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Automating your most labour-intensive tasks

13 July 2023

Castle Pumps explains how implementing flow and level control can automate pumps to free up operators’ time for more value adding tasks, while also preventing pump damage, reducing waste and improving accuracy in the process.

With labour costs being one of the most expensive overheads for any food processing company, it pays to consider automating labour-intensive manual operation of pumps in a production line. Consider the following:

Level/float switches: Level switches can be used to control a pump’s start/stop cycle. When the fluid in a container has reached a certain level, the pump will turn on or off and continue until the sensor detects the other specified level. This is a popular automation solution for tank filling and emptying applications such as waste product tanks.

Pump timers: Sometimes a pump needs to run for a specified period before stopping. For example, a circulating application may need a product to be pumped for 10 minutes every four hours to prevent the ingredients separating or the oil in pasta sauces from sinking to the bottom. Fitting a timer can not only reduce the amount of time spent by an operator walking to the pump and operating it, but it also eliminates the chance of operators forgetting to undertake the task.

Batch meters: Pumps used for dosing a specific volume of product can be supplied with a batch meter that can stop flow once the amount has been dispensed. This reduces reliance on the operator, and ensures the amount is accurate and easily repeated. Batch meters are well suited to use in food packaging applications and for adding a set amount of additive or ingredient into a mixture.

Stroke counters: A stroke counter is similar in principle to a batch meter, but specifically designed for air operated pumps. It counts the amount of times air is ejected by the pump and can turn it off once a specified number has been performed. By knowing how much fluid is transferred per stroke, it can be used for batching. However, if the viscosity of the fluid differs depending on the batch or temperature for example honey, it may be less accurate. 

Dry run protection: If a pump is left to run with no fluid passing through it, then it can overheat, cause component seizure and damage to the seals and impellers. Pauses in the production line or operators forgetting to turn the pump off can result in dry running. Some pump designs such as air operated double diaphragm (AODD) or peristaltic pumps can dry run without damage, but if using a pump that doesn’t, such as a centrifugal pump, then a dry run sensor can automatically turn the pump off when no flow is detected.

Variable speed drive (VSD): Where there are differing flow rate demands on the pump at different times, VSDs can help automate the speed of the motor to actual requirements rather than maximum capacity. They can be used to slow down or speed up the pump’s motor, and therefore the flow, depending upon the pressure detected in the system.

While these flow and level controls are all good ways to automate a pump, it is rare that a pump will utilise them all. Castle Pumps argues that the best solution will depend on what costs the most time or money in a particular process and from there it can be decided which feature will be the best fit to solve that issue.


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