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Bottom-line benefits of product recovery
18
Applications
WORLD PUMPS
January 2015
General processing
Bottom-line benefits of product recovery R
educing waste is critical for manufacturers in a range of industries from food and drink to pharmaceuticals. While many manufacturers turn to greater energy efficiency, innovative fluid-transfer methods now mean it is possible to achieve far greater savings than through other process improvements.
Product waste is one of the areas in hygienic manufacturing where extremely high costs are being incurred. The McKinsey Quarterly Food Waste Alliance has reported that more than US$120 bn of product goes to waste worldwide annually. The Natural Resources Defense Council (NRDC) also estimates the United States is losing 40% of its food from farm to fork to landfills.
Key focus The term ‘product recovery’ can relate to a number of different operations in hygienic manufacturing, but a key focus is raw ingredients or intermediate/finished products that may remain in the suction or discharge fluid-transfer lines at the end of production runs or between product changeovers. One specific type of pumping technology, positive displacement eccentric disc, possesses the line-stripping and
product-recovery capabilities necessary to help save hygienic manufacturers hundreds of thousands of dollars per manufacturing site annually. That means manufacturers have the potential to save millions of dollars annually in recovered, and still marketable and consumable end-products. There are many critical areas within a hygienicmanufacturing operation where fluid transfer is required. When transfer pumps are unable to adequately strip suction or discharge production lines, costs including energy and labor can spiral. For many years, standard manufacturing processes have included lobe, external circumferential piston (ECP), centrifugal, hose and progressive cavity-style pumps. While these technologies do perform the basic pumping task, lobe and ECP pumps, for example, do not possess the ability to adequately strip suction or discharge lines.
Hygienic manufacturing operations in the food and beverage, pharmaceutical and cosmetic industries offer many areas where product recovery can be optimized with the use of Mouvex® Eccentric Disc Pump technology, such as the SLS Series pumps.
Traditional pumps also wear constantly, which increases internal clearances over time resulting in product slip, reducing flow capacity and volumetric efficiency as operating pressures and fluid viscosities vary. Mouvex, a leading brand of positive displacement pumps from PSG, a Dover Company, has established itself as a leader in eccentric disc pump technology. The key is that it operates via a disc that moves on an eccentric plane within a circular channel, which gives the pump the ability to provide non-pulsing, low-slip operation with high volumetric consistency.
Mouvex Eccentric Disc Pumps are so efficient and versatile that they are able to pump air even when no fluid is present, which enables them to completely and safely clear both suction and discharge lines during hygienic pumping processes.
www.worldpumps.com
Flow rates This design also means that flow rates vary minimally with changes in viscosity, 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved
WORLD PUMPS
Applications January 2015
temperature, system back-pressure and even component wear. The Mouvex eccentric disc pumps can also pump air when no fluid is present so surface tension on any remaining fluid is not broken. Because the eccentric disc pump moves to the purging process by using air that is already in the feed tank, there should be no issues with maintaining product purity. The upshot of using eccentric disc pump technology for product-recovery applications within hygienic manufacturing operations results in product-recovery rates of 60-80 % or more.
Six figure savings
recovery. In large production operations, the savings can result in millions of dollars per year. Mouvex® is a registered trade mark of PSG, a Dover company.
Slip with some wear*
Dry priming
Wet priming low viscosity
Uses dynamic seal
Hygienic design
www.psgdover.com/product-recovery
Slip with change pressure*
to 80% and a bakery firm that is recovering the filling used in pastries. Reducing the operating costs in a manufacturing facility will be a major concern for plant managers for the foreseeable future. Operators would be wise to determine how much in cost savings can be realised in targeted product
0.23 gallons 8.3 lbs. 100 ft. 191 lbs. 134 lbs. $1.00 $134.00 $670.00 $2,680.0 $32,160.00
Slip with change viscosity*
Eccentric Yes Movement Progressive cavity No dry run Gear pump No Lobe pump No Circumferential No piston Sine style No Vane pump Yes
Product Per Foot with 2.5" Line Diameter Weight (Pounds per gallon) Discharge Distance (ft.) Total Weight (lbs.) Product Recovered (lbs.) at 70 % Recovery Rate Price Per Pound Total Cost Savings Per Day Cost Savings Per Week (×5 days) Cost Saving Per Month (×4 weeks) Cost Saving Per Year (×12 months)
Slip when new
Product recovery capability
Rotary pump type
Examples of six-figure savings include two global yogurt companies which recorded product recovery rates of up
Product-recovery cost savings per eccentric disc pump
Very low
Very low
Very low
Very low
Very good
Very good
No
Yes
Low Medium High
Medium Excessive Excessive
Medium Medium Poor
Medium High High
No Poor** No
Good Medium** Poor**
Yes Yes Yes
Some No Yes
Medium
Excessive
Medium
High
Poor
Medium**
Yes
Yes
Medium Low
Excessive Low
Medium Low
High Low
Medium** Good
Medium** Good
Yes Yes
Yes No
* Effect on slip assuming the pump has been in service a few weeks/months and is at 50% of life of parts. ** Typically will need to accelerate the pump to prime compared to product flow rate.
www.worldpumps.com
19
Applications
WORLD PUMPS
January 2015
General processing
Bottom-line benefits of product recovery R
educing waste is critical for manufacturers in a range of industries from food and drink to pharmaceuticals. While many manufacturers turn to greater energy efficiency, innovative fluid-transfer methods now mean it is possible to achieve far greater savings than through other process improvements.
Product waste is one of the areas in hygienic manufacturing where extremely high costs are being incurred. The McKinsey Quarterly Food Waste Alliance has reported that more than US$120 bn of product goes to waste worldwide annually. The Natural Resources Defense Council (NRDC) also estimates the United States is losing 40% of its food from farm to fork to landfills.
Key focus The term ‘product recovery’ can relate to a number of different operations in hygienic manufacturing, but a key focus is raw ingredients or intermediate/finished products that may remain in the suction or discharge fluid-transfer lines at the end of production runs or between product changeovers. One specific type of pumping technology, positive displacement eccentric disc, possesses the line-stripping and
product-recovery capabilities necessary to help save hygienic manufacturers hundreds of thousands of dollars per manufacturing site annually. That means manufacturers have the potential to save millions of dollars annually in recovered, and still marketable and consumable end-products. There are many critical areas within a hygienicmanufacturing operation where fluid transfer is required. When transfer pumps are unable to adequately strip suction or discharge production lines, costs including energy and labor can spiral. For many years, standard manufacturing processes have included lobe, external circumferential piston (ECP), centrifugal, hose and progressive cavity-style pumps. While these technologies do perform the basic pumping task, lobe and ECP pumps, for example, do not possess the ability to adequately strip suction or discharge lines.
Hygienic manufacturing operations in the food and beverage, pharmaceutical and cosmetic industries offer many areas where product recovery can be optimized with the use of Mouvex® Eccentric Disc Pump technology, such as the SLS Series pumps.
Traditional pumps also wear constantly, which increases internal clearances over time resulting in product slip, reducing flow capacity and volumetric efficiency as operating pressures and fluid viscosities vary. Mouvex, a leading brand of positive displacement pumps from PSG, a Dover Company, has established itself as a leader in eccentric disc pump technology. The key is that it operates via a disc that moves on an eccentric plane within a circular channel, which gives the pump the ability to provide non-pulsing, low-slip operation with high volumetric consistency.
Mouvex Eccentric Disc Pumps are so efficient and versatile that they are able to pump air even when no fluid is present, which enables them to completely and safely clear both suction and discharge lines during hygienic pumping processes.
www.worldpumps.com
Flow rates This design also means that flow rates vary minimally with changes in viscosity, 0262 1762/15 © 2015 Elsevier Ltd. All rights reserved
WORLD PUMPS
Applications January 2015
temperature, system back-pressure and even component wear. The Mouvex eccentric disc pumps can also pump air when no fluid is present so surface tension on any remaining fluid is not broken. Because the eccentric disc pump moves to the purging process by using air that is already in the feed tank, there should be no issues with maintaining product purity. The upshot of using eccentric disc pump technology for product-recovery applications within hygienic manufacturing operations results in product-recovery rates of 60-80 % or more.
Six figure savings
recovery. In large production operations, the savings can result in millions of dollars per year. Mouvex® is a registered trade mark of PSG, a Dover company.
Slip with some wear*
Dry priming
Wet priming low viscosity
Uses dynamic seal
Hygienic design
www.psgdover.com/product-recovery
Slip with change pressure*
to 80% and a bakery firm that is recovering the filling used in pastries. Reducing the operating costs in a manufacturing facility will be a major concern for plant managers for the foreseeable future. Operators would be wise to determine how much in cost savings can be realised in targeted product
0.23 gallons 8.3 lbs. 100 ft. 191 lbs. 134 lbs. $1.00 $134.00 $670.00 $2,680.0 $32,160.00
Slip with change viscosity*
Eccentric Yes Movement Progressive cavity No dry run Gear pump No Lobe pump No Circumferential No piston Sine style No Vane pump Yes
Product Per Foot with 2.5" Line Diameter Weight (Pounds per gallon) Discharge Distance (ft.) Total Weight (lbs.) Product Recovered (lbs.) at 70 % Recovery Rate Price Per Pound Total Cost Savings Per Day Cost Savings Per Week (×5 days) Cost Saving Per Month (×4 weeks) Cost Saving Per Year (×12 months)
Slip when new
Product recovery capability
Rotary pump type
Examples of six-figure savings include two global yogurt companies which recorded product recovery rates of up
Product-recovery cost savings per eccentric disc pump
Very low
Very low
Very low
Very low
Very good
Very good
No
Yes
Low Medium High
Medium Excessive Excessive
Medium Medium Poor
Medium High High
No Poor** No
Good Medium** Poor**
Yes Yes Yes
Some No Yes
Medium
Excessive
Medium
High
Poor
Medium**
Yes
Yes
Medium Low
Excessive Low
Medium Low
High Low
Medium** Good
Medium** Good
Yes Yes
Yes No
* Effect on slip assuming the pump has been in service a few weeks/months and is at 50% of life of parts. ** Typically will need to accelerate the pump to prime compared to product flow rate.
www.worldpumps.com
19