Knoll Maschinenbau GmbG

Archiv for: Cosmetics

Interpack Trade Show: What KNOLL will exhibit

From 12 to 18 May 2011 interpack trade show will be held in Duesseldorf (Germany). KNOLL Maschinenbau will be participating, our booth can be found in hall 4, stand 4E05. You are cordially invited to visit our booth. Pumps from KNOLL do fit very well to the “world’s most important trade fair for the packaging sector“, as it adresses also all things processing.

The wider focus on processing issues is of interest for companies in the food and beverage, pharmaceuticals and cosmetics. It offers a holistic view on the process chain featuring all aspects on processing, metering and finally packaging.

KNOLL Maschinenbau will introduce its new double spindle pump DSP. In addition, the pumps of the MX-series will be shown, including a new feature on the drives: a MX10 with stainless steel drive. Of course, all important models of the MX will be presented, too. Among them a version with double jacket for temperature control, a hopper version and of course a submerged version (for tank drainage).

All in all it may be worthwhile to stop by at KNOLL Maschinenbau in hall 4. You are very welcome and we look forward to meet you at interpack in Duesseldorf!

Cleaning Pumps Inside and Outside

Pumps need to be cleaned easily. But in most cases attention is paid only  to the interior of the pump while the pump housing and the drive get much less attention. In the American Food Industry there is an ever increasing demand on general hygiene that is being extended to the exterior of the pumps. It is now as important for the exterior of the pump to  be cleaned as easily as the interior.

Because of this requirement, pumps must be cleanable with high pressure cleaners. For instance, pumps cannot have painted parts that would discourage high pressure washing. This requires smooth outer contours without dead spaces, so that no dirt traps or residues of cleaning fluids occur. In addition the atmosphere side surfaces of the pump need to be corrosion resistant to aggressive cleaning agents.

KNOLL Maschinenbau can meet all of these requirements with its MX progressing cavity pump: The MX is designed completely in stainless steel, which also applies to the stator jacket and the drive. There are no covers on the drive. Covers normally accumulate a lot of dirt and are unsuitable for very hygiene-sensitive work environments. As a drive in stainless steel, gear, servo and stepper motors are offered, so that a wide range of use cases can be covered.

In addition, the MX from KNOLL Maschinenbau maintains the highest degree of internal sanitary standards (CIP and SIP) – like in the standard model. As a consequence this progressive cavity pump is ready not only for food industry, but may as well assist in pharmacy, biochemistry and cosmetics in order to meet highest hygiene requirements.

KNOLL’s MX-Pumps Meet the 3-A Sanitary Standards

The progressing cavity pumps from KNOLL Maschinenbau correspond now to the 3-A Sanitary Standard (United States of America). In addition to the EHEDG-certification the MX-Pumps now meet another very important standard of hygiene. This underlines once again the suitability of this pump for applications under the most stringent hygiene requirements.

The 3-A Sanitary Standard  goes back to the 3-A Organization founded in 1920, which was a merger of three non-profit organizations. The goal was to establish criteria for the equipment and thus the product quality of dairies. This was intended to protect the health of consumers of dairy products. Since 2002, there is also the 3-A Sanitary Standard Inc. as a subsidiary organization of the 3-A, defining mandatory standards and monitoring any compliance with them. The work of the 3-A organization is widely recognized outside the USA and no longer just used in the production of milk, but, for example in the pharmaceutical field, too.

The certification due to 3-A primarily relies on the structural features, namely the structural design, surface quality and the materials used (for example the elastomers). Even the manufacturers of the seals must comply with this and prove certification of their products. This even extends to the level of staff members involved in the production: They must be certified for certain activities themselves.

This method of certification differs fundamentally from a certification due to EHEDG, where the pump is running a trial subjected to practically similar circumstances as appearing in normal production cycles.

A special feature of the MX-Pump from KNOLL is the fact that it has received certification to 3-A in its standard version, only with very minor modifications, covering the series MX20, MX30 and MX50. For buyers of such pumps this brings a significant price advantage, as in most cases no (expensive) supplementary parts are needed. Moreover, the supply of spare parts can be kept easier and faster because the required high quality already is included in the standard version of the series.

Pumping and Tempering Sensitive Media

Today many manufacturing processes are not possible without the use of pumps. And often not only the role of pure pumping, but also tempering is important, as the transport media must be kept on a very specific temperature level. The pump must therefore be able to temper – which means cooling or heating due to the specific process.

In the case of sensitive goods in transit it must be ensured that they do not get into contact with the tempering media. Any contamination must be ruled out. KNOLL Maschinenbau has therefore  specially designed its MX progressive cavity pumps, so that tempering with steam, water or oil is possible without contamination of the sensitive transport media.

In order to achieve this a double jacket on the suction housing as well as on the pump assembly gets applied. This solution offers several advantages:

  1. High pressure stability: The double jacket keeps up with a pressure of up to 5 bar, for example when the pump gets tempered in the context of an overall tempering of pipes and containers.
  2. Good tempering properties: The stator in EvenWall-design provides a relatively large surface area with even elastomer wall thickness and thus very good characteristics for tempering.
  3. Extremely easy to service: Even when fitted with the double jacket for tempering the MX from KNOLL remains an extremely easy to service pump because all parts are still equally accessible.
  4. Stator-Relining: If there is wear on the stator, it can be reprocessed. For this, the elastomer used is burned out, so that the stator shell can be used for a re-vulcanization. Cost savings and protection of the environment are the consequences.

Finally, it should be mentioned that this progressive cavity pump offers high efficiency and carries only very little heat on its transport medium. Therefore heating will practically not occur, so that a “well-tempered” pumping and transport operation is guaranteed with the MX from KNOLL Maschinenbau.

KNOLL’s MX with EHEDG Approval

For machinery and equipment that are used in the production of food, compliance with EHEDG (European Hygienic Engineering & Design Group) is a mandatory standard which has gained wide application even beyond Europe. This is also true for pumps used in food production.

The basic aim of the EHEDG directive is to prevent the microbial contamination of food. Thus, the microbiological safety and quality of the food is taken into account. The guidelines relate to the structural design, surface finish, the materials used, cleaning ability and the prevention of penetration and the growth of microorganisms in the machinery and equipment.

As we’ve reported here on the blog, the MX-Pump is certified to EHEDG. KNOLL Maschinenbau was awarded the accompanying certificate in June 2010. A remarkable design feature of the pump was noted during the examination by the Research Centre Weihenstephan for Brewing and Food Quality of the Technical University (TU), Munich. It’s the fact that the MX, thanks to its aseptic design, usually is cleaned without an additional CIP-Pump.

Therefore bypasses and valves can be omitted. In most cases these only form unwanted dead spaces, which get traversed only in the cleaning process.

A further  hygienic advantage is the self-cleaning effect oft the MX-Pump: For emptying the pump its suction casing is fitted with a special suction nozzle that is welded horizontally and tangentially, so that the effect of self-draining occurs on the suction housing as well as on the progressive pressure joint.

The Benefits of Progressive Cavity Pumps Compared to Other Pumping Systems

When a new manufacturing plant gets planned or an existing plant needs to be modernized, often the question of the right pumping system is taken into consideration: What type of pump is the correct one? The following list speaks in favor of the progressive (progressing) cavity pump:

  1. Gentle conveying of the medium: the pumping chambers in the pump assembly remain constant, so that the product gets neither crushed nor sheared. The non metal to metal contact of the progressive cavity principle is far superior when pumping abrasive particles in suspension.
  2. Different viscosities are equally well served: From low to high viscosity media the progressive cavity pump handles everything, even thixotropic or entrained air fluids. This makes it extremely flexible and versatile in its range of applications.
  3. No backflow into the pump: When stopped the progressive cavity pump closes like a slider (valveless pump) so that practically no backflow returns to the pump.
  4. Very good suction performance: With its excellent suction performance this pump is the right choice for emptying barrels, mixers and containers of all kinds (big bags). Progressing cavity pumps from KNOLL Maschinenbau offer a negative pressure of up to 0.2 bar absolute, when fitted as suction, submergible and following plate version.
  5. Metering accuracy: Due to low pulsation the progressive cavity pump offers very exact metering. An additional valve is not required.
  6. Linear characteristic curve: Since there is no backflow into the pump, the flow rate is increasing always proportional to the speed. Thus, the optimal efficiency of this pump extends over a very wide range.
  7. Suitable for high pressures: Progressing cavity pumps from KNOLL achieve a pressure increase of up to 80 bars, which makes them an interesting proposition for sophisticated engineering. The higher pressures are desirable for moving product greater distances and for applications involving extrusions.

The MX-Pumps from KNOLL therefore are used in a wide range of  different applications. Here is a selection of media that will be optimally promoted by this progressive cavity pump:

  • In the food and beverage industry: dairy products, raw and cooked vegetables, fruit mash, concentrates (eg juices), liquid egg dough, color and flavor, butter, cooked dishes, raw and auxiliary materials and finished materials for the confectionery industry, chocolate (with and without lumpiness), animal food;
  • In chemistry, biochemistry, pharmaceuticals and cosmetics: paints and coatings, resins, waxes, adhesives, raw and auxiliary materials for the pharmaceutical industry, peels, cosmetic products (including products for organic and natural cosmetics).

Emptying Barrels containing Highly Viscous Media

High viscosity media are often stored in drums and must be retrieved from these for further processing. Since they can be so tough that there is no subsequent flow, special precautions have to be taken to make sure that their drum gets fully voided. Examples include ointments, pastes, greases, resins, silicones and adhesives. In the production of foodstuff highly viscous materials also appear: Peanut butter, tomato paste or dough are typical examples.

For these purposes KNOLL Maschinenbau offers its progressing cavity pump MX as submerged version for easy drainage of drums, mixers, agitators and big bags. The particular advantage of this type of pump is it that it can both transport tough to semisolid media and meter them while emptying the barrel except for very small rests. In addition to that transportation over relatively long distances with at the other end an exact placing in smaller containers is no problem. The MX-Pumps provide the pressure that is necessary in such situations, ranging from no pressure at up to 40 Bar.

The construction of the pump can follow very individual needs. A pneumatic control can be included (or omitted), as well as temperature regulation (heating for very high viscous media). In addition, the entire structure will be adapted to the size of the container to be emptied, so that both, normal 200-liter barrels, as well as smaller containers can be operated.

For the core of the system, the progressing cavity pump MX apply, of course, all the benefits of this series of pumps: Very good cleaning ability with intelligent separation points for easy disassembly and assembly as well as readiness for cleaning-in-place (CIP capability), gentle and low-pulsation conveyance of the cargo and the handling of high pressure due to the EvenWall technology, to name only a few.

In practical use the following plate is placed and fixed directly on the transport medium. Once the pumping starts, the following plate is moved down by using a pneumatic cylinder.

Seals between the plate and tap ensure that the cargo can escape only through the pump. The geometry of the following plate and the setting of the end points an almost complete emptying of the drum is reached. At the end of a discharge process, the follower plate is put back into its original position. It can then be easily cleaned or replaced.

Liquids, Metering Precision and Knoll’s MX Progressing Cavity Pumps

One of the main goals concerning the volumetric metering of aqueous to highly viscous liquids in containers (packages) is to achieve a high level of reproducibility. In Europe for example manufacturers of all industries have to comply with the (Council) Directive relating to the making-up by weight or by volume of certain prepackaged products.

Certain tolerances have to be respected, but of course not only for legal reasons: The metering accuracy is crucial to metering quantities and therefor for manufacturing costs. The smaller the tolerance, the smaller the fill quantity can be set.

The image (above) shows a “mono-pump” filling machine (named MFL) by Bünder & Schmitt, in which the MX-Pumps in CIP-capable version are employed. Such filling machines are used for example by Henkel or Bayer for filling of cleaning materials and pesticides.

The KNOLL MX progressing cavity pumps are highly competent in metering. In addition to the precise metering not only incompressible but also compressible fluids can get pumped without changing the structure of medium. A key feature is the standard set EVEN WALL (even elastomer wall thickness) which gives the MX-pump an absolutely precise and uniform sealing line. The precision of the sealing line helps to increase the quality of the reproducibility of the flow even under alternating pressure. Further it helps significantly to keep pulsation low.

So very shear sensitive media can be transported easily as they get prevented from damage by the EVEN WALL construction and the precise sealing line. In some cases heat input plays an important role. It is considerably lower in MX-pumps with their EVEN WALL stator compared to pumps with conventional cylindrical stators.

Another criterion which is important for metering, is the resistance of the materials not only for liquids to be pumped but also for the cleaning media and their temperatures. For this reason numerous materials are available from KNOLL, each corresponding to the fluids and carefully selected by our qualified laboratory.

Accessories used in the pump decide just as much on the level of metering accuracy as the metering pump itself. For each single request the necessary measurement and control technology gets individually designed and verified, so that a constant metering is demanded of a once calibrated pump or a simple on measured values dosage is, extensive accessories by KNOLL available.

Depending on the task, step motors, servo motors or induction motors can be used to support the MX-Pump in their exact metering.

The graph (above) shows the level of precision obtained in the measurement of a MX-Pump (for larger display click on the image). The idea was to code the amplitude and to measure its exact position with the help of a stepper motor and an encoder in order to be able to compensate it on the metering. Turned out that the metering was so extremly precise that it could get run without the encoder.
In practice MX-Pumps are already used in numerous cases where liquid amounts of a fraction of a drop have to be dosed under variances in viscosity, temperature and pressure.

Progressing Cavity Pumps for the Cosmetics Industry

Cosmetics, Perfumes and Toileteries are very demanding in their manufacturing process. The materials to be used must be handled carefully and of course a maximum of hygiene is indispensable. KNOLL’s progressing cavity pump MX can unfold its full potential here: It promotes special care commodities, whether they are based on mineral oils or vegetable (herbal) nature.

That’s why you will find the MX for example in the manufacturing of natural cosmetics. There it is especially important that the natural and therefore very sensitive ingredients get conserved the best possible way. The MX can be used either for draining or as transfer pump. The particular advantage in the field of primary products is its capacity of virtually non-destructive transportation of solids in the fluid transport: For example a basic product may contain pieces of (wooden) roots. The MX can pump it without any abrasion. Also finished products with abrasive components such as peelings are not a problem for the MX either.

Another important advantage of KNOLL’s MX-Pump: It can be easily and quickly cleaned (CIP and SIP) due to its special design. Clamp locks facilitate disassembly and assembly. Wear parts are to be replaced without delay via an interface opposite the product. The components of the MX fit logically into one another, so that when assembled after disassembly no “puzzle” of small parts occurs. Of course the MX series is designed and manufactured according to current GMP and EHEDG rules.

The foto shows the MX in a vertical arrangement, as used for emptying drums, mixers, agitators and big bags. KNOLL offers additional components that facilitate the pumping of high-viscosity and lumpy media.

The MX is generally made of stainless steel, but can also be carried out in other materials following customer specifications. KNOLL’s range of progressing cavity pumps therefore can serve a broad application area in the cosmetics industry.