In our modern world, adhesives are everywhere – from packaging and automotive parts to electronics and home goods. Without these sticky substances, a multitude of products would quite literally fall apart. But behind the scenes, there's a critical component ensuring adhesives are manufactured efficiently and effectively: the pump.
The Critical Role of Pumps in Adhesive Manufacturing
Adhesive manufacturing is a complex process. It involves mixing solvents, catalysts, and resins to create a finished product that is both functional and reliable. One of the key players in this process is the pump – specifically, the positive displacement air-operated double-diaphragm (AODD) pump.
However, the process of making adhesives is not without its challenges. Adhesives, by their very nature, are sticky and viscous, which makes them difficult to handle. This stickiness can lead to a range of issues for the pumps involved in their production.
The Challenges of Adhesive Production
One of the most significant challenges in adhesive manufacturing is dealing with the buildup of adhesive material on pump components. Traditional AODD pumps have a design that includes an outer piston, which is prone to accumulating adhesive residue. This buildup can lead to several problems:
Clogging: Hardened adhesive bits can clog filters, pipes, and other parts of the system.
Performance Issues: Buildup can reduce the pump's efficiency or cause it to stall.
Wear and Tear: Increased buildup can lead to premature wear on pump components, such as balls, seats, and diaphragms.
Maintenance Hassles: Removing adhesive buildup often requires manual cleaning methods like hammers and chisels, which are both time-consuming and labor-intensive.
In the worst-case scenario, excessive buildup can lead to premature pump failure, increased maintenance costs, and potential safety hazards if a leak occurs.
Enter the Wilden® Chem-Fuse™ Integral Piston Diaphragm (IPD)
To address these issues, Wilden® developed the Chem-Fuse™ Integral Piston Diaphragm (IPD), a next-generation diaphragm designed specifically for the challenges of adhesive manufacturing. Unlike traditional two-piece diaphragm designs, the Chem-Fuse IPD encases the outer piston within the diaphragm material itself.
Here’s how the Chem-Fuse IPD solves common adhesive pump problems:
Reduced Buildup: The design minimizes the potential for adhesive buildup by encapsulating the outer piston, significantly reducing the chance of residue formation.
Enhanced Durability: Made from Wil-Flex™, Bunalast®, and non-food grade Saniflex™, materials known for their excellent flex lives, chemical resistances, and abrasion resistances, the Chem-Fuse IPDs offer longer service life and lower maintenance costs.
Easier Cleaning: The design simplifies the cleaning process, facilitating faster product changeovers and reducing downtime.
Increased Reliability: By eliminating potential leak points and failure-causing abrasion areas, the Chem-Fuse IPD extends the lifespan of the diaphragm and improves overall pump reliability.
Why Chem-Fuse IPDs Stand Out
The Chem-Fuse IPD is not just another diaphragm on the market. It boasts full-length shafts that provide the same performance as standard diaphragms but without the drawbacks. Unlike other IPDs that require a shorter stroke, which can reduce flow and suction-lift capabilities, the Chem-Fuse IPD maintains high performance even with very viscous fluids.
Additionally, Chem-Fuse diaphragms are cost-effective. Constructed from Wil-Flex™, Bunalast®, and non-food grade Saniflex™ they are 50% less expensive than PTFE-laminate models and compatible with Wilden Pro-Flo® and Pro-Flo® SHIFT pumps across various sizes and temperatures.
Conclusion
Adhesives play a vital role in countless industries, and their production relies heavily on the right pumping technology. Wilden Pro-Flo and Pro-Flo SHIFT AODD Pumps, equipped with the Chem-Fuse Diaphragms, represent a significant advancement in handling adhesive manufacturing challenges. By reducing product buildup and improving pump efficiency, the Chem-Fuse IPD makes the manufacturing process safer, more efficient, and more reliable.
For more information, read the whitepaper: The Best AODD Pump Diaphragm for Eliminating Product Buildup.