FLUX Pumps for the Industry sector

Industry

Machine and mineral oils, hydraulic fluids and industrial greases are the lubricants that keep industrial equipment running. Engine oils and cleaning and degreasing agents are essential in the automotive and aerospace industries. The diversity of the media being processed is just as broad as the range of viscosities.

FLUX is happy to provide you with personal advice, even on site, and demonstrate which filling or dispensing concept should be used for which application. We will also discuss solutions to guarantee safe and reliable operation in potentially flammable atmospheres where ATEX explosion protection is required.

Application examples

  • Adhesives
  • Brake cleaner
  • Cleaner
  • Engine oils
  • Epoxy resin
  • Glue
  • Glycerin
  • Glycol
  • Hydraulic fluids
  • Latex emulsion
  • Lime
  • Liquid wax
  • Mineral oil
  • Mold oil
  • Oils
  • Paraffin emulsion
  • Phosphoric acid
  • Polish
  • Polyester resin
  • Resin solutions
  • Sodium silicate
  • White spirit

Application descriptions

Filling gearboxes with lubricant grease

Task:
In one division of a gearbox manufacturer, various gearboxes are to be filled with lubricant greases of classes 1 to 4 in quantities of 0.4 to 1.2 litres at room temperature. The grease is removed from 200-litre drums and the transfer path is up to 2 m. The grease drips in certain cases.

Customer's requirement:
- Filling accuracy:  +/- 10 g   
- Delivery pressure:  up to 4 bar  
- Flow rate: 20 l/min
- The transfer system must be able to fill for 2 hours per unit and do so several times a day.

Solution:
Drum emptying system VISCOFLUX lite
Eccentric worm-drive pump F 550 S
Spur gear drive motor
For the application designed accessories on request

Application description:
The VISCOFLUX lite drum emptying system for pumping high-viscosity, media barely capable of flowing offers precisely the suitable solution in this case.

The drum emptying system consists of an F 550 S eccentric worm-drive pump with a gear motor, a pump eccentric crossbeam and a follower plate. The plate is positioned on the lubricant grease and sealed air-tightly against the drum wall by the process seal. The pump eccentric crossbeam is placed on the drum. Then the eccentric worm-drive pump can be guided through the opening of the crossbeam and the guide of the follower plate down to the bottom of the drum. During pumping – i.e. removal – a negative pressure arises in this manner, with the result that the follower plate sinks.

The follower plate seals so flexibly that there is almost no medium residue left on the drum wall; ultimately there have been residual quantities of less than 1% in the drum. After emptying, the follower plate is released from the bottom of the drum by compressed air. At the end of the filling hose, there is a FLUX FAE filling unit, which prevents dripping of the medium thanks to a check valve.

Filling metalworking oils and various mineral oils from vertically stacked IBCs

Task:
Filling of 10, 20 and 60-litre canisters, plus 200-l drums. Since the IBCs are vertically stacked on the shelves, they are not "top" accessible. Filling is therefore only possible via the bottom outlet.

Solution:
Drum pump F 430 TR
Commutator motor F 457
Flow meter FMO
Evaluation electronic FLUXTRONIC®
Switched-mode amplifier
For the application designed accessories on request

Application description:
Whenever containers are not top accessible – and in the case of conventional drum pumps that go into the liquid but cannot be used – our dry well installation drum pumps (TR version) are the perfect solution.

These drum pumps can be mounted vertically on the IBC using a console, or can be mounted horizontally on a pump trolley.

If our flow meter FMO with evaluation electronic FLUXTRONIC® and a switched-mode amplifier are also used, the desired fill quantity can be predefined and filling can then be done as often as required at the push of a button. The filling starts by pressing the button on the outlet unit and switches off automatically after the filling process.

For an example, see our drum and container pump brochure, page 38.

Filling industrial greases

Task:
Greases (class 2) require filling into canisters of various sizes. As little as possible of the greases should be left in the ISO lidded drum containers. The filling should be automated, in other words done using a preconfigured volume.

Solution:
Drum emptying system VISCOFLUX lite
Eccentric worm-drive pump F 550 S
Three-phase motor
Flow meter FMO
Evaluation electronic FLUXTRONIC®
Switched-mode amplifier
For the application designed accessories on request

Application description:
Our VISCOFLUX lite drum emptying system will be placed directly on the surface of the grease in the open drum. Next, our F 550 S eccentric worm-drive pump will be attached by means of a crossbeam. Filling can begin immediately after the motor is put on. The follower plate skims the grease cleanly from the drum wall. In this way, after emptying completely, a residue of less than 1% remains in the drum.

The required volume can be predefined with the additional use of our FLUXTRONIC® evaluation electronic plus FMO flow meter and switched-mode amplifier. This volume can then be filled automatically at the push of a button. Our VISCOFLUX lite drum-emptying system is ideal for quickly and easily decanting high-viscosity media and high-quality or air-sensitive substances, without pulsations.

Overall, the filling is extremely economical: there is no need to warm the medium, only a tiny residue remains and all system components are cleaned quickly.

Filling polishes from mixing vessels

Task:
As an alternative to manual removal, various boot polishes require filling into drums from different mixing vessels – in particular quicker and more cost effectively than previously.

Solution:
Drum pump F 430 S with mechanical seal
Commutator motor F 460-1
For the application designed accessories on request

Application description:
Our drum pumps are perfect for filling low-viscosity media, e.g. boot polishes, and other applications as a quick and, in particular, simpler alternative to manual filling – especially the FLUX drum pump F 430 S in stainless steel with mechanical seal.

The mechanical seal on the shaft prevents the medium from being dispersed. This means that the drum pump can be used for different polishes or media one after the other with a minimum amount of cleaning.

To remove the medium, the drum pump – at immersion depths of up to 3000 mm – is simply placed in the mixing vessel and the polish is pumped via a hose into a drum or other container.

Filling lime milk from IBCs

Task:
Lime milk requires decanting from IBCs and dispensing into various wastewater tanks. A flow rate of approx. 60 l/min. is required by the customer. The wear on a previously used centrifugal pump was too much for the customer and our solution should significantly reduce this.

Solution:
Air-operated diaphragm pump RFM 25 with flap valves
Suction tube with IBC cover
Pressure reducer
For the application designed accessories on request

Application description:
Wastewater from production is collected in a tank and then requires neutralising with lime milk.

The lime milk is now supplied by our RFM 25 air-operated diaphragm pump. Our air-operated diaphragm pumps are self-priming and safe in dry operation.

In this case, the RFM 25 was equipped with flap valves. This is an advantage for abrasive media, such as lime milk here. With its solid construction, our RFM series air-operated diaphragm pump is made from highly resistant materials and has extremely low shear forces, meaning that the wear has also been significantly reduced.

Filling of silicone oils

Task:
Various silicone oils, with a viscosity of up to 12,500 mPas require filling into sealed containers from 200 l drums. In doing so, a height of 10 metres must be overcome.

Customer's requirements:
- Flow rate: min. 20 l/min
- Mobile use required

Solution:
Eccentric worm-drive pump F 550 GS 
Commutator motor F 458-1 
Overflow valve
Hose and hose sleeve
For the application designed accessories on request

Application description:
The F 550 GS model FLUX eccentric worm-drive pumps are outstanding for high-viscosity media such as silicone oil with a viscosity of up to 30,000 mPas. Their specific gearboxes make them suitable for a relatively lightweight AC motor, making mobile use and simple operation possible.

Simply insert the eccentric worm-drive pump into the drum and filling can begin.

With positive displacement pumps, counter-pressures of up to 8 bars are possible making the 10 m delivery head and pump capacity of min. 20 l/min. required here easily achievable.

An overflow valve can be fitted to the eccentric worm-drive pump. This makes it possible to push the end of the hose off while the pump is running without critical pressures occurring in the pump/hose system.

Mixing and filling of cooling lubricants

Task:
Various cooling lubricants require filling into smaller containers from an IBC at a flow rate of approx. 80 l/min. The liquid needs to be mixed continually.

Solution:
Drum pump F 426 for mixing and/or pumping
Commutator motor F 457-1 EL 
Hose and pump nozzles
For the application designed accessories on request

Application description:
FLUX drum pumps are ideal for low-viscosity media such as cooling lubricants. Our F 426 drum pump is the perfect solution in this case where the medium needs to be mixed and/or pumped.

The F 426 drum pump is recommended for the mixing and/or pumping of diverse media. It enables media prone to rapid separation to be kept moving even during the pumping process.

The transition between "Mix" and "Pump" is performed very easily by activating a control lever which can be changed even during operation. This makes it possible to switch flexibly between the filling and mixing process.

With the F 426 drum pump, the cooling lubricants are filled into smaller containers from the IBC and are then mixed for a certain period of time to ensure that the medium is kept moving.

Vehicle refuelling with various fuels

Task:
For component testing by a large automotive group, various vehicles require refuelling for test purposes.

Solution:
Drum pump F/FP 425 Ex for 99.98% drum emptying
Commutator motor F 460 Ex 
Flow meter FMC 100 
Chemical hose
Pump nozzle
For the application designed accessories on request

Application description:
To test the suitability of individual components, various vehicles will be refuelled from 200 l standard drums with different special fuels and country-specific special fuels. Consumption and emission measurements are taken at the same time.

Our 400 series drum pumps are perfect for low-viscosity and highly flammable media such as fuels. Our F/FP 425 stainless steel drum pump is tailor made for areas subject to explosion hazards. The FLUX F/FP 425F 425 drum pump ensures 99.98% drum emptying. The non-return device on the pump prevents the medium from flowing back into the emptied drum. This means that for a 200 l drum, residues of less than 0.05 l are ensured and, thanks to optimal product use, so are reduced drum cleaning and waste disposal costs.

The filling process is performed with maximum precision and the greatest possible safety with the FMC 100 flow meter, constructed based on the disk type displacement principle and equipped with FLUXTRONIC® evaluation electronics. An additional switched-mode amplifier ensures that predefined quantities of the various fuels can be filled in a semi-automated manner.

Operators set the desired flow rate and can fill the vehicle with the medium in question at the push of a button. Once the specified fill quantity is reached, the drum pump turns off automatically. This process can be repeated continuously.

Metering of transmission oil into various gearboxes

Task:
Different small quantities of transmission oils require filling into gearboxes directly with predefined quantities.

Solution:
Drum pump F 430 S with mechanical seal
Commutator motor F 457 
Flow meter FMO 102 
FLUXTRONIC® evaluation electronics
FSV 100 switched-mode amplifier
For the application designed accessories on request

Application description:
Prior to introducing our drum pumps, the transmission oil was filled in the gearboxes by hand using oil cans but this often lacked speed.

Our F 430 S drum pumps with mechanical seal are now used. These are ideal for low-viscosity media. The mechanical seal prevents the medium from being dispersed. This means that the drum pump can be used for quite different media one after another.

Each workstation has been equipped with a semi-automatic filling system specially designed for the application in question. This consists of drum pump, motor, flow meter, FLUXTRONIC® evaluation electronics, switched-mode amplifier and solenoid valve. Each employee can now fill the predefined quantity automatically at the push of a button via the external evaluation electronics. After the filling process, the drum pump turns off automatically and the process can be repeated. This prevents over and underfilling.