Case studies

Pump Disassembly and Parts Inspection

The maintenance process began with thorough cleaning, where the pumps were cleaned by Kiertopaine before disassembly. After disassembly, all pump parts were visually inspected and critical tolerances measured. Special attention was paid to the bronze vane, whose wear surfaces were assessed. These vanes were found to be fully usable, and no replacement was necessary.

Components to be Replaced

The following components were replaced during maintenance:

• All seals, which must always be replaced when the pump is opened to ensure tightness and prevent leaks.
• Carbon bearings on the shaft, whose wear can cause shaft imbalance and increase noise and vibration.

Technical Assessment and Next Steps

Based on the structure and materials of the pumps, it can be concluded that with minor repairs, the pumps are expected to achieve a long service life. The durability of the bronze vane and regular replacement of seals and bearings are key factors for pump reliability. The customer gained peace of mind and confidence in the pumps’ operational capability for the coming years.

Maintenance Documentation and Component Illustration

The image below shows all disassembled and inspected parts, including vane, shafts, bearings, seals, and pump housing components. The image and the spare parts used document the scope of maintenance for Kiertopaine’s archives.

Delivered Solution

Banmark and Scanjet supplied a comprehensive set of tank cleaning machines installed across nearly all process tanks. The jointly designed solution allows tanks to be cleaned either during planned shutdowns or—even more advantageously—while production is running. For a plant operating continuously at high intensity, this capability significantly improves both hygiene and operational efficiency.

The delivered equipment includes two Scanjet models:

• Scanjet SC 40RT
  • Available with two or four nozzles
  • Made of acid‑resistant steel and corrosion‑resistant materials
  • Patented magnetic drive minimizes seal failures
  • Key components positioned outside the tank for safe, fast and easy maintenance
• Scanjet SC 15TW
  • Scanjet’s most popular model
  • Available with two or four nozzles
  • Built‑in, robust gear mechanism provides high torque
  • Ideal for applications where wash water contains particles, such as fibers, without compromising performance

Customer Benefits

• Guaranteed hygiene level: Consistent, repeatable cleaning results that meet the strict standards of the food industry.
• Reduced downtime: Cleaning can be performed even during active production, improving overall operational efficiency.
• High reliability and long service life: Acid‑resistant construction and magnetic drive design minimize maintenance needs.
• Easy maintenance: Externally accessible service points shorten maintenance shutdowns.
• Process safety: The high‑torque gear system of the SC 15TW ensures stable operation even in challenging conditions, such as when the wash water carries fibers.

Outcome

The solution enables the customer to maintain an exceptionally high hygiene standard without sacrificing process reliability or causing unnecessary downtime. By combining Scanjet’s advanced cleaning technology with Banmark’s expertise in delivery and process optimization, the customer now benefits from clean tanks, improved process safety, and a predictable cleaning routine. We at Kiertopaine are happy to help you in finding a suitable model for your spesific needs!

Hungary is home to the country’s largest Coca-Cola HBC bottling plant. The plant emphasizes that product safety, minimizing environmental impact, and equipment reliability are central priorities. The previous bottleneck in their production chain was related to twin-screw pumps that were not able to unload raw materials (such as sugar and flavor syrups) efficiently or hygienically. This led to product loss, long unloading times, and high maintenance costs.

The Solution: Mouvex SLS Eccentric Disc Pumps

Mouvex SLS eccentric disc pumps were selected as the solution. The pumps’ seal-less and highly hygienic design reduces contamination risks, energy consumption, and maintenance needs. Unloading times shortened to as little as two hours. The pumps’ dry-run and vacuum capabilities improved product recovery and led to a significant reduction in production waste (up to more than 200 kg less waste per load). In addition, water is saved because the pumps do not require flushing water.

Overall, the implementation of Mouvex SLS pump technology improved product safety, reduced energy and water costs, lowered maintenance expenses, and enhanced operational reliability. This supports Coca-Cola HBC’s continuous goal to develop production methods in a sustainable, efficient, and innovative way.

Solution

The offered ATEX-compliant loading arm was technically demanding and expensive, including several sensors, heating, insulation, limiters, a vapor return hose, and actuators. The delivery time was about three months. As an option, a loading arm leg was also offered, which would be attached to the customer’s structures and included a fixed product pipeline.

Challenges and Progress

The structure was modified four times over several months, and each change required a new quotation. Eventually, the customer’s order arrived six weeks later without the leg. When confirming the order, the importance of the support was emphasized, and a new quotation for the support was made. However, the customer did not order the leg.

Results

Without a customer order, the leg was ordered from the factory at the last minute so that both products could be combined for delivery and packaging. Finally, about six months after delivery, the customer requested an urgent delivery of the missing leg. I explained that I would only invoice for the leg, which had already been delivered in the same package. The entire process took 16 months from the first quotation to invoicing for the support

As a solution, Wilden Saniflo™ FDA diaphragm pumps were selected, equipped with the Pro-Flo® SHIFT air distribution system and FSIPD diaphragms (Full-Stroke Integral Piston Diaphragm). The advantages of these pumps include:

• Gentle product handling: Diaphragm pumps circulate grape juice without breaking seeds, resulting in higher wine quality.
• Energy efficiency: The Pro-Flo SHIFT system reduces air consumption by up to 60% compared to traditional solutions, lowering energy costs.
• Easy cleanability: The pumps meet strict hygiene requirements, and their design enables quick and effortless cleaning.
• Reliability and flexibility: The pumps can run dry and allow easy adjustment of flow rates.
• Long service life: FSIPD diaphragms offer extended lifetime and improved suction, reducing maintenance needs.

Tests have shown that Wilden pumps are superior in terms of product quality, energy efficiency, and cleanability. Thanks to this solution, the winemaking process is now more efficient, higher in quality, and more environmentally friendly.

Challenges

The enzyme added to goat feed consists mainly of palm oil and is intended to:

– Improve palatability

– Reduce dust on the feed surface

– Enhance digestibility and gut health

The enzyme is transferred from an outdoor tank to a cabinet located 35 meters higher, where it flows through pumps, flow meters, pressure and temperature sensors, and filtration before reaching small 0.8 mm dosing nozzles.

Dosing requires extremely precise and stable flow, even at flow rates as low as 2 L/h and up to 60 L/h.

Production operates 24/7, so pump reliability is critical.

Solution: Almatec® E-Series AODD pumps

E-Series air-operated diaphragm pumps were chosen, meeting all process requirements:

Key benefits

– Very accurate and wide dosing range (2–60 L/h with the same pump)

– Polyethylene (PE) housing → excellent chemical resistance, 7× longer service life than PP pumps

– Solid-block construction → improved tightness, durability, and consistent bolt torque

– Optimized flow path → lower resistance, better efficiency, reduced air consumption

– PERSWING P® air control system → maintenance-free, highly precise stroke changeover

– IPD technology and internal dampeners → stable flow, pulses under 2%

– No rotating parts, no seals → easy to start and maintain

– Multiple sizes and material options for various applications

Results

The enzyme dosing became precise and reliable throughout the process.

Pulsations were minimized, ensuring flow meter accuracy.

The pumps withstand continuous year-round production without disruptions.

The customer received a complete solution where premium components and expert collaboration produced the best possible outcome.

Conclusion

Almatec® ESeries pumps proved to be an ideal solution for accurate dosing of warm, viscous enzyme. The E‑Series pumps meet strict requirements and ensure reliability in 24/7 production.