption. 

Predictable maintenance cycles 

“The main benefit of SEEPEX’s continuous 

condition monitoring, analysis 

and reporting is the ability to predict 

maintenance cycles, which significantly 

reduces operating costs,” explains 

the Project Manager for Digitali zation 

Projects at Ruhrverband. “We were 

very grateful for the in-depth analysis 

on how to monitor wear and minimize 

the energy consumed per cubic 

meter of sludge pumped.” 

The compact, easy-to-understand 

monthly report, which summarizes 

key performance indicators (KPIs), 

trends and error messages, is invaluable 

to Ruhrverband. Through close 

cooperation, the monthly report has 

been continuously adapted to the 

needs of Ruhrverband. Incidentally, 


15

Cover story 

Fig. 3: Permanent condition monitoring as well as pump and process expertise summarized in a monthly status report with recommendations 

for action. (Source: Seepex) 

Ruhrverband 

Ruhrverband is a municipal water utility plant that provides water to 

4.6 million people and wastewater treatment to 60 cities in the Ruhr region. 

Its 65 wastewater treatment plants treat wastewater from 2.2 million 

people and businesses in the region every day, ensuring that only purified 

water is returned to the river. 

Pump Monitoring and Connected Services 

SEEPEX Pump Monitoring provides comprehensive monitoring and optimization 

of progressive cavity pumps to protect components and improve 

maintenance and operation. Digital monitoring minimizes life cycle costs 

and increases overall efficiency. Using sensors for temperature, pressure 

or flow, SEEPEX Pump Monitoring can make the pump's operating data 

available in the intelligent cloud-based platform. This allows users to continuously 

monitor the pump and view live data. Users can also set alarms 

and trends, and log all data for later performance analysis. The ability to 

access the pump's performance data at any time and respond quickly to 

changes through notifications helps to avoid unplanned downtime. Additionally, 

the pump only reports when it notices that something is wrong. 

all SEEPEX customers will benefit 

from the results in the future - the extended 

monthly report is now part of 

the monitoring solution. 

Pump monitoring benefits 

at a glance 

– Continuous monitoring of pump 

status and components provides 

visibility across applications and 

processes 

– Early notification of deviations 

from optimal condition 

– Increased component life 

– Determine optimal operating 

point with minimum energy 

consumption 

In addition to providing convenient service for critical processes, the benefits 

include improved spare parts utilization. The knowledge gained from 

pump monitoring can be used to optimize maintenance cycles. The measurement 

data can be accessed via an app on a smartphone, tablet or from 

a control room. 

SEEPEX offers Connected Services, another module in its digital portfolio, 

to analyze and use the available data at any time. Benefits of the cloudbased 

service include predictive maintenance through early warnings and 

wear prediction, and full access to historical, live and trended data for advanced 

analysis. 

SEEPEX GmbH, Bottrop, Germany 

www.seepex.com 


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, 

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Bioenergy, Geothermal Energy, Battery 

Technology, System Integration and 

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The best control 

Jochen Krings 

High energy costs are once again 

calling attention to the savings potential 

of circulating pumps. But 

how big are the differences between 

the latest models and older 

ones? And when is it worth it to replace 

them? 

The key to the enormous efficiency 

gains from modern high-efficiency 

pumps is their motor design and control. 

The Grundfos Alpha2 series, for 

example, is equipped with a highly 

efficient permanent magnet motor. 

Unlike conventional asynchronous 

motors, this one does not require 

ener gy to magnetise the rotor, making 

it around 30 per cent more efficient. 

As well as this, the pump’s 

components have been optimised to 

reduce typical losses to a minimum. 

These include the stator windings, 

eddy currents in the stator and rotor 

fins, the flow of current in the rotor 

rods and end rings, and friction in the 

bearings. The hydraulic has been optimised 

down to the last detail using 

computational flow simulations. The 

impeller, for example, has been completely 

redesigned from previous 

generations to convert the rotation of 

the motor shaft into flow even more 

efficiently. 

The materials also help to improve 

efficiency. The permanent magnet rotor 

is made from neodymium, and the 

motor can is made from composite 

material. The housing has a cataphoretic 

coating (applied using an electrochemical 

dip coating process) that not 

only provides a high degree of protection 

from corrosion, but also reduces 

flow resistance thanks to its especially 

even surface. Here too, the developers 

have fine-tuned every detail to 

achieve maximum efficiency. 

Smart control 

The introduction of electronic speed 

control in the 1990s was an important 

step in making pumps more efficient. 

There has, however, been further 

significant progress in this area 

too. Conventional control only returns 

an output variable such as the 

differential pressure back to the control 

variable. The special system conditions, 

such as the loss coefficients 

of pipes, fixtures, boilers and radiators, 

are largely ignored. As a result, 

the pump does not run on the system’s 

optimum control curve. 

Modern self-adapting pumps 

such as the Grundfos Alpha2, on the 

other hand, regularly analyse the system 

conditions and optimise the position 

of the proportional pressure 

Fig. 2: The latest high-efficiency pumps, such as the Alpha2, are significantly more efficient 

even than their predecessors, which were already among the most efficient of their time 

Fig. 1: Permanent motor, hydronic optimisation down to the last detail and smart control 

enable the highest level of efficiency (Grundfos Alpha2) (All images: Grundfos) 

curve automatically. The advantage 

of this is that the pump always runs 

on the optimum curve, so it does not 

consume more energy than necessary. 

It is not affected by short-term 

fluctuations in demand as these are 

compensated for by the proportional 

pressure control. The AutoAdapt 

technology also simplifies the commissioning 

process. All the installer 

needs to do is connect the power 

supply, and the pump will take care 

of optimising its settings itself. 




Significant efficiency gains 

Since the EuP Directive came into 

force in 2013, virtually the only circulating 

pumps installed in Germany 

have been high-efficiency pumps. 

Nevertheless, there are still millions 

of old uncontrolled pumps running 

in boiler rooms. These are obviously 

worth replacing. A modern highefficiency 

pump is around 90 per 

cent more efficient than an old, uncontrolled 

circulating pump with 

the previous energy efficiency class 

D rating. For pumps with a typical 

size and standard load profile, this 

reduces power consumption by approximately 

450 kWh per year. With 

savings of some 150 euros per year, 

even without subsidies the new 

pump will have paid for itself within 

just a few years. 

est Alpha2 today will lead to savings 

of more than 100 kWh per year. 

Thanks to vast improvements in 

efficiency, the flow rates of pumps 

have changed so much that an existing 

pump can often be replaced 

with a smaller type and still provide 

the same performance. For example, 

an old Magna 40-100 can be replaced 

with a Magna3 32-100 or even 

a Magna3 25-120, depending on the 

operating point. This means that significant 

investment cost savings can 

be made too. With the right adapter 

sets provided for the Magna3 range, 

the smaller types can be adapted to 

the situation in which they are being 

installed. For example, pipe fitting 

models can be adapted to an existing 

flange connection and the installation 

length can be increased from 

180 to 220 mm. 

Fig. 4: The latest Alpha2 and Alpha3 models 

enable a simple hydronic balancing process 

that is eligible for a subsidy and saves additional 

energy 

Fig. 3: If a pump can be replaced with a smaller size to achieve the same flow rate, adapter 

sets can be used to adapt the pump to the situation where it is being installed (Grundfos 

Magna3) 

with the pump and is guided through 

the balancing process step by step by 

the GO Balance app. This simple procedure 

takes less than two hours for 

a typical single-family home and is eligible 

for a subsidy. 

Experience has shown that hydronic 

balancing increases the efficiency 

of the heating system by 10 

to 20 per cent. Despite this, it is estimated 

that up to 10 million German 

heating systems have not yet been 

balanced. This makes it all the more 

worthwhile to combine a pump replacement 

with hydronic balancing – 

yet another reason to get a modern 

high-efficiency pump. 

A less obvious point is that current 

high-efficiency models perform considerably 

better even than newer 

pumps. This becomes clear when 

looking at the best-selling Grundfos 

Alpha series, each generation of 

which was among the most efficient 

in its class at the time. Introduced in 

2005, the energy-saving Alpha Pro 

model with permanent magnet motor 

and integrated frequency converter 

was around 62 % more efficient than 

the original Alpha released in 2000. 

The latest Alpha2 generation is 68 % 

more efficient even than the Alpha 

Pro, and consumes 88 % less energy 

than the 2000 model. Replacing an 

energy-saving Alpha Pro with the lat- 

Replace and balance 

Today’s models, such as Alpha2 or 

Magna3, have been hydronically optimised 

so much that they are almost 

at the limits of what physics will allow. 

There are still further developments 

taking place, however, mainly 

in the area of digital integration. One 

example of this is hydronic balancing. 

When they leave the factory, both 

models are prepared for a process, 

developed by Grundfos, in which the 

pump provides the necessary data. 

The Alpha3 has the necessary wireless 

interface already built in, while 

the Alpha2 requires the Alpha Reader 

tool. The installer pairs a smartphone 

The Author: Jochen Krings, 

Professional Relations, 

Grundfos GmbH, Erkrath, Germany 

www.grundfos.de 


19



Production of biomolecules for pharmaceuticals 

Diaphragm metering pumps prove their 

worth for critical mixing tasks in industrial 

oligonucleotide production 

Dr. Hans-Joachim Johl 

The size of oligonucleotides lies between 

that of small, low-molecular-weight 

active pharmaceutical 

ingredients (APIs) and high-molecular-weight 

active pharmaceutical ingredients 

such as mAbs (monoclonal 

antibodies). Production facilities 

for the manufacture of oligonucleotides 

must be able to handle flammable, 

toxic compounds as well as 

meet hygienic standards to ensure 

biological integrity. Above all, however, 

they must be flexible and able 

to be scaled up from pilot plants 

so that they can ideally synthesize 

and purify a wide variety of drugs. 

In addition to standardized platform 

technologies, customer-specific 

GMP-compliant systems are 

also needed. Diaphragm metering 

pumps in these systems can meet 

the challenges of extreme chemical 

syntheses in the upstream process 

and also be used in contamination-free 

downstream processes. 

The flexible production of toxic and 

flammable fluid mixtures with widely 

varying flow rate requirements is 

particularly important here. 

From rare diseases to chronic indications, 

the demand for oligonucleotide-based 

drugs is steadily increasing. 

Oligonucleotides are short, small 

(= oligo) sections of genetic sequences 

(RNA and DNA). Nucleotides are 

the building blocks of nucleic acids 

occurring in DNA and RNA chains. Oligonucleotides 

are therefore among 

the most important components of 

modern molecular biology. One of 

the most important ways of producing 

oligonucleotides with modified 

nucleotides for therapeutic purposes 

is industrial DNA and RNA synthesis. 

In contrast to the frequently used, 

biopharmaceutically produced drugs 

that target proteins, oligonucleotides 

target disorders in the genetic 

code that are the cause of specific 

diseases. This makes them predestined 

for the treatment of previously 

incurable rare diseases, including 

neuronal diseases. The first antisense 

oligonucleotide drug was approved in 

1998 as Fomivirsen, under the trade 

name Vitravene, for the treatment of 

CMV virus in AIDS patients. 1 Several 

others followed, including Partisiran, 

approved in 2018 under the trade 

name Onpattro, a lipid nanoparticleformulated 

drug that is one of the 

newer oligonucleotide therapies for 

polyneuropathy. Although various 

oligonucleotide drugs have already 

been approved by the authorities, 

they have not yet been established 

on an industrial commercial scale. 

Many other drugs are currently in the 

clinical phase prior to industrial production 

and are therefore the focus 

of ongoing research efforts, which 

increasingly include economic and 

quantitative aspects. 

Challenge: Economical production 

of oligonucleotides 

As a result, many specialized companies 

are focusing on efficient and safe 

GMP production of oligonucleotides 

using suitable production facilities. 

The aim is to maximize yield while 

maintaining high purity. This means 

that manufacturers of active pharmaceutical 

ingredients are faced with 

the task of making their own production 

processes more and more economical 

and robust so that they can 

be scaled up from laboratory or pilot 

scale to industrial GMP production 

with the highest possible yield in synthesis 

and downstream steps, without 

sacrificing quality or neglecting 

economic aspects. 

An important step for oligonucleotide 

processes is known as media 

dilution, where the concentrations 

of a synthesized solution are 

adjusted. More concentrated storage 

solutions are continuously di- 

Fig. 1: Production facilities for the manufacture of oligonucleotides must be able to handle 

flammable, toxic compounds as well as meet hygienic standards to ensure biological 

integrity. (Source: LEWA) 




Fig. 2: The inline dilution systems use multihead 

diaphragm metering pumps specially 

designed for pharmaceutical applications. 

(Source: LEWA) 

luted to achieve the desired working 

concentration. The choice of solution 

depends on the subsequent steps in 

the downstream process. After the 

actual chemical synthesis, in which 

the nucleotides are added one after 

the other to a growing chain, the 

synthesized products undergo what 

is known as deprotection and purification 

steps to remove unwanted 

by-products. Accompanying process 

and quality control, e. g. in the form 

of mass spectrometry, ensures that 

the end product is within the defined 

specification window. 

Continuous flow regulation 

and keep the fluid quantity constant 

by controlling the speed of the metering 

pumps precisely. Pressure control 

valves with integrated electronically 

controlled pneumatic damping installed 

in the output-side manifold 

maintain low fluctuation and keep 

the mixing flow almost constant. This 

also applies to the pressure: Fluctuations 

are undesirable for the built-in 

measuring chains and interfere with 

the separation processes in the chromatography 

columns. Gas phase 

components and any temperature increase 

also have to be prevented. 

After the mixing result is combined 

in the manifold, the ratio is analyzed 

using appropriate measurement 

technology, e. g. via the pH 

value and electrical conductivity. After 

programming the stored target 

values in the higher-level control system, 

these are available as different 

methods for system control. The recorded 

measured values are determined 

at a high sampling rate and 

continuously evaluated centrally. The 

pumps used must be corrosion-resistant, 

hygienic and have a robust design 

for continuous use. LEWA has detailed 

knowledge and many years of 

experience in high-precision metering 

and mixing thanks to its de cades in 

the field of pump supply for the process 

chromatography of major OEMs. 

And this has also benefited the design 

of correspon ding mixing and metering 

systems for oligo synthesis customers 

for some years now. 

Fig. 4: Pressure control valve with damping 

properties equipped with an electronic pilot 

valve for automatic control. 

(Source: EQUILIBAR) 

Package units for individual 

dilution tasks 

The dilution systems designed and 

described are not standard systems, 

but customized inline metering and 

dilution systems that are designed 

and constructed as package units 

(PU) for the respective downstream 

process. A system of this type can 

have up to five process inlets and 

outlets – sometimes more – as well 

as various other connections, for example 

for flushing or waste water, to 

ensure flexible and continuous fluid 

transport. A cycle of chemical reactions 

is initiated by feeding in the 

respective synthesis fluids. Individual 

nucleotides are coupled and the 

desired modified chain sequence is 

In order to meet increased demand 

by expanding production capacities, 

precise and continuously operating 

inline dilution systems must be provided. 

One of the biggest challenges 

here is maintaining a consistently reproducible 

quality of the required 

buffer within the narrow window for 

permissible concentration deviations. 

Among other things, continuous 

monitoring of the flow rates and the 

resulting dilution ratios is essential 

for this. Therefore, inline dilution systems 

typically consist of several channels 

with valves, where each channel 

is equipped with a multi-head 

diaphragm pump and a Coriolis flow 

meter. They measure the mass flow 

Fig. 3: Pressure control valves with integrated electronically controlled pneumatic damping 

installed in the output-side manifold maintain low fluctuation and keep the mixing flow almost 

constant. (Source: LEWA) 


21



formed by repeating the reactions. 

Due to the highly flammable fluids 

required, including solvents such as 

ethanol, isopropanol, toluene and 

acetonitrile, the systems often have 

to be designed for use in Ex zone 2 IIB 

T3. Inert gas (nitrogen) further protects 

the process. The inline dilution 

system for aqueous fluid mixtures in 

the downstream area provides highaccuracy 

buffer solutions for semicontinuous 

chromatography after 

synthesis. HPLC, ion pairing reversed 

phase (IP-RP) and ion exchange (IEX) 

chromatography columns are used 

for chromatographic purification. 2 

Individual dilution tasks can thus 

be implemented precisely and flexibly. 

Several 1,000 liters of solvent 

and aqueous fluids are required per 

kilogram of active ingredient. In order 

to be able to implement large 

adjustment ranges from a few liters 

per hour up to 6,000 l/h, it must be 

possible to call up an automated 

and continuous supply of changing 

mixtures for the downstream purification 

process via the system control. 

Several multi-head diaphragm 

metering pumps specially designed 

for pharmaceutical applications are 

used here. Their phase-shifted drive 

charac teristics, typically with three 

to five pump heads, enable a lowpulsation 

overall flow rate. Thanks 

to the back pressure-independent 

characteristic curve, the entire metering 

and mixing process for oligonucleotide 

production is reliably continuous 

and absolutely reproducible 

at all times. No other type of pump 

can achieve stable linear and step 

gradients as well as reliable gradient 

charac teristics more consistently. 

These hermeti cally tight pumps 

rule out backflow or plunger packing 

problems. 

Large adjustment ranges and high 

production reliability 

Because the production of dilution 

solutions sometimes requires very 

different flow rates, the systems 

must be designed to be flexible. One 

practical example required flow rates 

of a minimum of 40 l/h and a maximum 

of 2,500 l/h. A total of five LEWA 

ecodos hygienic diaphragm metering 

Fig. 5: Basic flow diagram of a flexible dilution system from concentrates (example). (Source: LEWA) 

pumps were integrated into this system 

in order to be able to cover this tent, such as the more corrosion-re- 

and steels with a higher alloy con- 

large adjustment range flexibly. The sistant 1.4529 stainless steel or Hastelloy 

for fluids with a high chloride 

pump heads are equipped with mechanically 

actuated, four-layer sandwich 

safety diaphragms. Since the able for metering highly corrosive 

content. This makes the pumps suit- 

area behind the diaphragm is subject and flammable fluids in oligonucleotide 

production over the long term. 

to strictly regulated clean room environmental 

conditions, contamination The patented four-layer PTFE sandwich 

diaphragm also helps here: It 

with operating materials or process 

fluids cannot occur. Due to the GMP is extremely stable and ensures that 

environment, which strives for high operation can be continued safely 

even in the event of a diaphragm 

integrity with regard to contamination 

of any kind, hygienic versions of rupture, thus providing a high level of 

the pumps must also be used in this process safety. In an emergency, the 

area of downstream processing. This integrated diaphragm rupture signaling 

system immediately reports a 

goes hand in hand with accep tance 

test certificates 3.1 and consis tently corresponding fault during operation 

certified construction materials, such without contaminating the rest of the 

as FDA, USP or AOF certificates of process line. Only hermetic plunger 

conformity. All metal parts in contact diaphragm pumps offer such a high 

with the fluid are mechanically and level of production reliability. 

additionally electropolished and have 

a surface roughness of Ra ≤ 0.5 µm. Precise control and continuous 

Thanks to the hygienic design of the monitoring 

diaphragm body, which almost completely 

eliminates dead spaces, the In terms of control, the use of a servomotor 

and an intelligent control sys- 

pumps can be cleaned in the CIP process 

very easily and without prior dismantling. 

requirement profiles to be impletem 

enable different customer-side 

The EHEDG EL Class 1 certificate 

for the ecodos pump type used to be extended up to 1:200. The 

mented and the adjustment range 

is a decisive proof of quality with regard 

to the excellent inline cleanabi- 

via the stroke length and the speed 

flow rate is traditionally adjusted 

lity of the fluid-side pump head. The of the pump motor via the frequency 

of an inverter. In newer concepts, 

materials used are 1.4435 stainless 

steel with a low delta ferrite content the speed of a fanless synchronous 




motor or permanent magnet synchronous 

motor (PMSM) is variable 

and operating points can be approached 

precisely and reproducibly 

without manual stroke adjustment 

– thus making them compliant with 

GMP. At ±1 percent, metering accuracy 

is extremely accurate. To prepare 

the mixtures in the chromatographic 

environment, the flow rates 

of the individual pump lines must be 

precisely maintained. For this purpose, 

they are determined by Coriolis 

flow meters and precisely controlled 

at the specified target values using 

the speed control of the pumps. Additional 

online monitoring of the pH 

value and electrical conductivity ensures 

continuous control of the process 

conditions. 

To ensure that the specified accuracies 

are maintained over wide adjustment 

ranges, correct suction-side 

pressures (NPIPA) must be ensured 

at the pumps. The abbreviation NPIP 

stands for “Net Positive Inlet Pressure” 

and NPIPA for “Net Positive Inlet 

Pressure Available”. The NPIP is similar 

to the well-known NPSH, although 

the latter is only defined by the 

height. In contrast, the NPIPA is the 

measure of the pump inlet pressure 

present at the inlet valves through 

the system. The NPIP is determined 

Fig. 6: Pressure control unit for adjusting constant damped fluid flows upstream of chromatography 

columns. (Source: EQUILIBAR) 

by the static pressure upstream of 

the pump, for example by a vessel 

with or without pressure superposition 

or by the pressure in closed circular 

piping. If the NPIP is too low, cavitation 

may occur in the pump heads 

if the steam pressure falls below the 

value specified. If, on the other hand, 

a diaphragm metering pump has a 

net suction pressure that is too high, 

there is a risk of excessive and uncontrolled 

flow, particularly with low 

metering quantities in pumps that do 

not have built-in valve springs due 

to hygiene requirements, which can 

impair metering accuracy and dilution 

rate. To control the pump-specific 

hydraulic conditions, pressure 

(retaining) control valves are therefore 

used on the discharge side of 

the pumps after all installations with 

pressure losses to ensure a constant 

max. 4.000 bar 

max. 10.000 l/min 

max. 600 m 3 /h 

max. 3000 kW



back pressure. This can also be used 

to compensate for and smooth out 

small residual pulsations in the multiplex 

pump heads. A specific subset of 

sanitary control valves also contains 

a dampener to manage downstream 

pressure fluctuations which aid in the 

production stability of oligonucleotides. 

One such example is made by 

Equilibar, which are used in current 

package units. 3 

References 

1 

Text information from ABDATA database 

of pharmacies. 

2 

Large scale purification of oligonucleotides 

with ion exchange chromatography 

(U. Krop, T. Pöhlmann, N. 

Schneider). 

3 

Technical Information Equilibar, 320 

Rutledge Rd., Fletcher, North Carolina 

28732, United States 

The Author: Dr. Hans-Joachim Johl, 

Lead Product Manager Pharma, 

Food & Life Sciences at 

LEWA GmbH, Leonberg, Germany 

www.lewa.com/en/ 

Fig. 7: Theoretical flow rate curve of a reciprocating 3-head diaphragm plunger pump 

(directly actuated) with a volumetric efficiency of 90 percent (graph 1). 

Undamped real-time signal for the volume and pressure curve of a reciprocating 3-head 

diaphragm plunger pump (directly actuated) ( graph 2). (Source: LEWA) 

The specifications of LEWA diaphragm metering pumps fulfill all requirements 

for continuous operation of dilution systems in the industrial GMP 

production of oligonucleotides: 

– A large adjustment range of the pump systems for maximum flexibility 

– Precise operation and repeat accuracy of the metering pumps and thus 

process stability 

– Safety for operating personnel thanks to hermetically tight systems 

– Experience in the design of the hydraulic environment of reciprocating 

diaphragm metering pumps 

– Robust system operation to ensure consistent quality, high yield and 

economically efficient operation 


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Battery production in Europe drives 

pump manufacturers to new innovations 

It is well known that Europe needs 

to develop secure supply chains for 

the manufacture of Lithium Ion (LiB) 

Batteries especially for the rapidly 

increasing demand for full electric 

or hybrid electrical vehicles. Asian 

manufacturers have dominated the 

supply of lithium batteries in recent 

years but the rapidly expanding 

production capability in Europe presents 

challenges for battery manufacturers 

and consequently equipment 

suppliers. 

Such a challenge was presented to 

NETZSCH Pumpen & Systeme GmbH, 

a manufacturer of positive displacement 

pumps, regarding the difficulties 

of transferring and accurately 

dosing anode and cathode materials. 

One of the main challenges is the 

safe handling of anode slurries containing 

the solvent N-Methyl-2 pyrrolidone 

(NMP). Ideally, the pumping 

of such a toxic solvent would be handled 

by hermetically sealed pumps 

using a magnetic coupling. 

Magnetic couplings are used 

where leakage must be avoided 

when handling corrosive, hazardous 

or toxic fluids, or generally speaking 

to avoid the concerns associated 

with traditional mechanically sealed 

pumps. 

Such systems would be pumps 

equipped with packed glands or mechanical 

seals in various configurations. 

A pump fitted packed gland 

system in no way addresses the requirement 

for a leak free pump, 

whereas a pump fitted with a double 

mechanical seal with the requisite 

seal support system can fulfil the leak 

free requirement whilst introducing 

requirements for increased maintenance 

and control. 

Therefore, for a toxic product 

such as NMP, a magnetic coupling 

is an ideal solution addressing the 

need for a hermetically sealed pump. 

There are, however, drawbacks with 

proprietary magnetic couplings available 

from well-known manufacturers 

for applications requiring a progressing 

cavity pump. 

Conventional magnetic couplings 

are not suitable for battery 

production 

Progressing cavity pumps are used 

typically in applications where the 

fluid to be pumped is abrasive, contains 

solid particles, is viscous or 

shear sensitive or the application 

requires accurate dosing or any combination 

of two or more of these 

characteristics. 

Specifically, when handling 

cathode slurries for the production 

of lithium-ion batteries, the fluid is 

viscous, typically in the region of 

8000 to 20,000 mPas, naturally contains 

solid particles and for coating 

applications needs to be extremely 

accurately dosed. The combination 

of these characteristics means 

that standard magnetic couplings designed 

for direct coupling to a centrifugal 

pump, running at 2 pole and 4 

pole motor speeds, are not suitable 

for such types of applications. 

When running a magnetic coupled 

pump at high speeds, 1400 or 

2800 rpm, circulation of the pumped 

fluid will be required for cooling of 

the coupling. This is achieved by the 

fluid passing through cooling channels 

within the coupling. Such cooling 

channels are small in diameter 

and consequently are easily blocked 

by higher viscosity fluids. 

A progressing cavity pump 

pumping a product of up to 20,000 

mPas would typically run at speeds 

of around 100 to 200 rpm, although 

this should not be considered as the 

maximum viscosity capability for 

progressing cavity pumps. There are 

applications where progressing cavity 

pumps are used for products well 

in excess of 1 million mPas. 

NETZSCH designs new 

magnetic coupling for handling 

battery sludge 

Therefore, it was necessary to develop 

a magnetic coupling specifically 

designed to meet the requirements 

of typical progressing cavity applications. 

In the case of battery slurries, 

a coupling needed to be developed 

that would be capable of handling the 

viscosity of the slurries. 

As previously described, as the 

rotational speeds of the progressing 

cavity pump would be lower than 

would be usual for a centrifugal pump 

application, excessive heat generation 

within the coupling was not to 

be expected. There were, however, 

other challenges for which a solution 

would need to be found. One such 

challenge would be the torque that 

the coupling would have to transmit. 

NETZSCH successfully developed 

a magnetic coupling to meet the demands 

of battery slurry applications, 

that is to say a pump that is hermetically 

sealed preventing the escape 

of toxic vapours and also importantly 

the ingress of air bubbles into the 

slurry, a point that is of special importance 

in the foil coating process. 

However, customers then presented 

the NETZSCH development engineers 

with other challenges specifically related 

to battery applications. 

The newly developed magnetic 

coupling prevents air ingress into the 

product through the pump itself but 

nevertheless air bubbles can be present 

in the anode and cathode slurries 

originating from the slurry preparation 

process. Although deaerators 

can remove air bubbles from the slurries, 

customers have the experience 

that occasionally some bubbles find 

their way into the coating process. 

The newly developed magnetic coupling 

offers the possibility to add additional 

air extraction directly from the 

magnetic coupling when the pump is 




Fig. 1: The newly developed coupling rods are integrated into the battery pump. 

correctly orientated. Consequently, be fitted to the magnetic coupling 

for very little capital outlay, bubble where necessary. 

free coating of the anode and cathode 

slurries can be guaranteed, significantly 

increasing quality and re- 

Automatic cleaning of the pump 

ducing wastage and recycling costs. Where the battery foil production 

To meet the requirements of ATEX process is a batch operation, the 

regulations a temperature probe can pump, along with all of the other 

production equipment, needs to be 

cleaned between cycles. Often this 

would be a completely manual process 

with the corresponding effort 

and expenditure. 

The challenge was presented to 

the NETZSCH development engineers 

if it would be possible to construct 

the pump in order that it could be 

cleaned using an automated system. 

This would require additional 

constructional changes to the pump. 

These included adding a flushing connection 

into the magnetic coupling. 

However, major adjustments were 

needed in the area of the pump suction 

housing and coupling rod. 

A progressing cavity pump requires 

a coupling rod that accommodates 

the requirements of both the 

rotational and eccentric movements. 

For battery applications involving anode 

and cathode slurries, the most 

suitable solution would be to select 

a flexible shaft. Such an arrangement 

has the benefit of needing no joints 

to accommodate the eccentric move- 

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ment as would be fitted in the vast 

majority of applications. The main deciding 

factor for using a flexible rod 

would be that the lubrication required 

for joints is eliminated. The benefit 

would be that there would be no contamination 

of the slurries by the lubricant 

when using lubricated joints, in 

the event of a joint seal failure. 

nation of the anode and cathode slurries. 

This would lead to a reduction of 

final product quality. 

Therefore, a flexible shaft is the 

obvious choice, however there is a 

disadvantage to using a standard 

flexible shaft. The traditional flexible 

shaft is manufactured from metals, 

often titanium or duplex stainless 

steel. Due to the limited flexibility of 

Coupling rod is manufactured 

additively 

such a construction, the flexible shaft 

needs to be longer than would otherwise 

be the case with a coupling rod 

For hygienic applications, a coupling featuring a joint system. 

rod system is available with open When considering automated 

joints using a stainless-steel rod and 

pins. For battery applications, such 

a system is not suitable due to the 

abrasive nature of the slurries and 

the danger of metal particle contami- 

cleaning, the increased volume within 

the pump housing due to its increased 

length would lead to increased 

product wastage. Ideally 

therefore, a concept was needed to 

Fig. 2: The progressing cavity pump is designed for complex battery applications. 

reduce the length of the pump housing 

as much as possible whilst providing 

sufficient coupling rod flexibility 

to ensure reliable pump operation. 

New production techniques opened 

possibilities to resolve this conundrum 

without incurring the significant 

tooling costs associated with injection 

moulding. By using additive 

manufacturing, it was possible to rapidly 

prototype potential designs and 

subsequently manufacture the final 

production components. 

To develop a shorter coupling rod 

that would reduce the pump housing 

length, be able to withstand the 

mechanical loads and to fulfil the demands 

of automated cleaning presented 

a challenge. Using the latest 

CFD programs, a coupling rod design 

was eventually finalised and incorporated 

into the final battery pump 

configuration. Using experience from 

food applications where cleaning in 

place to hygienic levels is the standard, 

a tangential inlet connection was 

incorporated to improve the cleanability 

of the pump by providing optimised 

flow conditions within the 

housing. 

Pump stator is also manufactured 

additively 

Fig. 3+4: Elastomer stators and additively manufactured stators are compatible with a separable 

stator system. 

To successfully cover the demands 

of battery slurry applications, a new 

concept would be required also for 

the pump stator. Normally, progressing 

cavity pumps are fitted with a stator 

manufactured from an elastomeric 

material. However, due to the 

chemical aggressivity of some of the 

fluids used in battery production, especially 

the NMP for cathode slurries, 

an alternative stator material would 

need to be used. 

In such applications it was usual 

to use a stator manufactured from 

PTFE. The manufacture of PTFE stators 

is a mechanical process where 

the stators are produced on a lathe, 

the inside profile being turned to size. 

However, given the success of manufacturing 

the flexible rod using additive 

manufacturing, it was decided 

to try and produce stators using the 

same process. 

After extensive testing a new design 

was born offering increased ac- 




Fig. 5: The employees have a look at an innovatively manufactured stator. 

in the slurries from the rotor. Customers 

have the choice what combination 

of rotor and stator best suits 

their application. 

This is made simple by both elastomeric 

stators and additive manufacturing 

stators being compatible 

with a separable stator system as 

shown in figures 3 + 4. 

NETZSCH offers a progressing 

cavity pump with an optimized magnetic 

coupling manufactured using 

state-of-the-art production processes. 

It features a flow optimised housing 

for automatic cleaning as well as 

an additively manufactured coupling 

rod and stator. It therefore meets the 

high demands of the battery market. 

curacy in the production process as 

well as guaranteeing the necessary 

chemical resistance. The efficiency of 

the new stator design was such that 

for slot die coating applications the 

pump could easily exceed the accuracy 

requirements with regard to uniform 

film thickness both across and 

along the foil length. 

The counterpart of the stator, the rotor, 

also needs high levels of accuracy 

which can be achieved with both a 

metallic rotor or a ceramic rotor. The 

ceramic rotor offers a significant advantage 

over metal rotors in as much 

that the wear resistance is dramatically 

increased and more importantly 

there will be no metal wear particles 

NETZSCH Pumpen & Systeme GmbH, 

Waldkraiburg, Germany 

www.pumps-systems.netzsch.com 

Accurate chemical dosing pump 

for flow rates up to 600 L/h and 

pressures up to 7 bar 

_ 

wmfts.com | info.uk@wmfts.com | +44 1326 370 362 

Fluid 

Technology 

Solutions 


29


Smart Factory 

The intelligent path to the Smart Factory: 

How “pain points” become future-proof use 

cases thanks to the cloud 

Andreas Dangl 

With the help of a cloud-based data 

and document management system, 

pump specialist KSB not only 

creates future-proof quality processes, 

but also a close-knit ecosystem 

along the entire supply chain. 

The Deloitte study “Accelerating 

smart manufacturing – The value of 

an ecosystem approach” gets to the 

heart of the matter: The fastest way 

to a Smart Factory leads through 

partnerships, e. g. in the form of close 

interconnection with subcontractors 

along the supply chain. Thus, companies 

will not only save costs, but also 

advance the digital transformation 

and accelerate product life cycles. 

In order to achieve this goal, 

seamless interconnection is clearly 

needed – in other words, secure, 

multimodal real-time communication 

throughout the entire ecosystem 

as well as holistic decision-making, 

which the responsible parties can 

achieve by exchanging information 

across all silo and company boundaries, 

according to the study. 

One German company that has already 

mastered a large part of the path 

to the Smart Factory is KSB Group. 

With an annual sales revenue of 2.6 

billion EUR and more than 15,000 employees, 

it is one of the world’s leading 

suppliers of high-quality pumps, 

valves, and associated systems. 

The pump plant in Pegnitz plays 

a special role within the organization. 

With around 1,600 employees, it is 

one of the largest and most modern 

locations in the KSB Group. It is also 

the pilot location for 3D metal printing 

– and the digital transformation. 

Here, the responsible parties use individual 

use cases to drive forward 

the transformation to the Smart Factory, 

which is intended to serve as a 

model for other KSB plants and customers 

around the world. 

The company understands the term 

“digital factory” as a kind of target 

image. The destination of this journey 

is flexible and modular production 

that is highly automated, digitalized, 

and fully interconnected, from 

incoming orders to production planning 

and outgoing logistics. “This is 

the only way to ensure agile, lean, 

and maximally customer-oriented 

production, also in the future.” And: 

“The smart automation of processes 

in production plants offers immense 

potential for increasing efficiency and 

quality, reducing costs, and increasing 

customer satisfaction as well as 

competitiveness,” according to KSB’s 

vision for digital transformation. 

Thousands of working hours saved 

The first use case at KSB shows which 

benefits a shared data environment 

along the value chain can bring. Project-related 

mechanical engineering 

in particular is subject to extensive 

documentation requirements in 

the course of the production of special 

pumps. The supplier companies 

are required to provide the necessary 

documents in a timely manner. Different 

specialist departments must in 

turn check and approve these. If delays 

occur in this process – regardless 

of where in the supply chain they occur 

– it is not uncommon for contractual 

penalties and reputation damage 

to occur. 

The traditional handling of information 

is not suitable for satisfactorily 

fulfilling the documentation obligation. 

All too often, documents are 

stored in “silos”, e. g. in departmental 

filing systems or e-mail inboxes, 

which makes retrieving them a challenge. 

Moreover, it happens easily to 

find different versions of a document 

in circulation. Each control measure 

is therefore very time-consuming. For 

instance, KSB used to spend around 

130 hours tracking deadlines to obtain 

the necessary documents for 

each individual project. 

This situation has fundamentally 

changed with the introduction 

of a cloud-based data and document 

management system. The project 

documents are now stored in a 

shared data environment and are 

available worldwide – always in the 

latest version. They can be accessed 

conveniently via a web interface, 

which is available in different languages 

on request. 

Fig. 1: Running test plans using a mobile device, Photo © : Gorodenkoff Productions OU via 

Getty Images, Fabasoft Approve 


World Class. 

Fig. 2: Digital recording of defects, Photo © : Westend61 via Getty Images 

Another advantage of using the cloud is that a new supplier can quickly 

and easily find their way into the manufacturer’s ecosystem, as they 

are not forced to install software locally. 

All project staff are now able to call up the current documentation 

status. This includes information on project status, scope of documentation, 

approvals, revisions, and upcoming deadlines. To prevent unauthorized 

persons from accessing sensitive data, the software is also 

equipped with an intelligent authorization and role concept that precisely 

defines who has access to which documents. 

The cloud provider also ensures that the overall system is secure 

– as long as companies obtain the service from a European provider 

with corresponding certifications such as the C5 requirements catalogue 

(“Cloud Computing Compliance Criteria Catalogue”) issued by 

the German Federal Office for Information Security (BSI). 

As to collaboration, a smart document management system scores 

highly with an integrated function set that includes typical workflows 

such as coordination, review and approval processes. If these are not 

sufficient, a low-code process editor is available, which can also be 

used by employees in the specialist departments. 

First conclusion: The use of digital supplier documentation helps 

KSB to save 4,500 working hours per year which were previously spent 

on time-consuming searches and accompanying measures. Thanks to 

the cloud, the company has thus managed to transform the original 

“pain point” into an efficient system. 

Cutting-edge quality management 

The second use case on the path to intelligent production is the creation 

of an end-to-end, highly automated digital quality process, which 

also impressively demonstrates the benefits of the close interconnection 

of players along the supply chain. 

Background: During product development, employees carry out 

and document various tests in order to ensure that KSB Group’s highquality 

standards are met. The technical order processing team draws 

up an order-related “Quality Control Plan” (QCP) for this purpose, 

which it coordinates with and adapts to the customer. 

The basis for the QCP are standard test plans that specify all requirements 

in detail, including those that define where the tests are to 

take place: directly at KSB or at one of the suppliers. A decisive criterion 

for the functioning of these process steps is the quality of communication 

between the responsible parties. 

With 1,200 QCPs per year and the manual inspection of around 

8,500 test certificates, the collaboration between the players has been 

LEWA ecoflow ® – the gamechanging 

metering pump series. 

Each purpose demands its own metering 

solution. That is why the LEWA ecoflow 

series for diaphragm and packed plunger 

pumps combines various drive unit sizes 

with different pump heads. 

Added to this is the process know-how 

of the LEWA experts: Our drive is the 

customized solution. 

More information: 

www.lewa.com/ecoflow


Smart Factory 

Fig. 3: Construction drawings in Fabasoft Approve, Photo © : Fabasoft Approve 

data and document management 

system, which serves as the linchpin 

of the quality processes. The team 

members have direct access to the 

digitized lists, which ensures that no 

outdated specifications are in use. 

Whenever a standard changes, the 

software automatically replaces the 

relevant sections. As a result, the 

smart quality documentation always 

meets current legal requirements. 

The supplier companies benefit from 

this system as well. They are now always 

in the know as to when which 

inspections are to be carried out and 

which documents are to be submitted. 

If correction loops become necessary, 

these can also be mapped 

via the newly created, end-to-end digital 

quality process. 

Successful path to the 

Smart Factory 

Fig. 4: Digital supplier documentation, Photo © : Tom Werner via Getty Images 

a challenge in the past. The reason: tachments – the manufacturer printed 

out the documents, checked and 

The teams created the standard test 

plans and the QCPs using Microsoft 

Excel – with the disadvantage in SAP. 

scanned them, and then saved them 

that it required a lot of manual effort 

and was prone to errors. Each or- 

a use case as well. The company in- 

KSB turned this “pain point” into 

der was accompanied by a document troduced a platform on which it modeled 

an end-to-end digital process 

containing the collected quality requirements 

for all components. The – including an interface to SAP. This 

docu ment was sent by e-mail to the platform enabled the technical order 

processing team to digitize the 

responsible supplier, who then had 

to face the task of filtering out the information 

relating to their part of the plans at the Pegnitz plant. In concrete 

majority of the existing standard test 

delivery from the overall inspection terms, this means that the applicable 

norms and standards are now 

plan. After sending back the requested 

test certificates – again as email at- always available in the cloud-based 

The two use cases show the potential 

opened up by the intelligent automation 

of processes at KSB. A 

cloud-based data and document 

management system now enables 

the Group to take its quality management 

processes to a new, futureproof 

level. KSB also benefits from 

the smart data environment created 

along the supply chain, in which 

the exchange of information works 

seamlessly – ideal prerequisites for 

successfully navigating the path towards 

a Smart Factory. 

The Author 

Andreas Dangl is an entrepreneur 

and Managing Director of Fabasoft 

Approve GmbH. In his function, he 

supports industrial companies in 

the introduction of smart software 

for the management of technical 

data and documents. 

www.fabasoft.com/approve 




Metering of flocculants in drinking water treatment 

“Peristaltic pumps are an economical solution“ 

Surface water from reservoirs plays 

an important role in the drinking 

water supply. Flocculation and filtration 

of colloidal particles is one 

of the central process steps in the 

purification process of turning raw 

water into drinking water. Metering 

pumps for flocculants must therefore 

meet the highest standards in 

terms of durability and operational 

reliability. For this reason, Thüringer 

Fernwasserversorgung (TFW) relies 

on Qdos peristaltic metering 

pumps from Watson-Marlow in the 

Luisenthal treatment plant. These 

pumps not only impress with their 

simple installation, operation, and 

low pulsation, but provide long operating 

times and easy maintenance 

in just a few minutes. This results in 

a highly economic solution. 

With an annual delivery volume of 

36.9 million m³ of drinking water, 

Thüringer Fernwasserversorgung (TFW) 

is one of the largest suppliers of longdistance 

drinking water in Germany. 

The public company TFW supplies 

drinking water to municipalities, municipal 

associations and municipal 

utilities via long-distance water pipelines 

with a total length of around 

550 km, thus ensuring the drinking 

water supply of more than one million 

inhabitants in the German state 

of Thuringia together with the local 

supply companies. 

TFW is the only German longdistance 

water supplier to exclusively 

provide surface water from six of 

its own drinking water reservoirs. It 

operates two modern and efficient 

drinking water treatment plants to 

process the surface water (raw water) 

into drinking water. 

Surface water as drinking water 

The importance of surface water for 

securing the drinking water supply 

should not be underestimated. Already 

today, a total of 55 % of total 

drinking water demand in Thuringia 

is supplied from reservoirs and their 

relevance for drinking water is likely 

to increase further in times of climate 

change, as current research shows 

Fig. 1: The Luisenthal plant, located at the Ohra water reservoir processes raw into drinking 

water – circa 21.5 million m³ per year. 

that reservoirs have a higher resilience 

to climate change than groundwater 

supplies. Due to the more frequent 

occurrence of local extreme 

weather conditions such as heavy 

rainfall, heatwaves and dry spells associated 

with climate change, longdistance 

water supplies are also likely 

to play a particularly important role in 

ensuring a secure drinking water supply 

through efficient water management 

in the future. 

Located in the Thuringian Forest 

Nature Park, the Ohra reservoir managed 

by TFW has a maximum storage 

capacity of up to 17.82 million 

m³. The raw water is extracted at different 

heights via an extraction tower. 

Around 700,000 people, including 

those in the cities of Jena and Erfurt 

and the nearby district town of Gotha, 

are supplied daily with water from the 

dam via the North and Central Thuringia 

long distance water supply system. 

Around 21.5 million m³ of raw 

water from the Ohra reservoir is being 

processed into drinking water every 

year in the Luisenthal plant located 

directly below the reservoir. 

From raw water to drinking water 

Depending on the quality of the raw 

water, various process steps have to 

be carried out, explains Ms. Hövel, a 

specialist engineer at Thüringer Fernwasserversorgung. 

“As the water usually 

only has a very small passage 

through the ground before it reaches 

the reservoirs, it is softer than 

groundwater. The equilibrium pH value 

of the raw water is often above the 

permitted pH value of the Drinking 

Water Regulation. In order to be able 

to adjust this pH value at the end of 

treatment and to increase miscibility 

with other drinking waters, our raw 

water is hardened at the beginning 

of the treatment process.” The local 

suppliers often add groundwater 

from their own extraction to the district 

water to produce a mixed water. 

The water is also subjected to a final 

disinfection process after filtration. 


33



One of the central treatment steps 

from raw water to drinking water is 

flocculation to eliminate finely dispersed, 

difficult to remove colloidal 

particles and humic substances that 

could cause turbidity, as well as microorganisms. 

By adding flocculants, 

the electrostatic repulsion of the particles 

and dissolved substances can 

be overcome. They then bind together 

to form larger flocs that are easier 

to remove. This means that organic 

and mineral particles can be safely 

filtered out. 

“We use the flocculant ferric chloride 

(FeCl 3 

) as an aqueous solution with 

a concentration of 40 %. It is dosed 

into the supply lines to our four 300 m³ 

mixing and reaction basins,” explains 

the water technician at Thüringer 

Fernwasser. “Static mixers ensure the 

necessary turbulence in the water directly 

at the metering point, and flocculation 

then takes place in the basins. 

The flocs are then retained in a total 

of 14 open multi-layer filters. Anthracite, 

quartz sand and gravel are used 

as filter material. Flocculant additives 

and activated carbon can be added if 

required. The retained flocs are processed 

and used as dewatered sludge 

in biogas production.” 

Fig. 2: Flocculation is one of the central steps in the purification process of turning raw water 

into drinking water and allows the filtration colloidal particles and humic substances. 

Metering pumps for efficient 

flocculation 

The flocculant metering system is at 

the heart of the flocculation process. 

The metering pumps convey the ferric 

chloride from the siphon vessels 

of the storage tanks to the mixing and 

reaction tanks. One metering pump is 

in continuous 24/7 operation for each 

mixing and reaction tank. For optimum 

flocculation and filtration, the 

metering quantity is adjusted to the 

respective flocculant requirement; as 

a rule, the pumps each dose at a rate 

of around ten litres per hour, which 

corresponds to a daily flocculant consumption 

of around 1,000 litres of 

ferric chloride solution. 

Frequent maintenance of 

diaphragms necessary 

Diaphragm metering pumps, which 

are standard in many metering stations, 

were initially used in the new 

Fig. 3: Check the dosing concentration at the outlet into the mixing and reaction basins 

metering system installed in 2017. 

However, after just a few months, it became 

apparent that this type of pump 

could not offer the reliability and longevity 

required for continuous use. “After 

just a few months, numerous, often 

lengthy repairs became necessary. 

The diaphragms had to be replaced approximately 

every three months,” reports 

the water technician. “While this 

maintenance could at least be carried 

In order to ensure uninterrupted operation 

of the flocculation in all four 

mixing and reaction basins, in addition 

to frequent maintenance and repair 

work, further measures became 

necessary. “We had two more diaphragm 

pumps than planned in stock 

as spare pumps and at some point, 

even had to bring in other pump 

technologies as an additional solution,” 

she recalls. 

out in-house, we often had to hire an Increasingly dissatisfied with 

external company for frequent repairs. 

The manufacturer of the diaphragm 

pumps advised us to reduce the stroke 

length - unfortunately, this did not lead 

to any improvement either and this 

the unreliability of the diaphragm 

pumps and the associated high 

operating costs, and with no prospect 

of fundamentally improving the 

situation with the existing equipment, 

measure was also associated with a reduction 

the Thüringer Fernwasser 

in the maximum possible metering 

quantity,” adds the engineer. 

team joined forces with an engineering 

firm to look for a better alterna- 




tive. They found what they were looking 

for with the peristaltic metering 

pumps from Watson-Marlow Fluid 

Technology Solutions. 

Peristaltic metering pumps for 

water treatment 

Fig. 4: A total of five pumps have been in use in the dosing station for flocculants for more 

than a year. 

The decision was made to initially test 

Qdos as part of a six-month field trial 

- first with a certain amount of scepticism. 

“At that time, I was mainly familiar 

with peristaltic pumps as a solution 

for sterile applications in medical 

technology and pharmaceuticals, but 

not as a metering solution for the water 

industry,” reports the engineer. 

“I was therefore initially unsure about 

the cost-effectiveness of peristaltic 

pumps in water treatment. Especially 

as peristaltic pumps are somewhat 

more expensive to purchase.” 

The peristaltic pump from 

Watson-Marlow was developed specifically 

for metering chemicals and 

treatment substances in the water industry. 

“As a peristaltic pump, Qdos 

has no diaphragms, valves or seals to 

clog or leak. As a result, it offers particularly 

low installation costs and 

can be easily installed in existing metering 

systems to replace previously 

used pumps without additional equipment,” 

explains the Sales Engineer at 

Watson-Marlow. 

In addition, the peristaltic metering 

pump has a particularly innovative 

design principle: the only wearing 

part on the entire pump is the 

patented ReNu pumphead, which can 

be replaced as a single component in 

just a few minutes. The pump is then 

available “as new”. As the pumphead 

is completely encapsulated, any leakage 

of liquid is reliably prevented. 

The operator does not come into contact 

with the pumped liquid. 

Wide range of sizes, pump head 

and control options 

The versatile Qdos metering pumps 

are used in countless applications in 

the water and wastewater industry, 

Fig. 5: The only wearing part on the entire 

pump is the patented ReNu pumphead, 

which can be replaced as a single component 

in just a few minutes 

Drinking water approval – end in sight! 

KLINGERSIL ® C-4240 

Germany 

The drinking water supply 

without compromises – 

Test confi rmation 

according to KTW-BWGL 

until August 2028 

KLINGER GmbH, 65510 Idstein, Tel. +49 6126 40160, mail@klinger.de, www.klinger.de 


35



as well as in the chemical industry 

and other process industries. A large 

selection of different pump models is 

available depending on the requirements 

profile: Different sizes are 

available for different flow rates, with 

maximum flow rates ranging from 

333 ml/min to 600 l/h. Depending on 

the model, they offer a wide range of 

control options, from manual control, 

4-20 mA to EtherNet/IP, PROFINET 

and PROFIBUS. Depending on the application, 

there are suitable pumphead 

options for the pump. A Santoprene 

tube is included as standard, 

which is suitable for a wide range of 

chemicals. Specially designed pumpheads, 

for example with SEBS or PU 

tubing materials, are also available 

for metering sodium hypochlorite or 

polymers. 

Fig. 6: The dosing pumps convey the flocculant ferric chloride from the siphon vessels of the 

storage tanks to the mixing and reaction basins. 

Peristaltic metering pumps 

impresses in trial 

Fig. 7: The Qdos metering pump is available in different sizes with maximum flow rates 

ranging from 333 ml/min to 600 l/h 

During the six-month trial in the 

drinking water treatment plant in 

Luisenthal, the pump was already 

able to fully convince. “The first thing 

we noticed was the significantly reduced 

noise level compared to the 

diaphragm pumps,” reports the water 

technician. “It is also much more 

user-friendly and doses much more 

evenly - i. e. with less pulsation - than 

a diaphragm pump.” 

However, the decisive criterion 

was: “As we are part of the critical infrastructure, 

reliability and low maintenance 

requirements, as well as quick 

and easy maintenance, if necessary, 

are of course the be-all and end-all 

for us,” says the engineer. “This is because 

flocculation and filtration is perhaps 

the most critical and important 

treatment step in the entire process; 

as soon as a pump breaks down, even 

briefly, this results in an immediate 

loss of our purification capacity.” 

Offering the required operational 

reliability 

In terms of reliability, the peristaltic 

metering pumps have impressed 

in these respects since their installation: 

a total of five pumps have now 

been in use in the metering station 

for more than one year and are running 

smoothly. Four pumps dose the 

flocculant into the four basins in continuous 

operation, while one pump 

is available as a reserve pump in the 

event of a failure. The current level 

of redundancy with one spare pump 

and four pumps in constant use 

would not have been practicable with 

the previous diaphragm pumps. 

The high level of operational safety 

is made possible not only by enormous 

reliability, but also by quick and 

easy maintenance. So far, the pumps 

are still working smoothly and reliably 

with the first pump head, and 

Thüringer Fernwasser is relaxed 

about future maintenance work. 

“Replacing the pump head is really 

easy and takes a maximum of ten minutes, 

including flushing and installing 

the pipes,” says an enthusias tic water 

technician, demonstrating the replacement 

process on the metering system’s 

reserve pump. No tools are re- 

quired and the pump does not need to 

be removed. 

The engineer gives an insight into 

the economic side of the application: 

“Despite higher initial investments for 

the Qdos peristaltic pumps, we are 

already saving considerable money 

in the second year due to lower costs 

for spare parts and maintenance 

compared to the diaphragm pumps.” 

The metering pumps quickly dispelled 

any initial scepticism regarding 

cost efficiency. “We have not only 

seen that peristaltic pumps are a reliable 

and efficient solution for metering 

applications in the drinking water 

industry. But that they are also a very 

economical solution here.” 

Watson-Marlow GmbH 

Rommerskirchen, Germany 

www.wmfts.com/de-de/ 


Make your business flow 

13th International Valve Trade Fair & Conference 

03 – 05 December 

2024 

Düsseldorf, Germany 

valveworldexpo.com



Service life extended, lighter workload on staff 

Conical progressive cavity pump for 

demanding applications in the industrial 

and wastewater sectors 

Markus Liebich 

Whether it’s high pressures or abrasive 

substances in the fluid: especially 

in the wastewater and industrial 

sectors, applications place high 

demands on pump technology. Progressive 

cavity pumps are designed 

to pump demanding media and 

have proven themselves as a pump 

technology in these industries. 

An example from the wastewater 

sector: digester feeding 

Progressive cavity pumps are often 

used to feed sludge digesters: the 

pumps push the thickened primary 

or raw sludge over long pumping 

distances into the digester towers, 

some of which are twenty meters 

high. A combination of abrasive media 

and high pressures of up to six 

bar put a lot of strain on the pumps. 

Often, the rotor and stator have to 

be replaced once or twice a year. 

This not only means that the pump 

is out of operation, but also requires 

a lot of time and resources: replacing 

spare parts is cost-intensive and requires 

at least two workers. 

Industrial users need flexible, lowmaintenance 

pumping solutions 

In industrial companies, too, pump 

technology conveys demanding media 

such as ceramic slurry. This watermineral 

mixture is required for the 

manufacture of ceramic products. 

The pulpy or semifluid consistency 

of ceramic slurry puts a lot of strain 

on the pumping elements during 

pumping. Slurried clay is also highly 

viscous, requiring powerful, robust 

industrial pumps that meet the requirements 

of the ceramics industry. 

For companies in the industrial 

and wastewater sectors, it is impor- 

Fig. 1: Energy-efficient and durable: The HiCone progressive cavity pump. 

(Source of all images: Vogelsang GmbH & Co. KG) 

Fig. 2: The conical geometry of the rotor and stator enables precise readjustment in the 

event of wear and replaces the need to replace parts. 

times longer than that of a conventant 

to have pump technology that is 

suitable for demanding applications 

and can be flexibly adapted to operating 

parameters. This reduces the 

costs and time required for maintenance 

work. 

HiCone with conical rotor-stator 

geometry: adjustment instead of 

part replacement 

The HiCone progressive cavity pump 

from Vogelsang GmbH & Co. KG is 

designed to meet these requirements. 

The rotor and stator of the 

pump are conical in shape. If a gap 

occurs between the two parts as a result 

of wear, this can be compensated 

during operation: the rotor is adjusted 

axially. The pump then regains the 

same characteristics as when it was 

new. There is no need for time-consuming 

and costly part changes. 

Cut down on repeated 

maintenance work 

Thanks to the precise adjustment, the 

service life of the HiCone is up to four 




Fig. 3: The smart adjustment system allows the HiCone to be individually readjusted 

to suit a variety of operating parameters. 

tional progressive cavity pump. 

Maintenance work is required 

less frequently and is easier to 

plan. This relieves the burden on 

maintenance personnel and creates 

free capacity – which is also 

financially beneficial, especially 

in times of a shortage of skilled 

workers. This is particularly advantageous 

for companies with 

pumps in remote use. If the 

HiCone is equipped with automatic 

readjustment, the company 

has the option of observing 

and recording the wear of the 

pump on its monitors and optionally 

also on the pump. This 

means that maintenance work 

can be planned very precisely. 

Responding to process changes 

The fact that the HiCone can be 

individually adapted to the applicable 

operating parameters at 

any given time, such as temperature 

or viscosity, also contributes 

to this. The adjustment system 

ensures that the rotor and stator 

are optimally positioned in relation 

to each other. For example, 

the user can adjust them to different 

viscosities in the best possible 

way. The higher the viscosity, 

the better they seal the gap 

in the pump. The clamping can 

therefore be reduced. This is 

done by the user pulling the rotor 

out slightly. 

This also applies to applications 

with high temperatures or 

temperature changes: if the rubber 

in the stator expands due to 

high temperatures, there is increased 

clamping between the 

rotor and stator. To reduce this, 

the rotor is retracted. If the temperature 

then drops again, the 

rubber in the stator contracts. As 

a result, the clamping force is reduced 

and the pumping capacity 

decreases. In this case, the rotor 

is pushed in further until the desired 

clamping is achieved again. 

High flexibility: mobile sludge 

dewatering 

Companies working in the area 

of mobile sludge dewatering also 

benefit from this high flexibility 

of the HiCone. Here, the pump 

technology must be designed 

for high temperature fluctuations. 

The sludge is sucked out of 

the respective system by a progressive 

cavity pump and dewatered 

in a container. The operator 

uses this device at a number 

of different industrial companies. 

The sludge there varies between 

temperatures of 20 to 60 

degrees Celsius. To cover all applications, 

the operator therefore 

uses two progressive cavity 

pumps: a “normal” one for temperatures 

of up to 40 degrees 

and a progressive cavity pump 

with an undersized stator. 

By using the HiCone, the 

operator now saves the cost of a 

conventional progressive cavity 

pump and the associated power 

electronics. The company benefits 

from lower acquisition costs 

and more space in the container 

and can therefore react even more 

flexibly to the conditions on site. 

Energy-efficient pumping 

The HiCone is also particularly 

energy-efficient. This is due to its 

intelligent automatic startup. The 

size of the drive motor in a progressive 

cavity pump is usually 

determined by the high starting 

torque. Thanks to the adjustable 

clamping between rotor and stator, 

the motor needs less power 

than in a conventional progressive 

cavity pump. The torque 

when starting up the pump is 

minimized and the power requirement 

is reduced. The startup 

process is fully automatic. 

Due to the smaller drive motor, 

the frequency converter on the 

pump is also smaller. 

Experience the HiCone live: 

Vogelsang at IFAT and 

Achema 

Interested parties can find out 

more about the HiCone conical 

progressive cavity pump at 

various trade fairs this year: 

IFAT: May 13-17, Munich, 

Vogelsang booth in 

hall B1, booth 347/446 

Achema: June 10-14, 

Frankfurt am Main, 

Vogelsang booth in 

hall 8.0, booth F64 

The Author: Markus Liebich, 

Key Account Manager Wastewater 

and Biogas, 

Vogelsang GmbH & Co. KG, 

Essen (Oldenburg), Germany 

www.vogelsang.info 

Team Digital for more efficiency. 

Pump monitoring, pump control and frequency 

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Take advantage of these benefits: 

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

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


Screw pumps 

Advancing fluid conveyance 

beyond conventional boundaries 

Peter Volkert 

In the realm of chemical applications, 

precision, safety, and efficiency 

reign supreme. When it comes 

to handling viscous fluids, positive 

displacement pumps play a pivotal 

role. Among these pumps, screw 

pumps stand out as they offer distinct 

advantages over their rotating 

counterparts. They excel in 

characteristics such as zero pulsation, 

exceptional suction capacity, 

low noise emissions, a broad flow 

rate range achievable with a single 

pump, and gentle fluid handling, all 

while maintaining exceptional efficiency 

and high performance. 

Screw pumps fall into two major categories, 

distinguished by the placement 

of their bearings: outer bearing 

and internal bearing pumps. 

Fig. 1: Diagram of the volumetric efficiency of the L2MG at 1,500 rpm 

Outer bearing pumps 

These pumps shine when it comes 

to handling liquids with higher solid 

contents or extremely high gas fractions, 

allowing for the conveyance of 

substantial flow rates. However, due 

to the necessity of four sealings and 

complex supply systems, they can 

become a costly solution. 

Internal bearing pumps 

In contrast, internal bearing pumps 

offer a host of advantages. They require 

only one mechanical seal, in 

contrast to the four needed in their 

external bearing counterparts, and 

can also be equipped with a magnetic 

coupling. 

Screw pumps with magnetic coupling 

represent a cutting-edge innovation 

that has revolutionized fluid 

handling across various industries, 

particularly in chemical applications. 

Leistritz, a revered name in the pump 

technology sector, has been at the 

forefront of this transformative development. 

Fig. 2: L2MG twin screw pump rendering 

A prime example 

Handling isocyanates exemplifies the 

prowess of this pump application, 

and Leistritz has amassed a wealth 

of experience in this regard with its 

magnetic-coupled internal bearing 

pumps. 

Regrettably, the use of this pump 

type has been limited in the handling 

of low-viscosity solvents like hexane or 

toluene, as the hydrodynamic bearing 

systems necessitate higher viscosity. 

Consequently, this highly secure and 

cost-efficient solution remained inapplicable 

for processes that required 

solvent flushing, such as polymerization 

loop processes. This limitation is 

rooted in a fundamental fact. 

This limitation has propelled conventional 

screw pumps with external 

bearings into a multifaceted role, excelling 

in handling low-viscosity products 

at the expense of higher costs. 

For the Leistritz engineers, rejuvenating 

screw pumps has become 

an exciting challenge – and they conquered 

it! 



Screw pumps 

A quantum leap forward 

The development of the L2MG pump 

series represents a significant milestone, 

especially in the aforementioned 

industries. Capable of seamlessly 

handling viscosities spanning 

from 0.3 to 100,000 mPas and delivering 

differential pressures up to 

40 bar, this innovative pump series 

optimizes processes, enhances efficiency, 

and ensures compliance 

with safety standards. The choice between 

magnetic and mechanical coupling 

offers versatility, while the sealless 

design minimizes maintenance 

concerns, all of which contribute to 

reduced life cycle costs. 

In conclusion, the Leistritz L2MG 

pump series is a game-changer for 

the polymerization and general 

chemical industry. Its versatility and 

performance enhancements usher 

in a new era of efficiency and safety, 

ultimately boosting productivity and 

cost savings for operators. As polymerization 

processes continue to 

evolve, the L2MG series is poised to 

play a pivotal role in driving progress 

and innovation in the field. 

Additionally, there is another decisive 

advantage: Due to the design 

of the L2MG, characterized by significantly 

higher efficiency and minimal 

backflow, sheer-sensitive products 

are handled with exceptional 

smoothness, eliminating concerns 

that molecule chains could be severed. 

Leistritz has introduced this 

groundbreaking pump series, the 

L2MG, which vastly extends the 

range of viscosities it can handle, accommodating 

increased differential 

pressures. The chemical industry 

now has access to a product capable 

of managing viscosities ranging from 

0.3 to 100,000 mPas at differential 

pressures up to 40 bars, no matter 

if magnetic or mechanical coupling 

is used. 

In terms of efficiency, safety, and 

life cycle costs, this development is a 

true game-changer that seemed unimaginable 

just five years ago. 

The Author: Peter Volkert, 

Head of Sales Chemistry & Life 

Science Leistritz Pumpen GmbH, 

Nuremberg, Germany 

https://pumps.leistritz.com 

We tackle the 

challenges of the 

future – with our 

intelligent vacuum 

solutions. 

www.buschvacuum.com



Tracking the Big Bang 

Vacuum Systems for technology development 

in gravitational wave detection 

Prof. Dr. Oliver Gerberding, Jens Grundmann, Dr. René Wutzler, Dr. Artem Basalaev 

How did our universe come into being? 

What is our universe made of? 

And what events occurred during the 

creation process? These and other 

questions are on the minds of astronomers 

and physicists around the 

world today. To answer these questions, 

we need information about 

the dark objects in our Universe and 

about the time close to the Big Bang, 

about 13.8 billion years ago. But how 

do we get information about objects 

that we cannot see and therefore 

cannot observe with electromagnetic 

radiation? How is it possible 

to observe objects and events close 

to the Big Bang, at a time when the 

universe was opaque? One carrier 

of such “old” information is what we 

call gravitational waves. 

As early as 1915, Albert Einstein described 

the influence of mass on space 

and time, or spacetime for short, in his 

general theory of relati vity [1]. Masses 

bend spacetime, which in turn affects 

the motion of masses, describing the 

phenomenon of gravity. The propagation 

of spacetime distortions caused 

by accelerated masses is now known 

as gravitational waves, and they produce 

tiny changes in distance at great 

distances from their source. Although 

Einstein developed the theory of the 

existence of these gravitational waves 

in 1915, he assumed at the time that 

we would not be able to detect them 

on Earth. In 2015, scientists succeeded 

in detecting exactly these gravitational 

waves [2]. With the help of the 

LIGO (Laser Interferometer Gravitational-Wave 

Observatory) in the USA, 

the collision of two black holes, both 

many times the mass of our Sun, was 

detected. This collision occurred at a 

distance of 1.3 billion light-years from 

Earth, making it possible to observe a 

cosmic event that took place 1.3 billion 

years ago. Since then, more than 100 

such events have been recorded [3]. 

How can we think of gravitational 

waves? A simple analogy is a large, 

still lake into which a stone is thrown. 

Waves are created at the point where 

the stone hits the surface of the water. 

These waves slowly lose strength 

with distance from the point of impact, 

so that the waves are barely 

noticeable on the shore of the lake. 

If this observation were applied to 

space, the lake would be our universe 

and the rock would symbolize a disturbance 

of space-time by an accelerated 

mass, such as a moving star or a 

collapsing black hole. We would hardly 

notice the effect in terms of gravitational 

waves at our measuring position, 

the Earth as an analogy to the 

shore of the lake. This is because, 

in addition to the distance from the 

events, space-time is very rigid and 

much less susceptible to oscillation 

than water. This means that only extreme 

events, such as the merging of 

black holes, can generate measurable 

gravitational waves. 

The distance changes caused 

by gravitational waves are extremely 

small. For example, a gravitational 

wave caused by the merging of black 

a second. These tiny measurements 

also place special demands on the 

measurement technology to be used. 

The central property of special 

relativity, that the speed of light is 

constant for any observer, was demonstrated 

by Michelson and Morley 

using a Michelson interferometer. 

The principle on which this instrument 

is based is laser interferometry 

[4]. Such laser interferometers 

are also used to detect gravitational 

waves, as they can measure tiny 

changes in distance extremely well. 

The special challenge of this method 

is the L-shaped arrangement and the 

longest possible optical paths (called 

arms) of infrared laser light. Long 

arms amplify the effect of the gravitational 

wave so that the changes in 

distance can still be detected. The laser 

light is directed into these arms 

by semi-transparent mirrors, reflected 

at the end by more mirrors, and 

returned to its point of origin. There, 

the light waves are superimposed (interference). 

Interfering, i. e. superimposed, 

waves can amplify each other if “wave 

crest meets wave crest” at the same 

holes in the Milky Way would change wavelength (constructive interference). 

the distance between the Sun and the 

Earth by only the diameter of a hydrogen 

atom. Moreover, for many of the 

objects we observe today, this change 

in distance lasts only a thousandth of 

Or, when the “wave crest and 

trough” meet, extinction occurs (destructive 

interference). In the experiment, 

the system is set up so that no 

light is visible at the output. When a 

Fig. 1: Screw pump and magnetically levitated turbopump from Pfeiffer Vacuum 




gravitational wave hits the plane in 

which the arms of the interferometer 

lie, one arm (or both, depending on 

the direction of incidence) is periodically 

shortened and lengthened. This 

changes the conditions for optical 

superposition, i. e. destructive interference, 

which produces a signal at 

the so-called dark finge. This is what 

makes the gravitational wave visible, 

or rather audible. LIGO is based on 

the same principle. At the two LIGO 

sites in the US states of Washington 

and Louisiana, great care is taken to 

ensure that the highly sensitive mirrors 

and their reflective properties 

are not affected by dirt. Therefore, 

only dry, hydrocarbon-free pumps 

are used to create the necessary vacuum. 

The pumping stations used consist 

of dry screw pumps and magnetically 

levitated turbopumps. This is 

the only way to achieve the limit of 

< 1 monolayer in 10 years on the mirrors. 

In addition to cleanliness, low vibration 

plays an important role. 

To ensure that new and more 

gravitational wave signals can be detected 

in the future, continuous improvements 

are needed to reduce 

interference. Detectors on Earth are 

limited in particular by the suspension 

and regulation of the mirrors in a 

vacuum. This suspension is necessary 

to isolate the mirrors from disturbances 

such as seismic waves. At the 

same time, however, it must allow the 

mirrors to be perfectly positioned. In 

particular, the next generation of detectors, 

such as the European Einstein 

Telescope [5], will be even more sensitive 

at lower frequencies and therefore 

require mirror suspensions with 

improved control and less noise. In 

order to develop the necessary technologies, 

smaller laboratories are trying 

to simulate the environmental 

conditions for the development of 

better instruments and components 

as accurately as possible, also in order 

not to reduce the observation 

times in the large detectors. 

As part of the “Quantum Universe” 

Cluster of Excellence (EXC2121: 

German Research Foundation - project 

number 390833306), the research 

group headed by Prof. Dr. Oliver 

Gerberding at the University of Hamburg 

is working on improving optomechanical 

sensors. Pfeiffer Vacuum the system, a second optical table is 

GmbH is supporting the working mounted on a side wall of the vacuum 

chamber and enables the trans- 

group with a special vacuum system. 

The vacuum system developed mission of laser light from the outside 

to the inside via transparent 

and manufactured within the project 

“VatiGrav” (vacuum chamber with flanges in the same plane as both 

seismic isolation of an optical test experimental tables. For easy access 

platform, funded by the University of to the chamber and the experiment 

Hamburg/State of Hamburg and the table inside, there are doors on both 

German Research Foundation, DFG, sides of the vacuum chamber. There 

project number 455096128) fulfills is a single large door at the front to 

several functions at once with its size make the entire interior volume accessible 

for experiments. This can 

of approx. 1.5 m long, 2 m wide and 

2.5 m high. The stainless-steel vacuum also be used to remove the internal 

chamber with a free internal dimension 

of 1.74 x 1.02 x 1.51 m (LxWxH) the vacuum chamber is divided and 

optical table if required. The rear of 

serves as a container for the experimental 

setups of Prof. Gerberding’s via two separate doors. 

allows access to the experiment table 

research group. For this purpose, the In addition to the dual functions 

vacuum chamber is equipped with of test chamber and vibration damping, 

the vacuum system is responsi- 

an optical table, which rests on passive 

vibration dampers on the chamber 

floor and on which the laser in- 

are performed under vacuum condible 

for ensuring that the experiments 

terferometry experiments and the tions. For this purpose, two oil-free 

pendulum systems can be set up. The ACP 40 multistage Roots pumps from 

purpose of the passive dampers is to Pfeiffer Vacuum are installed in the 

allow low-vibration experiments under 

vacuum conditions. In addition, in an adjacent room of the laboratory 

vacuum chamber. These are located 

the vacuum chamber itself rests on and are connected to the chamber by 

active vibration dampers that use internal 

sensor and control technology The two pumps are used to gener- 

approximately 4 m of vacuum piping. 

to ensure that vibrations and oscillations 

from the environment are sup- 

Once the pre-vacuum pressure of 

ate the pre-vacuum in the chamber. 

pressed and do not affect the experiments. 

Frequencies above 2 Hz are the ATH 3204 M turbomolecular 

about 1e-1 mbar has been reached, 

absorbed with over 90 % damping. pump located on the chamber ceiling 

This isolation concept is based on can be switched on to achieve even 

correspondingly more complex systems 

at LIGO [6] and in other spe- 

magnetically levitated turbomolecu- 

lower pressures. The ATH 3204 M is a 

cial laboratories around the world. To lar pump from Pfeiffer Vacuum and 

couple experimental setups outside has a maximum pumping speed of 

Fig. 2: Vacuum chamber with seismic isolation of an optical test platform 


43



05A20GU5 & 05A23GU5). After successful 

demonstration, new methods, 

algorithms and sensors can be 

integrated into larger prototypes [8, 

9] and finally into current and future 

detectors. The goal is to improve the 

detection of gravitational waves, especially 

at low frequencies. Since 

most signals enter the measurement 

band at low frequencies, such 

improvements can, among other 

things, increase the observation time 

enormously. In the long run, it should 

be possible to detect the signals of 

merging black holes many minutes 

before the event and thus determine 

the position of the objects. Then 

other telescopes can point in that direction 

and “check” for electromagnetic 

traces of such events, which in 

turn allows us to better understand 

the physics of such objects. 

References 

Fig. 3: Oil-free multistage Roots pumps ACP 40 

3050 l/s for nitrogen. The magnetic 

bearing enables low-vibration evacuation 

of the volume. When connecting 

the individual pumps to each other, 

care was taken to use connecting 

elements that reduce vibration transmission. 

With the pump system, a vacuum 

pressure of approx. 1e-6 mbar 

can be achieved in less than 2 h and a 

final pressure of < 1e-7 mbar. 

During the course of the project, 

which lasted just over a year, other 

challenges arose in addition to the 

technical requirements for the system. 

In addition to the ubiquitous 

shortages of materials and components 

during the pandemic years and 

the associated delays, the future site 

of the vacuum system was undergoing 

reconstruction and expansion. 

This meant that not only the realization 

of the vacuum system, but also 

the coordination of the laboratory 

setup was an important task during 

the project. The interfaces and contact 

points between the vacuum system 

and the laboratory extension included 

the space requirements. Due 

to the existing room height, it was 

necessary to harmonize the room 

installations, the clean room tent in 

which the system would be located, 

and the height of the vacuum system. 

Other challenges included the 

weight of the system and the maximum 

floor load capacity, which could 

be undercut with floor reinforcements 

and additional support plates. 

In addition, the final installation of 

the system had to take into account 

the low passage heights and widths. 

However, all challenges were overcome 

and the system is now ready 

for use by Prof. Gerberding’s team. 

Scientists at the University of 

Hamburg have now begun to characterize 

and optimize the vacuum 

chamber and, in particular, the seismic 

isolation systems. Many further 

investigations and adjustments 

will be necessary before the system 

reaches its optimal performance - 

a process that usually takes several 

years. The first experiments to be 

performed in and with the chamber 

include studies on new methods of 

seismic isolation using artificial intelligence 

and the characterization 

of compact laser interferometers 

to be integrated into the pendulum 

systems as ultra-precise displacement 

sensors [7] (BMBF projects 

Einstein, A. (1915). Erklärung der 

Perihelbewegung des Merkur aus der 

allgemeinen Relativitätstheorie. Sitzungsberichte 

der Königlich Preußischen 

Akademie der Wissenschaften 

(Berlin, 831-839. 

Abbott, B. P., Abbott, R., Abbott, T. D., 

Abernathy, M. R., Acernese, F., Ackley, 

K., ... & Cavalieri, R. (2016). Observation 

of gravitational waves from a binary 

black hole merger. Physical review 

letters, 116(6), 061102. 

The LIGO Scientific Collaboration, the 

Virgo Collaboration, the KAGRA Collaboration 

et al., GWTC-3: Compact 

Binary Coalescences Observed by 

LIGO and Virgo During the Se cond 

Part of the Third Observing Run, General 

Rela tivitry and Quantum Cosmology 

(gr-qc), 2021, https://doi. 

org/10.48550/arXiv.2111.03606 

Saulson, P. R. (1994). Fundamentals of 

interferometric gravitational wave detectors. 

Punturo, M., Abernathy, M., Acernese, 

F., Allen, B., Andersson, N., Arun, K., ... 

& Yamamoto, K. (2010). The Einstein 

Telescope: a third-generation gravitational 

wave observatory. Classical and 

Quantum Gravity, 27(19), 194002. 

Matichard, F., Lantz, B., Mittleman, 

R., Mason, K., Kissel, J., Abbott, B., ... 

& Wen, S. (2015). Seismic isolation of 

Advanced LIGO: Review of strategy, 




instrumentation and performance. 

Classical and Quantum Gravity, 

32(18), 185003. 

Gerberding, O., & Isleif, K. S. (2021). 

Ghost Beam Suppression in Deep Frequency 

Modulation Interferometry 

for Compact On-Axis Optical Heads. 

Sensors, 21(5), 1708. 

Kirchhoff, R., Mow-Lowry, C. M., Bergmann, 

G., Hanke, M. M., Koch, P., 

Köhlenbeck, S. M., ... & Strain, K. A. 

(2020). Local active isolation of the 

AEI-SAS for the AEI 10 m prototype facility. 

Classical and Quantum Gravity, 

37(11), 115004. 

Di Pace, S., Mangano, V., Pierini, L., 

Rezaei, A., Hennig, J. S., Hennig, M., 

... & Van Heijningen, J. (2022). Research 

Facilities for Europe’s Next 

Generation Gravitational-Wave Detector 

Einstein Telescope. Galaxies, 

10(3), 65. 

Acknowledgements 

This project was funded by the German 

Research Foundation (DFG) as 

part of the “Large-scale research facilities” 

programme, project number 

455096128. Furthermore, O. 

Gerberding and A. Basalaev were 

funded within the framework of 

the Excellence Strategy - EXC 2121 

“Quantum Universe”, project number 

390833306 and by the Federal Ministry 

of Education and Research (BMBF) 

within the framework programm “Exploration 

of the Universe and Matter”, 

project 05A20GU5. 

The Authors: 

Prof. Dr. Oliver Gerberding, junior professor of physics at the University of 

Hamburg, where he is setting up a working group for gravitational wave detection 

as part of the Quantum Universe Cluster of Excellence. The group researches and 

develops techniques for the improvement and realization of detectors on Earth and 

in space and is involved in LIGO, the Einstein Telescope and the LISA mission. 

Jens Grundmann and Dr René Wutzler, both project manager at Dreebit GmbH, a 

wholly owned subsidiary of Pfeiffer Vacuum GmbH, since 2020. 

Dr Artem Basalaevis, experimental physicist at the University of Hamburg in the 

working group of Prof Dr Oliver Gerberding in the Quantum Universe Cluster of 

Excellence. 

WATER AS A TOOL. 

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45



Potential of surface structures for the 

reduction of vacuum gap flows 

Sven Brock, Heiko Pleskun, Gero Polus, Jannis Saelzer, Prof. Dr.-Ing. Prof h.c. Dirk Biermann, 

Prof. Dr.-Ing. Andreas Brümmer 

Abstract 

This article presents a patented approach 

for the fluid-mechanical and 

thermodynamic improvement of screw 

spindle vacuum pumps [Brü21]. These 

machines belong to the group of rotary 

positive displacement vacuum pumps 

and have two parallel rotors that convey 

the gas along the rotor axes. Chambers 

are formed between the rotors and 

the surrounding housing. Due to rotation 

the fluid is carried in axial direction 

and expelled on the high-pressure side 

(which is typically atmosphere) by reducing 

the chamber volume. The main 

loss mechanism of such machines is 

identified as the operational gaps, 

through which the fluid can flow in the 

opposite direction. These gap flows are 

usually minimized by selecting the lowest 

possible gap height. 

As the reduction of the gap height 

is limited by the operational safety due 

to manufacturing tolerances and thermal 

expansion, this study concentrates 

on the reduction of gap mass flow 

rates through surface structures without 

simultaneously reducing the gap 

height. These structures have a profile 

depth that is significantly less than the 

minimal gap height between the housing 

and the rotor. The main objective 

is to specifically manipulate the reflection 

properties of molecules in the region 

of rarefied gas flows where gassurface 

interactions dominate. The 

strategic arrangement of these surface 

structures should increase the rate of 

back scattering of the molecules in opposite 

direction of flow. This is intended 

to achieve a reduced gap mass flow 

without jeopardising the operational 

safety of the machine. 

they are able to generate a technically 

clean vacuum and at the same 

time have a good tolerance for dirt 

particles and small amounts of liquid. 

As only a few machine parts are required 

due to their design, the assembly 

and maintenance costs of 

these machines are comparatively 

low. Together with their high suction 

speed (up to S eff 

= 2500 m³/h), these 

machines are particularly interesting 

for industrial purposes. They offer 

suction pressures from p suction 

= 0.1 Pa 

up to atmospheric pressure p at 

and 

are therefore suitable for low and 

medium vacuum applications. In 

many applications, they are used as 

fore vacuum pumps in combination 

with roots pumps or other vacuum 

pumps for high suction speeds in the 

fine or high vacuum regime [Jou18]. 

The most important parameter for 

SSVPs is the effective pumping speed 

S eff 

, which describes the volume flow 

on the low-pressure side. The lowest 

achievable pressure that can be 

reached in a recipient with a vacuum 

pump without external leakage is 

referred to as the ultimate pressure 

[Jou18]. The characteristic curve describing 

the machine is the so-called 

suction speed curve, which describes 

the suction speed as a function of the 

suction pressure, whereby the discharge 

pressure corresponds to the 

atmospheric pressure. In measurements, 

Dreifert and Müller have observed 

that the suction speed curve 

of an SSVP is significantly influenced 

by the clearance between the rotors 

and the enclosing housing (the socalled 

housing gap). Fig. 2 shows that 

even a ten per cent change in the gap 

height causes a significant change in 

the characteristic curve, with an increasing 

effect for lower suction pressures 

[Dre14]. Accordingly, minimising 

the housing gap mass flow rate is 

essential for the efficiency of the machine, 

whereby the reduction of the 

gap height has limits in terms of operational 

safety, as the clearance must 

be guaranteed minus the manufacturing 

tolerances, possible vibrations 

and, in particular, thermal expansion 

for friction-free operation. 

In general, the suction speed of 

the machine initially increases with 

decreasing suction pressure until 

a maxi mum - the so-called nominal 

suction speed - is reached. The 

suction speed then drops to zero as 

the pressure is lowered further and 

the machine’s ultimate pressure is 

Introduction 

Screw spindle vacuum pumps (SSVP) 

(see Fig. 1) have become increasingly 

important in recent years, because 

Fig. 1: Principle sketch of a screw spindle vacuum pump (SSVP) 




Fig. 2: Suctions speed curve of an SSVP with different housing gap heights [Dre14]. 

reached. As less and less mass enters 

the machine at lower pressures, 

an equilibrium is established at this 

pressure between the intake mass 

flow rate and the mass flow rate that 

returns through the gaps, so that 

the machine effectively no longer 

conveys anything, thus preventing 

a further reduction in pressure. The 

charac teristic of the machine with initially 

increasing suction speed results 

from the fluid mechanical properties 

within the gap. At high suction pressure, 

the molecular density is high, 

so that a molecule collides very frequently 

with other molecules until 

it encounters a boundary (rotor and 

housing). In this way, the momentum 

and energy transport are dominated 

by intermolecular collisions and the 

fluid moves as a continuum. When 

the pressure is reduced, the molecular 

density also decreases so that a 

particle can travel a greater distance 

until it collides with another particle. 

This increases the proportion of gassurface 

collisions, which leads to increased 

friction. If the pressure is so 

low that the number of intermolecular 

collisions is negligible compared to 

the particle-wall collisions, this is referred 

to as a molecular flow. A qualitative 

course of the normalised mass 

flow rate of a gap through which air 

flows is shown in Fig. 3. The normalisation 

is chosen so that a normalised 

mass flow rate of one corresponds to 

an isentropic choked nozzle flow. The 

gap height is set to h = 0.3 mm and 

T = 293 K is assumed for the ambient 

temperature. It is shown that the normalised 

mass flow rate with an initial 

continuum flow decreases significantly 

with decreasing inlet pressure 

until a minimum is reached and then 

increases again asymptotically with 

further pressure reduction towards 

molecular flow. The greater proportion 

of gas-surface interactions also 

increases the influence of relative 

wall movement on the mass flow 

rate. Such a wall movement is caused 

by the rotational speed of the rotors. 

Accordingly, the red line results from 

a wall movement in the direction of 

flow, the green line for a wall movement 

against the direction of flow 

and the black line describes a purely 

pressure-driven flow with static 

boundaries. 

In order to realise the highpressure 

ratios over the machine 

(e. g. p at 

/p suction 

= 10 5 ), the rotors have 

a significantly larger wrap than conventional 

screw machines in high 

pressure applications. This results in 

a kind of multi-stage design with several 

encapsulated working chambers 

in axial direction, which leads to a reduction 

in the pressure ratio between 

individual working chambers. In order 

to avoid continuous gap connections 

from the high-pressure to the lowpressure 

side, the number of teeth is 

limited to a maximum of two, or even 

one for some profiles. Internal compression 

is usually achieved by successively 

reducing the chamber volume 

by changing the rotor pitch, but 

more recently also by using conical 

rotors [Moe23]. The advantage of reducing 

the chamber volume continuously 

instead of using an end plate is a 

more uniform compression along the 

rotor and therefore better heat distribution 

in the machine. Furthermore, 

throttling losses can be reduced by 

avoiding control edges [Jou18]. One 

problem with the internal compression 

of the machines is that the machine 

has to cover very large pressure 

ranges. In nominal oper ation, a very 

large internal compression would 

be desirable, which would reduce 

the energy consumption on the one 

hand and possibly also the size on 

the other. For example, a large suction 

chamber takes up a lot of mass, 

which can then be compressed to a 

small volume and then pushed out 

on the high-pressure side at a low 

Fig. 3: Schematic course of the normalised mass flow rate through the housing gap of an 

SSVP as a function of the inlet pressure and the influence of relatively moved walls. 


47



rotor lead. However, at high suction 

pressures, especially when starting 

up the machine and a recipient has 

to be evacuated initially, this leads to 

considerable over-compression and 

thus to temperature peaks, but above 

all to increased power consumption 

and thus to a high torque. This can 

be avoided by using a pressure relief 

valve, for example, but this requires 

a certain amount of maintenance. In 

order to ensure high internal compression 

while avoiding a pressure 

relief valve, Kösters and Eickhoff suggest 

that the housing gap on the lowpressure 

side of the machine should 

be deliberately made larger [Kös06]. 

Therefore, the significantly improved 

gap situation in the low suction pressure 

range (see Fig. 3) is exploited. 

The idea is therefore that more mass 

flows back during start-up, which reduces 

or prevents over-compression, 

and a good machine is still obtained 

because the gaps become tighter as 

the pressure falls. 

This article proposes an approach 

that can significantly reduce the machine's 

housing gap mass flow rate 

in the low-pressure range without reducing 

the gap height and thus compromising 

operational safety. Since 

the gas-surface interactions dominate 

in rarefied gas flows, the scattering 

direction of the molecules is to be 

influenced by a microscopic surface 

structure so that they have a greater 

probability of being scattered back 

against the direction of flow. 

the exact normal vector in relation to 

the reflection point is not defined, as 

the roughness peaks are statistically 

distributed. It is therefore assumed 

that the particle carries out any number 

of collisions in the roughness 

structure, spends enough time to be 

in equilibrium with the wall in terms 

of energy and is then scattered away 

from the wall in any direction. The 

scattered velocity vector is therefore 

independent of the incidence angle, 

whereby the particles are scattered 

on average perpendicular to the wall. 

The result is the so-called cosine distribution, 

which is shown schematically 

in Fig. 4. On this basis, mathematical 

models for calculating the 

mass flow rate can be derived, which 

are in good agreement with measurement 

results for many technical surfaces 

[Jou18]. 

The idea is now to manufacture 

a pattern on the surface transversal 

to the flow direction, as shown schematically 

in Fig. 5, through which the 

molecules have a greater probability 

of being scattered back in the opposite 

direction. The profile depth Λ of 

the pattern should be much smaller 

than the gap height h, but still large 

compared to the molecular diameter, 

so that the local surface structure is 

characterized as rough in relation to 

the individual molecule. With standard 

gap heights in the order of h ≈ 0.1- 

0.3 mm, the profile depth is in the order 

of Λ ≈ 1-30 µm. Assuming that 

the surface pattern has a roughness 

that is significantly smaller than the 

profile depth, this is still much larger 

than the molecular diameter, so that 

the assumption of diffuse scattering 

applies locally. Using the triangular 

profile as an example, the profile angles 

α and β are defined here. 

Simulation and modelling 

The influence of surface structures 

on the mass flow rate of gap flows is 

analysed using the direct simulation 

Monte Carlo (DSMC) method. This is 

a statistical simulation method for 

flows based on molecular movements 

and interactions. A special feature of 

the method is that a simulated particle 

represents a large number of identical 

molecules that perform identical 

movements at the same time. Furthermore, 

the particle movement 

and the particle collision are decoupled 

from each other, so that in one 

time step all particles are first moved 

along their trajectory and then collisions 

between the particles are carried 

out using statistical methods. In 

this way, the colliding particles receive 

modified velocity vectors and internal 

energies in compliance with the conservation 

of momentum and energy. 

This assumption makes it possible to 

analyse larger systems on a technical 

scale. Although each individual time 

step is subject to a large statistical uncertainty, 

this can be successively reduced 

by averaging many time steps 

over time. The gas-wall interaction fol- 

Gas-surface interaction 

The most common assumption of 

gas-surface interactions with technically 

smooth surfaces is the so-called 

diffuse wall scattering. In contrast to 

specular reflection, in which the molecule 

retains its entire tangential momentum 

and energy before the collision 

according to the principle of the 

incidence angle equalling the angle of 

reflection, diffuse scattering is based 

on the model assumption that the 

surface is very rough in relation to the 

molecular diameter since roughness 

peaks are usually specified in micrometres 

and the mole cular diameter is 

still about four powers smaller in the 

order of angstroms. This means that 

Fig. 4: Diffuse wall scattering on a technically smooth surface 




Fig. 5: Molecular scattering on a structured surface 

lows the diffuse wall model described generated at the beginning of each 

above. If a particle leaves the simulation 

area during the movement step, ary conditions. [Bir94] 

time step on the basis of the bound- 

it is eliminated from the simulation. The macroscopic variables such 

At the open edges, new particles are as pressure, temperature and flow 

velocity are then derived from the 

particle distribution with the respective 

particle masses, the momentum 

and the corresponding energy. 

Sazhin already used this method to 

investigate a pressure-driven flow, 

starting from a high-pressure reservoir 

with pressure p 1 

and temperature 

T 1 

through a channel with a triangular 

structure on the channel walls 

into a perfect vacuum (p 2 

= 0) [Saz20]. 

An exemplary simulation domain 

is shown in Fig. 6. The channel 

width is considered to be much larger 

than the channel height, so that a 

2D flow is considered. The dash-dot 

line indicates a symmetry plane so 

that both edges have the same surface 

structure. Fig. 7 shows the mass 

flow through the channel with surface 

structures in relation to the mass 

flow that occurs with smooth walls at 

the same gap height as a function of 

the gap inlet pressure p 1 

for different 

profile angles α = β. 

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49



Fig. 6: Simulation domain for a pressure-driven flow through a channel with structured 

surfaces 

a) L/h=1 b) L/h=10 

Fig. 7: Mass flow rate through a channel with structured surfaces related to the respective 

mass flow rate through a channel with smooth surfaces as a function of the inlet pressure p 1 

for different profile parameters α = β [Saz20]. 

Fig. 7a shows this for a length to 

height ratio of one, which corresponds 

approximately to an orifice 

flow. It can be seen that all four 

curves cause an increased throttling 

effect with decreasing pressure, 

which can be explained analogously 

to Fig. 3 by the fact that the proportion 

of gas-surface interactions increases. 

Furthermore, the throttling 

effect depends on the shape of the 

surface structure. A very wide profile 

angle causes only a slight reduction 

in the mass flow rate, while a profile 

angle α = β = 45° already causes 

a reduction in the mass flow rate of 

about 10 % in the orifice flow. If the 

profile angle is reduced further, the 

flow stagnates. This can also be seen 

in Fig. 7b, where the same situation 

is shown for a length to height ratio 

of ten and the molecules therefore 

have to pass through a significantly 

longer channel. Here, a reduction of 

about 25 % can already be achieved 

for smaller profile angles. It is also 

noticeable that the effect becomes 

smaller for increasing inlet pressures, 

so that a transfer to the vacuum 

pump is particularly interesting 

for the low-pressure side of the machine. 

This results in promising synergy 

possibilities with the previously 

described approach by Kösters 

and Eickhoff, as larger machine gaps 

could be realised on the low-pressure 

side in order to prevent overcompression 

during start-up. As soon 

as the pressure on the low-pressure 

side is low enough, the increased gap 

size would be compensated for with 

the help of the surface structures by 

reducing the mass flow rate even further 

than is already the case due to 

the rarefied gas flow with technically 

smooth walls. 

Since there is always a superposition 

of a pressure-driven Poiseuille 

flow and a shear-driven Couette flow 

in the gaps of vacuum pumps, the 

DSMC method is used to analyse the 

effect of such a surface structure on 

a pure Couette flow. The corresponding 

simulation domain is shown in 

Fig. 8. With a gap height of h = 0.3 

mm, a profile depth Λ = 0.03 mm is 

used. Since the gap length and the 

gap width in vacuum pumps are 

much greater than the gap height, 

an infinitely wide and long channel is 

simulated for simplification, so that 

symmetrical boundary conditions are 

used in the depth direction (z) and 

cyclic boundary conditions in the flow 

direction (x) to reduce the computational 

effort. The latter have the property 

that the left and right cells are 

linked to each other as if the channel 

were continuing. Accordingly, a particle 

that crosses the cyclic boundary 

condition on the right-hand side 

is initialised again on the left-hand 

side and vice versa. The lower wall 

has a wall velocity of U = 10 m/s in 

the positive x-direction. In the reference 

plane shown in green, the mass 

flow rate is determined by calculating 

the sum of the particle masses in the 

positive x-direction minus the sum 

of the particle masses that cross the 

plane in the negative direction within 

a time step and then dividing by the 

time step: 

Eq. 1 

Regardless of the pressure range, 

the mass flow rate 

for a pure 

Couette flow with technically smooth 

surfaces can be calculated via 

Eq. 2 

incorporating the density ρ and the 

smallest cross-section area A = h b 

[Ple22a, Ple22b]. 

Fig. 8: DSMC simulation domain of a pure 

Couette flow through a channel with onesided 

surface structure. 

Fig. 9 shows the simulated mass 

flow rate of a Couette flow for different 

profile angles α = β in relation to 

the mass flow rate through a channel 

with smooth walls with the same 

gap height as a function of the pres- 




Fig. 9: Mass flow rate of a pure Couette 

flow through a channel with surface 

structures related to the respective 

mass flow rate with technically smooth 

walls as a function of the pressure p 

for different profile angles α = β. 

sure p for air at T = 293 K. The error 

bars show the maximum statistical 

uncertainty of the results. 

It can be seen that - as with the 

pressure-driven flow - a reduction 

in the mass flow rate at same 

minimal gap height can also be 

achieved with a shear-driven flow 

using surface structures. The 

smaller the pressure, the greater 

the effect, whereas the effect disappears 

at high pressures. Here 

too, the greatest reduction of 

about 30 % can be achieved for 

profile angles α = β = 30°. 

Conclusion and outlook 

The theoretical investigations 

suggest that a microscopic surface 

structure in the low-pressure 

range can achieve a significant reduction 

of up to 30 % in the gap 

mass flow rates in vacuum pumps 

without jeopardising operational 

safety. On the one hand, this 

can be used to ensure that the 

machine has a significantly better 

suction speed at lower suction 

pressure ranges with the same 

gap height, as the measurement 

results from Dreifert and Müller 

show with regard to the change 

in gap height. On the other hand, 

the idea of Kösters and Eickhoff 

could be pursued, with which the 

gap height on the low-pressure 

side of the machine is increased 

in order to reduce over-compression 

at high suction pressures. 

As the surface structure produces 

a significantly greater throttling 

effect, particularly at low 

suction pressures, but has hardly 

any effect at high suction pres- 

sures, over-compression can be 

reduced without the machine deteriorating 

at low suction pressures. 

Due to the great potential for 

improvement, the applicability 

of surface structures in rarefied 

gas flows is being investigated in 

more detail in a current cooperative 

research project between 

the Chair of Fluidics and the Institute 

of Machining Technology 

at TU Dortmund University. In the 

course of the project, the shape of 

the structure is being optimised 

in order to achieve the greatest 

possible throttling effect on the 

one hand and to enable efficient 

production on the other hand. A 

central challenge in production is 

the small profile depth of the surface 

structure - this is referred to 

as micro-machining. The dimensions 

of the burrs can be of the 

same order of magnitude as the 

profile depth. For this reason, a 

special tool is developed with the 

aid of a finite element chip formation 

simulation, whereby various 

geometric adjustments to the 

tool can be simulatively investigated 

to minimise burr formation. 

The most promising tool variants 

are then manufactured and 

used to prepare samples with the 

identified surface structures. On 

the one hand, these are analysed 

metrologically, which enables the 

chip formation simulation to be 

validated, and on the other hand 

they are used on a vacuum test 

rig in which the throttling effect 

can be investigated. 

Acknowledgements 

Funded by the Deutsche 

Forschungsgemeinschaft (DFG, 

German Research Foundation). 

Gefördert durch die Deutsche 

Forschungsgemeinschaft (DFG) – 

Projektnummer 513663608. 

Bibliography 

[Bir94] Bird, G. A.: Molecular gas 

dynamics and the direct simulation 

of gas flows (Clarendon 

Press, Oxford, 1994). 

[Brü21] Brümmer, B.; Pleskun, 

H.: Verfahren und Vorrichtung 

zur Beeinflussung verdünnter 

Gasströmungen mit Hilfe von 

Rauheiten aufweisenden Oberflächen, 

insbesondere an Vakuumpumpen, 

MEMS, Patent, DE 

102021002290, 2021. 

[Dre14] Dreifert, T.; Müller, R.: 

Screw Vacuum pumps - The state 

of the art: International Conference 

on Screw machines 2014: 

VDI-Berichte 2228, pp. 29-42 

(VDI-Verlag, 2014). 

[Jou18] Jousten, K.: Wutz - Handbuch 

der Vakuumtechnik, Vol. 12 

(Vieweg+Teubner, 

2018). 

Symbols and abbreviations 

symbol unit explanation 

b m gap width 

h m gap height 

L m gap length 

. 

m kg⁄s mass flow rate 

m kg mass 

p Pa pressure 

t s time 

T K temperature 

U m⁄s wall velocity 

α ° profile angle 

β ° profile angle 

Λ m profile depth 

ρ kg⁄m 3 density 

index or abbreviation 

eff 

suction 

Wiesbaden, 

[Kös06] Kösters, H.; Eickhoff, J.: 

Trockene Schraubenvakuumpumpe 

mit hoher innerer Verdichtung, 

Schraubenmaschinen 2006: VDI- 

Berichte 1932, pp. 423-428 (VDI- 

Verlag, 2006). 

1 inlet 

2 outlet 

explanation 

effective value 

suction value 

+ positive direction 

- negative direction 

The Authors: 

Sven Brock 1 , Heiko Pleskun 1 , Gero Polus 2 , Jannis Saelzer 2 , 

Prof. Dr.-Ing. Prof. h.c. Dirk Biermann 2 , Prof. Dr.-Ing. Andreas Brümmer 1 

1 

Chair of Fluidics, TU Dortmund University, 44227 Dortmund, Germany 

https://ft.mb.tu-dortmund.de/ 

2 

Institute of Machining Technology, TU Dortmund University, 

44227 Dortmund, Germany 

https://isf.mb.tu-dortmund.de/ 

[Moe23] Moesch, T. W. et al.: 

Thermodynamic analysis of a 

conical screw spindle compressor 

for R718: ICR2023 - 26th International 

Congress of Refrigeration, 

p. 012016, 2023. 

[Ple22a] Pleskun, H.; Bode, T., 

Brümmer, B.: Couette flow in 

a rectangular channel in the 

whole range of the gas rarefaction, 

Physics of Fluids, Vol. 34, p. 

032004, 2022. 

[Ple22b] Pleskun, H.; Brümmer, 

B.: Gas-surface interactions of a 

Couette-Poiseuille flow in a rectangular 

channel, Physics of Fluids, 

Vol. 34, p. 082009, 2022. 

[Saz20] Sazhin, O.: Rarefied gas 

flow through a rough channel 

into a vacuum: Microfluid Nanofluid, 

Vol. 24, 2020. 


51


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When to repair vs. replace your 

vacuum pump: A guide 

Cons 

Potential for higher costs in the long 

term: If the vacuum pump’s issues are 

difficult to repair, they may crop up 

again. 

Fixes only one specific problem: Vacuum 

pump repair doesn’t guarantee 

that other, different problems won’t 

arise in the future. 

Replacement 

If your vacuum pump is malfunctioning, 

you are faced with a choice: 

repair or replacement. Our guide 

will take you through both options 

and provide recommendations on 

when it makes sense to repair vacuum 

pumps and when to replace 

them. We will also take a look at 

how to spot and diagnose common 

issues before they lead to system 

failure. 

The basics 

Whatever the path of action, the decision 

to repair or replace always begins 

with testing and diagnosis. A factory-trained 

service technician who 

specializes in vacuum pump services 

All photos: Busch Vacuum Solutions 

inspects the equipment and identifies 

the problem. 

Repair 

If your vacuum pump can be repaired, 

faulty components are removed 

and replaced, and the equipment 

is returned to manufacturer 

specifications. 

Pros 

Cost effective: If the issue is minor, or 

the vacuum pump is relatively new, 

there may only be a few spare parts 

to replace. 

Low environmental impact: Fewer resources 

are used, and less waste is 

produced. 

If you opt to replace your vacuum 

pump, the existing one will be removed 

and a brand-new pump will 

be installed. 

Pros 

Higher reliability: New vacuum pumps 

have entirely new components and 

may be more energy efficient. 

New warranty: A new unit comes with 

a new warranty, offering peace of 

mind, and potentially reducing future 

repair costs. 

Cons 

Higher upfront costs: Purchasing a 

new vacuum pump means higher initial 

costs. 

Longer installation time: Installing and 

integrating a new vacuum pump usually 

takes longer than to carry out a 

small repair. 

Key considerations 

Before you make a decision for vacuum 

pump repair or replacement, 

there are five criteria to assess. 

1) Costs 

If your existing vacuum pump has 

only a minor issue, repair may be the 

more economical option. How ever, 

you should also consider longer-term 

maintenance and repair costs. As a 

vacuum pump gets older, for example, 

it may require more frequent servicing. 

This could add up to more than 

the price of a replacement over time, 

even though this will require a much 

larger immediate outlay. 


53



2) Process requirements 

Evaluate whether your existing vacuum 

pump is still the best option for 

your process. If your vacuum pump 

is always running flat-out, or reserve 

pumps are regularly coming online to 

meet demand, the process may have 

outgrown the pump’s current capabilities. 

Replacement could therefore 

be a sensible option. This will help 

avoid production delays and ensure 

you maintain optimal quality and performance. 

and your process. This could sway 

your decision between repair or replacement. 

vice providers and specialist factorytrained 

technicians to diagnose and 

troubleshoot these issues. Fixing 

3) Service history 

Has this same problem occurred before? 

Examine the service history to 

be sure. Regular maintenance actions 

like replacing spare parts such 

as seals, gaskets, or vanes is usually 

nothing to be concerned about, but 

if larger issues keep cropping up, repairs 

may no longer be an option. 

4) Energy efficiency 

Many new generations of vacuum 

pumps are more energy efficient than 

the one before. You should therefore 

consider the benefit of replacing 

your current vacuum pump with one 

that consumes less energy. Depending 

on the difference in consumption 

between your current vacuum pump 

and the newest technology, your energy 

bills could sink considerably. 

And your carbon footprint too. 

5) Technical features 

Consider how state-of-the-art your 

current vacuum pump is. Do more 

modern vacuum pumps come with 

new technical features that could 

benefit your process? This could be 

the right time to invest. You could 

also look into retrofitting. Some features 

can be added to an existing 

vacu um pump – such as a variable 

speed drive or intelligent monitoring 

of your vacuum pump. This allows 

you to upgrade without investing in a 

full new system. 

However, if your pump is getting 

older, it may no longer be compatible 

with these newer features that have 

become available since its purchase. 

As a result, your process could miss 

out on some optimization possibilities. 

You should therefore consider 

how important this option is to you 

Diagnosing and troubleshooting 

common issues 

Vacuum pumps rarely fail with no 

warning. However, it can be hard to 

catch the early symptoms of a problem. 

Regular maintenance is the 

first step: A problem spotted early 

is g enerally easier to repair. It is also 

helpful to familiarize yourself with 

common issues and the telltale signs 

of a failing vacuum pump: 

– excessive noise or vibrations 

– leaks 

– reduced pumping speed 

– overheating 

Don’t hesitate to ask for assistance 

from professional vacuum pump serthem 

promptly is crucial to ensuring 

cost-effective vacuum pump repairs 

and minimizing the risk of downtime. 

It is also worth considering investing 

in an intelligent monitoring system. 

This will continuously monitor each 

vacuum pump’s performance data 

and flag any anomalies. 

Real-world example: weighing 

repair vs. replacement 

In a food packaging plant, the performance 

of the vacuum pump is critical 

for the quality and shelf-life of the 

foodstuffs. However, a vacuum pump 

was experiencing increased noise 

and reduced pumping speed, leading 

to production delays. 




After careful inspection, the technician 

from the vacuum pump repair 

service provider determined that the 

problem was the result of a leak. The 

vacuum pump had been in operation 

for several years, but this was 

the first time the issue had occurred. 

And, although the initial symptoms 

looked troubling, it was a simple fix. 

Vacuum pump repair was therefore 

the most sensible option. The service 

technician replaced the worn seal, 

and the vacuum pump was back up 

and running. 

Conclusion 

When your vacuum pump isn’t running 

as it should be, you should carefully 

weigh your options. Consult the 

experts from vacuum pump repair 

service providers and have them conduct 

a proper inspection and diagnosis. 

You should also assess efficiency, 

performance, and the cost of repairs 

– both now and in the future – versus 

the cost of a new vacuum pump. 

This will help you determine the best 

course of action. Ultimately, your decision 

should be based on what is 

most cost-effective and beneficial for 

your production process. 

These criteria can be tricky to assess 

by yourself, so Busch will be 

happy to assist. Our specialists will 

visit you on site, evaluate your current 

equipment and give you a recommendation 

on how to move forward. 

Whatever you decide, we offer 

to carry out any necessary repairs, replace 

the vacuum pump if necessary 

or take care of maintenance. We offer 

suitable service contracts, intelligent 

IoT solutions and and 24/7 remote 

condition monitoring of your vacuum 

pump. With 60 years of experience in 

the world of vacuum, you can be sure 

your vacuum supply is in good hands. 

Busch Vacuum Solutions 

Mary MacGregor Velhinho 

https://www.buschvacuum.com 

HYPER SERIES: 

HYGIENIC EFFICIENCY. 

HYPER3 

Triple Screw Pump 

PATENTED 

HYPER TWIN 

Twin Screw Pump 

An unbeatable combination: maximum efficiency and 

groundbreaking design. Leistritz screw pumps for the 

F&B industry. Proven many times over in demanding 

applications, unrivalled in reliability, energy efficiency 

and cleanability. 

hygienic.leistritz.com

Pumps/Vacuum technology 


Optimal Pump Monitoring with 

Artificial Intelligence (AI) 

ABEL has reached a new milestone in the world of pump technology. 

The intelligent monitoring system “Smart Pump Assistant”, developed 

in-house, now also enables predictive pump maintenance. With the introduction 

of artificial intelligence (AI) in pump monitoring, ABEL has 

reached the next level. The North German pump manufacturer is thus 

setting new standards for the industry. 

This pioneering technology is characterized by several key elements. 

This innovative solution makes it possible to generate precise predictions 

for maintenance requirements by integrating artificial intelligence. 

ABEL is the first company on the market to offer predictive 

maintenance for piston diaphragm pumps. 

By using AI, we can realize proactive maintenance that minimizes 

downtime and revolutionizes efficiency in pump maintenance. The application 

of predictive maintenance offers numerous customer benefits, 

including increased system availability, significant reduction in 

maintenance costs and improved overall performance of piston diaphragm 

pumps. 

Fig. 2: Smart Messaging System 

Fig. 3: Smart Pump Assistant optimizes the use of ABEL pumps 

Fig. 1: Scheme: Predictive vs. Preventive Maintenance 

Maximum reliability 

Thanks to our AI-driven solution, potential problems with piston diaphragm 

pumps can be detected early, long before they lead to costly 

failures. This means maximum uptime and minimum downtime. 

Cost savings 

Predictive fault detection not only enables smooth operation, but also 

leads to significant savings. Repairs can be planned and expensive 

emergency measures avoided. 

Efficiency improvements 

Our AI technology continuously optimizes pump operation to maximize 

energy efficiency and resource utilization. This means not only 

cost savings, but also more environmentally friendly production. 

Competitive advantage 

Companies that use our AI-driven pump monitoring are one step 

ahead of their competitors. They can prevent breakdowns, increase 

productivity and strengthen their market position. 

The fact that ABEL has received support from the German Federal 

Ministry of Education and Research for this innovation shows the economic 

importance and innovative spirit behind this technology. Our customers 

benefit from a solution that is recognized at the highest level. 

24/7 Error Detection with AI 

The ABEL Smart Pump Assistant provides customers with important 

insights into the pump’s performance, health status and pumping process. 

With the help of the SPA, can optimize the operation of the pump. 

In addition, the SPA regularly calculates the optimum next maintenance 

time based on individual usage profile. With the help of artificial 

intelligence, data is not only digitally illustrated, but also evaluated 

and understood. 

The SPA informs fully automatically when errors or malfunctions 

occur on your pump. It shows on which component of the pump the 

error occurs, how high the efficiency loss is and gives recommendations/instructions 

on how the fault can be rectified. Alternatively, the 

app can use to request help directly from ABEL. 

Practical example: Use of the SPA monitor system optimizes 

filter press feeding 

The ABEL 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. 

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. 

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. 




and energy within the production process, while at the same time 

increasing productivity. 

Figure 5 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. 

ABEL’s introduction of AI into pump monitoring is more than just a 

technological achievement - it is a game changer for companies around 

the world. Customers can look forward to a future where pumping systems 

are more reliable, cost-efficient, and environmentally friendly. It's 

time to open the next chapter in the world of pump technology! 

smart-pump-assistant - ABEL Pump Technology (abelpumps.com) 

Fig. 4: Application of the ABEL HM-pumps for filter press feeding at the French 

company SOLVALOR 

Immediate anomalies are detected based on the data and appropriate 

corrective action is suggested. 

Furthermore, the ABEL 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.” - 

Maxime Jolly, Industrial Director, SOLVALOR. 

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

calculated throughput capacity which saves them costly 

flow meters. Thus, information on the state of their ABEL pumps is 

constantly available to the ABEL customer. 

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 

Less maintenance effort thanks to 

advanced vacuum generation 

Porzellanfabrik Hermsdorf GmbH, Germany 

Higher quality, less maintenance and lower costs – two standard vacuum 

systems from Busch Vacuum Solutions prove that everything is 

possible at the Hermsdorf porcelain factory in Thuringia. There, they 

are used for extruder degassing. 

Industrial ceramics have been produced in Hermsdorf, near Jena, since 

1890. In the past, high-voltage insulators; now, ceramic honeycomb 

bodies for heat exchangers, ventilation and emission control systems. 

They have always kept up with the times, developing innovative materials, 

products and state-of-the-art production processes to do so. Just 

like the two new SIMPLEX vacuum systems from Busch that are used to 

degas the ceramic mass. In 2021, these replaced four oil-lubricated rotary 

vane vacuum pumps and have been providing four extrusion lines 

with the required vacuum ever since. More than 100 employees currently 

work in the historic halls of the porcelain factory. 

Fig. 5: “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!” – 

Maxime Jolly, Industrial Director, SOLVALOR 

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. By implementing 

the insights gained through the Smart Pump Assistant, the customer 

SOLVALOR was able to save considerable amounts of time, costs 

Fig. 1: The honeycomb bodies are given their fine holes and thin walls by a 

template behind the screw press. (all photos: Busch Vacuum Solutions) 


57



1600 holes, no air bubbles 

The strand of square-shaped ceramic, still damp, slides smoothly out 

of the screw press. But after 1.50 metres, the race is over. Clever hands 

then cut off the front piece and place it on a large rack to dry. They 

do this continuously in three shifts. After around nine days, when the 

mass only contains one percent residual moisture, the honeycombs 

are fired in an oven at 1,200 degrees. 1,600 small holes run through 

them lengthwise like honeycomb cells, separated only by fine walls, all 

precise and symmetrical. To ensure that this remains the case after the 

combustion process, the mass must not contain any air pockets. These 

would expand with the heat in the oven and cause the entire honeycomb 

body to burst. For this reason, the mass must be degassed beforehand 

with SIMPLEX vacuum systems from Busch. At the heart of 

each control cabinet and vacuum vessel is a MINK MV Synchro dry claw 

vacuum pump. What other vacuum pumps see as a challenge, namely 

handling very moist, paste-like masses, they can master with ease. 

This is precisely why they have been developed for extruder degassing. 

tems from Busch are completely different. They do not require oil in 

the compression chamber and are virtually maintenance-free, quiet 

and frequency controlled. While the previous pumps were constantly 

running and had to be manually controlled by means of false air valves, 

the new vacuum systems from Busch automatically adapt to the required 

vacuum level and switch off when no vacuum is required. “We 

initially used a Busch loaner system for testing purposes and were immediately 

impressed. We are still completely satisfied with our own 

SIMPLEX systems today. In terms of maintenance, the new systems really 

make things much easier,” says the Managing Director. 

From Hermsdorf to the world 

Two energy-saving, extremely low-maintenance dry standard systems 

that replace four old, energy- and maintenance-intensive oil-lubricated 

pumps: “Thanks to the good advice we received from Busch, we have 

saved 10,000 kWh per year. Since installation, the two vacuum systems 

have been running absolutely trouble-free. There’s no comparison with 

the predecessor pumps at all,” says the Managing Director. And thanks 

to the new vacuum solution from Busch, 80,000 to 90,000 high-quality 

honeycomb bodies in various shapes and sizes leave the traditional 

plant in Hermsdorf every month. They ensure efficient heat recovery 

and clean air in ventilation systems of passive houses or afterburning 

plants on large container ships and cruise ships worldwide. 


Schauinslandstr. 1 

79689 Maulburg, Germany 

Phone +49 (7622) 681-0 

Fax +49 (7622) 5484 

info@busch.de 

www.buschvacuum.com 

Fig. 2: The intelligent vacuum system SIMPLEX VO from Busch degasses the mass 

in the extruder. 

No muddy matter 

The previously used oil-lubricated rotary vane vacuum pumps did not 

cope as well with the process conditions. “The oil quickly became an 

emulsion with the condensed water vapour. They were noisy, they 

stank, and the filters were permanently clogged. This resulted in excessive 

wear and pump failure. Once a month we had to change the filters 

and oil, which was a lovely muddy job,” says the Managing Director of 

Porzellanfabrik Hermsdorf GmbH. The new SIMPLEX VO vacuum sys- 

Fig. 3: The dried honeycomb bodies waiting to be fired. They do not contain air 

pockets that could burst in the oven. 

Compressed-air diaphragm pumps 

for adhesives 

Within furniture and woodworking industries, diaphragm pumps powered 

by compressed air are used to pump adhesives and glues as well 

as piston pumps. 

And this is also why pump manufacturer JESSBERGER, based in Ottobrunn 

near Munich, offers the JP-810 series of air-operated diaphragm 

pumps. 

The advantage of a diaphragm pump is that it is self-priming, will 

operate even when it runs dry and the delivery rate is customer-adjustable 

via the compressed air supply. If you close the delivery side of the 

pump, it will stop immediately and restart again as soon as the need 

for glue or adhesive arises and the delivery side is reopened. 

The pumps are also available in an ATEX version for Ex Zone 1 

(standard: Ex Zone 2, II 3/3 G Ex h IIC T4 Gb, II 3 D Ex h IIIB T 135°C 

Db X) and are suitable for almost all applications. As well as neutral 

liquids, the aluminium or adhesive pumps are also usable for slightly 

aggressive, flammable substances and highly viscous media such as 

adhesives or glues up to 50,000 mPas. 

The manufacturer's diaphragm pumps have been designed using 

various materials (polypropylene, stainless steel, aluminium and PVDF) 

and sizes (connections ¼" to 3") and hence cover wide-ranging capacities, 

from 8 l/min to 1,050 l/min. The use of 100 % oil-free compressed 




air for the drive source is imperative. A maximum operating pressure 

of 8 bar is required to operate the pumps. 

Automatic pulsation dampers and suction and discharge hose connectors 

are available as accessories and likewise stroke counters for 

accurate dosing. 

The reliable functioning of I&C systems can be impaired by the following 

influences: 

– Method of operation, i.e. the ability to meet the requirements that 

are essential for the intended use of the I&C systems (identification 

of overfilling, stopping an incipient explosion, turning on ventilation) 

– The process error tolerance time 

– External events such as overvoltage, power loss 

– Errors with a common cause, such as contaminated compressed air, 

defective insulation 

Temperature Monitoring 

Test setup 

Idler drum, 

Heating of new 

bearing (5) 


Jägerweg 5-7 

85521 Ottobrunn, Germany 

Tel +49 (89) 6666 33-400 

Fax +49 (89) 6666 33-411 

info@jesspumpen.de 

www.jesspumpen.de 

Risk reduction in explosion zones: 

Read the manual! Reliable pump 

moni toring keeps company management 

out of prison 

Pump monitoring in industrial processes is far more than just a safety 

measure for the pump unit. Aside from preventive maintenance and 

the recording of operating data, ignition source monitoring has become 

significantly more important in recent years – especially in explosion 

zones. Precise risk classification is crucial for explosion prevention. 

Reliable pump monitoring is essential to ensure smooth 

processes and therefore operating efficiency. 

TÜV safety experts are familiar with this scenario: Pumps that lack adequate 

stability can quickly run hot. This heat can lead to an explosion 

with devastating damage in production. The company may be liable 

for part of the damage if the liability insurance provider can prove negligence 

on the company’s part. This makes unprotected pump units a 

high operational risk. Beyond that, the responsible managers commit 

a crime if they fail to comply with legal requirements. In short, reliable 

pump monitoring keeps company management out of prison! 

Drive drum 

JUMO Sensor (3) 

In threaded hole 

for cover 

PT100 (2) 

at bearing housing 

Shaft 

temperature (1) 

Temperature at 

grease nippel 

position (4) 

Air temperature (6) 

Safety in the production process is a top priority for companies 

Safety in the production process is a top priority for companies. 

Numerous interrelated standards and directives are therefore in place. 

Consistent application is essential for all of them, for example, the Industrial 

Safety Directive (BetrSichV) and the Technical Guideline for the 

Handling of Hazardous Materials (TRGS) 725. 

What may appear simple and logical at first glance quickly turns 

out to be complex after entering the jungle of standards, guidelines, 

directives, technical rules and manufacturer recommendations that 

need to be observed for the monitoring of ignition sources. 

The IEC/EN 60079-xx standards on the topic of explosion protection, 

DIN EN 50495 (Safety devices required for the safe functioning of 

equipment with respect to explosion risks) and DIN EN 14597 (Temperature 

control devices and temperature limiters for heat generating 

systems) are all relevant for this topic. An examination of the DIN EN 

14597 standard always comprises a complete measuring, control and 

limiting system consisting of sensors, logic and actuating elements. 

The following aspects, for example, are certified for the individual components: 

Confusing jungle of standards and directives 

Few manufacturers cover the entire safety chain for instrumentation 

and control (I&C) with their products and solutions. 

– Response characteristics of the sensor technology 

– Reactions (modes of action) of the evaluation electronics 

– Reliability/service life of the actuating elements 


59




Thermal images 

Notice: The face side of the shaft was coated for better reflectiveness. Therefore, the temperatures of the radial surfaces may be distorted. 


Thermal images 

Notice: The face side of the shaft was coated for better reflectiveness. Therefore, the temperatures of the radial surfaces may be distorted. 

IEC/EN 61508, EN/ISO 13849 and EN/IEC 62061 & 61511 in the area of 

functional safety as well as the Technical Guideline for the Handling 

of Hazardous Materials (TRGS) 725 also apply, along with additional 

product- specific standards where applicable. 

Safety precautions have traditionally focused primarily on electrical 

explosion protection. However, the mechanical components as a potential 

ignition source has increasingly come into focus in recent years. 

Users have to understand and carefully evaluate this background, and 

incorporate that into their decision-making processes. Particular challenges 

in this regard are the correct application of explosion protec- 

tion marking and the evaluation of the safety integrity level (SIL) and 

performance level (PL). 

Attention: The company bears the burden of proof 

SIL and PL are becoming more and more important in the process industry 

and machine construction. Engineering the interconnection of 

sensor, logic and actuator units to form a safety measuring chain is increasingly 

becoming a central aspect in SIL calculations. 

A detailed examination of the entire measuring chain is crucial 

here! The principle that everyone is considered innocent until proven 




guilty generally applies. However, shifting the burden of proof reverses 

this obligation to produce evidence, so the accused must prove their 

innocence if they have acted negligently. 

Application of the standards is considered the state of the art in 

our case. Deviating from these standards shifts the burden of proof 

in case of damage. This burden of proof means that evidence must be 

provided, showing that the implementation was equal to or better than 

the standard. Based on my many years of practical experience, I can 

only recommend to you: Read the manual! 

Safety yes – headaches no 

Machinery and facility planners who have come into contact with the 

topic of functional safety are sure to have realised just how complex 

and multifaceted it is. Operators and planners of protective devices 

bear tremendous responsibility for the risk of damage. Needing to procure 

components that are safe, they are faced by a mountain of figures 

and formulas. In the end, they still don’t know whether everything was 

calculated correctly. 

JUMO SAFETY PERFORMANCE shows that there is an easier way. 

All JUMO products and services for SIL and PL are combined under 

this brand name. With JUMO SAFETY PERFORMANCE, we offer a certified, 

compact system for functional safety in accordance with SIL 

and PL that has been established for many years. No calculations are 

necessary. It is also suitable for ATEX/IECEx/EAC applicationsand the 

Machinery Directive. 

JUMO guarantees safety in compliance with standards and the law. 

In short: It is a complete safety system consisting of a sensor, logic and 

relay output to operate the actuator – from one source. 

The application of the technical rules and standards presented 

above, in combination with the overall system certification of JSP for 

pump monitoring, can lead to a different kind of error analysis. Up to 

45 % of systematic and systemic errors can be prevented by this complete 

solution. 

Fig. 1: Valve arrangement of a combined test system 

and 3. subjected to pressure retention tests. Until now, testing options 

for large vessels have been limited. Pneumatic or hydraulic intensifier 

pumps are often used when high pressure is required. However, the 

flow rates of these pumps are limited, which means that the desired 

cycle times cannot be achieved or that life tests of 20,000 cycles take 

too long. Other pump technologies must be used. Plunger pumps are 

the first choice because they can provide both high pressures and high 

flow rates. KAMAT pumps operate at pressures of up to 3500 bar and 

flow rates in excess of 280 m³/h. 

JUMO GmbH & Co. KG 

Moritz-Juchheim-Straße 1 

36039 Fulda, Germany 

Tel +49 (661) 6003-0 

Fax +49 (661) 6003-500 

mail@jumo.net 

www.jumo.de 

Growing market for container 

pressure testing pumps 

Fig. 2: Suitable for big vessel testing: KAMAT high-pressure pump of type 

K50018A-3G 

The market for pressure vessels for energy storage and for the transport 

and utilization of industrial gases is growing, mainly due to the desire 

to use hydrogen as a fuel. 

KAMAT has recently developed market-ready and standardized pump 

systems that are specially adapted to the testing of pressure vessels 

and take into account all aspects of this task. This includes the pressure 

test itself, but also the temperature control of the test medium and the 

modeling of test and pressure curves. 

The task: Vessels from small to very large volumes must be tested 

in three categories. Using water as the test medium, also with anti-corrosion 

additives, pressure vessels are 1. burst tested, 2. cycled 

Fig. 3: KAMAT control throttle 3000 bar for modulation of cycling test curves 


61



When designing a pump system, it is important to consider that, depending 

on the size of the tank, 1-10 cycles per minute are performed 

when pressurizing a tank, i. e. the tank is pressurized to test pressure 

and then depressurized. At 10 cycles per minute, a flow rate of 

250 l/min or more is quickly required. Despite the high flow rate, the 

upper and lower test pressures must be approached very precisely. 

This is a challenge in a dynamic hydraulic system. KAMAT therefore 

develops both the necessary valve technology (valves, control throttle, 

sensors) and the control algorithms of the control system itself. This 

ensures that upper test pressures are not exceeded and lower holding 

pressures are not undershot. Due to the design of the KAMAT pump, 

test pressures up to 3500 bar can be achieved in this setup. Burst tests 

are also possible at up to 3500 bar. 

Fig. 4-6: Test curves for pressure vessel testing 

KAMAT units can be quickly and optimally customized to meet 

customer requirements. The optimized modular pump system can be 

used for the high-pressure section. This results in three categories of 

equipment: 

– Cycling unit with the necessary valve technology, regulating throttle 

and control technology 

– Bursting device with the necessary valve technology and control 

technology. This is already possible, for example, with KAMAT's 

smallest pump, the K108. 

– Device for pressure retention tests (leak detection) 

Of course, the functionalities can also be combined if required. 

In a world increasingly focused on sustainability and efficiency, KAMAT's 

innovative pump systems stand at the forefront of the container pressure 

testing market. By offering solutions that blend high performance 

with precision and adaptability, KAMAT is not only meeting the growing 

demand for safe and efficient energy storage and transport but is 

also paving the way for a more sustainable future powered by hydrogen 

fuel. 

KAMAT - 50 years of pump innovation: A succinct success story 

KAMAT has been a beacon of innovation and sustainability since its inception 

in 1974 as Myers Europe GmbH, laying the groundwork for a 

broad range of high-pressure pumps by focusing on triplex high-pressure 

plunger pump manufacture. 

In 1979, after the separation from its American parent company, 

Dipl.-Ing. Karl J. Sprakel took the helm, rebranding to Myers-Europe 

Pumps and initiating product development and international market 

expansion, setting the stage for KAMAT’s growth. 

The period from 1983 to 1987 marked a phase of organic growth 

and strategic acquisitions, notably the Hochdruck-Apparatebau Witten 

merger, enhancing the product line and necessitating a production 

area expansion in the Witten-Annen industrial park. 




Between 1987 and 2012, KAMAT experienced significant technological 

advancements and expansion, led by Jan Sprakel and 

Dirk K. Sprakel. This era saw the introduction of the “water mist” division, 

later becoming the independent FOGTEC GmbH. 

2012 was a transformative year for KAMAT, with upgrades to 

facilities and expansion of the production space. This period also introduced 

unmanned production capabilities and modernized infrastructure, 

reflecting the company’s adaptability and innovation drive. 

With the generation change in 2012, Jan Sprakel and 

Dr.-Ing. Andreas Wahl took over the management and continue 

the legacy of innovation and expansion. With the name change to 

KAMAT GmbH & Co. KG in 2014 demonstrated that KAMAT manufactures 

much more than just pumps. 

KAMAT’s 50-year history has been marked by continuous innovation, 

strategic development and a commitment to quality and sustainability. 

The company’s pioneering spirit promises to keep it at 

the forefront of the high-pressure pump industry for the foreseeable 

future. Right down to the sourcing of materials that are truly “Made in 

Germany”. 

the metering of the blowing agent into the plastic melt must be consistently 

precise in order to achieve a homogeneous and high-quality 

end product. The proven LEWA ecofoam metering system was therefore 

specially designed to meter all common blowing agents precisely 

and reliably. 

KAMAT GmbH & Co. KG 

Salinger Feld 10 

58454 Witten, Germany 

Tel +49 (2302) 89 030 

info@KAMAT.de 

www.KAMAT.de/en/ 

Foam extrusion 

Risk-free process optimization: 

Rentable testing system precisely 

meters different blowing agents even 

with fluctuating extruder pressure 

Includes cooling unit for CO 2 

and explosion-proof design 

for flammable media 

A lower density, better mechanical and insulating properties and significantly 

reduced raw material consumption. Given these advantages, 

it is no wonder that foamed plastics have taken the market by storm 

in recent years. They are mainly used as packaging components and 

for shock absorption, thermal insulation and soundproofing. However, 

the variance in blowing agents and their process conditions, such as 

high pressure or deviating temperatures, require specified systems 

and quickly make the extrusion process relatively complex. The LEWA 

ecofoam metering system provides a remedy. A fail-safe complete solution 

for all known blowing agents, it is characterized by consistently 

precise metering even for fluctuating parameters. The LEWA ecofoam 

testing system offers users a cost-efficient opportunity to see the reliable 

quality of the extruder system and the end products for themselves 

in everyday operation without obligation. 

Depending on the intended use and desired properties of the plastic 

product, different blowing agents are used in foam extrusion. For example, 

they can be carbon dioxide, propane, butane, pentane or halogenated 

hydrocarbons such as Freon 152a. Although the discharge 

pressures and temperatures of these media differ from one another, 

Universal extruder system for testing with all blowing agents 

To ensure the required constant foam quality, the quantity of blowing 

agent in the LEWA ecofoam is adjusted proportionally to the rotation 

speed of the extruder. The smart control technology developed by 

LEWA itself comes into play here. It continuously compares the signal 

from the flow meter with the guide signal and regulates the rotation 

speed of the drive motor accordingly. Due to the pump's pressure-stiff 

characteristic curve, metering remains constant even for fluctuating 

extruder pressure. 

At its core, the hermetically tight and therefore low-maintenance 

system consists of a LEWA ecoflow diaphragm metering pump, which 

delivers the blowing agent at a pressure of 50 to 350 bar. The flow rate 

depends on the set pressure and the compressibility of the medium. 

For example, it can be 13 kg/h CO 2 

, 8 kg/h i-butane or 20 kg/h H 2 

O at 

250 bar. Since the LEWA ecofoam testing system was designed for all 

known blowing agents, it is already explosion-proof for flammable media 

such as propane or butane as standard and is equipped with a 

cooling unit for carbon dioxide. 

To ensure that the system can be easily transported for testing 

purposes, all components are securely mounted on a common mount 

base. It can be rented for up to six weeks without obligation, although 

longer periods are also possible by arrangement. This gives users the 


63



Watson-Marlow Fluid Technology Solutions (WMFTS) has launched the 

Qdos H-FLO chemical metering and dosing pump, designed specifically 

for higher flow rates up to 600 l/h. 

Qdos H-FLO delivers the same outstanding accuracy and reliability 

as other Qdos pumps but for higher flow rates with a variety of 

pump heads and a range of different tube material to ensure chemical 

compatibility with the process fluid. 

The Qdos H-FLO high-precision pump offers flexibility to be scalable 

with a customer’s process, whether it is in water and wastewater 

treatment, mining and mineral processing, chemical applications in 

food and beverage or pulp and paper. 

The release of Qdos H-FLO enhances the range of Qdos pumps 

by offering flow rates up to 600 l/h and pressure capability up to 7 bar 

(102 psi). 

Like the rest of the Qdos range of peristaltic pumps, Qdos H-FLO 

cuts costs through higher precision chemical metering, with an accuracy 

of ±1% and repeatability of ±0.5% in dosing. 

Qdos H-FLO will bring benefits to applications including: 

– Disinfectants 

– Coagulants 

– Flocculants 

– Acids/alkalis 

– Mining reagents 

– Surfactants 

opportunity to test the reliable quality of the system and the consistently 

precise metering of different blowing agents in a real application 

environment – entirely without financial risk. 

Further information at: 

https://www.lewa.com/en-US/systems/lewa-ecofoam 

LEWA GmbH 

Ulmer Str. 10 

71229 Leonberg, Germany 

Tel +49 (7152) 14-0 

Fax +49 (7152) 14-1303 

lewa@lewa.de 

www.lewa.de 

New Qdos H-FLO chemical metering 

and dosing pump offers higher 

flow rates for a wide range of dosing 

applications 

– Latest pump in the Qdos range is for higher flow rates up to 600 l/h 

– New peristaltic pump makes chemical dosing simpler, safer and 

cost-effective 

– Qdos H-FLO serves a wide variety of applications and industries 

Fig. 1: Qdos chemical metering and dosing pumps showing Qdos H-FLO 

(pictured centre), Qdos 60 and Qdos CWT 

Adeel Hassan, Product Manager at WMFTS, said: “At Watson-Marlow 

Fluid Technology Solutions, we believe in engineering innovation to 

solve complex customer problems by providing simple-to-use solutions. 

The high accuracy and repeatability of our pumps helps to 

achieve cost savings in chemical usage which also assists our customers 

in their journey towards net zero targets. While the pump has inherited 

unique features from the current Qdos range, it also brings several 

new-to-market features to make chemical dosing simpler, safer and 

cost-effective. 

“Customer feedback has been a fundamental driver in developing 

Qdos for higher flow rate applications. Qdos H-FLO aims to make 

chemical dosing simpler and efficient for operations, maintenance and 

EHS teams. It offers several onboard communication options for SCA- 

DA and PLC integration to achieve process optimisation.” 




Fig. 2: Qdos H-FLO Universal+ chemical metering and dosing pump with hose 

With the new Certa Compact, Watson-Marlow is expanding MasoSine's 

Certa Sine pump series, which is well established in the food and beverage 

sector. Thanks to a more flexible and simplified design, the new 

Certa Compact models offer a 30 % smaller footprint compared to the 

existing Certa models. This benefits integrators and manufacturers of 

modular system concepts and complete turnkey plant systems, among 

others. In addition to saving space in their systems, they also save valuable 

assembly time and costs during installation. 

Despite its compact design, the new pump retains all the advantages 

of Sine pump technology: in addition to a high suction capabilities 

combined with gentle pumping action with low shear forces and 

minimal pulsation, all Certa pumps offer outstanding hygienic properties 

with certification in accordance with EHEDG Type EL Aseptic Class I. 

In addition, users of Sine pumps benefit from up to 50 % lower power 

consumption compared to other pump types when pumping highly 

viscous media. 

Benefits of the new Qdos H-FLO include: 

– Flowrates from 2.0 ml/min to 600 l/h 

– Pressure capability up to 7 bar pressure 

– RFID Pump head detection ensures confirmation of correct pump 

head 

– Revolution counter for pump head service maintenance 

– Leak detection and fluid containment prevent spills and chemical 

exposure upon pump head expiry 

– Network integration, control and communication options include 

EtherNet/IP, PROFINET and PROFIBUS for easy integration with 

SCADA/PLC 

– One common pump drive with several pump head options for 

changing process conditions and chemistries 

Qdos H-FLO is supported with an optional pressure sensing kit that 

provides real-time pressure monitoring, which ensures process security 

and improves safety. The optional pressure sensing kit comes with 

configurable alarms for process monitoring. The pressure sensing kit 

will be available across the entire Qdos range and is compatible with 

commonly used chemicals in process industries. 

Fig. 1: The new Certa Compact models offer a particularly small footprint 

(both photos: Watson-Marlow Fluid Technology Solutions 


Kurt-Alder-Str. 1 

41569 Rommerskirchen, Germany 

Tel +49 (2183) 42040 

info.de@wmfts.com 

www.wmfts.com 

New Certa Compact Sine ® pump reduces 

space and energy requirements 

Watson-Marlow Fluid Technology Solutions is expanding its range of 

MasoSine Certa Sine pumps. The new Certa Compact models take up 

30% less space than the existing Certa pumps. Certa Compact pumps 

retain all the advantages of Sine pump technology, such as high suction 

capabilities, gentle pumping and excellent hygienic properties. 

Like all Certa models, Certa Compact offers particularly high energy 

efficiency. 

Fig. 2: Thanks to the design principle with just one rotor, one shaft and one seal, 

Sine pumps offer particularly low energy consumption 

Gentle on sensitive food products 

The new Certa Compact models offer a flow rate of up to 99,000 litres 

per hour at a pressure of up to 6 bar. It handles high viscosity fluids of 

up to eight million centipoise. Thanks to their unrivalled gentle pumping 

action, Sine pumps are particularly suitable for sensitive media in 

the food and beverage industry. They maintain product integrity and 


65



prevent product loss. In the dairy industry, for example, they prevent 

damage to the cheese curd, the formation of cheese dust or loss of viscosity. 

In breweries, the pumps are particularly suitable for use in yeast 

management and protect the sensitive cells thanks to their powerful 

pumping speed and unrivaled gentle pumping action. In the beverage 

industry, the Sine pumps can offer efficient loading and unloading of 

tanks and fast processing times without the risk of cavitation thanks to 

their high pumping speed. 




Tel +49 (2183) 42040 


www.wmfts.com 

Full containment 

By using a hermetically tight magnetic coupling, the pumped liquid is 

safely contained within the pump. This prevents loss of the liquid and 

at the same time eliminates any contamination from the outside. 

A magnetic drive pump utilizes a magnetic field to transfer torque 

from the drive to the pump shaft without any physical connection. The 

containment shell plays a crucial role in maintaining the hermetic integrity 

as it separates the pumped liquid from its environment. There 

are no dynamic seals from which leaks can escape to the environment, 

but even more important, from which abrasives over time could pollute 

the pumped liquid. 

Magnetic drive pumps 

Powering The Hydrogen Revolution 

Towards a greener, hydrogenpowered 

world 

As the world seeks sustainable energy solutions, hydrogen is emerging 

as a key player in the transition to a greener future. At Klaus Union, we 

are proud to be at the forefront of this revolutionary journey by manufacturing 

state-of-the-art magnetic drive pumps for hydrogen production 

applications. 

Magnetic drive pumps play a crucial role in the production of hydrogen. 

They ensure the safe and efficient pumping of fluids in processes 

like alkaline water (for KOH or NaOH) and PEM electrolysis, where hydrogen 

is generated from ultra-pure water. 

So, what makes Klaus Union magnetic drive pumps essential 

for hydrogen production? 

Fig. 2: Heavy duty containment shells made from industrial ceramics 

for up to 63 bar 

Ideal for ultra-pure water 

By electrochemical polishing (electropolishing) the wetted parts of the 

pump and using journal bearings made of silicon carbide, pollution 

with ions or abrasives is prevented. 

Electropolishing removes surface defects and local stresses contained 

in the thin layer of material on the surface, providing optimum 

properties of the base material. The risk of pollution is eliminated as 

the process reduces the micro-roughness of the material. 

Further the parts are supplied in an oil- and grease-free execution. In 

this case, the assembly is meticulously performed within our dedicated, 

state-of-the-art clean room facility. The degree of purity achieved is 

equivalent to some of our valves which are used in air separation applications 

(pumping of oxygen). 

Close-coupled design 

Especially for large pumps and motors, the compact close-coupled design 

is indispensable for installation in tight spaces like containerized 

modules. 

Close-coupled design means, that the driver is connected to the 

pump’s intermediate lantern by an adapter flange, eliminating the 

need of a coupling or guard. Thus, the risk of misaligning is eliminated 

plus there are no limited lifetime ball bearings in the pump. 

Fig. 1: Close-coupled centrifugal pump with magnetic drive and electropolished 

pump casing 

Maintenance free 

Due to the contactless transmission of torque and highly durable journal 

bearing materials, in close-coupled design no scheduled maintenance 

is required. 




Scheduled maintenance of a magnetic drive pump depends only on 

the type of bearings installed making it obsolete in a close-coupled 

pump. The magnetic coupling itself is maintenance free and wear free, 

provided it is operated within agreed limits. 

Erdinger has been relying on sera’s expertise and experience in the 

beverage industry for almost 30 years. Around 150 dosing pumps and 

dosing systems are in use at the private brewery and ensure smooth 

processes and consistent quality in production. 

Energy efficiency 

Magnetic drive pumps, especially with non-metallic containment shell, 

are highly efficient, contributing to energy savings and reducing the 

carbon footprint of hydrogen production. 

Non-metallic containment shells made of zirconium oxide are not 

electrically conductive. Due to this characteristic there are no eddy 

current losses impacting the pump performance. The energy consumption 

can thus be reduced by 10 to 15 %, compared to metallic 

containment shells. 

Belt lubrication 

Smooth product transport, in the truest sense of the word, between 

individual systems such as bottling or packaging is essential for efficient 

production. To reduce friction between the conveyor belt and the 

bottle or crate, the conveyor belts at Erdinger are also lubricated. sera 

dosing technology is used here to add the right amount of chemicals to 

the water circuit for belt lubrication. 

Join us 

By manufacturing these cutting-edge pumps, Klaus Union is committed 

to advancing the hydrogen economy. We are sure that hydrogen holds 

the potential to reshape industries, reduce greenhouse gas emissions, 

and provide sustainable energy solutions for generations to come. Depending 

on the application, these essentials are available for all Klaus 

Union pump types. 

Join us on this exciting journey towards a greener, hydrogenpowered 

world. Feel free to contact us if you have any further 

questions: info@klaus-union.com 

KLAUS UNION GmbH & Co. KG 

P.O. Box 10 13 49 

44713 Bochum, Germany 

Phone +49 (234) 4595-0 

Fax +49 (234) 4595-7000 

info@klaus-union.com 

www.klaus-union.com 

sera dosing technology at 

Erdinger Privatbrauerei 

Cleaning in Place (CIP) 

Cleaning in Place (CIP) is used in the food and beverage industry to cyclically 

clean the entire production system, including tanks and pipework. 

The product remaining in the system is first rinsed out, then 

organic trace substances are removed with lye, mineral deposits are 

„Des Erdinger Weißbier, des is hoid a Pracht hollara-di-riad-dei, 

des schmeckt uns beim Tag und bei der Nacht.“ 

Everyone in the German-speaking world knows this Bavarian jingle. No 

wonder – Erdinger Privatbrauerei has been using it unchanged in TV 

and radio adverts since the 1970s. Consistency, reliability and quality – 

that’s what Erdinger stands for, and not just in advertising. 

Founded in 1886, the company has always been committed to 

wheat beer. With the world-famous Erdinger Weißbier, they have 

created a classic that has enjoyed great popularity for over 130 years. 

In the meantime, the portfolio has of course been supplemented by 

other beers, such as non-alcoholic wheat beers. 

With an output of 1.7 million hectolitres, the wheat beer brewery in 

Erding is the largest wheat beer brewery in the world and the private 

brewery’s only production site. From here, Erdinger sells its beers in 

over 100 countries. Erdinger wheat beers are traditionally produced by 

bottle fermentation. 

Consistency, reliability and quality – these are the factors behind 

Erdinger’s success story. And, of course, strong partners who share the 

same values as Erdinger. 


67



removed with acid and finally the system is rinsed with fresh water. 

The chemicals required for cleaning are stored in stacking tanks. The 

chemicals (lye, acid and disinfectant) are mixed in the required concentration 

(usually 98 % H 2 

O and 2 % additive) and dosed into the cleaning 

process using sera compact dosing systems of the CVD (Compact Vertical 

Dosing) type. CIP is not only safe, but above all economical, as 

the cleaning agents and water used are only consumed in the desired 

quantity and can be partially recycled. 

Alexander Kreuter, Product Manager at Pfeiffer Vacuum: “As one of 

the leading suppliers of vacuum technology, we are proud to be able 

to present the smallest hybrid-bearing high-power turbopump on the 

market. It combines high performance with practicality. This small 

pump is particularly versatile in the area of analytics and is portable. 

And, with our patented Laser Balancing technology, it has the lowest vibration 

level on the market. This makes it perfect for applications that 

are sensitive to vibrations!” 

Design in the food and beverage industry 

To ensure that CIP works perfectly, dosing systems and pumps must 

have special design features. The products used are designed and constructed 

by sera in such a way that there are no so-called dead spaces 

in the respective interior (part in contact with the media) in which solids 

or bacteria can be deposited. 

Process and waste water treatment 

Efficiency and sustainability are important factors in every production 

process – and Erdinger is no exception. The treatment of process and 

waste water can therefore make a difference. Treated with the right 

chemicals, the water can be reused and thus contribute to sustainable 

production. 

Erdinger draws its brewing water directly from two of the brewery’s 

own wells with a depth of 160 metres. If necessary, the brewing water 

is also treated to ensure a constant pH value, for example. Dosing 

technology from sera is also used here, thus ensuring the sustainable 

use of water. 

Dosing technology in the beverage industry 

– Cleaning in Place (CIP) 

– IBC emptying stations 

– Tank filling and emptying 

– Dosing of chemicals and additives 

Smallest Hybrid-Bearing High-Power turbopump HiPace 30 Neo 

sera ProDos GmbH 

sera-Str. 1 

34376 Immenhausen, Germany 

Tel +49 (5673) 999-02 

sales.prodos@sera-web.com 

www.sera-web.com 

HiPace 30 Neo: Smallest Hybrid- 

Bearing High-Power turbopump 

on the market 

– For light gases 

– Compact and portable 

– Patented Laser Balancing Technology 

The HiPace 30 Neo combines compactness, drive efficiency and intelligence. 

It thus makes a further contribution to the sustainability of 

the turbopump portfolio. For example, the more compact design and 

the associated material savings mean that a significant proportion of 

CO 2 

can be saved. Thanks to the use of intelligent sensor technology, 

the pump is always operated with the best possible energy input. 

Thanks to the intelligent control system, the pumps can be interconnected 

without great effort, i. e. upstream and turbo pumps interact 

with each other. In this way, a complex, IoT-capable vacuum system 

can be realized in just a few steps. 

The pump is both compact and smart: With its special Pfeiffer Vacuum 

accessory interface, AccessLink, which recognizes accessories automatically, 

the system can be up and running quickly in just a few steps. 

The HiPace 30 Neo incorporates a new high-performance lubricant, 

which guarantees safety and reliability with improved aging resistance, 

optimized lubrication behaviour and high temperature resistance. The 

HiPace 30 Neo pumps run maintenance-free for up to 5 years. 

The new HiPace 30 Neo turbopump from Pfeiffer Vacuum is a vacuum 

pump for compact analysis systems and portable applications. Due 

to its high gas throughput and exceptional compression, it is suitable 

for light gases and has excellent critical backing pressure. The good 

balancing quality of the rotor, which runs at up to 1,500 revolutions 

per second, makes the vacuum pump ideal for vibration-sensitive 

applications. 


Berliner Str. 43 

35614 Asslar, Germany 

Tel +49 (6441) 802-0 

Fax +49 6441 802-1202 

info@pfeiffer-vacuum.com 

www.pfeiffer-vacuum.com 


Come and see for yourself: 


Perfectly 

positioned. 

The international specialist magazines from Dr. Harnisch Publications 

In addition to the haptic charm of 

classic print magazines, we also 

offer newsletters, news, events and 

subscriptions on our magazine 

websites in addition to the digital 

editions that can be read free of charge. 

Take a look at www.harnisch.com 

for all relevant content. 

Our publications include: 

- Technology & Marketing -


IFAT Munich 2024 

IFAT Munich 2024 

Municipalities: core target group for 

the environmental industry 

– Tackling the consequences of 

climate change 

– Maintaining quality and safety 

in water management 

– Day of resilient municipalities 

on May 16 

Municipalities are among the most 

important users of the products 

and processes presented at the IFAT 

Munich 2024 environmental technology 

trade fair. New challenges, 

opportunities and solutions also 

create a great need for information 

and discussion for cities and municipalities. 

From May 13 to 17, 2024, IFAT Munich 

will bring the global environmental 

technology industry together again in 

one place. The exhibitors at the Munich 

exhibition center will then once 

again present their latest products, 

processes and services from the 

fields of water and wastewater, waste 

and raw materials management to 

the specialist audience. For many of 

them, cities and municipalities, with 

their wide range of environmentally 

relevant tasks, are part of their key 

customer base. Municipalities, for example, 

face the permanent challenge 

of ensuring the quantity and quality 

of the drinking water supply, maintaining 

infrastructural values, and 

averting potential risks to society and 

the environment—all at a reason able 

cost. In line with that, the German 

Technical and Scientific Association 

for Gas and Water (DVGW) is offering 

three solution tours at the world’s 

leading trade fair in Munich entitled 

“Innovative technologies for assessing 

the condition of buried pipelines,” 

“Protection of critical infrastructure 

in drinking water supply,” and “Increased 

water temperature in the 

distribution network.” At the association’s 

stand, keynote speeches will 

first explain the respective problem 

before guided tours lead participants 

to corresponding exhibitor solutions. 

New PFAS limit values affect treatment 

requirements 

The revised Drinking Water Ordinance 

came into force in Germany 

in June 2023. It implements significant 

elements of the EU Drinking 

Water Directive from 2020. Among 

the new and amended limit values, 

the toxicologically relevant per- and 

polyfluoroalkyl substances, PFAS for 

short, clearly play the most important 

role. Water suppliers may have 

to filter out PFAS with considerable 

technical effort. “However, end-ofpipe 

approaches are not a solution. 

The production and use of PFAS must 

be limited to a few essential purposes. 

The aim must be to already 

avoid these substances at the pollution 

source. These substances must 

not be released into the environment 

in the first place,” says Wolf Merkel, 

DVGW Board Member for Water. The 

association is taking this as an oppor- 

Photo: Messe München GmbH 

tunity to present new technological 

approaches to the treatment of water 

containing PFAS at IFAT Munich 

as part of its “TechLIFT” event format, 

and to discuss them with a panel of 

experts. 

“The list of challenges facing 

local authorities in the wastewater 

sector is also long,” as Dr. Friedrich 

Hetzel stresses. As examples, the 

head of the Water and Waste Management 

Department at the German 

Association for Water, Wastewater 

and Waste (DWA) cites the separation 

of phosphorus from wastewater and 

sewage sludge, the lower limit values 

for nutrients such as phosphorus in 

the effluent of wastewater treatment 

plants expected as a result of the 

amendment to the EU Urban Wastewater 

Directive, the removal of trace 

substances from the water cycle, and 

combined sewer overflows. 

For a water-conscious, resilient 

municipality 

Driven by the consequences of climate 

change, he also believes that wa- 


ter-conscious urban development should 

be high up on the municipal agenda. “A central 

aspect here is the intelligent handling 

of rainwater, especially in the context of extreme 

events. What is needed are solutions 

that help deal with their consequences or 

minimize them in advance through appropriate 

technical measures,” says Hetzel. Specifically 

for the public sector, the DWA, in collaboration 

with the DVGW and the German 

Association of Local Utilities (VKU), is offering 

the Day of Resilient Municipalities on 

Thursday, May 16, as well as various solution 

tours at IFAT Munich. 

Digitalization and protection of critical 

infrastructure 

As with society as a whole, cities and municipalities 

are of course also called upon 

to address the opportunities and risks of 

the megatrend of digitalization. The VKU, 

for example, is organizing a panel discussion 

on the forum stage entitled “AI: Detection 

systems and reusable materials 

scanners—how much AI does the waste industry 

need?” It will examine the question 

of whether AI is really suitable for minimizing 

resource consumption and improving 

the quality of the individual categories of 

waste collected in the interests of a functioning 

circular economy. 

The public utility and waste disposal industry 

is also a critical infrastructure (KRI- 

TIS). “The physical and virtual threat has 

been growing here for years. It is essential 

to protect these services,” emphasizes 

VKU Vice President Patrick Hasenkamp. On 

the forum stage, the association will show 

which legal obligations KRITIS operators 

must already fulfill now and, more importantly, 

in the future. 

The VKU solution tour “Waste Logistics 

2035” also takes a look into the future. 

“Waste logistics will play a decisive role 

in resource management by minimizing 

waste, preserving valuable resources, and 

hence reducing the environmental impact,” 

Hasenkamp is convinced. After a presentation, 

the trade fair visitors will be guided to 

selected VKU member companies, where 

they will learn more about current developments. 

Clean drives for municipal vehicles 

“When it comes to municipal vehicles and 

equipment, the use of alternative drive systems, 

especially hydrogen and battery solutions, 

and the development of the required 

charging infrastructure are still key issues,” 

says Burkard Oppmann, President of the 

German Municipal Vehicles and Equipment 

Industry Association (VAK). The VAK will, for 

the first time, be holding a 45-minute panel 

discussion with industry experts on these 

and other topics on each day of IFAT Munich 

2024. The discussion will deal, among other 

things, with an emission-free municipal vehicle 

industry and municipal economy, the 

promotion of CO 2 

-free waste disposal, and 

professional driver qualifications. 

The future topic of hydrogen 

What role can hydrogen play in the municipal 

circular economy? A Spotlight Area is 

dedicated to this question. According to 

the organizers, the DVGW and the Zentrum 

Wasserstoff.Bayern (H2.B), it will show that 

there are interesting starting points both 

in the production and use of the climatefriendly 

energy source and its by-products. 

For example, the energy generated in wasteto-energy 

and biogas plants can be used for 

carbon-neutral hydrogen production. In addition 

to hydrogen, the electrolysis of water 

also produces oxygen, which can be used to 

effectively aerate clarifiers. Methane from 

sewage sludge treatment or also plastic 

waste can be processed into hydrogen and 

carbon that can be used in agriculture or industry. 

And the fact that the first waste collection 

vehicles are already running on hydrogen 

has already been mentioned above. 

Messe München 

www.ifat.de 

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


IVS - INDUSTRIAL VALVE SUMMIT 2024 

The countdown to IVS – 

INDUSTRIAL VALVE SUMMIT 2024 has started 

The fifth edition of IVS – Industrial 

Valve Summit, the most important 

international event dedicated 

to reference technologies and flow 

control solutions, is only one month 

away. The fair trade, organised 

by Confindustria Bergamo and 

Promoberg, will take place at the 

Bergamo Exhibition Centre, in Italy, 

on May 15 th and 16 th , 2024. 

During the IVS 2024, the organisers 

will enrich the offer with side events 

and moments of interaction, creating 

a true 'valve week', continuing along 

the event’s growth path. Starting on 

14th May with the opening ceremony, 

followed by the opening of the pavilions 

reserved to exhibitors, IVS will 

offer a valuable opportunity for the 

players in the supply chain to meet 

and discuss. The event will get into 

full swing on 15 th and 16 th May with 

the halls opening the doors to the international 

public, with hundreds of 

exhibitors and thousands of trade 

visitors expected. And after the twoday 

exhibition, there will be a further 

opportunity for foreign delegations 

attending the fair to meet the players 

in the extended Oil & Gas supply 

chain, on Friday 17 th May. In 2022, 

the Summit welcomed 12,000 visitors 

(+12 % compared to 2019) representing 

over 60 countries, in addition 

to 300 exhibiting companies (+17 % 

compared to 2019) representing 12 

countries. 

Over the years, the Summit has 

established itself as a space where 

change can be interpreted and the 

latest innovations can be explored, 

identifying and examining the challenges 

facing the industry. IVS 2024 

will hold the widest scientific calendar 

ever proposed by the event, which 

will be structured by a total of 46 conferences, 

round tables, workshops, 

case studies and laboratories. The experts 

who will take the floor will delve 

around eight macro-themes: additive 

manufacturing; digital technologies 

applied to valves, actuators, and 

flow control systems; seals and fugitive 

emissions; valve and material design 

for harsh weather conditions; 

regulatory standards and developments; 

supply chain management; 

artificial intelligence applied to mechanical 

design, supply, and manufacturing; 

energy transition and carbon 

capture and storage systems. 

These are complemented by round 

tables discussing hydrogen, analysing 

market trends, the Corporate Sustainability 

Reporting Directive (CSRD), 

greenhouse gas management and 

other topics. The update of the IVS- 

Prometeia Observatory “The Oil&Gas 

Valve Industry 2024”, developed with 

the contribution of the Confindustria 

Bergamo research office, will also be 

presented at the exhibition. 

Photo: IVS - Industrial Valve Summit 

Bergamo is ready to welcome thousands 

of people from all over the 

world. Not only in terms of hospitality 

and infrastructural efficiency, 

but also through a cultural, networking 

and leisure offer that goes 

beyond the two-day exhibition. The 

Bergamo district is a strategic centre 

of gravity for the entire industry: a 

100-kilometre radius of the province 

is home to 90 % of the companies 

that contribute to the industrial valve 

value chain in Italy. A leading territory 

for the sector and in the national 

panorama, which is distinguished by 

elements such as manufacturing expertise, 

excellence on international 

markets and entrepreneurial culture. 

Get your pass to access IVS: registration.industrialvalvesummit.com/ 

site/home.xsp 



ACHEMA 2024 

ACHEMA 2024: 

Multifaceted lecture programme for the 

world of the process industry 

ACHEMA 2024 will once again fully 

integrate the lecture and supporting 

programme with the exhibition. 

In 2022, ACHEMA integrated 

the congress and the so-called Innovation 

Stages into the exhibition 

for the first time. Due to the positive 

feedback, the concept will be continued 

this year. In total, more than 

750 presentations await visitors in 

the lecture halls and on the stages 

in the exhibition. 

“Science and Industry in Dialogue 

has always been DECHEMA’s credo 

and since the last ACHEMA it has 

also been a living practice in the lecture 

and congress programme. The 

success proves us right: With more 

than 20,000 listeners, the number 

of attendees in 2022 was significantly 

higher than at ACHEMA 2018, 

which had more participants overall,” 

says Dr Andreas Förster, Executive 

Director of DECHEMA e. V. and thus 

organiser of ACHEMA. This year’s congress 

programme focuses on the topics 

of hydrogen, sustainability, circular 

economy and digitalisation. At the 

six Innovation Stages in the exhibition 

and in the five highlight sessions 

of the congress, ACHEMA 2024 will 

address these and other top topics of 

the process industry. 

Process Innovation 

The GEA Process Innovation Stage in 

Hall 9.0 will focus on topics such as 

electrification, flexibilisation and biotechnologisation 

of chemical processes 

as well as contributions to smart 

digital technologies in plant construction 

and operation. In the Process 

Highlight Session “Nature as a 

role model – maximum resource efficiency 

in the chemical industry”, experts 

will discuss the vision of a fully 

resource-efficient chemical industry 

and its implementation. The highlight 

session will take place on Friday, 14 

June 2024 from 12:00 to 13:00. 

Pharma Innovation 

The ZETA Pharma Innovation Stage in 

Hall 4.1 will cover biopharmaceutical 

production in addition to many other 

topics related to pharmaceutical production 

and packaging, which is also 

the focus of the Pharma Highlight Session 

on Monday, 10 June 2024 from 

13:00 to 14:00: Under the title “Next 

generation pharma manufacturing 

– current advances in cell and gene 

therapy”, the Pharma Highlight Session 

will have a closer look on the centralised 

and decentralised production 

of cell therapeutics and the current 

challenges of translational research 

and the marketing of therapies. 

Lab Innovation 

More than ever, success in the laboratory 

is determined by the technologies 

used in the laboratory and 

at the interfaces to engineering and 

production. This is the focus of the 

presentations on the Lab Innovation 

Stage in Hall 12.0. In addition 

to the Lab Innovation Stage, ACHE- 

MA 2024 will also feature an action 

area dedi cated to the digitalised, 

miniaturised and auto mated laboratory 

of the future. Besides innovative 

bio analytics and (bio)pharmaceutical 

applications, sustainability as well 

as the planning, construction, equipment 

and operation of laboratories 

will also be highlighted. The latter is 

a particular focus in the SEFA Theatre 

of the Scientific Equipment and 

Furniture Association: at ACHEMA, it 

is the contact point for laboratory operators, 

architects, users and experts 

from the laboratory community who 

want to find out more about the laboratory-grade 

environment and gain 

insights into successful examples 

from around the world. 

Green Innovation 

all photos: DECHEMA/ e.V./Hannibal 

The challenge of climate-neutral 

production in the process industries, 

the circular economy, the integration 

of molecular and industrial 

biotechnolo gy, sustainable innovations 

and investments – these are the 

topics that are the focus of the EY 



ACHEMA 2024 

Green Innovation Stage in Hall 6.0. 

“The chemical industry is looking to 

innovative technologies to bolster 

sustainability, such as green chemistry 

and circular economy practices. 

ACHEMA is a key platform for bringing 

industry experts together to address 

these challenges and foster 

innovation”, emphasises Matthias 

Brey, Head of Sustainability Consulting 

Europe West at EY. In the highlight 

session “Beyond fossil fuels – exploring 

alternative carbon sources for a 

sustainable chemical industry”, on 

Thursday, 13 June 2024 from 13:00 

to 14:00, experts from science and 

industry will discuss how fossil-free 

production can become a reality. 

Digital Innovation 

Industry 4.0, artificial intelligence, 

autonomous systems, digital twins 

and, last but not least, cybersecurity: 

The Siemens Digital Innovation Stage 

in Hall 11.0 offers a comprehensive 

and practical overview of key digital 

trends and their use in the process 

industry. “For the process industry, 

ACHEMA is the key platform 

where innovation and practical application 

come together. We will show 

how Siemens is connecting the real 

world with the digital world to create 

a more sustainable future for 

our customers”, says Axel Lorenz, 

CEO Process Automation at Siemens. 

The highlight session “Artificial intelligence 

and auto nomous systems in 

the process industry” on Wednesday, 

12 June 2024 from 13:00 to 14:00 will 

discuss the steps towards autonomous 

systems and explore the technological 

and cultural challenges that 

lie ahead. 

Hydrogen Innovation 

exhibitors at ACHEMA will present the 

milestones of the hydrogen economy 

to date as well as future challenges. 

The highlight session “Hyperscaling 

hydrogen – turning strategy into reality” 

on Tuesday, 11 June 2024 from 

13:00 to 14:00 will deal with the central 

questions of the hydrogen rampup: 

What does hyperscaling mean for 

plant engineering, its suppliers and 

users? What investments and partnerships 

do we need for technology 

development and infrastructure? All 

highlight sessions will take place in 

the room Europa in Hall 4.0. 

While the congress sessions 

will primarily focus on applicationoriented 

research and the development 

from proof-of-concept to the 

threshold of market entry, the Innovation 

Stages will focus on current 

production issues, best practices and 

ready-to-use technologies via short 

presen tations – always with application 

in mind. With the exhibition 

and the closer integration of the various 

components, ACHEMA will offer 

a complete 360-degree perspective 

on all trends and technologies in the 

process industries. The lecture programme 

is therefore an important 

reason why experts and users from 

130 countries will once again be coming 

to ACHEMA in Frankfurt this year. 

www.achema.de/en 

The process industry stands like no 

other sector for the technological 

backbone of a functioning hydrogen 

economy: The Siemens Hydrogen Innovation 

Stage in Hall 6.0, the Special 

Show Hydrogen and numerous other 

Flexible chemical twin screw pumps made by Jung Process Systems 

Visit us 

Hall 8, Stand F27 

Pumping different viscosities and pressures with one and the same pump? 

Twin screw pumps from the CHEMSPIN series are multi-talented pumps for the 

chemical industry. Whether aqueous, highly viscous, lumpy, fibrous, corrosive, 

abrasive or gas-laden, the pumps are characterized by maximum efficiency 

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Jung Process Systems GmbH Auweg 8 25495 Kummerfeld T. +49 4101 80409-0 E-Mail: sales@jung-process-systems.de


FILTECH 2024 

Filtration and separation: 

trends for the process industry 

With constant growth rates, the 

global market for industrial filtration 

continues to surprise with innovations 

– this was also evident at 

FILTECH. An overview of promising 

trends. 

Separation and filtration are becoming 

finer and more precise, more digital 

and more intelligent. With the defining 

trends in mind, industry players 

are preparing for the most important 

platform in the sector. When FILTECH 

invites visitors to the trade fair and 

congress in November 2024, experts 

from all areas will exchange ideas, 

discover new technologies and shape 

the future of separation technology. 

Which topics will occupy the industry 

in the near future? An overview of application-specific 

developments. 

AI: Boost for soft drinks 

Artificial intelligence has enormous 

potential for various industries, including 

filtration. It enables real-time 

monitoring and optimization of filtration 

systems, improves efficiency 

and minimizes energy consumption. 

Adaptive systems automatically adjust 

to changing conditions, while AIbased 

quality control increases filtration 

accuracy and efficiency. 

Filtration as a Service 

Filtration as a Service (FaaS) is a new 

concept for the business use of filtration 

technology: instead of filter elements, 

operators book throughputs. 

Companies can use filtration services 

on demand without having to deal 

with equipment investments or maintenance. 

FaaS enables a focus on core 

competencies and always up-to-date 

filtration technology with an integration 

of monitoring and optimization. 

Pharmaceutical production: 

Safe products thanks to 

activated carbon 

In the food and pharmaceutical industries, 

filtration requirements are becoming 

particularly stringent. Activated 

carbon is increasingly being used 

to remove unwanted by-products, 

discoloration and odours. Two trends 

can be identified: pro ducts in powder 

form and filter sheets with bonded 

activated carbon, which offer even 

greater safety and purity. 

Wine: Filtration problems due to 

Botrytis- and Oidium-contaminated 

grapes 

The 2023 wine year brought various 

challenges for producers, such 

as oversupply in various regions and 

climatic extremes. The filterability of 

the wine is impaired by unclear young 

wines and clogged filters, especially 

in the case of botrytis- or oidium-infested 

grapes. Filtration specialists 

offer solutions such as enzymes and 

laboratory tests. Climatic conditions 

could increasingly force such measures, 

which is why winegrowing specialists 

are already preparing for 

them. 

Food: Stricter regulations through 

better testing procedures 

Increasing precision in food testing 

increases the demands on filtration. 

Systems must meet higher standards 

and be regularly monitored and 

maintained. Fine filtration technologies 

such as membrane or nanofiltration 

are becoming more popular because 

they remove even the smallest 

impurities. 

Innovative solutions for complex 

processes 

Separation technology is diverse. In 

all areas, the filtration and separation 

market is poised for growth and 

change. As companies recognize the 

importance of filtration in maintaining 

product quality and environmental 

responsibility, the demand for 

advanced filtration solutions will continue 

to grow. At FILTECH, attendees 

will find solutions that can meet every 

need - today and in the future. 

www.filtech.de 

Photo: Filtech GmbH 



VALVE WORLD EXPO 2024 

VALVE WORLD EXPO 2024 in Düsseldorf 

Industry reacts to economic policy challenges 

a “must” for the high performers in 

industry,” promises the Director at 

Messe Düsseldorf. Together with his 

team he looks to the trade fair kickoff 

on 3 December with anticipation. 

In 2024 the ecoMetals campaign by 

Messe Düsseldorf will again accompany 

the VALVE WORLD EXPO. With 

the help of a QR code visitors can decide 

themselves when to plan their 

tours to the exhibitors at the fair to 

find out live at the stand how sustainably 

these firms manufacture at their 

plants. 

Hydrogen seems to be one everyone’s 

lips but how do the key technology 

sectors of industrial fittings 

and valves confront it? 

How can existing gas pipelines be refitted 

cost-efficiently, when will sufficient 

new pipelines be produced and 

used throughout the country, and will 

hydrogen production become more 

inexpensive in future? Where is the 

skilled labour to build and fill these 

pipelines? 

So many questions for an industry 

that is undergoing rapid transition. 

The currently 327 exhibitors from 29 

countries taking part in the VALVE 

WORLD EXPO with Congress in Düsseldorf 

from 3 to 5 December 2024 

will showcase the innovations this 

sector has in store for the energy 

transition. 

all photos: Messe Düsseldorf/tillmann 

the sector firmly believes in its leading 

event as an innovation driver and 

international community platform. 

Alongside German companies, exhibitors 

from Italy, Spain, the UK, Turkey, 

the USA, India and China will be represented 

in Düsseldorf again. 

Here, every two years, the industry 

gets together at the international industrial 

valve summit to exchange 

ideas on innovations, trends and solutions. 

“Düsseldorf as a hotspot of 

the industrial valve industries – accompanied 

by a high-calibre Congress, 

the Valve Star Awards and 

the sustainable ecoMetal trails – is 

After their successful debut in 2022, 

the Valve Star Awards will also be presented 

to especially innovative companies 

and their products in 2024. 

Organised by the Vulkan-Verlag publishing 

house, exhibitors can submit 

their products with a brief description 

in the run-up to the trade fair 

and thereby nominate them for participation 

in the Valve Star Awards. 

Votes are cast online. The winners will 

be recognised in the four categories 

Valves, Actuators, Sealing Technology 

and the special category Industry 

4.0/Automation during the trade fair 

in Düsseldorf. 

www.valveworldexpo.de. 

The exhibits on show at the No. 1 

trade fair for industrial valves range 

from powerful machinery and equipment 

to tiny special valves, thereby 

mapping the entire value chain in industrial 

valves. 

The convincing interim registration 

figures already reflect today that 


77


DIAM & DDM 2025 

DIAM & DDM - Review of a successful 

anniversary year 2023 & preview 2025 

2023 was a very special year for the 

organisers of DIAM & DDM. In addition 

to the two face-to-face events 

in Leipzig/Schkeuditz and Bochum, 

the 10 th anniversary of the trade 

fair was also celebrated. Since the 

founding of the then stand-alone 

DIAM, these were events number 10 

and 11, which were held last year. 

This special year came to a successful 

conclusion with the 6 th edition at 

the premiere location in Bochum’s 

Jahrhunderthalle. 

“We are very proud that we have been 

around for more than 10 years and 

that we have been able to develop 

DIAM & DDM together with our exhibitors 

into the largest national industry 

gathering for industrial valves 

& sealing technology. As in the past, 

our 6 th edition in Bochum was once 

again a very good presence event. 

We are highly satisfied!”, summarised 

Malte Theuerkauf and Kevin Hildach. 

Almost 150 exhibitors came to the 

Jahrhunderthalle. The joy of the exhibitors 

at the well-known “family 

reunion” was clearly recognisable. 

The satisfaction of the organisers is 

also reflected in the statement from 

the premium partner from 2023: 

“We at SAMSON AG supported DIAM 

& DDM as a premium partner in order 

to accompany the successful format 

of this important industry trade 

fair into the future. DIAM & DDM was 

very successful for us and we look 

forward to innovative events in 2025!” 

In the future, the organisers of the 

largest national industry meeting for 

industrial valves & sealing technology 

will continue to stick to their proven 

concept and make further adjustments 

to expand the success of the 

trade fair. 

The next DIAM & DDM trade fairs 

will take place on 2 nd and 3 rd April 

2025 in Leipzig/Schkeuditz and on 

12 th and 13 th November 2025 in the 

“Jahrhunderthalle” Bochum. 

The dates: 

GLOBANA Trade Centre 

Leipzig/Schkeuditz 

2 nd and 3 rd April 2025 

Jahrhunderthalle Bochum 

12 th and 13 th November 2025 

Opening hours: 

1 st day of the fair from 09:00-17:00 

2 nd day of the fair from 09:00-16:00 

www.diam-ddm.de 


Save 

the 

Date 

industrial valves & 

sealing technology 

/ 2nd – 3rd April 2025 

/ Globana Eventhallen 

Leipzig/Schkeuditz 

/ 12th – 13th November 2025 

/ Jahrhunderthalle Bochum 

DIAM-DDM.DE

Compressors and Systems 



So that the packages do not run out of air 

The machine room - 

The unnoticed stepchild 

Compressors, blowers and turbos 

are at the heart of countless processes 

worldwide. They are generally 

designed for maximum efficiency 

and maximal energy savings, thus 

reducing costs and CO 2 

emissions. 

However, 15 per cent of 100 per cent 

of the energy used is typically lost in a 

poorly designed machine room - thermal 

losses due to heat radiation from 

the packages and mechanical losses 

due to underpressure in the machine 

room and intake losses. It is therefore 

essential to include the machine 

room in the efficiency concept to ensure 

the most economical operation 

possible. Room ventilation plays a 

central role here, as the air pressure 

and temperature in the room where 

the machines are installed are crucial 

for efficient operation. Or in short: 

Without a professional machine 

room ventilation system, users literally 

lose their money in the air. 

There is still plenty of room 

for improvement 

Machine room ventilation is rarely 

at the top of the priority list. This is 

a big mistake, because if the ambient 

conditions in the installation room 

are not appropriate, the blowers and 

compressors have to work harder or 

run longer to achieve the required capacity. 

System operators often do not 

realise how much they are counteracting 

the efficiency benefits of their 

packages with inadequate ventilation 

of the installation rooms. The losses 

caused by excessively high temperatures 

and/or incorrect air pressure 

are striking. That quickly adds up to 

more than 10,000 euros per year. 

– Faster wear of the system 

components 

– Reduced machine service life 

– Unhindered sound propagation 

– Higher energy and maintenance 

costs 

Air pressure, temperature and 

sound - The values must be right 

It is completely irrelevant where the 

packages get their intake air from: It 

is important that there is enough air 

at correct temperature. Sounds banal, 

but it is by no means trivial. 

Without supplies, the machines 

run out of air 

AERZEN packages work according to 

the positive displacement principle 

(compressor with internal compression, 

blower without) and are socalled 

forced conveying systems. This 

means that they extract air from their 

surroundings - continuously. If no or 

too little air can flow in, there is lack 

of air in the room. An underpres- 

sure is created. This can go so far that 

doors can no longer be opened. For 

example, with a 2 m 2 door leaf and 

25 mbar underpressure in the room, 

a compressive force of 5,000 N acts 

on the door. This corresponds to approx. 

510 kg. People in the machine 

room would then no longer be able to 

leave it - a dangerous situation. 

In addition, there is a loss of efficiency 

in the machines. As the air 

pressure drops, the density of the 

air decreases and the blowers (compressors) 

must increase their power 

requirement to achieve the intended 

performance. For applications with 

a differential pressure of 500 mbar, 

this quickly means an increase in performance 

of 10 per cent. 

Process air generators like it cool 

When air is compressed, a lot of heat 

is generated during the process - 

both in the generated air flow and 

under the acoustic hood due to the 

waste heat from the motor, silencer 

and compressor. If this waste heat 

is not conducted out of the room, 

the ambient temperature can rise to 

unacceptable levels. As a result, the 

packages can overheat, which leads 

to a loss of efficiency, faster wear and 

The consequences of inadequate 

room ventilation: 

– Higher energy demand of the 

packages 




a shorter service life - up to and including 

acute (total) damage. This effect 

occurs with all machine technologies, 

but to varying degrees. Positive 

displacement blowers, which are very 

common in pneumatics and wastewater 

technology, generate particularly 

high levels of heat. As a result, 

these are increasingly being replaced 

by rotary lobe compressors and turbos, 

which offer higher energy efficiency 

and lower heat dissipation. 

Loud instead of warm? 

Not a good idea. 

Anyone who thinks they can simply 

open the door or window of a machine 

room to improve the indoor 

climate in operation has made the 

invoice without the sound. This is because 

sound can escape unhindered 

through the openings - an undesirable 

side effect that makes it difficult 

to comply with occupational health 

and safety and noise protection regulations. 

The other extreme is just as 

ineffective. If the focus in the design 

of the machine room was solely on 

making the external shell as soundproof 

as possible, too little outside 

air could flow into the internals due 

to the sound insulation. The packages 

would literally run out of air due to a 

lack of replenishment. Suction of the 

machines via piping, i. e. directly from 

the outside, can also have disadvantages, 

as the suction noise is shifted 

almost directly to the outside. 

Supplementary problems 

in pneumatics 

When pneumatically conveying sensitive 

media in the food industry - for example 

sugar, cocoa powder or similar 

- certain temperature ranges must be 

maintained. If the conveying air is too 

warm, the conveying material will be 

damaged. If sensitive products are to 

be conveyed, operators must ensure 

that the intake air is cool. The higher 

the suction temperature, the higher 

the discharge temperature of the 

compressor. As a rule of thumb: For 

every 100 mbar increase in pressure 

in the compression process, the temperature 

on the outlet side rises by 

10 Kelvin. With a conveying pressure 

of 500 mbar and an ambient temperature 

of 20 degrees, this results in a 

discharge temperature of 70 degrees 

(20 degrees suction temperature plus 

50 degrees temperature increase due 

to the compression process). 

every 100 mbar more pressure = 

10 Kelvin warmer conveying air 

If the discharge temperature is too 

warm for the conveying medium, the 

conveying air must be cooled down. 

For blowers up to 1,000 mbar, this is 

done on the intake side. The advantage 

here is that intake cooling systems 

usually pre-dry the air. 

For screw compressors, on the 

other hand, cooling on the discharge 

side is recommended. Due to the 

higher pressures, compression temperatures 

of approx. 200 degrees are 

achieved. However, this is not possible 

without pressure losses through 

aftercoolers, condensate drains and, 

if necessary, dryers to dry the cooled 

air. In the case of longer conveying 

distances, convection on the piping 

also leads to cooling of the conveying 

air and thus, under certain circumstances, 

to remaining under the pressure 

dew point. If the pressure falls 

below the pressure dew point, water 

wastes. Temperature management 

is therefore of crucial importance for 

the efficiency and quality of the conveying 

processes. 

The biggest sins of efficiency - 

Costs without benefits 

If the supply and exhaust air ducts 

are insufficiently dimensioned and/ 

or the internal temperatures are too 

high, the packages must increase 

their performance in order to provide 

the necessary quantity of process air. 

At the end of the day, these reductions 

in efficiency add up to a glaring 

loss in energy efficiency and thus to 

rising electricity costs. It is therefore 

not insignificant for the efficiency of 

the process and compressed air generators 

how the machine room is designed. 

The key points are above all 

sufficient volume flow, the correct air 

pressure, effective limitation of the 

temperature in the installation room 

and the alignment of the room or 

building according to the direction of 

the compass. 

The following faults should 

be avoided: 

– Ventilation openings too narrow 

– Ventilation grilles blocked 

– Internal temperatures too high 

– Intake air too warm 

– Clogged filter mats 

– Noise protection concept without 

consideration of sufficient air 

supply (hazard of underpressure) 

– Open machine room doors 

(keyword: noise emissions) 

– Frequency inverter in the machine 

room (= heat source) 

The consequences of inadequate or 

non-existing machine room ventilation 

are losses - losses in efficiency, 

losses in the service life of the packages, 

losses in the supply of the pneumatic 

conveying system and losses in 

finances. 

In a poorly designed machine room, 

the blowers and compressors must 

typically have a 15 per cent higher capacity 

to provide the required quantity 

of process air. 


81



Optimum room ventilation - 

The heat must be blown out, 

the sound stays in 

Whether suction of cooling and/or 

conveying air directly from the machine 

room or from outside via a separate 

piping: Sufficiently dimensioned 

room ventilation is required for all intake 

types. The machine room ventilation 

fulfils three functions: Supply 

of conveying air, temperature regulation 

and noise protection. 

velocity and installation height as well 

as other relevant data in the online 

tool - the room ventilation calculator 

then automatically calculates the necessary 

room ventilation. 

Louvre silencer for the supply 

and exhaust air side 

The main work is taken over by supply 

and exhaust air louvre silencers. 

They ensure that sufficient air is available 

for compression, that the room 

does not heat up and that noise emissions 

do not exceed the limit values. 

The louvres inside are designed to 

effectively reduce noise and generate 

little flow resistance so that the 

packages in the machine room do 

not draw underpressure. The inlet 

air louvre is completed by a weather 

protection grille, which also prevents 

birds and leaves from getting into the 

intake duct. 

From north to south 

The main purpose of the exhaust air 

louvre is to conduct excess heat to 

the external air. As a rule, it is only 

half the size of the inlet air louvre 

and should be positioned in the ma- 

An art in itself 

When calculating, designing and implementing 

the ideal machine room 

ventilation, a large number of factors 

must be taken into account - from the 

performance data of the packages and 

the geographical conditions to the optimum 

position of the supply and exhaust 

air louvres in the room. The design 

of the machine room ventilation 

should therefore exclusively be carried 

out by professionals. The room 

ventilation calculator from AERZEN 

provides initial assistance for planning 

and optimisation. Planning offices and 

system manufacturers can enter existing 

values such as motor rating, ambient 

temperature, volume flow, flow 

Ideally, the supply and exhaust air louvres in the machine room should be positioned so 

that the air flows through the interior as diagonally as possible. 

Functions of the machine room ventilation: 

– Supply of conveying air 

– Temperature regulation 

– Noise protection 

chine room - in relation to the inlet air 

louvre - so that the air flows through 

the interior as diagonally as possible. 

For exhaust air, the same applies in 

terms of noise emissions as for inlet 

air: The heat must be blown out, 

the sound stays in. The exhaust air 

louvres are therefore equipped with 

sound-absorbing elements and use 

exhaust fans to ensure that the warm 

air leaves the room quickly. The exhaust 

fans are best assembled at ceiling 

height, as this is where the air is 

warmest. 

The cardinal points also play a 

role. For example, the inlet air in the 




northern hemisphere is ideally located 

in the north, as the air there 

is colder and therefore has a higher 

density. The exhaust air is ideally 

aligned to the south. 

Louvre blades against the cold 

Optional louvre blades can be used 

to close and open the supply and exhaust 

air louvres - either manually 

by hand control or automatically using 

a thermostat and switchgear. This 

is useful for application in cold outside 

temperatures. If it is below freezing 

outside, it is neither desirable for 

heat to leave the room nor for cold to 

enter the room. By closing and opening 

the supply and exhaust air louvres 

as required using louvre blades, 

both can be prevented while still securing 

good room ventilation. 

This is what ideal machine room ventilation 

looks like: 

– Sufficiently dimensioned ventilation 

openings 

– In the northern hemisphere: Alignment 

of the inlet air to the north 

(colder air with higher density) and 

the exhaust air to the south 

– Room is flowed through diagonally 

Regular filter changes pay off 

The filter is normally changed once a 

year. In most cases, this is too rarely 

the case. In view of the immense efficiency 

and cost losses caused by filter 

contamination of the suction filter, a 

replacement cycle of two months is 

recommended. It is not enough to 

blow out the clogged filter with compressed 

air. Clogged filters quickly 

cause a pressure resistance of 25 and 

more millibars. In an average plant 

with four blowers, each with a motor 

rating of 37 kW, a total of 6,900 operating 

hours per year and 40 cents per 

kilowatt hour, the clogged suction filter 

alone would demand five per cent 

more performance from the blowers. 

That's more than € 20,000 a year. 

Frequently changing the suction filters 

is therefore worthwhile and also 

saves costs. 

Engine room with ventilation on the south and north sides 

Realising efficiency potential 

– Use of louvre silencers on the supply 

and exhaust air side 

To summarise: Any reduction in efficiency 

- even if it is only a few percentage 

points - has a negative impact on (where the air is warmest) 

– Exhaust fans at ceiling height 

the energy balance and thus increases 

electricity costs. To ensure that side temperatures (with manual 

– Louvre blades for use in cold out- 

the machine room does not become adjustment or automated) 

an efficiency killer, criteria such as a – Regular maintenance of the suction 

filters 

sufficient air supply, a cooler suction 

temperature, optimum air pressure, 

alignment of the supply and exhaust Invest once, profit forever - Modern 

air to the direction of the compass ventilation concepts make the difference 

and regular filter cleaning should not 

be ignored. 

High energy costs, increasing scarcity 

of resources, growing environmental 

awareness and increased cost 

pressure are forcing companies and 

plant operators to optimise their processes 

and use resources more economically 

and efficiently. The use of 

high-performance technologies and 

energy-saving packages is an important 

step. However, the key to maximal 

energy and cost efficiency lies in 

a holistic approach - and this includes 

optimising the design of the installation 

room for the blowers, compressors 

and turbos. 


83



The following calculation example illustrates 

the costs incurred due to inadequate 

room ventilation. 

Calculation example: Losses due to inadequate room ventilation 

Initial situation: 

– 4 packages with a motor rating 

of 37 kW each 

– 6,900 operating hours per year 

– 40 ct/kWh electricity costs 

– Application with a differential 

pressure of 500 mbar at an ambient 

pressure of 1,000 mbar (1 bar) 

In the application example, excessive 

temperatures, underpressure in the 

room and dirty suction filters result in 

annual costs of around € 40,848 - an 

enormous sum. 

These costs are absolutely avoidable. 

Even simple measures help to eliminate 

these unnecessary losses and at 

the same time solve the noise problems 

that can occur during process 

and compressed air generation. 

tion room can be eliminated with little 

effort and a manageable financial 

investment. Compared to the annual 

savings, the costs for the one-off investment 

in a machine room ventilation 

system are negligible. 

Minimum costs, maximum 

efficiency 

Efficiency losses of blowers and compressors 

resulting from insufficient 

ambient conditions in the installa- 

Maschinenfabrik Aerzen GmbH 

Aerzen, Germany 

www.aerzen.com 


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Biogas Backfeed in Leoben 

Ralf Deichelmann 

The best-known Austrian beer 

brand on the global stage is Gösser 

Bräu, owned by Brau Union Österreich 

AG. And the brewery, located 

in Leoben, Styria, has traditions 

that date back more than 1000 

years. In 1860, the brewer Max Kober 

breathed new life into the brewery, 

which had been started by the 

nuns of Göss and later abandoned. 

Nowadays, the green portion of the 

logo also signifies the company's 

commitment to a climate-friendly 

business policy. Gösser is pulling out 

all the stops to reduce its fossil fuel 

consumption in production, procurement 

and delivery. As well as rolling 

out a large solar installation and 

lever aging waste heat during the 

brewing process, tapping into its own 

biogas is one pillar of the company's 

sustainability strategy. 

In fact, the biogas supply is a joint project 

between Brau Union, the energy 

supplier Energienetze Steiermark 

and the compressor specialist BAUER 

KOMPRESSOREN. The biogas used in 

the production process is extracted 

from the brewery's spent grains, the 

residue from the brewing process, in 

Brau Union's own bio gas plant and 

then transferred to “Energienetze 

Steiermark” (Styrian Energy Networks), 

which then converts the raw 

gas into ready-to-use, compressed 

and purified biomethane. 

To ensure it is usable down the line, 

the freshly extracted raw gas must 

first be treated. It undergoes a process 

called amine scrubbing, which 

removes unwanted by-products from 

the raw gas. 

Fig. 1: The Gösser brewery uses biogas compressed by BAUER 

Typical uses include to remove carbon 

dioxide, hydrogen sulphide and 

other acid gases from gas mixtures. 

Amine scrubbing is based on the 

chemisorption principle, which paves 

the way for high purities, even at relatively 

low pressures. The gas is only 

under a few millibars of pressure 

when it enters the feed system. Prior 

to compression, the quality of the 

processed biomethane is measured 

with a gas analyser to determine the 

methane content and its accompanying 

substances and thus comply with 

the benchmark values specified in 

the relevant standards. 

Fig. 2: Biogas recompressor station from BAUER KOMPRESSOREN as a containerised 

solution for outdoor use 

Two technically different compressor 

systems were planned because 

the power is fed into different grids 

according to demand. And this is 

where the cutting-edge compressor 

technolo gy of natural gas and biogas 

specialist BAUER KOMPRESSOREN 

comes into play. The first of the two 

systems uses a CNK9-55 water-cooled 

screw compressor, which is designed 

to deliver high capacity at low pres- 




sure. This feeds the processed biomethane 

into a 4 bar network, which is 

used in the brewing process at the 

brewery. 

Fig. 3: Leoben gas feed circuit diagram 

After compression, the biomethane 

is re-cleaned via special filter 

systems and cooled down to a gas 

temperature of around 20°C using 

a chiller, as the pipes in the brewery 

process are made of temperaturesensitive 

PE. If the extraction during 

the brewing process is too low, the 

second compressor, a water-cooled 

CS23.8-37 medium-pressure compressor, 

switches over fully automatically. 

This high-pressure booster, developed 

by BAUER KOMPRESSOREN, 

makes it possible to handle high inlet 

pressure without reducing it. This 

operating mode is particularly energy-efficient 

and reduces energy consumption. 

Specially developed control 

and valve technology ensures 

uninterrupted operation. The compressors 

are housed in heated and 

ventilated containers, allowing them 

to operate in highly variable outdoor 

conditions. 

Fig. 4: Water-cooled CNK9-55 screw compressor 

Gösser Bräu has added another important 

building block to its sustainability 

strategy with the commissioning 

of the fully installed systems 

following final acceptance. 

The Author: Ralf Deichelmann, 

Marketing and PR 

BAUER KOMPRESSOREN GmbH 

Munich, Germany 

www.bauer-kompressoren.de 

Fig. 5: Water-cooled medium-pressure compressor type CS23.8-37 


87



Compressed air specialist committed to the climate 

and customers 

Sustainability on the rise 

The use of compressed air consumes 

a lot of energy. However, work is also 

being done on the ecological balance 

in this area. Manufacturers such as 

BOGE support their customers in 

saving electricity and CO 2 

and are 

involved in cross-industry projects 

that contribute to environmental 

and climate protection. 

BOGE is also involved in the Haru Oni 

project. The Bielefeld-based manufacturer 

of compressors and compressed 

air systems supplies the compressed 

air required to operate the 

system. It is required as instrument 

air - for example to control pneumatic 

valves - but also to generate the nitrogen. 

The generator works according 

to the pressure swing adsorption 

(PSA) process and supplies nitrogen 

with a purity of 99.99 per cent. BOGE 

has also developed a system for compressing 

the carbon dioxide extracted 

from the air. “Unlike usual, the CO 2 

is not stored in a solid container, but 

in a bubble made of rubberised fabric 

that inflates to the specified filling 

level,” explains the Senior Project 

Manager at BOGE. Many of the sys- 

One of these projects is “Haru Oni” - in 

the language of the indigenous people 

of Chile, this means “strong wind”. 

There is more than enough of it in the 

southernmost region of Chile. In the 

“Haru Oni” pilot project, wind energy 

is to be used to produce e-fuel. In 

other words, the substance that will 

power some cars, ships and airplanes 

as well as countless machines in the 

future. Companies from several countries 

have joined forces under the 

leadership of the Chilean project company 

HIF (Highly Innovative Fuels). The 

common goal is to initially produce 

130 cubic metres of the green fuel. In 

a second phase, production is to be increased 

to 55,000 cubic metres and 

from 2026 to 550,000 cubic metres. 

The climate-neutral fuel is obtained 

from hydrogen and carbon dioxide. 

To do this, water is split into its 

components hydrogen and oxygen 

using electrical energy. The hydrogen 

is mixed with carbon dioxide, which 

is absorbed and collected directly 

from the air, to form a synthesis gas. 

This is then processed into methanol 

and finally into synthetic petrol. The 

companies involved in the project, 

including Siemens Energy, are trialling 

various new processes for this. 

Fig. 1: As part of the Haru Oni project, BOGE has developed a system for compressing the 

carbon dioxide extracted from the air. The CO 2 

is stored in a bubble made of rubberised fabric, 

which inflates to the specified level. 

Nitrogen with a purity of 

99.99 per cent 

Fig. 2: With the new components for screw compressors, up to 94 per cent of the energy 

used can be recovered. 




tems used in the project are pilot systems, 

some of which are being operated 

for the first time and need to be 

harmonised with each other. 

More heat equals less energy 

Renewable energies from wind and 

sun play a key role in achieving the internationally 

agreed climate targets. 

But this alone will hardly be enough 

- energy must also be wasted less, 

saved wherever possible and utilised 

several times. This is why BOGE offers 

its customers the option of recovering 

some of the energy used to 

generate compressed air and utilising 

it further: the heat generated is no 

longer released into the environment 

but can be used, for example, to heat 

operating areas and to heat water or 

oils. With the new components for 

screw compressors, up to 94 per cent 

of the energy used can be recovered. 

As the heat generated is dissipated, 

the energy required to cool the compressors 

is also reduced. The investment 

is therefore usually amortised 

within a few months: a double benefit 

for the environment and for the 

company. 

Clean drinking water with 

compressed air 

In addition to utilising renewable 

energy sources and saving process 

heat, there are other ways to contribute 

to climate protection. For 

example, the issue of drinking water 

is being given even greater attention 

than before since climate change 

has been accompanied by water 

shortages in large parts of Europe. 

A Belgian supplier maintains a drinking 

water network of over 2,300 kilometres, 

supplying almost 200,000 

people. The water comes from the 

Albert Canal and the Nete Canal as 

well as the Eekhoven reservoir. As 

it is a shallow, stagnant body of water, 

blue-green algae quickly develop 

there in the hot summer months. 

They discolour the water, form unsightly 

foam and floating mats on 

its surface and also pose a threat to 

human health. 

To prevent this, the utility company 

has developed a plan together 

Fig. 3: With the “Blueprotect” solution 

developed by BOGE, the insects are exposed 

to nitrogen for 30 to 40 days so that no 

broods can develop. 

with BOGE for an aeration system to 

thwart the formation of algae. The 

system supplies oil-free compressed 

air and pumps it into the water via 

five-point aerators. The aeration 

ensures good mixing, leading to increased 

oxygen levels, reduced nutrient 

release through the soil and the 

elimination of dead zones. This prevents 

algae from forming layers and 

keeps the drinking water clean. 

Customised solutions for customers 

Generating renewable energy, utilising 

waste heat, ensuring clean drinking 

water - ecological and sustainable 

management has many facets. One 

aspect that seems rather unusual is 

of great importance for grain silos: 

the use of nitrogen for pest control. 

In the food industry, the use of the 

gas has long been common practice 

to displace oxygen from packaging 

and thus protect food from spoiling. 

BOGE is now applying the same principle 

to grain silos: Nitrogen extracted 

from the ambient air is channelled 

into the silos, where it displaces the 

oxygen without which aerobic animals 

- in this case grain beetles in 

particular - cannot exist. The economic 

losses caused by pest infestation 

in silos can quickly amount to 

hundreds of thousands of euros. If, 

for example, breweries detect pests 

during quality control of the grain delivered 

by a malting plant, they often 

refuse to accept the grain and the delivery 

is returned. 

With the “Blueprotect” solution 

developed by BOGE, the insects are 

exposed to nitrogen for 30 to 40 days 

so that no broods can develop. The 

devices required for nitrogen production 

- compressor, dryer and filter - 

are integrated into a container in sizes 

10 and 20 feet. The container can be 

used for several silos via plug-andplay. 

Nitrogen is supplied to the silo 

via pipes or hoses, whereby existing 

fire brigade connections or ventilation 

pipes can be used. “We focus 

on the customer's requirements and 

offer customised solutions,” says the 

expert for special gases at BOGE. 

The tighter a silo is, the more 

efficient the process is. However, 

fine cracks are often not recognisable, 

and it is not uncommon for there 

to be leaks in the area of the grain 

feed and discharge openings, air inlet 

openings or manholes. On request, 

BOGE can therefore provide a test 

container that supplies nitrogen at 

a flow rate of 40 to 60 cubic metres 

per hour. This allows the tightness of 

the silo to be determined within a few 

days and the system to be designed 

accordingly. “Blueprotect is ecological 

and therefore a forward-looking alternative 

to the use of conventional 

methods,” explains the expert. 

Sustainability pays off 

For a long time, sustainability was 

a term that only played a role in 

forestry. This has now changed, because 

there is a growing realisation 

that ecological action and management 

is necessary in all areas: also 

in mechanical engineering - also in 

the compressed air segment. With its 

vari ous initiatives and projects, the 

Bielefeld-based compressor manufacturer 

BOGE shows how diverse 

the areas are in which sustainability 

is worthwhile - for the environment 

as well as for the company. 

BOGE KOMPRESSOREN 

Otto Boge GmbH & Co. KG, 

Bielefeld, Germany 

www.boge.com 


89


Heat recovery 

Heat recovery 

Save money and benefit the environment 

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

Compressors and the compressed 

air they generate are used in a multitude 

of industrial applica-tions. 

However, the fact that compressor 

exhaust heat can be harnessed often 

remains forgot-ten. The magic 

words here are “heat recovery”: up 

to 96 % of the drive energy supplied 

to a compressor is available for reuse. 

This not only saves energy and 

costs, but also reduces the operator’s 

CO 2 

footprint. 

Fully 100 % of the drive energy supplied 

to a compressor is converted 

into heat. Both air- and fluid-cooled 

rotary screw compressors are exceptionally 

well-suited to comprehensive 

recovery and reuse of this energy; 

around 76 % of their energy input remains 

as heat in the cooling fluid and 

is removed in the fluid cooler. A further 

15 % can be recovered as heat 

via the compressed air aftercooler. 

Up to 5 % of the heat produced is 

emitted by the electric motor – with 

targeted cooling, fully enclosed rotary 

screw compressors can even recover 

this energy as well. Only 2 % of the total 

energy input is lost as heat radiation, 

whilst a further 2 % remains as 

heat in the compressed air. 

Of course, this heat could simply 

be conveyed away. However, there 

are plenty of ways to make use of this 

readily available energy source that 

occurs as a by-product of the compression 

process. The simplest and 

most efficient method is to use the 

compressor exhaust heat directly, 

e. g. for heating adjoining rooms or 

spaces. Here, instead of discharging 

hot air from the compressed air station 

outside, an air ducting system directs 

it to neighbouring warehouses 

or work-shops. When no hot air is 

required, the heated exhaust air is 

simply conveyed outdoors by means 

of a flap or louvre. A thermostatically 

controlled louvre enables hot air to 

be provided as and when required 

in order to maintain a constant temperature. 

In addition to providing full or supplementary 

heating for operating spaces, 

hot compressor exhaust air can 

be used to support applications such 

as drying processes, generating hot air 

curtains or preheating burner air for 

heating systems. The corresponding 

investment costs can often be amortised 

within a period of one year. 

Compressor exhaust heat can also 

be used to supply existing hot water 

heating and service water systems; depending 

on the available storage capacity, 

water temperatures of 70 ºC 

and even higher can be gener ated. 

There are several ways to achieve this. 

The most cost-effective method is to 

use a plate-type heat exchanger integrated 

into the compressor, which is 

connected to the compressor cooling 

fluid circuit and transfers energy from 

the heated cooling fluid to the water 

that requires heating. Depending on 

whether the hot water is required for 

particularly sensitive production or 

cleaning processes, for showering and 

washing, or for general heating systems, 

special safety heat exchangers 

or conventional plate-type heat exchangers 

may be used. These enable 

70 – 80 % of the installed compressor 

output to be used for heating purposes 

without the need for any additional 

expenditure on energy. 

Fig. 1: Virtually the full amount of energy supplied for compressed air generation can be 

used for heat recovery. 

Fig. 2: Heated compressor cooling air can be used for simple and effective heating of neighbouring 

spaces via air ducting. 


FILTECH 

This variant of heat recovery is also possible 

with primary water-cooled rotary screw compressors. 

Heat recovery is principally worthwhile 

when the compressors in question feature 

a power output of at least 5.5 kW. 

Establishing actual requirement 

Since very few operators know their exact 

air demand, it is worth conducting a compressed 

air audit before installing a compressor 

system. Performed swiftly and seamlessly 

using state-of-the-art analysis tools such as 

the ADA/KESS (Air Demand Ana lysis/Kaeser 

Energy Saving System), this audit can determine 

the precise demand data for a project. 

The web-based system transmits measured 

data and system data for the audited station, 

and rapidly provides an initial report for the 

operator. These data can then be transferred 

to the KESS system and subsequently used to 

determine the planning steps for the air station 

operator, as well as the investment costs 

and potential for energy savings. In the case 

of a completely new installation, optimised solutions 

are devised and suggested from the 

outset so that the operator can compare independently 

between different system variants 

and select the most cost-efficient choice. 

Where building management systems are 

used, it is recommended to conduct a thermal 

audit in conjunction with the compressed 

air audit so that the heat balance can be determined 

in parallel with the air consumption. 

This allows thermal data such as temperature 

flow and return to be investigated in addition 

to compressed air data such as volume, pressure 

and required air quality. 

Once these details are established, it can 

be determined what percentage of the compressor 

exhaust heat can be absorbed into 

the normal heat requirement of the project. 

This in turn allows the size of the storage vessel 

and the required temperature to be calculated. 

In the best-case scenario, 96 % of the 

heat output can be used. 

What to consider 

A few points must be taken into account when 

planning or optimising a compressed air station. 

For example, compressors and heating 

systems should not be placed in the same 

room, since optimal use of these requires 

different room climate conditions and the 

compressor must not be permitted to draw 

in dangerous admixtures. The compressor 

room needs to be well venti-lated; the room 

for the heating system does not. In an ideal 

world, the two rooms would be separate but 

situated near to one another, so that the ducting 

route between compressors and heating 

system can be as short as possible. Even 

when the two systems are positioned apart, 

the heat from the compressors can be used 

to heat the burner intake air for the heating 

system. 

Since the volume of accumulating heat 

and the heat requirement are rarely identical, 

it is im-portant to ensure that there is sufficient 

thermal storage potential in the form of 

large vessels. This guarantees optimum sup- 

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Fig. 3: Compressed air station with air ducts for heat recovery. The ducts convey hot air to neighbouring spaces. 


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Heat recovery 

ply when generation and consumption 

volumes differ, as happens in the 

case of a house equipped with solar 

heating, where it also necessary to install 

a means of thermal storage so 

that hot water is still available when 

the sun is not shining. 

Air- or water-cooled compressors? 

Once the design has been decided, it 

is vital to select the correct compressors. 

In general, two different cooling 

methods are available for compressors: 

air cooling and water cooling. As 

al-ready mentioned, in the case of the 

former, air ducts with thermostatically 

controlled flaps con-vey the hot exhaust 

air directly from the compressors 

to the neighbouring operating 

spaces, in order to provide heating 

for example. To minimise heat losses, 

the distance the exhaust air needs 

to travel from the compressor to the 

point of use should not be too far. 

Today, air-cooled rotary screw compressors 

are available with up to 315 

kW of power. Even if it is not required 

year-round, heat recovery with this 

type of system pays dividends: the 

required investment for heat recovery 

is relatively low and can usually 

be amortised within just a year. 

Systems equipped with additional 

hot water heat recovery can supply 

water at temperatures up to 70 °C 

throughout the year, and even higher 

if needed. However, since these 

systems have an impact on compressor 

power consumption, it should be 

checked beforehand that their use 

is justifiable from a cost-efficiency 

point of view. 

In the case of water-cooled compressors, 

the user-end requirements 

and cooling water costs also play an 

important role; in principle, how ever, 

heat recovery as described above 

can also be achieved here by means 

of a se cond connected circuit. 

Summary 

Heat recovery can significantly increase 

the efficiency of a compressed 

air system and reduce environmental 

damage by preventing emissions 

of greenhouse gas. The required investment 

costs depend on local conditions, 

the intended purpose and the 

method of heat recovery chosen. 

The Authors: 

Dipl. Betriebswirtin Daniela Koehler, 

Press Officer, 

Dipl.-Ing. (FH) Gerhart Hobusch, 

Lead Project Engineer, 

both Kaeser Kompressoren 

Coburg, Germany 

www.kaeser.com 




Getting started is easier than you think 

Plant Documentation 4.0 – an essential enabler for Industry 4.0 

Dipl.-Ing. (BA) Martin Dubovy, Dipl.-Betriebsw. (FH) Evelyn Landgraf 

Specialist articles on Industry 4.0 

generally emphasize the aspect of 

technical feasibility of the consistent, 

intelligent networking of machines, 

processes and personnel: What gateways, 

protocols and platforms will be 

needed to interlink machines from 

different manufacturers? What legal 

requirements have to be observed? 

How can security be designed to 

avoid hacker attacks? However, one 

aspect that is often overlooked is 

this: Digitalized plants and processes 

can only be reliably administered 

if documentation is available that reflects 

the current status of the production 

plants. In many places reality 

is still far removed from Plant 

Documentation 4.0 – despite the fact 

that it is just as essential to the success 

of Industry 4.0 as the necessary 

communication techniques and all 

security concepts. 

We are living in a time of perpetual 

change. This is also reflected in industrial 

production. Manufacturing processes 

are continually adapted and 

optimized; products are increasingly 

being individually manufactured. This 

is not new, because in the past, too, 

production plants were in a state of 

perpetual change: failed components 

were replaced, software patches and 

updates were installed, process optimization 

programs were developed, 

and much more. Nevertheless, this 

trend is gaining speed and processes 

are becoming more dynamic. 

tally with plant reality, is always very 

time-consuming – thus quality control 

process is generally confined to 

some random checks. Thus, often 

enough, plant documentation does 

not even correspond to plant reality 

at the start – and even if it does correspond 

initially, the task of keeping 

the status of this documentation up 

to date is anything but trivial. The bigger 

and more complex the plant, the 

greater this challenge appears. It may 

even sound a little schizophrenic to 

be talking about digital twins on the 

one hand, whereas in many places a 

daily struggle is still going on to master 

plant documentation with the aid 

of paper documents, Excel lists and 

complex file structures. However, this 

is exactly where Plant Documentation 

4.0 can make a vital contribution, especially 

if a system is also able to simplify 

the management of changes. 

Current status of all built-in 

components – and much more 

In sectors such as petrochemicals, 

chemicals, logistics, manufacturing, 

in power plants, plant construction 

or the pharmaceutical industry, production 

processes are generally complex, 

and plants often assume gigantic 

proportions. Thus, these sectors 

of industry have had to rely on digital 

documentation for a long time 

now to keep track of the as-built status 

of their plants and manage the 

relevant interrelated processes. So, 

it is not surprising that a company 

like Rösberg Engineering GmbH from 

Karlsruhe – already active in these 

sectors for decades – developed digital 

solutions many years ago in order 

to keep an overview of the flood 

of information in these types of 

plants. The Account Manager Plant 

Solutions at RÖSBERG Engineering 

GmbH comments: “With our I&C-CAE 

system ProDOK (Fig. 1) we primarily 

document the planning and construction 

of plants. However, it is also 

important to know the current status 

and components built in during 

the operational phase. Our software 

tool LiveDOK (Fig. 2) helps with the 

administration and documentation 

of changes. A main focus of the tool 

is on simply find documentation updates 

and enabling the changes to be 

made available to everyone quickly 

and easily.” 

Reliable documentation of 

as-built status 

As-built documentation – meaning 

documentation that reflects the actual 

state of a new plant – has always 

been required for commissioning, 

but in fact the time and resources 

involved in preparing the relevant 

documents is always immense. 

And controlling the delivered documents, 

to make sure they really do 

Fig. 1: ProDOK is the I&C-CAE system for the planning and operational support of process 

control equipment in process plants. ProDOK enables rational, consistent project planning 

and consistent documentation, ensuring an integrated planning process that follows unified 

rules. (Copyright: Rösberg) 


93



When envisaging Plant Documentation 

4.0 probably the first aspect to 

be considered is the advantages for 

maintenance. Here, of course, it is extremely 

useful to know the current 

state of the plant and be able to easily 

document the changes. To do this, 

maintenance crews can simply enter 

the change on a tablet with a stylus 

(Fig. 3), and it is saved together with 

the information about who made the 

change, when, and explanation if necessary. 

Workflows built into the system 

then ensure that the original 

documentation is reviewed regularly 

and thus stays clear and up-to-date. 

In addition to maintenance, many 

other areas benefit from digital documentation 

(Fig. 4). These include 

e. g., troubleshooting, large-scale revisions, 

project-related documentation, 

loop checks and the management 

of assets, the integration of 

package units, and know-how transfer. 

And when it comes to audits, it 

certainly pays off to have up-to-date, 

legally compliant documentation at 

hand at all times. 

Fig. 2: LiveDOK makes distributed documentation of large-scale plants digitally available 

to engineers and plant operators: all relevant documents and drawings are presented in a 

structured way on one unified, intuitive user interface – regardless of their format and medium. 

Plant data can be administered, searched and corrected in real time – from planning 

to operation, anytime, anywhere. (Copyright: Rösberg) 

Troubleshooting, large-scale 

revisions and loop checks 

When something goes wrong, every 

minute counts. In a situation of 

Various use cases benefit from 

Plant Documentation 4.0 

Fig. 4: Very diverse use cases benefit from the use of LiveDOK. (Graphic Rösberg) 

Fig. 3: Redlining: Changes can be very simply noted, for example by a handwritten notice on 

a tablet. (Photo: Rösberg) 

this kind valuable time is lost if the 

current documentation status of 

the plant first has to be assembled 

– in the worst case, inability to react 

fast enough may result in damage 

or danger to people and the environment. 

In large-scale revisions, 

too, time is usually tight. Numerous 

employees need to be coordinated 

and very many changes made to 

the documentation simultaneously. 

This makes it all the more important 

to ensure that everyone involved in 

the process has access to the current 

documentation at all times. Similarly, 

loop checks also involve the coordination 

of large numbers of employees 

and the structured execution of 

various tasks. 




Managing assets and 

package units 

Digital documentation is also beneficial 

for effective asset management 

– for instance, when a manufacturer 

discontinues an asset, 

making it necessary to know how 

many of the relevant components 

are built into the plant and where; 

or when compiling an overview 

of components that will no longer 

receive support in the near future. 

Only a company managing 

its assets effectively can keep production 

running reliably. Another 

aspect that necessitates digital 

documentation is the trend in 

the process industry towards integrating 

Package Units, meaning 

the distribution of large plants into 

smaller units. This raises the question 

of how the documentation 

that is delivered together with a 

functional unit can most easily be 

transferred into the already-existing 

plant documentation. 

When engaging in extensive plant 

retrofit or extensions, or for inspection 

purposes, many project-related 

documents also have 

to be immediately available as 

and when required. If these documents 

only exist in paper form, 

or are only available from different 

sources and in assorted file 

formats, compiling them is effortintensive 

and not overly efficient. 

Another advantage of consistent 

digital documentation is that 

know-how can be preserved, because 

the knowledge no longer 

exists solely in the minds of experienced 

employees. This substantially 

facilitates knowledge transfer 

to new employees. 

“In all these and many other 

use cases, LiveDOK has been 

proving its worth for decades 

now” the Account Manager Plant 

Solutions says, and adds: “With 

digitalization the focus was on 

the PC, but with Industry 4.0 the 

focus is on the Internet. This also 

applies, so to speak, to Plant Documentation 

4.0. We have been 

creating digital documentation 

for a long time now, but we have 

consistently developed our concepts 

further, for instance regarding 

cloud enablement, in order to 

stay with the pulse of the times. 

Thus, our customers get a tried 

and tested product that uses today’s 

state-of-the-art technologies 

to fulfill the technical and legal requirements 

of tomorrow.” In the 

use cases described above, the 

documentation tool enables documents 

to be found fast, provides 

a realistic overview of the components 

built into the plant while 

helping to keep docu mentation 

up-to-date, ensures standardization 

in documentation in line 

with current legal requirements, 

gives all disciplines involved in a 

project access to the documentation 

without media discontinuity, 

and ensures that everyone in 

the team is working with the same 

documents. 

Rösberg Engineering GmbH 

Rösberg Engineering GmbH, founded in Karlsruhe in 1962, 

offers tailored automation solutions created by 180 employees 

working at seven locations in Germany and one in India and 

China, for internationally active enterprises in the process industry. 

Today RÖSBERG is an internationally successful automation 

specialist and developer of software solutions. Its scope includes 

basic and detail engineering for the automation of process 

and production plants as well as the configuration, delivery 

and commissioning of distributed control systems. The enterprise 

also has extensive project planning and application experience 

in the implementation of safety-related controls, is an 

expert in functional safety, and offers sector-specific software 

solutions in the area of information technology. The I&C-CAE 

system ProDOK has enjoyed international success for more 

than 30 years now. Together under the name of Plant Solutions, 

ProDOK, the digital plant documentation LiveDOK and the Plant 

Assist Manager (PAM) support plants over their whole life cycle, 

from planning, construction and commissioning through to 

modernization, expansion and decommissioning. 

Project-related documentation 

and know-how transfer 

Getting started is easier 

than you think 

Companies who wish to consistently 

implement Industry 4.0 cannot 

do so without digital, cloud 

capable plant documentation, especially 

where large plants are 

concerned. Nevertheless, many 

companies are still put off by the 

initial effort and expense of digitalizing 

their documentation at all 

in the first place. Here the process 

automation experts can reassure 

them – numerous projects carried 

out in the past have shown 

that getting started is much easier 

than users generally fear. And 

not only that – very often digitalization 

opens up many optimization 

opportunities, so the effort 

pays off much faster than many 

people think. 

The Authors: 

Dipl.-Ing. (BA) Martin Dubovy, 

Account Manager Plant Solutions 

and Dipl.-Betriebsw. (FH) 

Evelyn Landgraf, Marketing, at 

Rösberg Engineering GmbH 

https://livedok.roesberg.com/ 

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Frequency converter series SD4M for high-speed applications 

Multilevel technology: What it can do 

and what it enables 

Markus Finselberger 

Motor-driven and generator-driven 

high-speed applications with high 

output powers push the standard 

converter technologies to their 

limits. Especially in the field of renewable 

energy as well as efficient 

compressed air supply, the demand 

for converters that enable 

high rotating field frequencies 

grows. Therefore, the high-speed 

specialists at SIEB & MEYER AG 

have developed a solution based 

on three-level technology. With the 

series SD4M, motor losses, electromagnetic 

radiation as well as insulation 

stress can be reduced significantly. 

The following article answers 

important questions regarding use 

and function of the multilevel frequency 

converters. 

How does a multilevel frequency 

converter work? 

The majority of frequency converters 

used in modern drive technology is 

based on two-level technology. That 

means, at first the converters rectify 

the mains AC voltage into DC voltage 

and then convert this DC voltage to 

an AC voltage with variable frequency 

and amplitude, which can be supplied 

to motors with adjustable speed. The 

AC voltage is generated with alternating 

polarity – plus and minus – on 

two levels. Many converters use the 

modulation type PWM (pulse-width 

modulation) for this purpose. Multilevel 

converters use at least one more 

intermediate voltage level, which 

makes a quite different output stage 

topology neces sary. A conventional 

three-phase two-level converter requires, 

for example, six electronic 

power switches (transistors), whereas 

a three-level converter requires 

twelve switches. 

For which applications are multilevel 

converters suitable? 

Multilevel converters enable, for 

example, a significant increase in the 

efficiency of turbomachinery such as 

turbo compressors and blowers (e. g. 

for wastewater treatment) and of rotating 

energy storage units (flywheel) 

as well as ORC systems for the conversion 

of waste energy into electric 

energy. The efficiency of these 

systems increases with their speed. 

However, until now the market hardly 

offered any converters for output 

powers >100 kW and rotating 

field frequencies up to 2,000 Hz – 

especially when sensorless control 

of synchronous motors is required. 

Multi level technology closes this gap. 

What requirements do HS motors 

demand of the converter technology? 

The applications mentioned above 

employ high-speed motors (HS motors) 

that generate power via speed 

and not via torque. As a general rule, 

the rotor volume changes at the same 

rate as the reciprocal of the speed increase. 

That means, at 10 times of 

the speed the rotor volume has decreased 

to one-tenth. This in turn results 

in limited heat dissipation. The 

negative effects are amplified when 

the motor is operated in vacuo or in 

a gas with low thermal conductivity, 

for example in flywheel applications. 

Therefore, the used frequency converters 

must reduce motor losses 

and the resulting heat development 

as far as possible. 

What influence do high speeds have 

on the motor design? 

Fig. 1: Multilevel frequency converters support applications that require high rotating field 

frequencies. They enable, for example, a significant increase in the efficiency of turbo 

compressors and blowers that are used e. g. for wastewater treatment. 

(Image © : Kletr_261344590 - adobestock.com ) 

The motor design must be adapted 

according to the power/speed ratio 

required by the application. Beside 

the permissible circumferential speed 

of the rotor, the bending-critical frequency 

of the corresponding shaft 

have to be considered. That means, 

a synchronous motor with 100 kW at 

60,000 rpm, for example, can reach 

the required power density only by 

means of a 4-pole motor design. With 




a 2-pole design, the distribution of the 

magnetic field would be worse and the 

resulting unsymmetrical utilization of 

the magnetic field would increase the 

rotor volume by 1.5 times. However, 

the required length of the shaft for 

this construction would not work due 

to bending-critical frequencies. For 

this reason, a rotating field frequency 

of 2,000 Hz instead of 1,000 Hz is required 

to operate a motor with 60,000 

rpm, which makes using a high-speed 

converter necessary. 

… and what impact do they have on 

motor losses? 

Up to now, two-level frequency 

converters were used in these 

applications. They generate the required 

output frequency via pulse 

width modulation (PWM). Depending 

on the used switching frequency 

and the inductance of the motor, 

this method causes a current ripple 

of the motor current, though: the 

Fig. 2: The three-level technology of the SD4M series by SIEB & MEYER combined with devicedependent 

switching frequencies of up to 32 kHz ensures excellent current quality, which reduces 

motor losses and increases the efficiency accordingly. (Fig. 2-6: SIEB & MEYER AG) 

effective motor inductance of HS motors 

drops when the speed increases 

and the smoothing of the current 

ripple decreases proportionally. 

These high-frequency currents cause 

additional losses in the motor that 

are not negligible as they in turn lead 

to increased heat development and 

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Fig. 3: The three-level technology plus the higher switching frequency compared to standard 

converters reduce the harmonic current parts (ripple current) to 10 % so that the converterbased 

rotor losses are significantly lower. 

PWM pattern. Using three-level technology, 

the voltage level is cut by half, 

which in turn reduces the current 

ripple by half in the first approximation. 

This in turn results in much 

lower rotor heat. With the same PWM 

frequency, three-level converters can 

reduce the losses generated in the 

rotor by about 75 %. Therefore, many 

applications can work without motor 

filters or smoothing chokes between 

motor and converter, which reduces 

the weight, the installation space and 

the costs of the system. Furthermore, 

users benefit from the optimized 

overall efficiency. 

bearing loads. It is therefore necessary 

to reduce these losses to a level 

that ensures safe operation. Limit 

temperatures of synchronous rotors 

range between 90 and 150 °C. 

Why are the switching frequencies 

of two-level frequency converters 

limited? 

In the power range >100 kW, the 

available two-level frequency converters 

usually provide maximum admissible 

switching frequencies of 4 or 

6 kHz because an intermediate circuit 

voltage up to 600 V requires semiconductor 

switches (IGBTs) with a cut-off 

voltage of 1,200 V. Higher switching 

frequencies are not practical for technical 

and economic reasons since the 

higher switching losses would cause 

disproportionate heating and a reduction 

of the ampacity. Therefore, 

the maximum possible effective rotating 

field frequency is between 600 

and 800 Hz as the PWM frequency 

must be 8 to 10 times of the rotating 

field frequency to realize an approximately 

sinusoidal output current. 

… and why does three-level technology 

enable higher switching 

frequencies? 

Three-level frequency converters 

enable higher switching frequencies 

because each semiconductor 

switch must switch only half the intermediate 

circuit voltage of 300 V. 

This makes using semiconductors 

with a cut-off voltage of 600 V possible. 

These semiconductors come 

Fig. 4: Influence of speed and rotating field frequency on the motor design 

Fig. 5: The three-level technology cuts the voltage level in half, which in turn reduces the 

current ripple by half in the first approximation 

with significantly better switching 

characteris tics, which makes the resulting 

power losses controllable 

and generates only low converterrelated 

losses in the rotor in spite of 

switching frequencies up to 32 kHz. 

To what extent can three-level technology 

reduce motor losses? 

Beside the PWM switching frequency, 

another important variable affecting 

the motor losses is the voltage level 

added to the motor winding with the 

How does the three-level technology 

reduce insulation stress? 

The three-level technology solves the 

‘partial discharge problem’ feared 

by many. Partial discharge means 

a gradual destruction of the stator 

insulation due to voltage peaks at 

the motor. These are generated by 

switching edges of the power transistors 

in modern converters. If the 

insulation is eventually destroyed 

completely, the motor is permanently 

damaged. Beside the length 




with DC supply. SIEB & MEYER has 

applied for NRTL/CSA certification 

for all device variants so that users 

can soon integrate the devices into 

machines for the US market without 

additional approvals. 

Advantages of multilevel 

technology at a glance: 

Fig. 6: Innovative applications that were developed due to the German turnaround in energy 

policy also benefit greatly from multilevel technology. SD4M ensures, for example, a significant 

increase in the efficiency of regenerative systems such as rotating energy storage units 

(flywheel). 

Operation of high-speed motors 

with 

– very good current quality 

– low power loss 

– low rotor heating 

– high system efficiency 

– low insulation stress and 

– reduced CO 2 

emissions 

of the motor cable, the amplitude 

of the voltage jumps causes this effect. 

Three-level converters use only 

50 % of the voltage amplitude at each 

switching operation, reducing the 

partial discharge problem even with 

longer motor cables to a great extent. 

Therefore, the effect can be neglected 

in the most cases. 

What does the SD4M series 

by SIEB & MEYER offer? 

For the development of the SD4M series, 

SIEB & MEYER combined tried and 

tested technology with the latest control 

and communication technology. 

The three-level technolo gy of SD4M 

combined with device-dependent 

switching frequencies of up to 32 kHz 

ensures excellent current quality, 

which reduces motor losses and increases 

the efficiency accordingly. 

The available SD4M vari ants cover a 

power range between 70 and 490 kW 

or 120 and 800 A rated current. The 

multiprotocol real-time Ethernet interface, 

available on the device as 

standard (including PROFINET IO and 

EtherCAT), enables hassle-free implementation 

of the SD4M in the higherranking 

control. An optimal operation 

with an external regenerative power 

supply is possible using the variants 

The Author: Markus Finselberger, 

head of sales drive electronics at 

SIEB & MEYER AG, 

Lüneburg, Germany 

www.sieb-meyer.de 

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99



Energy saving support 

Electrical drives in production and 

logistics carry a significant savings 

potential. With the NORD ECO service, 

NORD DRIVESYSTEMS supports 

its customers in achieving this 

potential and finding the most energy-efficient 

drive solution. 

70 percent! That is the share of the 

total energy consumption of all industries 

that is required for electric 

drives according to expert estimates. 

This is not only a significant cost factor 

– there is also a great optimisation 

and savings potential. NORD 

DRIVESYSTEMS provides a special 

service so that its customers can exploit 

this potential: the NORD ECO 

service. 

NORD DRIVESYSTEMS is one of 

the world market leaders for electronic 

drive components and offers 

an extensive portfolio of electronic 

motors, gear units and electronic 

drive technologies adapted to the 

challenges of the individual industries. 

“We are continuously working 

on improving the energy efficiency 

of our components so we can offer 

power ful and, at the same time, economical 

products to our customers”, 

the Head of Marketing, emphasises. 

Measurement of the 

performance data 

The NORD ECO service helps to find 

the most energy-efficient drive solution 

for a specific application case. 

The first step is the comprehensive 

survey of measured values. In order 

to optimise a drive solution with regard 

to energy efficiency, it is necessary 

to first know the details of the 

application. For this purpose, the socalled 

NORD ECO BOX, a mobile control 

cabinet, is connected between 

the motor and the power supply. The 

ECO BOX consists of an energy measuring 

device with data logger function, 

current transformer and cable 

connections. Whether a conveyor belt 

or the lifting gear of a crane – the type 

Fig. 1: The NORD modular system allows us to provide an assembly of a gear unit, motor 

and frequency inverter into a configuration with optimum energy efficiency 

(all images: NORD DRIVESYSTEMS) 

of application that drives the motor is 

irrelevant for the measurement. 

Over a period of about two weeks, 

the box records data in real time 

about permanent loads, load peaks 

and irregular conditions. You need 

this longer period and thus a higher 

data density in order to identify patterns 

and eliminate random outliers. 

Evaluation of the data 

Once the survey is completed, the 

results are uploaded to software developed 

by NORD that automatically 

evaluates the data. The customer 

Fig. 2: With the service components analysis, 

consultation and optimisation, NORD 

helps its customers to achieve an energyefficient 

system design 

receives the evaluation in the form 

of a PDF document which presents 

the main key data. “Of course, we 

support the customer in the interpretation 

of the data”, the Head of 

Marketing highlights. 

The NORD ECO box contains an 

energy measuring device that measures 

the drive’s current and voltage. 

It determines the effective or reactive 

power, i. e. the energy actually used 

or not used – and from this calculates 

the relative power factor. This measurement 

over time makes it possible 

to create a load cycle for the system. 

This shows whether a system’s 

dimensioning corresponds to the requirements 

of the respective application. 

“We often encounter drive 

systems that are clearly overdimensioned 

for the corresponding application”, 

the Head of Marketing says, 

“and that is obviously not efficient.” 

Alternative components 

A practical example: NORD examines 

a drive system and observes an 

average power consumption of 

1.1 kW with a peak of 1.9 kW. The 

system is driven by a 4-kW motor 

that is operating at less than 30 percent 

capacity on average. A typical 

case of overdimensioning. NORD recommends 

a motor with a power of 

2.2 kW that is operating at a capacity 

of around 50 percent on average. 

There are also cases where we rec- 




If NORD recommends a different 

drive after a measurement, the company 

also offers an additional service. 

“We then offer to operate the system 

with the drive recommended by us 

and to perform a second measurement 

in the same period”, the Head 

of Marketing says. The evaluations 

can be compared in a TCO analysis 

(Total Cost of Ownership), and the 

most cost- and energy-efficient solution 

can be determined. 

Fig. 3: The gear unit, motor and frequency 

inverter in NORD’s DuoDrive are optimally 

matched and enable a system efficiency of 

up to 92 percent 

ommend replacing an IE3 or IE4 motor 

with a high- efficiency IE5+ drive. 

In case a standard drive does not 

cover the requirements, NORD also 

offers a customised solution. 

Reduction of variants 

As significant as the advantages of a 

NORD ECO measurement are for an 

individual drive system, they increase 

even further when viewed over an 

entire system. For large systems with 

several drives, such as in intralogistics, 

the ECO service can significantly 

reduce the number of different 

drive systems. Such a variant reduction 

helps to minimise administrative 

costs over an entire system and 

streamline production, logistics, storage 

and service processes. The high- 

Fig. 5: The NORD ECO service compares the 

installed power with the actual consumption, 

frequently resulting in a reduction of 

variants in a system 

efficiency NORD motors, which provide 

a constant torque over a large 

speed range, are particularly suitable 

for a reduction of variants. 

NORD DRIVESYSTEMS has already 

created the load profiles of drive systems 

in numerous measurements. 

The company offers this service for 

systems with both its own and thirdparty 

components. “It goes without 

saying that we treat the recorded customer 

data with confidentiality”, the 

drive expert emphasises. “With our 

ECO service, we have already helped 

many customers in improving the 

energy efficiency of their production 

and therefore reducing their carbon 

footprint.” 

NORD DRIVESYSTEMS 

Bargteheide, Deutschland 

www.nord.com 

Fig. 4: NORD ECO: In five steps, the NORD service achieves energy savings, cost reduction 

and CO 2 

reduction 


101


Gaskets 

The complete, worry-free package for drinking 

water gaskets with KTW-BWGL conformity 

Dipl.-Ing. Norbert Weimer 

With the KTW-BWGL (assessment 

basis for plastics and other organic 

materials in contact with drinking 

water), a new regulation has come 

into force that has a strong influence 

on the handling of gasket materials 

in drinking water. The use of 

established gasket materials is now 

prohibited and there are few options 

for new types of gaskets that 

conform to the regulation. 

Buyers of drinking water gaskets 

need new options 

The UBA (German Environment Agency) 

has defined new requirements for 

drinking water supply components. 

The KTW-BWGL is authoritative for 

organic materials used in elastomer 

and compressed fibre gaskets. Products 

and components made of organic 

materials are evaluated with 

regard to the raw materials (primary 

materials) used and the transfer of 

substances to drinking water. 

Those raw materials that may be 

used to manufacture elastomers in 

contact with drinking water are included 

in the UBA’s positive list. The 

list for organic materials also applies 

to fibre-reinforced gasket sheets 

bonded with elastomers (FA – fibrebased 

gasket sheets). The positive 

list contains the fully evaluated substances 

(monomers, fillers, plasticisers, 

anti-ageing agents, processing 

aids, cross-linking agents, etc.). Only a 

few months remain before the end of 

the transition period for gasket materials 

containing raw materials that 

have not been evaluated fully or at 

all. Switching to new gasket materials 

then becomes mandatory. 

intended for drinking water applications 

can no longer be used in this 

field. It is painful that the established 

range of applications is no longer 

guaranteed due to the curtailment of 

the possible ingredients. 

This also affects processors in 

particular, such as cutting shops and 

technical distributors, who have to 

readjust (storage and costing) with 

regard to the utilisation of gasket 

sheets in cutting as well as storage for 

different applications (e. g. drinking 

water, gas, temperature ranges, etc.). 

Manufacturers of valves, pumps and 

equipment may also encounter problems 

when the assignment of various 

gasket materials to different fields of 

application in production is not manageable 

(example: heating appliances 

with gaskets for gas as well as heating 

water and drinking water) and an allpurpose 

gasket is no longer available. 

All of this means that users and 

the supply chain should look for a 

well-functioning alternative in good 

time. This is where the gasket material 

manufacturer KLINGER comes 

in with a new product. KLINGERSIL 

C-4240 is a new fibre-based (FA) gasket 

that is extremely well suited as a 

solution to this problem. 

This gasket type (FA) is commonly 

used in drinking water systems, and 

is affected by the new KTW-BWGL 

regulation due to the binder (elastomer). 

The reduction in the permitted 

ingredients for the production process 

is so great that the rolling and 

vulcanisation process requires the 

highest level of know-how in order 

to be able to produce a gasket sheet 

under these conditions at all. To date, 

KLINGER is the only manufacturer to 

have successfully developed an FA 

gasket sheet in conformity with KTW- 

BWGL in risk class P2. Meeting the requirements 

of risk class P2 is mandatory 

when the surface in contact with 

drinking water is more than 1% of the 

component’s total surface area. 

Reliability is also important in 

assembly 

There are two typical fields of application 

in drinking water systems. 

In one of these, we have the service 

technician with a mobile workshop 

who makes service calls. The service 

technician, a tradesperson with experience 

and qualifications, replaces or 

installs new components on site under 

often adverse conditions. 

The other field of application is 

the industrial production of composite 

components and equipment from 

water filters to valves or pumps to 

The supply chain needs to respond 

– only a few months remain 

For the manufacturer of FA gasket 

sheets, this situation means that the 

previous formulations for products 

Fig. 1: The new KLINGERSIL C-4240 fibre-based gasket 



Gaskets 

heating appliances. Exact assembly 

conditions and a high repeat accuracy 

of assembly processes are to be 

expected here. 

The gasket material must therefore 

have a consistent quality in order 

to ensure industrial production with 

consistent properties. In addition, it 

must have a wide range of applications 

in order to also enable manual 

assembly under different conditions. 

With the new product, the manufacturer 

has developed a gasket 

sheet that is very similar to previous 

gasket materials with regard to its 

properties. It is precisely these properties 

that make it possible for the 

user to use the new gasket material 

without making any special adjustments. 

The compression properties 

and stability are just what the user 

wants. Although it is difficult to produce 

a well-vulcanised product due 

to the extremely reduced cross-linking 

chemistry, the KLINGER development 

team did an excellent job. 

conformity confirmation is already 

on hand for this material. 

Rubber-steel gaskets are frequently 

used in the drinking water 

supply as well – mostly in production 

and distribution systems where 

flange connections with coated surfaces 

are installed. The situation is 

similar for these gasket types. To 

date, conformity with KTW-BWGL has 

only been confirmed for the KLINGER 

KGS GII made of special EPDM. 

Fig. 3: KLINGER KGS GII rubber-steel gasket 

made of special EPDM 

al Institute for Risk Assessment (BfR) 

is given as well! Tests for approval under 

the French ACS are currently ongoing. 

Testing the raw materials was 

successfully completed at press time. 

All of this is highly advantageous 

for manufacturers of water heating 

appliances because differentiating 

between drinking water gaskets and 

gas supply gaskets in series production 

is difficult. The numerous approvals 

and conformities also facilitate 

the export of drinking water 

supply products and equipment to 

various European countries and regions 

– or make this possible in the 

first place. 

What’s more, the broad range of 

approvals and conformities is helpful 

for the cutting shop and technical 

distributor; utilisation of the gasket 

sheets is significantly improved 

thanks to the additional application 

possibilities. 

The bottom line for developers, 

designers, planners and installers 

Fig. 2: KLINGERtop-chem 2000 PTFE-based 

gasket sheet 

What gaskets can also be used in 

drinking water with higher surface 

proportions? Aside from the fibre 

materials, additional gasket materials 

are available in the form of sheets 

for cutting as well as ready-made 

gaskets that meet the new requirements. 

The PTFE-based “KLINGERtop-chem 

2000” gasket sheet highly 

filled with silicon carbide falls into 

the synthetic materials category. A 

Additional approvals and certificates 

for the KLINGERSIL C-4240 

fibre gasket 

Having gasket materials tested by institutes 

and organisations and obtaining 

corresponding certificates has 

become very time-consuming in recent 

years. As a result, this information 

only becomes available gradually 

for a new product. After the drinking 

water hygiene assessment according 

to the elastomer directive and DVGW 

worksheet W 270 was completed in 

2021, KLINGER was also able to provide 

proof of leak tightness for use 

in gas applications in 2022. The DIN- 

DVGW type testing certificate according 

to DIN 3535-6 has been issued 

for use in gas applications. 

Now in 2024, we have also obtained 

the English drinking water approval 

WRAS and the statement according 

to EU 1935/2004. Conformity with the 

amended requirements of the Feder- 

For the responsible manufacturer 

and distributor of valves, pumps and 

equipment in the drinking water field 

of application, starting the process of 

converting to the officially required 

gasket quality is becoming more and 

more urgent. Especially with regard 

to industrially produced components, 

equipment and systems, action must 

be taken now in order to successfully 

complete the conversion process 

before the deadline. With three different 

gasket types, KLINGER lets you 

choose appropriate gaskets for new 

components and equipment subject 

to certification. The required verification 

can be completed without great 

effort, even for the P2 risk category. 

The Author: 

Dipl.-Ing. Norbert Weimer, 

KLINGER GmbH, Idstein, Germany 

www.klinger.de 


103


OT security 

New standards affect the OT network 

OT security must be planned from the outset 

Denise Fritzsche und Dipl.-Ing. (FH) Nora Crocoll 

Security is becoming an increasingly 

important topic for machine builders 

and plant operators. Standards 

such as IEC 62443 (international series 

of standards for “Industrial communication 

networks - IT security 

for networks and systems”), among 

other things, set requirements for 

system security and security levels. 

The objective is to strengthen industry’s 

cyber resilience, above all 

on the OT (Operational Technology) 

level too. For this is affected by attacks 

on the IT level with increased 

regularity, effectively as “bycatch”. 

At the same time, it should also be 

protected from direct attacks, which 

occur in the production environment. 

Security is therefore a topic 

that not only concerns the individual 

system parts, but above all the 

communication platform used too. 

Plants in automated production or 

the process industry are made up 

of numerous individual machines. 

The management initiates digitalisation 

projects such as process optimisation, 

increasing process transparency, 

energy management, etc. 

As a result, the requirements for 

network communication and its security 

change. As matters currently 

stand, IEC 62443, Part 3-3 (“System 

security requirements and security 

levels”) will also be incorporated in 

the (EU) Machinery Regulation via 

Annex III 1.1.9 and will create the 

circumstances for secure communication. 

Regardless of this, the Directive’s 

regulations are already helpful 

requirements for ensuring security 

in an OT network. It can be assumed 

that plant builders and operators will 

soon be required to have more network 

know-how. Or they will bring in 

external expertise, as is the case for 

mechanical engineering. 

Security concepts 

OT security is not something that can 

be simply “pulled on” after completion 

of a plant. Rather, the topic affects 

every installed component of 

the plant and extends to the depth 

of the physical network structure. 

Cyber security must therefore be 

planned from the outset. To this end, 

IEC 62443 provides various security 

concepts, which not only concern the 

hardware and systems used, but also 

Fig. 1: Tools and strategies for cyber security concern the entire life cycle of a plant. 

(Copyright holder: Indu-Sol) 

processes in the company and the 

organisation’s degree of maturity, in 

other words, the employees’ understanding 

of the existing processes 

and their ability to know what to do in 

the respective problem case. 

The network experts of Indu-Sol 

have been dealing with the reliability 

of industrial networks since the 

company was founded a good twenty 

years ago. A network that does not 

function reliably, for whatever reasons, 

always also influences the security 

of the whole plant. The tools can 

be used to make transparent what is 

going on in the network. Above all in 

relation to the security of networks, 

plant builders and operators can be 

supported in the areas of hardware 

and systems as well as the maturity 

of the organisation by providing appropriate 

system training courses. 

Network in the plant life cycle 

Whoever plans for OT security in 

plants should also do the same for 

the network. But this is a complex 

undertaking, which cannot be simply 

dealt with as an aside. It needs a 

network engineering expert, not only 

for the plant planning but also during 

subsequent operation. But this is 

usually not feasible from a financial 

point of view, and as a consequence 

of the shortage of skilled personnel, 

well-trained employees for network 

engineering are hard to find. This is 

where it can make sense to outsource 

the network topic to external service 

providers from the initial period of 

the plant’s life cycle (Fig. 1). This provides 

the additional advantage that, 

on handover of the finished plant 

from plant builder to plant operator, 

there is no change in responsibility 

for the network engineering. 

Network experts are able to provide 

advisory support during the 

strategic planning phase. They then 

undertake the network planning in 



OT security 

the implementation and performance 

requirements period. 

During the setting up and commissioning 

they take care of the 

network acceptance, during operation 

they ensure condition 

monitoring and predictive maintenance 

through appropriate 

service level agreements. They 

are also there to provide advice 

for plant retrofits and help with 

network modifications. All these 

tasks need three things: Knowhow, 

the right hardware and services 

suitable for the respective 

period in the life of the plant. 

Tools with integrated expertise 

The times in which OT networks 

were still islands independent 

from the rest of the world are 

largely in the past. The advantages 

that can result from convergent 

networks and direct access 

to the smart sensor data of 

the machines and plants are too 

great. Therefore, OT networks are 

increasingly internally linked to 

the IT level. This also then means 

that each component in which a 

CPU is installed is vulnerable. The 

topic of OT security is thus highly 

interwoven with the hardware 

used. The clou is that the solutions, 

which have proven their 

worth in recent years for the reliable 

operation of networks with 

the focus on predictive maintenance, 

are also suitable for monitoring 

network security. The system 

is therefore now referred to 

as a CM&SM (Fig. 2), a condition 

monitoring & security management 

system. 

To ensure OT security, IEC 

62443-3-3 sets various requirements, 

which ultimately provide 

the condition for the principle 

of “Defence in Depth” (Fig. 3). 

The requirements relate to identification 

or authentication, use 

control, system integrity, confidentiality 

of the data, prompt response 

to events and the availability 

of the resources. Each of 

these seven requirements needs 

different tools or measures to 

implement them. The various 

solutions of Indu-Sol can help in 

completely different areas. Here 

are a few examples: An initial topology 

scan for the identification 

or authentication of OT networks 

and a periodic scan, for example, 

can be implemented and managed 

with our condition monitoring 

& security management 

system. The tools of the network 

experts check the data commu- 

Fig. 4: OT cyber security and digitalisation in accordance with ISA/IEC 62443, 

Part 3-3 (copyright holder: Indu-Sol) 

nication for unwanted changes, 

use encryption methods for secure 

data transmission, segment 

individual network areas for security 

reasons, ensure continuous 

data monitoring and auto- 

Fig. 3: Excursus: ISA/IEC 62443 – The layers of defence in depth from the view of OT 

(copyright holder: Indu-Sol) 

service providers with the appropriate 

know-how. Indu-Sol contributes 

this know-how on an 

equal footing within the scope of 

an OT competence partnership. 

The good news is that it is not 

necessary to reinvent the wheel, 

but instead, tried and tested solutions 

are on hand to face these 

new requirements confidently. 

Fig. 2: Condition monitoring and security management system (CM&SM) for plants 

and OT networks with Profinet and Ethernet/IP (Copyright holder: Indu-Sol) 

mated alerting or help with the 

backup and restoring of device 

configurations. 

The list of requirements 

and how they can be met with 

the system is long. One trend is 

clear: With the requirements of 

IEC 62443 and also the new Machinery 

Regulation that will soon 

come into effect, in future greater 

focus will be placed on the OT 

security of industrial communication 

networks (Fig. 4). This requires 

solutions in the form of 

components, supporting systems 

as well as skilled employees or 

The Authors: 

Denise Fritzsche, 

Marketing at Indu-Sol and 

Dipl.-Ing. (FH) Nora Crocoll, 

Redaktionsbüro Stutensee 

Indu-Sol GmbH, Schmoelln 

www.indu-sol.com 


105


Sensors 

Sensors measure axle temperature: 

JUMO continues the success story of the TGV 

Lars Ronge 

If they are not detected in time, 

overheating in rail vehicles can lead 

to considerable material damage 

and even disasters with personal 

injury. Railroad experts and technicians 

have increasingly focused 

on this problem in recent years 

and have continually optimized solutions, 

such as the high-precision 

JUMO sensors. Special temperature 

sensors measure the axle temperature 

in the new TGV generation. 

The French JUMO subsidiary based 

in Metz supplies temperature sensors 

for the axle bearings of the bogies 

of the new Alstom Avelia Horizon 

high-speed trains. The French state 

railroad company SNFC has ordered 

100 of these trains, which will be deployed 

from 2023 as part of the TGV 

fleet, the counterpart to the German 

ICE series. 

The Avelia Horizon is one of the 

trains with the lowest carbon footprint 

on the market. 97 percent of the 

train set is recyclable. This makes the 

new generation 20 percent more economical 

and significantly less energyintensive. 

The trains, called TGV-M, 

can accommodate up to 740 passengers, 

which is 140 more than in the 

previous trains. 

Alstom chose JUMO France as its 

partner for the supply of HABD (Hot 

Axle Box Detection) temperature sensors, 

not least because of the many 

years of successful cooperation. 

These are mounted on the bogies of 

the high-speed trains. These sensors 

are part of the BMS (Bogie Monitoring 

System) and play a crucial role as they 

are directly connected to an alarm 

system that can lead to a total stop of 

the train in case of overheating of the 

axle boxes. 

The sensors are customized special 

designs that are exposed to extreme 

conditions such as high temperatures, 

vibrations or humidity. 

They must therefore meet particularly 

demanding specifications in 

order to comply with the required 

standards. 

An alarm is triggered if the operating 

temperature is exceeded 

The safe operation of rail transportation 

cannot be guaranteed by maintenance 

alone. During a train journey, 

bearing damage repeatedly occurs in 

wheelset bearings, which can lead to 

broken shafts and thus to serious accidents. 

The reason for this is the inadmissible 

heating of the bearings, 

which causes the lubricating grease 

to lose its function and destroy the 

bearing. The resulting uneven axle 

pressures can lead to derailments. In 

order to ensure a high level of operational 

safety, sensor systems have 

been developed that can detect defective, 

overheating bearings (socalled 

hot-running bearings). The 

temperature inside the warehouse 

is continuously recorded and processed. 

If the operating temperature 

is exceeded, an alarm is triggered at 

two thresholds. 

A hot-running bearing is classified 

as dangerous damage, which is 

Fig. 1: The new Alstom Avelia Horizon high-speed train. (Image source: Alstom) 



Sensors 

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Fig. 2: The sensors are customised special designs. (Image source: JUMO) 

why the vehicle must be taken out of service 

immediately. In order to meet Alstom’s 

high demands, the wheelset sensor, which 

has proven itself over many years, was completely 

modified once again. The result was 

a new stainless steel temperature probe 

based on PT1000, which, in two different 

versions, fully complies with the current 

“railroad standards” with regard to fire protection, 

vibrations, etc. 

JUMO’s many years of experience in the 

demanding railroad industry made it possible 

to meet Alstom’s high expectations. The 

current order includes the delivery of several 

thousand temperature sensors for the first 50 

trains. Production started at the end of 2020 

and the deliveries will be staggered until 2025. 

The TGV 2020 project is a 

prestige project 

The TGV 2020 project is a prestige project for 

the French government. Everyone involved is 

working flat out because the Summer Olympics 

will be held in Paris this year - and the 

whole world will be watching the French metropolis. 

50 trains are to be put into service by 

March 2027, with a further 50 trains by October 

2031. In the second tender, there is a possibility 

that JUMO will once again participate in 

the project with its proven technology. 

The TGV “belongs to France” like French wine, 

hundreds of different types of cheese or the 

Tour de France. Around 42 years ago, a Train 

à Grande Vitesse (TGV) left Paris for Lyon for 

the first time. In September 1981, it was not 

yet possible to travel from Paris to Lyon, 400 

kilometers to the south-east, in two hours because 

the new high-speed line was not yet fully 

completed. 

Today, the TGV speeds through the country 

at 320 km/h and connects Paris with Lyon 

in two hours. The TGV only needs three hours 

and eleven minutes to cover the 765 kilometers 

between the capital and the port city of 

Marseille. 

Since July 2023, there has been a direct 

connection between Frankfurt/Main and the 

terminus station not far from the French Atlantic 

coast, Bordeaux, which is around 1,300 

kilometers away. The TGV covers the distance 

directly in around seven hours and 40 minutes. 

Previously, rail travelers had to change 

trains in Paris and also had to use the station 

in the French capital. 

The Author: 

Lars Ronge, Market Segment Manager Rail 

at JUMO, Fulda, Germany 

www.jumo.de 

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107


Drives 

New filling system for reusable bottles 

in Klosterbrauerei Andechs 

Modern pioneer with a long tradition 

Gunthart Mau 

In 2019, Klosterbrauerei Andechs installed 

a new line for reusable glass 

bottles. This boosted the brewery’s 

production capacity, while also minimizing 

the use of resources. The tradition-steeped 

brewery brought in 

real cutting-edge, energy-efficient 

technology in the form of 70 decentralized 

MOVIGEAR ® performance 

drive units from SEW-EURODRIVE. 

On Bavaria’s “holy mountain”, above 

Lake Ammer and around 45 km southwest 

of Munich, you will find Andechs 

monastery. It has its own agri cultural 

operations – and, of course, the famous 

brewery. The brewing tradition 

in Andechs is cons tantly being 

updated with the latest methods and 

processes. Rising demand for traditional 

beer means exis ting production 

capacities will reach their limits at 

some point. A few years ago, Klosterbrauerei 

Andechs therefore came to 

the decision to invest in new, cuttingedge 

filling and transportation technology 

to increase its production output. 

“Having been in operation for 

almost 30 years, the bottle-filling system 

needed up grading,” explains the 

head of operating technology at the 

brewery. The components installed 

at the time were simply no longer 

state-of-the-art. Another priority was 

the environmental sustainability of 

the system, especially in relation to 

energy consumption. He continues, 

“The renovation needed to be done 

very quickly. To avoid a longer period 

of downtime, a new building was 

constructed for the filling system.” As 

a result, switching production only 

took a few days. At the same time, 

new storage capacity was to be created. 

The old building is therefore now 

used as storage for approximately 

1500 pallets of empties. 

Drive components for decentralized 

installation 

Klosterbrauerei Andechs commissioned 

BMS Maschinenfabrik in 

Pfatter, near Regensburg, with designing 

the overall layout of the filling 

line for reusable bottles in the new 

building. Implementation of transport 

modules in the wet and dry areas was 

conducted at the same time. “When 

it came to the drives, there were 

several reasons why we chose SEW- 

EURODRIVE,” says the head of operating 

technology. “We have used the decentralized 

MOVIMOT ® drives before, 

and have had good experience with 

this technology. SEW-EURODRIVE 

assured us that we would receive 

complete support in the startup of 

the new technology.” The account 

manager at SEW-EURODRIVE’s Drive 

Technology Center South in Kirchheim/Munich 

confirms: “It goes without 

saying that support from Kirchheim 

was guaranteed at all times. 

There were lots of new aspects to 

this project – for both Klosterbrauerei 

Andechs and SEW-EURODRIVE. I recommended 

MOVI-C ® , our latest 

technology, to the customer. It was 

the correct decision for both sides.” 

The new filling system has been in 

operation for four years now, and 

the customer is completely satisfied. 

The new system boosted filling capacity 

from 20 000 to 24 000 bottles per 

hour. At the same time, the amount 

of energy needed was reduced. 

Process technology for the 

filling system 

Fig. 1: The new bottle filler has a capacity of 24 000 bottles an hour. It communicates 

directly with the higher-level controller. (all photos: SEW-EURODRIVE) 

The material flow in the new filling 

system is as follows: Beer crates containing 

empty, used bottles are delivered 

to the storage area on pallets, 

where they are unloaded. BMS 

opted for two Unipal 105 palletizers 

for loading and unloading the crates 

from the pallets. The crates are then 

transported on roller conveyors to 

the neighboring filling system, where 

they are first checked to ensure they 

are OK and that the bottles can be unloaded 

automatically. Any crates that 

fail this check are ejected and unpacked 

manually. This might be ne- 



Drives 

Fig. 2: The MOVIGEAR ® performance drive unit combines energy-efficient 

synchronous motors, gear units and new inverters from the MOVI-C ® modular 

system. The integrated communication interface enables direct connection to the 

BMS controller. 

cessary if something is jammed, 

for example, or if a bottle is lying 

the wrong way in the crate. After 

this, the crates are transported 

to the decapping unit, then to 

the bottle check. “An identification 

system checks the crates to 

see which ones contain standard 

NRW bottles, which we process, 

and which crates contain 

other bottles,” explains the head 

of operating technology. 

A Unipack 103 sorting and 

unloading machine from BMS, 

which has individually controllable 

gripping heads, reliably sorts 

out the NRW bottles. All other 

bottle types are placed on a separate 

belt, where they are manually 

packed into crates and transported 

to an exchange store. The 

empty crates travel to the crate 

washing system, where they are 

cleaned, and they are then transported 

to the bottle packaging 

machine and put back into circulation. 

Bottle cleaning and inspection 

The empty NRW bottles are conveyed 

to the Lavatec E2 bottle 

cleaning machine. In addition 

to boasting high throughput, 

this machine is effi cient when 

it comes to the resources 

of gas and fresh water. The 

MOVIGEAR ® performance drive 

units that drive the input and 

output belts with the bottles 

also provide greater energy efficiency. 

After cleaning, the empty 

bottles pass through the empty 

bottle inspection machine. Using 

a camera system, complete with 

infrared and ultrasound technology, 

this machine checks 

whether there is any liquid left 

in the bottles, whether they are 

dirty or cracked, and whether 

the mouth of the bottle is OK – 

in other words, everything that 

can currently be checked using 

technology. 

Filling, capping, labeling, 

and packing 

The inspected bottles are then 

transported on conveyor belts 

for filling. A Krones bottle filling 

carousel first evacuates the 

bottles and then rinses them 

with CO 2 

. To prevent oxygen deposits 

and to balance the pressure 

from the drink, they are 

evacuated and rinsed a second 

time. The beer bottles are filled 

to overflowing and then capped 

immediately. The fill level is then 

checked, before the bottles are 

rinsed off externally and labeled. 

Finally, a BMS Unipack 2.0 gantry 

machine packs the bottles into 

crates that are then transported 

to the warehouse for palletizing. 

This is where the two BMS Unipal 

105 palletizers come back into 

play, this time to palletize the 

beer crates, closing the circle of 

the material flow. 

Fig. 3: Standard asynchronous motors (left in the image) are used for angled conveyor 

lines that require a brake. The energy for these motors comes from MOVIMOT ® 

flexible inverters mounted close to the motor. The particularly energy-efficient 

MOVIGEAR ® performance drive units (right) are only used for horizontal conveyor 

lines. They feed kinetic energy back completely, and therefore need no brake. 

Horizontal and angled 

conveyor lines 

“The customer wanted to use 

energy-efficient, 

decentralized 

drives at the various conveyor 

lines for the crates and bottles,” 

explains the account manager. 

“This is precisely what the 

MOVIGEAR ® performance drive 

units from the MOVI-C ® modular 

automation system are designed 

for. They are certified as energy 

efficiency class IE5 and can be 

controlled via PROFINET, which 

was another thing the customer 

had asked for.” The MOVIGEAR ® 

performance drive units are used 

for horizontal conveyor lines, 

and therefore require no brake. 

Standard asynchronous motors 

are used for angled conveyor 

lines that require a brake. The energy 

for these motors comes from 

MOVIMOT ® flexible inverters from 

the MOVI-C ® modular automation 

system that are mounted close to 

the motor. Thanks to horizontal 

compatibility across all electronic 

products, the full range of motor 

types can be controlled with just a 

single inverter type, and only one 

piece of engineering software is 

needed. 

Good communication 

between the holy mountain 

and Kirchheim 

“This project was the first system 

with MOVIGEAR ® performance and 

integrated drive electronics that 

SEW-EURODRIVE had designed for 

a brewery customer, and the first 

to be installed in Germany,” the account 

manager recalls. The head 

of opera ting technology adds: 

“We enjoyed good communication 

with Kirchheim, and always trusted 

in SEW-EURODRIVE. What's 

more, we really appreciated how 

open and honest SEW-EURODRIVE 

was with us.” 

The Author: Gunthart Mau, 

Trade Press Officer, 

SEW-EURODRIVE, 

Bruchsal, Germany 

www.sew-eurodrive.de 


109


Seals 

New sealing options for CIP/SIP processes 

Food industry challenges for elastomer seals 

Dipl.-Ing. (FH) Michael Krüger 

Demands are becoming ever-more 

stringent in the food industry nowadays, 

due to continually refined 

production processes. But greater 

streamlining depends on having 

more aggressive cleaning media or 

higher sterilisation temperatures. 

As hygienic design is used in modern 

production systems more and more, 

the tighter installation spaces it entails 

means that elastomer seals 

need to exhibit even lower swell. 

This is a major challenge for those 

in the industry and a frequent problem 

which the designers or users of 

such production systems have to 

solve. 

All materials that come into contact 

with the food to be produced during 

the production process must fulfil the 

relevant standards/approvals (e. g. 

FDA, Regulation (EC) 1935/2004). But 

it involves far more as well. Additional 

too having general media resistance, 

such as withstanding greasy media 

or aromatics and essential oils, which 

are critical for elastomeric sealing 

materials, the seals must also be 

usable in today's CIP or SIP processes 

Fig. 1: Plant in food production (Image credit: Shutterstock@Parilov) 

Fig. 2: O-Ring in Aseptic sterile screw connection according to Hygienic Design 

(Image credit: COG) 

(CIP = cleaning in place; SIP = sterilisation 

in place). The interaction between 

the media having to be sealed 

and what are, at times, very aggressive 

disinfectants/cleaners or hot 

steam used in the sterilisation process, 

with operating temperatures of 

up to 149 °C, imposes huge strain on 

the material. All of which is why many 

elastomer seals fail in the long term. 

Costly consequences include more 

frequent maintenance intervals, a 

greater need for repair work or even 

production downtime. 

Increasingly stringent production 

requirements 

The demands imposed on elastomer 

seals in the food industry are 

becoming increasingly complex. As 

the stakeholders involved gradually 

phase out or eliminate the use 

of preservatives, the contamination 

genera ted during the production 

process in pipework, valves and 

pumps has to be cleaned and removed 

using ever-improving detergents 

in the CIP process. At the same 

time, people are accelerating production 

cycles to boost productivity. 

This means the cleaning process has 

to be shortened further still, using 

even more aggressive CIP media. Although 

this may ultimately benefit 

production, it poses a major challenge 

for seal manufacturers, given 

the enormous demands imposed on 

elastomer materials from this kind of 

approach and the fact that few can 

withstand long-term use. 



Seals 

Resistances always depend 

on temperature 

As a general rule for designers and 

users, one should be aware that resistance 

of the electrometric sealing 

materials depends highly on the actual 

operating temperatures. For 

example, positive resistance to a seal 

medium may be given over a lower 

temperature range, but not at significantly 

higher temperatures. 

New FEPM seal material for the 

food industry 

EPDM seals are often used in the food 

industry, given their resistance to hot 

water and steam. The downside? 

They are far less resistant to grease 

or acids at higher temperatures. That 

is why FKM materials are preferred 

for applications with higher grease 

content or more aggressive media. 

These, in turn, have downsides when 

used with hot water or steam, although 

special FKM materials can be 

used in such applications. But even 

these materials reach their limits 

when the temperature of the media 

in the cleaning process is excessive 

or the material swells too much within 

the hygienic design spaces. The resulting 

balancing act for designers 

and users is far from easy. 

The independent manufacturer 

C. Otto Gehrckens (COG) has 

de veloped a new FEPM compound, 

“AF 680”, for these critical areas in 

the food industry. This innovative 

formulation also features a specially 

designed AFLAS ® base polymer. 

This AFLAS ® -based FEPM compound 

is the first to be approved to FDA 

21 CFR § 177.2600. The special seal 

material compounded by COG is absolutely 

reliable in use with SIP and 

CIP processes, paving the way to deploy 

it in exceptionally wide-ranging 

applications in critical food production 

areas or the periphery. 

Unlike peroxide cross-linked 

high performance FKM materials, 

this new FEPM compound can easily 

withstand the increasingly aggressive 

alkaline (base) cleaning cycles at 

high tempera tures (approx. 140 °C). 

An EPDM material, conversely, would 

be unusable in these areas due to 

Fig. 3: COG FEPM "AF 680” seal (Image credit: COG) 

the high temperatures and acidic 

cleaning media involved. Even in 

the high-temperature SIP process 

at around 150 °C, the volume swell 

of the FEPM sealing material is low 

enough to render it still perfectly installable 

within the confined spaces 

of the sterile, hygienic-design fittings. 

With an operating temperature range 

of -10 °C to +230 °C and exceptional 

chemical resistance, including to flavourings 

and essential oils, this FEPM 

material is ideal for use in demanding 

food production applications. 

The very appealing pricing, compared 

to many peroxide cross-linked 

high performance FKM or even the 

extremely expensive FFKM (perfluorine) 

materials, rounds off the AF 680 

performance profile, as a pro duct offering 

designers and users a clean solution 

for demanding food industry 

applications. 

Conclusion 

The use of modern elastomer sealing 

materials in the food industry requires 

professional support. More often 

than not, approvals in accordance 

with food regulations such as FDA 

and Regulation (EC) 1935/2004 may 

no longer suffice. These materials 

must also cope with the usual interactions 

in a production process. This 

is often a difficult balancing act that 

few sealing materials can achieve. 

Manufacturer expertise, experienced 

application advice and external, independent 

testing make up optimum 

conditions for a safe and satisfactory 

sealing result. This is the only approach 

offering ultimate peace of 

mind for users and designers. 

Expert advice from COG's application 

engineers can be invaluable, especially 

if the material is being used 

in borderline areas or with significant 

deviations from the test parameters. 

Thanks to their extensive experience, 

these specialists - all qualified engineers 

- can often make sound recommendations 

to designers and users 

without the need for extensive and 

costly testing. With numerous projects 

in the food and pharmaceutical 

industries already under our belt, 

our wealth of experience can easily 

be tailored to suit market needs. In 

fact, our consultants often remain 

one step ahead of users and their 

requirements, applying their knowledge 

to the problems faced by designers/users. 

The Author: 

Dipl.-Ing (FH) Michael Krüger, 

Head of Application Technology, 

C. Otto Gehrckens GmbH & Co. KG 

Pinneberg, Germany 

www.cog.de 


111

Compressors/Compressed air/Components 


Hydrogen as a storage medium and 

key element for the global energy 

transition 

The energy transition and the use of sustainable resources to generate 

electricity pose major challenges for the energy industry. A way is 

needed to make electricity from renewable sources storable. Particularly 

in light of the growing awareness of the need to meet the Paris 

climate protection targets and the increasing pressure to act, new, 

long-term viable options for the economy, especially for industrial 

companies, must be developed as quickly as possible. 

Hydrogen is already being produced using fossil fuels. However, thanks 

to innovative splitting processes and the use of electricity from renewable 

energies, this valuable substance can also be produced without 

the use of fossil fuels. This process, as well as its further utilisation, 

makes hydrogen a substance with a promising future 

Water electrolysis is the key technology here. It enables hydrogen 

to be produced from water and electricity, thus helping to balance out 

fluctuations in the supply of renewable energy sources. Renewable 

energy can be stored and is available for further energy supply when 

there is a lull in the wind or low solar radiation. GOETZE safety valves 

made of stainless steel and gunmetal protect both the gas phase and 

the water supply of the electrolyser against excessive pressure. Thanks 

to oil- and grease free production and ATEX approval, these safety 

valves are optimally sized for use in hydrogen applications. 

Fig. 2: Hydrogen storage for a refuelling system (Photo © : Goetze KG Armaturen) 

Materials 

Pay attention to high-quality stainless steels. Austenitic steels with a 

nickel content >10 % have proven themselves here. 

Sealings 

Pressure, temperature and permeation (diffusion) play an important 

role here. Pay attention to the NORSOK M-710 standard for Elastomere 

sealing materials. 

Fig. 1: GOETZE high-pressure safety valve 492 made of high-quality stainless steel 

for pressure ranges up to 1500 bar (Photo © : Goetze KG Armaturen) 

The hydrogen challenge 

On the one hand, it is a colourless, odourless and completely non-toxic 

gas, which on the other hand is very volatile, highly flammable and has 

a high flame speed. Depending on the application and environment, 

the challenge with hydrogen is to produce, transport, store and utilise 

the gas safely. As the last mechanical component in the safety chain, 

safety valves are an important and indispensable part of this. This applies 

in particular to the materials and seals used, the valve manufacturing 

process and certain approvals. 

As the last mechanical component in the safety chain, safety valves 

are an important and indispensable part of hydrogen applications. It is 

therefore all the more important that all components of a safety valve 

and the manufacturing process have certain properties. 

Manufacturing process 

Place high demands on the cleaning requirements. In addition to the 

necessary oil- and grease free production, production in a clean room 

is expressly recommended for a hydrogen purity of > 5.0 (> 99.999 %). 

Sound technical advice from the valve manufacturer is essential 

in all cases. Only in this way can your specific conditions be taken into 

account and the valve correctly sized according to the conditions prevailing 

on site. 

GOETZE safety valves help to ensure that the hydrogen reaches the 

consumer safely - whether for Industrial applications or as fuel for fuel 

cell vehicles. Safety valves reliably protect refuelling processes that are 

under high pressure and ensure a safe system when storing gases in 

large tanks. This means that there is no danger to the user during use 

and the new technology can be utilised profitably for people and the 

environment. 

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 




CSG series rotary screw compressors 

Purity and efficiency at the forefront 

Pharmaceuticals, foodstuff, healthcare, chemicals – these industrial 

sectors place especially high demands when it comes to compressed 

air quality. For those who wish to achieve these requirements costeffectively, 

CSG rotary screw compressors from Kaeser represent the 

perfect choice. These new models are particularly efficient and require 

very little installation space. 

The CSG series provides highly efficient compressed air generation, 

yet requires 19 percent less floor space than its predecessor range. 

Models are available with air- or water-cooling, with integrated refrigeration 

dryer or i.HOC (Heat of Compression dryer), and for flow rates 

ranging from 4 to 15 m³/min. For applications with fluctuating compressed 

air demand, speed-controlled “SFC” versions are available. 

The CSG series is equipped with high-quality, durable airends 

featuring the energy-efficient Sigma Profile for which Kaeser is 

world- renowned. The rotors now feature an innovative new wearfree 

PEEK coating, which is also particularly temperature-resistant. 

Biocompatible, FDA-certified and in compliance with European requirements 

for food contact materials, this coating is perfectly adapted 

for the pharmaceuticals and foodstuff industries. 

When it comes to energy efficiency, the CSG series is the star of its 

class. Kaeser was uncompromising in its pursuit of efficiency when developing 

the drive, cooling and compression systems for these models. 

Therefore, the range is equipped with IE5 Ultra Premium Efficiency 

synchronous reluctance motors and water jacket cooling on both compression 

stages – on both air- and water-cooled systems. The fibre-free 

pulse dampers fitted to the CSG operate on a broad spectrum and at 

very little pressure loss. 

These and other optimisation measures have enabled system efficiency 

to be improved further. This means that the CSG series delivers 

16 percent higher flow rate for the same rated motor power, whilst 

maximum working pressure has been increased from 10 to 11 bar. 

A further aim of product development was to make the compressor 

heat easily available for use by customers, thus allowing maximum 

The CSG series (on the right with integrated i.HOC rotation dryer) delivers compressed 

air dependably and efficiently for oil-free applications 

reduction of their CO 2 

footprint. To this end, Kaeser offers an integrated 

i.HOC desiccant dryer on both air- and water-cooled systems. 

It cleverly uses compressor exhaust heat to regenerate the desiccant 

with minimal energy consumption, thereby providing reliable and stable, 

oil-free compressed air with pressure dew points down to -30 degrees 

C, even under harsh ambient conditions. 

For water-cooled models, Kaeser offers innovative, integrated heat 

recovery options which can easily be adapted to customer requirements. 

The integrated Sigma Control 2 compressor controller not only 

provides dependable and energy-efficient control of compressor operation, 

but also enables connection to master compressed air management 

systems. Furthermore, it provides bearing and winding temperature 

monitoring for the drive motor as standard, as well as vibration 

monitoring for the compressor. 

All Kaeser rotary screw compressors impress when it comes to 

the question of sustainability. Not only do they operate extremely 

economi cally, but they are produced in Germany to the highest quality 

standards and requirements. Exceptional durability means they can 

serve a company for many decades to come. Should it ever become 

necessary to replace them, many of the materials used in their manufacture 

are recyclable. When it comes to your compressed air supply, 

Kaeser also represents a plus point with regard to nature and the environment. 


P.O. Box 2143 

96410 Coburg, Germany 

Tel +49 9561 640-0 

productinfo@kaeser.com 


Precise aeration air flow control on 

Stendal WWTP 

Economical constant and sliding pressure control with 

Iris ® Control Valves 

In wastewater treatment plants with activated sludge process, up to 

60 % of the total energy requirement is needed for compressors that 

ensure the air input into the biology. The blower station supplies the 

compressed air required for the activated sludge tanks, which operate 

continuously. A precise control of the air flow significantly increases 

the quality of the required oxygen content for the process and at the 

same time significantly reduces the energy consumption. 

During the upgrade of the Stendal wastewater treatment plant, 20 

butterfly valves were replaced by 4’’ (DN 100) Egger Iris ® Control Valves 

with a SCADA control strategy. 

As a result, a significant improvement of the oxygen control 

accuracy could be achieved. The measured dissolved oxygen concentrations 

(DO) are within ± 0.04 mg/l of the setpoint. This precise control 

and the utilization of the large control range of the Iris ® process 

control valves enabled a reduction of the compressor pressure. With 

the sliding pressure control used, the pressure could be reduced to 

0.42 psi (29 mbar) above the static pressure (blow-in depth). The Iris ® 

diaphragm control valves operate at an optimum aperture value between 

70 and 95 %. Furthermore, the high control quality and repeatability 

have a positive effect on the overall process as well as on the energy 

consumption of the aeration tanks. 


113



The pressure downstream of the Iris ® Process Control Valves can be 

read from the graphs of this SCADA print out shown in Fig. 3. This information 

is helpful to identify any need for maintenance of the diffusors. 

The Iris ® valves have been working for over 10 years to full satisfaction. 

Fig. 1: Egger Iris ® diaphragm control valve for precise air control at the biology of 

the Stendal wastewater treatment plant 

Besides the significant energy savings due to the lowered DO set point, 

the oxygen transfer could be improved. In addition, the diffusers can 

be flushed more effectively because of to the higher flow capacity of 

the Egger Iris ® valves compared to the former butterfly valves. 

Fig. 3: Achieved oxygen content in aeration tank lines 1 and 2 with downstream 

pressure of the valves, printout from the process control system at Stendal WWTP 



2088 Cressier NE, Switzerland 

Phone +41 (0)32 758 71 11 

info@eggerpumps.com 

www.eggerpumps.com 

Bredel NR Transfer pump hose 

launched for general fluid transfer 

applications 

Fig. 2: Iris ® Diaphragm Control Valve DN 100 with Auma drive at the Stendal 

sewage treatment plant 

Optimization of process control technology 

The programming of the process control system for the activated sludge 

air control was carried out by the company S & W Automatisierung 

Prozeßleittechnik in cooperation with the Stendal sewage treatment 

plant. A constant pressure control and a sliding pressure control were 

programmed. The system is designed in such a way that the sewage 

treatment plant can switch between the two types of control and adjust 

parameters individually. This allows the potential of the system 

to be optimally utilized. The oxygen content varies between 1.78 and 

1.84 mg/l with a default value of 1.8 mg/l. 

There are two control loops for the sliding and constant pressure 

control: One is the dissolved oxygen control loop, and the other is the 

control loop for the compressors. The compressors receive only one 

preset value, which must be maintained. 

Bredel hose pumps, which is part of Watson-Marlow Fluid Technology 

Solutions (WMFTS), has expanded its range of pump hoses by releasing 

the new and versatile Bredel NR Transfer hose for general fluid 

transfer applications at pressures up to 12 bar (174 psi). The Bredel NR 

(Natural Rubber) Transfer hose can be used for handling sludge with a 

high solid content, food and beverage waste and abrasive slurries. This 

solution complements the Bredel NR Metering hose, which is designed 

for heavier duties with pressure capability up to 16 bar (232 psi), already 

available from Bredel hose pumps. 

All Photos: Watson-Marlow Fluid Technology Solutions 




Bredel is now the only manufacturer to offer optimised NR hoses for 

different customer needs, for example for metering or transfer applications. 

Bredel customers can now rely on a single source — WMFTS 

— for all applications. 

Lars Varnbueler, Product Manager at Bredel, said: “Bredel is best-inclass 

in hose pump technology. With the new NR Transfer hose, Bredel 

is specialising its offering for each application. Whether long life, pressure 

capability or chemical compatibility is critical to your process, 

Bredel has the solution. In a wide range of standard hose pump applications, 

the NR Transfer hose has superior life and therefore requires 

less frequent maintenance.” 

“Our precision-machined NR Metering hose provides high accuracy, 

suction capability and discharge pressure stability over the full hose 

life for heavy duty applications.” 

The hose element is critical to ensure pump performance, durability 

and efficiency. Composite reinforced transfer hoses are constructed 

from high-quality compounded rubbers reinforced with four individual 

layers of braided nylon. The Bredel NR Transfer hose is manufactured 

to dimension with advanced wrapping technology, optimised for long 

life in fluid transfer applications. 




Tel +49 (2183) 42040 


www.wmfts.com 

Built for the future: GF Piping Systems 

introduces the Butterfly Valve 565 

Lug-Style 

With the addition of the new valve, the portfolio of the lightweight and 

corrosion-free Butterfly Valve 565 is now completed. Its lug-style design 

allows for additional use cases in water applications in industries 

such as water treatment and cooling applications. The Wafer-Style 

Butterfly Valve 565 was first introduced in 2021 and was developed 

as an alternative to metal valves. Due to its lightweight plastic design, 

identical installation lengths, as well as high pressure and temperature 

resistance, the 565 is cost-effective and long lasting. 

The abrasion-resistant Bredel NR Transfer hose is engineered so it 

lasts longer than competitor hoses and optimises the performance of 

a peristaltic pump in applications in: water and wastewater treatment; 

construction; ceramics; pulp and paper; power generation (biogas, biomass); 

and food and beverage. 

With the release of the NR Transfer hose, Bredel is responding to 

its customers’ needs for a hose to transfer any fluids. The Bredel NR 

Transfer hose is suitable for water-based liquids, diluted acids and alcohols, 

lightly corrosive chemicals, and slurries. 

Benefits and features of the Bredel NR Transfer hose include: 

– Engineered for exceptional long life in fluid transfer applications 

– Pressure capability: 12 bar (174 psi) 

– Maximum suction lift: 9 m (30 ft) 

– Maximum fluid temperature: 80°C (176°F); Minimum fluid 

temperature: -20°C (-4°F) 

– Global support for pump and hose from original manufacturer 

Fig. 1: Due to its lightweight plastic design, identical installation lengths, as well as 

high pressure and temperature resistance, the 565 is cost-effective and long lasting. 

(Source: GF Piping Systems) 


115



The new valve also adopts the same general specifications as the rest 

of the line-up. It is made from plastics that protect it against corrosion 

and abrasion while reducing the overall weight compared to metal. In 

addition, it features a Data-Matrix-Code for traceability and an optional 

LED position feedback sensor. The 565 Lug-Style comes with many 

marine and water approvals, including NSF, DNV, Loyds Register, and 

KTW-BWGL. Furthermore, it is the first industrial valve with an Environmental 

Product Declaration (EPD). 

Fig. 2: The lug-style and wafer-style versions of the Butterfly Valve 565 extend the 

application possibilities of the product range. (Source: GF Piping Systems) 

The 565 Lug-Style can be used as an end valve which enables piping systems 

to be disassembled one-sided. This facilitates the maintenance 

and operation of filters, tanks, and other installations. As standard, the 

565 Lug-Style features plug-in inserts that can be configured to fulfill 

the needs of a wide variety of applications. The removable inserts have 

been designed to increase flexibility and customization during operation 

and improve material separation at the end of the valve’s service 

life. The 565 Lug-Style also features a patented housing with open 

sides which reduces the material usage and offers easier access to the 

threaded plug-in inserts. 

Depending on the application, the 565 range can be configured to 

meet different requirements. The 565 can be operated manually with 

a lockable hand lever or a hand wheel, but it also features a digital 

interface as standard for plug-and-play process automation. Optional 

equipment includes pneumatic, electric, or smart actuators and positioners, 

as well as compatibility with inductive double sensors and a 

switching ring for precise feedback on position and performance. As a 

result, the 565 is designed to be seamlessly integrated into automation 

loops, which can be controlled and monitored remotely. 

More information here: https://www.gfps.com/com/en/productssolutions/innovation/565/butterfly-valve-565_gc.html 

Meet us at the upcoming trade fairs and learn more about our solutions 

for process automation, water treatment and dosing applications! 

GF Piping Systems at the IFAT in Munich (May 13-17, 2024): 

Hall B3.351/450 

GF Piping Systems at the ACHEMA in Frankfurt (June 10-14, 2024): 

Hall 8.0 Stand E64 

GF Georg Fischer GmbH 

Piping Systems 

Daimlerstr. 6 

73095 Albershausen, Germany 

Tel +49 (7161) 3020 

Fax +49 (7161) 302259 

info.de.ps@georgfischer.com 

www.gfps.com 


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Water Wastewater Environmental Technology 

Energy Oil Gas Hydrogen 

Automotive 


Shipbuilding Heavy Industry 

Chemistry Pharmaceutics Biotechnology 

Food and Beverage Industry 

PUMP MONITORING AND 

PROCESS EXPERTISE 

FOR WWT PLANTS 

2024 

Technical Data Purchasing >>> 

Independent magazine for Pumps, Compressors and Process Components 

117

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 

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 

Jung Process Systems GmbH 

Auweg 8, 25495 Kummerfeld/Germany 

Phone: +49 (0)4101 80 409-0, Fax: +49 (0)4101 80 409-142 

E-mail: info@jung-process-systems.de 

Website: www.jung-process-systems.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 


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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118

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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119

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 

Vogelsang GmbH & Co. KG 

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 

Watson-Marlow Limited 

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.karcher.com 

Website: www.woma-group.com 

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120

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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121

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 

Progressive cavity pumps 

Gear 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 





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)4101 80 409-0, Fax: +49 (0)4101 80 409-142 



• • • • • • • • 

• 



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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122

Drive concept Design features Conveyed media Service 

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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123

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 

• • • 



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)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 



• • 

124

Drive concept Design features Conveyed media Service 

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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125

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 



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 



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)4101 80 409-0, Fax: +49 (0)4101 80 409-142 





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 



126



Vortex pumps 



Gear pumps 



Screw pumps 

Vane pumps 







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 

T,Y, 

on 

reques 

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 

127

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)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 



128



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 

U 

U 

A, B, C A, B, C, 

D, F, G, 

H, I 

K, L, M, 

N, P, R, 

S, V, 

W, X 

K, L, M, 

N, P, R, 

S, V, 

W, X 

129






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 


Aerzen Maschinenfabrik GmbH 

Reherweg 28, 31855 Aerzen/Germany 

Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 

E-mail: info@aerzen.com 

Website: www.aerzen.com 


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 

• • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • 

130

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 

• • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

131


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 

Screw vacuum pumps (Helicoidal gear vacuum pumps) 

Scroll vacuum pumps 

Rotary vane vacuum pumps 

Steam ejectors 

Turbomolecular vacuum pumps 




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 



• 

• • • • • • • • • • • 

• • 

• • • • • • • 

132

Vacuum pumping stations 

Service 

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 






• • • • • • • • • • • 

• • • 

• • • • • • • • • • • • • 

133


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 

134

Screw vacuum pumps (Helicoidal gear vacuum pumps) 

Scroll vacuum pumps 

Rotary vane vacuum pumps 

Steam ejectors 

Turbomolecular vacuum pumps 


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, B A, B A, B C 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 

135

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 



• • • • • • • • • • • • • • • • • • • • 

• • • • 

• • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • 

• • • • • • • • • • • • • • • • • • • 

136

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 


• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

137

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 



• • • 

• • • • • • • • • • 

138

Conveyed media 

Service 

Scroll compressors 

Side channel compressors 

Small and very small compressors 

Turbines/Expander 

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 






• • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • 

• • • • • • • • 

• • • • • • • • 

• • • • • • • • • • 

139

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 

140

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 

A, B, C, 

D 

B, C 

on B, C, D, 

request E 

B, C, D, 

E 

H, I G, H, I, 

L, M, N 

D, E 

141

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 



• • • • • • • • • • • 

• • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • 

142

Pressure 

distribution 

Compressed air tools Other Service 

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 






• • • • • • • • 

• • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • 

143


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 


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 



Georg Fischer GmbH 

Daimlerstrasse 6 

73095 Albershausen/Germany 

E-mail: info.de.ps@georgfischer.com 

Website: www.gfps.com/de 


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 


• • • • • • • 

• • • • • • • • • 

144

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 

• • • 

• • • 

• • • • • • • 

• • • • • • • • • • • • • 

145


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 



146

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 

• • • • • • • • • • • 

• • • 

147


Components and assemblies 

Butterfly/Gate valves 


Compensators 

Condensate separators 

Couplings 

Filters 

Gear drives 

Pipelines and hoses 

Pipe fittings 

Pressure vessels 

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 


Gehrstücken 9, 25421 Pinneberg/Germany 

Phone: +49 (0)4101 5002-0, Fax: +49 (0)4101 5002-83 



• • 



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 




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 



• • • • 

• 



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 





Tel +44 (1326) 370 370 



• • • • • • • • • • • • 

• 

148

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 

• 

• • • 

• • • • • • • • • • 

• • • 

• • • • 

• • • • • • • • • • • • • • 

• 

149

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 

ABEL HMQ - Hydraulic membrane pumps Quadruplex 

ABEL HP / HPT - High pressure pumps 

ABEL SH - Solids handling pumps 

ABEL Marine - Marine pumps 

For exhibition-participation 

please visit our homepage: 

www.abelpumps.com 


Reherweg 28 

31855 Aerzen/Germany 

Phone: +49 (0)5154 81-0 

Fax: +49 (0)5154 81-9191 



Positive displacement blowers 

Rotary piston compressors 

Screw compressors 

Turbo blowers 

Rotary piston gas meters 


please visit our homepage 

www.aerzen.com 

AF Compressors 

Ateliers François S.A. 

Rue côte d‘Or 274 

4000 Liège/Belgium 

Phone: +43 (0)664 9207 944 

E-mail: opc@afcompressors.com 

Website: www.afcompressors.com 

AF offers a complete range of oil-free compressors 

“high and low” pressure. 

20-40 bar oil-free piston PET compressors for PET 

bottling or other applications. 

8 and 10 bar oil-free OPC range of piston 

compressors for any industrial applications 

(possibilities from 6-15 bar). 

- Compressor management systems 

- Smart Inverter Starter 

- Variable speed drive 

- Separate cooling systems 

For our presence on international 

exhibitions, please visit our website: 

www.afcompressors.com 

APOLLO Gößnitz GmbH 

Walter-Rabold-Str. 26 

04639 Gößnitz 

Phone: +49 (0)34493 77-0 

Fax: +49 (0)34493 77-210 

E-Mail: info@apollo-goessnitz.de 

Website: www.apollo-goessnitz.de 

Manufacturer for heavy-duty process pumps acc. to 

API 610 in all types, DIN ISO pumps and pumping 

systems for Oil-, Gas-, Offshore- and Power Plant 

applications as well special engineered solutions 

ACHEMA 

June 10-14, Frankfurt 

Hall 8, Stand E11 

For more information, please visit 

our website: 

www.apollo-goessnitz.de 


Schlehenweg 15 

50999 Köln/Germany 

Phone: +49 (0)2236 9650 0 

E-mail: 

atlascopco.energas@de.atlascopco.com 

Website: 

www.atlascopco-gap.com 

Industrial heat pumps and heat pumps systems 

using turbocompressors, integrally-geared 

turbocompressors, direct-driven turbocompressors, 

turboexpanders (integrally-geared and direct-driven), 

Companders, oil-free gas screw compressors, 

API 610 centrifugal pumps, as well as corresponding 

services. Markets served: Energy (conventional + 

renewable), hydrocarbon processing, chemical/ 

petrochemical, new markets (i.e., hydrogen, CCUS 

etc.), industrial gases. 


please visit our homepage 

www.atlascopco-gap.com 


Stäblistr. 8 

81477 München/Germany 

Phone: +49 (0)89 78049-0 

Fax: +49 (0)89 78049-167 



BAUER KOMPRESSOREN is one of the leading 

manufacturers of medium and high-pressure system 

for the compression of air and gases worldwide. 

- Medium and high-pressure compressors 

- 25 – 500 bar, 2.2 – 315 kW 

- Air and gas treatment 

- Storage systems 

- Air and gas distribution 

- Gas measurement systems 

- Controls 

For current trade fairs please visit: 

www.bauer-kompressoren.de/ 

news-events/trade-show-dates/ 

150


Gebr. Becker GmbH 

Hoelker Feld 29-31 

42279 Wuppertal/Germany 

Phone: +49 (0)202 697-0 

E-mail: info@becker-international.com 

Website: www.becker-international.com 

Rotary vane vacuum pumps and compressors 

Screw vacuum pumps and compressors 

Claw vacuum pumps and compressors 

Side channel vacuum pumps and blowers 

Radial vacuum pumps and blowers 

Roots Booster Packages 

Vacuum systems with tanks 

Centralized air supply systems 

For current exhibition activities 

please visit our website 

www.becker-international.com 

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 



BOGE AIR – THE AIR TO WORK: 

Customers in more than 120 countries worldwide 

trust the BOGE brand. 

The BOGE product range includes oil-free and 

oil-lubricated screw compressors and piston 

compressors, scroll and turbo compressors, 

compressed air treatment, control units, heat 

recovery devices as well as tailored special solutions. 

For up-to-date exhibition activities 

please visit our website: 

www.boge.com 

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 



BRINKMANN PUMPS offers a complete range 

of powerful pump solutions based on centrifugal 

pumps or screw spindle pumps for various 

applications: 

- Multiphase conveyance 

- Plastic recycling 

- Mechanical engineering 

- Electric mobility 

- Optical machines 

- Dosing technology 

- Pump control 

- Drive technology 

- Renewable energies 

For current trade fairs, please visit 

our website: 

www.brinkmannpumps.de 


Schauinslandstr. 1 

79689 Maulburg/Germany 

Phone: +49 (0)7622 681-0 



Busch Vacuum Solutions operates worldwide 

as one of the largest manufacturers of vacuum 

pumps, blowers and compressors. The extensive 

product portfolio covers vacuum and overpressure 

applications in all industry sectors. A dense service 

network coupled with many years of experience and 

expertise in developing vacuum systems makes it 

possible to provide customised integrated solutions. 

For trade show dates and more information 

about the world of vacuum, 

please visit 

www.buschvacuum.com 


Gehrstücken 9 

25421 Pinneberg/Germany 

Phone: +49 (0)4101 5002-0 

Fax: +49 (0)4101 5002-83 



Elastomer seals from the specialist. COG delivers 

from the world‘s largest O-Ring warehouse 

(over 45,000 items in stock) a wide variety of 

compounds, incl. FFKM/FFPM and has offered 

premium quality, innovation and know-how for over 

150 years. 

Product range: 

- Precision O-Rings and elastomer seals 

- Tools for over 23,000 different O-Ring sizes 

available 

- In-house mixing, mixture development and 

production 

- Various certifications, e. g. FDA, USP, NORSOK 

- Also small-scale production 

For further information please visit 

www.cog.de/en 


Kreiselpumpen und Regulierschieber 


2088 Cressier NE/ Switzerland 

Phone: +41 (0)32 758 71 11 



Egger is a medium-sized, independent and ownermanaged 

Swiss industrial company with its focus 

on development and manufacturing of centrifugal 

pumps and Iris ® Diaphragm Control Valves. 

Pumps and slides for the chemical industry, 

wastewater technology, steel industry, automotive 

industry, salt industry. 


our homepage: 

www.eggerpumps.com/en-us/ 

news-downloads/exhibitions-events 

151


FELUWA Pumpen GmbH 

Beulertweg 10 

54570 Mürlenbach/Germany 

Phone: +49 (0)6594 10-0 

Fax: +49 (0)6594 10-200 

E-mail: info@feluwa.de 

Website: www.feluwa.com 

FELUWA specialises in the construction of 

MULTISAFE ® double hose-diaphragm pumps. 

Wherever abrasive, aggressive and toxic media 

are conveyed, the hermetically sealed, oscillating 

displacement pumps from FELUWA are used. The 

MULTISAFE ® technology offers ideal pump systems 

to the customers for various applications, even for 

extreme operating temperatures and heterogeneous 

mixtures with high solids content. 


our website: 

www.feluwa.com 






MULTI/JOINT couplings (wide range to DN1025) 

Butterfly valve 565 

Ball valves 

ELGEF Fitting System 

SYGEF ECTFE 

Intelligent actuators 

Measurement and control systems 

IFAT 

May 13-17, München 

Hall B3.351/450 

ACHEMA 

June 10-14, Frankfurt 

Hall 8.0 Stand E64 


Robert-Mayer-Str.21 

71636 Ludwigsburg/Germany 

Phone: +49 (0)7141 48894 60 



For more than 70 years, Goetze KG Armaturen has 

been manufacturing high-performance fittings 

and valves. The family-run company with its 

Headquarters in Ludwigsburg, has made a name 

for itself worldwide with its quality level (“Made 

in Germany”) - meanwhile more than half of its 

production now goes to foreign markets. 


our website: 

www.goetze-group.com/ 

de-de/unternehmen/messen 

GRUNDFOS GmbH 

Schlüterstr. 33 

40699 Erkrath/Germany 

Phone: +49 (0)211 92969-0 

Fax: +49 (0)211 92969-3799 



Intelligent pumps and solutions for building services, 

industry and water utility, including circulator pumps, 

endsuction pumps, multistage pumps, pressure 

boosting systems, immersible pumps, inline pumps, 

dosing pumps, lifting stations, submersible ground 

and wastewater pumps 

For current trade fairs, 

please visit your local Grundfos 

website 


Carl-Zeiss-Str. 6-8 

59302 Oelde/Germany 

Phone: +49 (0)2522 76-0 

Fax: +49 (0)2522 76-140 



High-pressure plunger pumps 

Process pumps 

Sewer cleaning pumps 

Mining pumps (deep mining industry) 

Hot water appliances 

Operating pressure up to 4000 bar 

Flow rate up to 3000 l/min 

Applications systems for cleaning, removing, 

cutting, coating removal, decorning, deburring 

with high pressure water 

Worldwide participations in trade 

fairs,for current trade fairs, please 

visit our homepage: 

www.hammelmann.com 

We are looking forward to your visit! 


Jägerweg 5-7 

85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400 

Fax: +49 (0)89 666633-411 



The family-run company JESSBERGER headquartered 

in Ottobrunn near Munich is manufacturer of electric 

and pneumatic driven drum- and container pumps, 

vertical and horizontal progressive cavity pumps, 

dosing pumps for high viscous media, hand operated 

pumps and a comprehensive range of accessories 

like flowmeters, nozzles etc. Air operated diaphragm 

pumps, horizontal centifugal pumps (also available 

as magnetically coupled seal-less centrifugal pumps) 

and vertical centrifugal pumps complete the delivery 

program beside further industrial pumps. 


www.jesspumpen.de 


152


JUMO GmbH & Co. KG 

Moritz-Juchheim-Straße 1 

36039 Fulda/Germany 

Phone: +49 (0)661 6003-0 

Fax: +49 (0)661 6003-881-2346 

E-mail: info@jumo.net 

Website: www.jumo.net 

Delivery program 

• Temperature sensors and heat meters 

• Transmitters and controllers 

• Automation system and digital indicators 

• Hygro transducers and hygrothermal transducers 

• Measuring devices and flow sensors 

• Level probes and float switches 

• Level sensors and level switches 

• Solid state relays and power controllers 

LOUNGES 

April 23 - 25, Karlsruhe 

IFAT 

May 13 - 17, München 

ACHEMA 

June 10 - 14, Frankfurt 

Other scheduled trade fairs: 

messen.jumo.info 


Auweg 8 

25495 Kummerfeld/Germany 

Phone: +49 (0)4101 80 409-0 

Fax: +49 (0)4101 80 409-142 



Jung Process Systems GmbH has specialized in the 

development of twin screw pumps. 

This type of pump offers maximum flexibility for 

a wide variety of applications. Hygienic twin screw 

pumps under the brand name HYGHSPIN are 

designed for the use in the food, pharmaceutical and 

cosmetics industry. The new CHEMSPIN series was 

specially developed for industrial applications in the 

chemical industry. 

Current trade fair dates 

can be found at: 

www.jung-process-systems.de 


Postfach 21 43 

96410 Coburg/Germany 

Phone: +49 (0)9561 640-0 

Fax: +49 (0)9561 640-130 



Screw compressors oil-cooled/dry-running, 

compressor controllers, reciprocating compressors, 

oil-lubricated and dry, high pressure compressors, 

boosters, portable compressors, screw vacuum 

pumps, compressed air treatment components, 

pneumatic accessories, refrigeration dryers, rotary 

blowers, screw blowers, magnetic, bearing turbo 

blower, services around compressed air (analyse, 

services, contracting) 




Salinger Feld 10 

58454 Witten/Germany 

Phone: +49 (0)2302 8903-0 

Fax: +49 (0)2302 801917 



High pressure plunger pumps + systems 

Mining pumps + systems 

Process pumps + Systems 

Water hydraulic pumps + Systems 

Operating pressures up to 3500 bar 

Flow rates up to 4700 l/min 

Systems in mobile and stationary design 

KAMAT valve technology and water tools 

For KAMAT‘S current global trade fair 

partipcipations, visit 

www.KAMAT.de/en/innovations-and - 

exhibitions.html 



Blumenfeldstr. 18 

44795 Bochum/Germany 

Phone: +49 (0)234 4595-0 

Fax: +49 (0)234 4595-7000 



PUMPS: Magnetic drive and shaft sealed pumps for 

the chemical and petrochemical industry, the oil and 

gas industry and the renewable energy sector. 

Single-/multi-stage centrifugal pumps, side channel 

pumps, submerged pumps, propeller pumps, single/ 

double volute twin screw pumps. Pumps according 

DIN EN ISO, ANSI, API and custom designs. 

VALVES: Gate valves, globe valves, check valves, 

control valves, butterfly valves metal seated. 

Please visit our website for upcoming 

exhibitions 

www.klaus-union.com 

KLINGER GmbH 

RicharKlinger-Str. 37 

65510 Idstein/Germany 

Phone: +49 (0)6126 4016-0 

Fax: +49 (0)6126 4016-11 



Gasket sheets based on PTFE: KLINGERtop-chem, 

KLINGERsoft-chem 

Sheets based on graphite and mica: 

KLINGERgraphit, KLINGERgraphit-Folie, 

KLINGERgraphit-Laminat, KLINGERmilam 

Gasket sheets based on fibers: KLINGER Quantum, 

KLINGERSIL, KLINGERtop-sil, KLINGERtop-graph 

Sealing tapes: KLINGERtop-flon multi, 

KLINGERsealex, KLINGERflon-sealing tape, 

KLINGERgraphit sealing tape 

Spray: KLINGERflon-Spray 

Rubber products: Rubber-Steel Gaskets 

KLINGER-KGS, KLINGER Wall Seal Ring, moulded and 

extruded parts 

Special products on request 

Current trade fair dates: 

www.klinger.de/de/unternehmen/ 

news/events 


153


KRACHT GmbH 

Gewerbestr. 20 

58791 Werdohl/Germany 

Phone: +49 (0)2392 935-0 

Fax: +49 (0)2392 935-209 

E-mail: info@kracht.eu 

Website: www.kracht.eu 

We are a leading German technology provider for 

pumps, fluid measurement, valves, hydraulic drives 

and customised system solutions. 

Our modular gear pumps are used as transfer 

pumps, as process pumps for abrasive and poorly 

lubricating liquids, as high precision metering pumps 

and as hydraulic pumps for pressures up to 315 bar. 

We develop application-oriented special pumps in 

close cooperation with our customers. 

Current trade fair dates: 

www.kracht.eu 


KRAL GmbH 

Bildgasse 40, Industrie Nord 

6890 Lustenau/Austria 

Phone: +43 (0)5577 86644-0 

E-mail: kral@kral.at 

Website: www.kral.at 

KRAL GmbH is manufacturer of high-quality 

displacement pumps and flowmeters. 

KRAL screw pumps offer high capacities with little 

space required even at high differential pressures. 

Oils and other lubricating non-aggressive liquids 

are delivered in a pulsfree way with low noise 

development. Particularly noteworthy is the 

hermetically sealed pump with magnetic coupling 

which can be operated up to 300° C. 

KRAL flowmeters are robust and offer laboratory 

measurement accuracy even under harsh industrial 

conditions. 

Current trade fair dates and details 

can be found at 

www.kral.at 


Markgrafenstraße 36-39 

90459 Nürnberg/Germany 

Phone: +49 (0)911 4306-9650 

Fax: +49 (0)911 4306-439 



Leistritz Pumpen GmbH has been producing and 

selling screw pumps since 1924. 

Leistritz pumps have internal or external bearings 

with single- or double-volute design. The product 

range includes the Type Series L2, L3, L4, L5 with 

2 to 5 spindles and offers solutions for a wide range 

of applications, for example the oil & gas or the 

chemical industry. 

For trade shows please visit 

pumps.leistritz.com 

LEWA GmbH 

Ulmer Str. 10 

71229 Leonberg/Germany 

Phone: +49 (0)7152 14-0 

Fax: +49 (0)7152 14-1303 


- Metering Pumps 

- Process Diaphragm Pumps 

- Metering Systems 

- Packages 

- After sales service 

Current trade fair dates 

can be found at: 

www.lewa.com/en/ 

lewa-group/exhibitions-and-events 

Lutz Pumpen GmbH 

Erlenstr. 5-7 

97877 Wertheim/Germany 

Phone: +49 (0)9342 879-0 

E-mail: info@lutz-pumpen.de 

Website: www.lutz-pumpen.de 

Lutz Pumpen GmbH is a leading manufacturer of 

industrial pumps with a focus on work safety and the 

highest demands. 

The product range includes drum pumps, container 

pumps, air-operated diaphragm pumps, flow meters, 

centrifugal pumps as well as system solutions. 

Current trade fair dates can be found 

on our website: 

www.lutz-pumpen.de 


Geretsrieder Str. 1 

84478 Waldkraiburg/Germany 

Phone: +49 (0)8638 63-0 


Website: 

www.pumps-systems.netzsch.com 

As a specialist for complex fluid management, 

NETZSCH develops customised and sophisticated 

pump solutions on a global level. The product 

spectrum ranges from the industry’s smallest 

metering pumps to high-volume pumps for 

applications in the oil & gas or mining industries. 

NETZSCH offers NEMO ® progressing cavity pumps, 

TORNADO ® rotary lobe pumps, NOTOS ® multi screw 

pumps, PERIPRO peristaltic pumps, grinders, dosing 

technology and barrel emptying units, accessories 

and service. 

For current trade fairs, please visit: 

www.pumps-systems.netzsch.com/ 

en/events 

154



Berliner Str. 43 

35614 Asslar/Germany 

Phone: +49 (0)6441 802-0 

Fax: +49 (0)6441 802-1202 


Founded in 1890, Pfeiffer Vacuum stands for 

innovative vacuum technology, high quality 

standards and first-class customer service. The 

company offers a complete range of turbopumps 

with hybrid and magnetic bearings, backing pumps, 

leak detectors, components, measurement and 

analysis equipment, as well as vacuum systems 

and chambers. Pfeiffer Vacuum employs over 4,000 

people worldwide and has 10 production sites and 

more than 20 sales and service companies. 

Current information can be found at: 

https://www.pfeiffer-vacuum.com/ 

en/markets/ 


Simoniusstr. 17 

88239 Wangen im Allgäu/Germany 

Phone: +49 (0)7522 997-0 

Fax: +49 (0)7522 997-199 



WANGEN PUMPEN offers a comprehensive product 

range of progressing cavity and twin screw pumps 

that are in reliable operation worldwide. We have 

the perfect pump for your media and support you 

with our experience in the fields of agricultural 

engineering, biogas/A.D., hygienic applications, 

wastewater and environmental technology. 

Since 2022 we are part of the Atlas Copco Group. 


trade shows 

www.wangen.com/en/tradeshow 

J.P. Sauer & Sohn 

Maschinenbau GmbH 

Brauner Berg 15 

24159 Kiel/Germany 

Phone: +49 (0)431 3940-0 

Fax: +49 (0)431 3940-24 

E-mail: info@sauercompressors.de 

Website: www.sauercompressors.com 

Sauer Compressors offers medium- and 

high-pressure compressors for applications in the 

general industry, offshore, commercial shipping and 

defence sectors. The modern reciprocating piston 

compressors for compressing air as well as all kinds 

of gases reach pressures of 20 bar to 500 bar. 

The SAUER product line comprises high-pressure 

compressors, while HAUG stands for oil-free, dryrunning 

and hermetically gas-tight compressors. 


trade shows 

www.sauercompressors.com 

SEEPEX GmbH 

Scharnhölzstr. 344 

46240 Bottrop/Germany 

Phone: +49 (0)2041 996-0 



SEEPEX is one of the leading worldwide specialists in 

the field of pump technology. 

Our portfolio comprises progressive cavity pumps, 

pump systems, and digital solutions. 

Our pumps are used wherever low to highly viscous, 

aggresive or abrasive media must be conveyed at 

low pulsation rates. 

Please visit our website for 

upcoming exhibitions 

www.seepex.com 

sera Hydrogen GmbH 

sera-Str. 1 

34376 Immenhausen/Germany 

Phone: +49 (0)5673 999-04 

Fax: +49 (0)5673 999-05 

E-mail: info-hydrogen@sera-web.com 

Website: www.sera-web.com 

Hydrogen technology 

Corporate Hydrogen Fuelling Stations 

Power-to-Gas-Stations 

System solutions 

Single and multiple stage metal diaphragm 

compressors 


After sales service 


trade shows 


sera ProDos GmbH 

sera-Str. 1 

34376 Immenhausen/Germany 

Phone: +49 (0)5673 999-02 

Fax: +49 (0)5673 999-03 

E-mail: info-prodos@sera-web.com 

Website: www.sera-web.com 

Diaphragm pumps, piston diaphragm pumps, 

piston pumps, air driven diaphragm pumps, 

centrifugal pumps, feeding pumps, 

solenoid diaphragm pumps, metal diaphragm 

pumps, controllable dosing pumps, profibus-pumps, 

automatic dosing and control units, packaged units, 

gas pumps, diaphragm-type relief valves, pulsation 

dampers, system fittings, high pressure technology. 


trade shows 


155


Vogelsang GmbH &Co. KG 

Holthoege 10-14 

49632 Essen (Oldenburg)/Germany 

Phone: +49 (0)5434 83-0 

Fax: +49 (0)5434 83-10 

E-mail: germany@vogelsang.info 


- Rotary lobe pumps 

- Macerators 

- Shredder 

- Vacuum pumps 

- Biogas technology 

- Agricultural technology 

Further trade shows at 

www.vogelsang.info 


Bickland Water Road, Falmouth 

Cornwall, TR11 4RU, United Kingdom 

Tel +44 (0)1326 370 370 



Watson-Marlow Pumps: accurate and repeatable 

peristaltic tube pumps for food, pharmaceuticals 

and industry 

Watson-Marlow Tubing: precision tubing for 

pumping and other purposes, in a range of materials 

Bredel Hose Pumps: heavy duty hose pumps for 

viscous and abrasive slurries and sludge 

Alitea: unique peristaltic panel-mount pumps and 

pumphead solutions for OEM customers 

Flexicon Liquid Filling: benchtop filling, semiautomatic 

systems and fully automatic filling, 

stoppering and capping machines 

MasoSine Process Pumps: low shear sinusoidal 

pumps for high viscosity food, beverage and 

cosmetics application 

BioPure Technology: advanced single-use tubing 

connector systems with LOT traceability on every 

component 

ASEPCO: Weirless Radial diaphragm in-line and tankbottom 

valves for pharmaceutical industries 

FlowSmart: reinforced platinum-cured silicone 

hoses and high performance sanitary gasket 

products 

Aflex Hose: specialist in the design and manufacture 

of PTFE-lined flexible hoses 

For trade fairs please visit 

www.watson-marlow.com/ 

gb-en/about/exhibitions/ 


Werthauser Str. 77-79 

47226 Duisburg/Germany 

Phone: +49 (0)2065 304-0 

Fax: +49 (0)20650 304-200 



WATER AS A TOOL 

• High-pressure plunger pumps for industrial 

cleaning and process applications 

• Ultra-high-pressure water jetting units 

• High-pressure hot water units 

• Water tools and accessories for various water 

blasting applications in industry and construction 

• Industrial Jetting Solutions 

• Service, maintenance and training 

Current Trade show dates events 

are listed on our website 

www.woma-group.com 


156

& 

Pumps 

Systems 

for process technology 

• Manual hand pumps 

• Electric drum pumps 

• Air operated drum pumps 

• Air operated diaphragm pumps 

• Eccentric screw pumps 

• Dosing pumps 

• Magnetic centrifugal pumps 

• Centrifugal pumps 

• Filling systems 

• Pump accessories 

Made in 

Germany 

ATEX 

2014/34/EC 

Proofed 

Quality 

Jaegerweg 5 –7 

D-85521 Ottobrunn 

Phone: +49 (0) 89 - 66 66 33 400 

Fax: +49 (0) 89 - 66 66 33 411 

info@jesspumpen.de 

www.jesspumpen.com

Your global partner 

for conveying complex media 

This is how you convey complex media effectively 

Choosing the right pump optimizes the processes and reduces 

energy costs. NETZSCH offers: 

Individual consultation 

More than 70 years of experience 

5 different technologies 

Each technology offers specific benefits for 

you. Contact us, we will find the optimal 

solution for your application. 

 

 

 

Partnership does not end 

with the purchase 

Maintenance 

& repairs 

10,000 NETZSCH 

spare parts on call 

176 service 

locations 

worldwide 

We support you from commissioning, 

maintenance up to repair and 

modernisation of your pump. 

Visit us at the trade fairs: 

IFAT, 13-17 May, 2024 

Munich, Germany, Booth B1.451/550 

 

ACHEMA, 10-14 June, 2024 

Frankfurt, Germany, Hall 8.0, Booth C27 


Geretsrieder Str.1, D - 84478 Waldkraiburg 

Tel.: +49 8638 63 0 ∙ info.nps@netzsch.com 

www.pumps-systems.netzsch.com

PuK - Process Technology & Components 2024

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