At the customer's site, production is running at full speed around the clock. Before the loaders can be painted, they undergo thorough washing and pickling baths to remove all traces of oil and dirt. It's an extremely harsh environment where the pumps are constantly working with aggressive chemical mixtures with both sky-high and extremely low pH values, while the fluid is full of abrasive particles.

When the customer's existing pump reached the end of its life, the maintenance team urgently needed a reliable replacement. But the real-world requirements were tough: the new pump had to withstand the chemicals, handle the dirt and, most importantly, fit directly onto the existing baseplate and motor. Changing or rebuilding the piping system in a process that never stops was never an option for the plant maintenance team at the factory.

Our focus: Understanding the challenge from floor to management

For us at Colly Flowtech, a successful project is about making our customers' working day as safe and efficient as possible. Small details quickly become decisive factors when chemicals and mechanical wear meet during continuous operation, and we want the maintenance team on site to be able to rely on their equipment in all situations.

Our task was therefore to find the right chemical resistance while ensuring a physical drop-in pump according to the ISO 2858 standard. This allowed the maintenance team to reuse their existing baseplate and motor, without any extra time-consuming customization.

Together with our supplier Affetti Pumps, we analyzed the customer's process data and drawings to develop the optimal solution: a Affetti CGI-S plastic-lined centrifugal pump.

Below you will find the critical components that were selected to cope with the harsh process environment and secure the plant's operation.

Smart material choices for maximum reliability:

• Polypropylene (PP) pump casing and semi-open impeller: Provides superior chemical protection and high resistance to abrasive dirt particles, minimizing the risk of unexpected stoppages.
• Mechanical single seal in silicon carbide with Hastelloy retainer: A rock-solid material choice that resists wear and tear over time, reducing the need for emergency maintenance.
• Perfluoroelastomer (FFKM) O-rings: The absolute safest choice for total chemical resistance and long-term reliability.

The result: Easy installation, reduced stress and close collaboration

By aligning the drop-in pump exactly with the factory's existing infrastructure, we turned a potentially complex project into a quick and smooth routine stop.

This resulted in clear benefits at several levels of the business. This summarizes the tangible value for the operations and maintenance team in the facility:

• Relief for the maintenance team: No pipelines had to be re-routed under time pressure. The changeover went so quickly and smoothly that production could be kept on schedule.
• Economic and functional security: By reusing the base plate and motor, the customer saved both valuable time and large investment costs.
• A local partner who is on the ground: The best thing about the project is the positive feedback from the maintenance and production department. They now have a fleet of machines they can rely on and a local partner in us at Colly Flowtech who is close at hand for future support and process optimization.

The success of the preparation and technical matching is confirmed by how well the new equipment was integrated into the plant. Mattias Jansson, Product Manager Pump at Colly Flowtech, describes the project and the close cooperation as follows:

”Affetti Pumps has an incredibly innovative way of looking at solutions, nothing is impossible and the customizations requested by the customer are never a problem. In this case, we analyzed the drawings together and customized the pump for a total fit. Since all sealing options and manufacturers are available through them, it is safe to say that they do exactly what is required to meet the customer's unique needs.”

Affetti Pumps and Colly Flowtech: Flexibility that makes a difference

This project is a clear proof of how we at Colly Flowtech want to work. We are driven by delivering reliable pump solutions that simplify and secure our customers' everyday lives. Thanks to our close cooperation with Affetti Pumps, we have a very flexible and solution-oriented manufacturer behind us who shares our view of long-term relationships. No customization is too difficult, and we will do whatever it takes to ensure that you and your team have the smoothest and safest work process possible.

Secure your uptime before an expiring pump becomes a problem

Don't wait for the next emergency machine breakdown or time-consuming pipeline rebuild. By mapping your critical process pumps well in advance, we can work together to develop customized drop-in solutions that save time, money and energy when the time comes to replace them.

Take the step towards safer uptime today. Contact us for a free needs analysis of your facility.

Oskar Karlsson, Pump specialist: oskar.karlsson@colly.se

Mattias Jansson, Product Manager Pump: mattias.jansson@colly.se

Do you have a similar challenge? Maybe an application where wear and tear leads to recurring problems, high maintenance costs or unnecessary stops?