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Large Frozen Food Manufacturer Avoids Downtime

18 April 2021

Just like a car, the older a pump gets, the more you start having to spend on maintenance and the less efficient it becomes, resulting in increased energy costs. The additional costs involved in operating an older pump can mount up, so it is important for a process engineer to know when the time is right to invest in a new pump. 

Castle Pumps received an enquiry for a new AODD pump from one of the largest frozen food manufacturer brands in the UK, who were looking to replace their existing pump. Their existing model, used for transferring various alkaline-based detergents for cleaning down their processing plant and equipment, was still in working order but had been installed for a while.

As the pump is so vital in ensuring the food processing plant’s strictest hygiene standards are met, their process engineer who contacted us wanted to replace the pump before it reached the end of its lifespan to prevent any unexpected downtime further down the line. As Castle Pumps’ technical sales team recommend, pump replacement can be a sensible solution for increasing efficiency and ensuring their process remains operating without interruption.

A Speedy Solution
As Castle Pumps had specified the original pump that was installed, there were no tweaks required to the specification, enabling a like for like model to be manufactured and supplied within a couple of weeks. 

The beauty of the air operated diaphragm pump design for this application is that the absence of seals reduces leaking, which is perfect when transferring chemicals such as these alkaline-based detergents. Secondly, this particular Debem model has fewer wearing parts than other AODDs (30 vs a typical 72) and it’s diaphragm can run for 50 million cycles before needing replacing, enabling considerable maintenance savings.

So, what can you look out for?
If you have a pump onsite that hasn’t been replaced for years, think about the following and whether keeping an old pump going to avoid the expenditure is actually defeating the object. Comparing the annual costs to the initial outlay of a new pump may surprise you.

1. Maintenance costs:
Are they becoming more regular? Are sparts parts needing replacing more often that previously? Are out of the ordinary repairs starting to be needed i.e. those that aren’t typical wearing parts such as the pump casing?

2. Energy costs: Is your pump less energy efficient than it once was? Is the pump costing you more to run in power for the same output? Or are you noticing that other, newer pumps in your plant manage to consume a lot less?
For more information on how you can make long term savings when it comes to your pump, contact Castle Pumps Ltd.

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