In corrugated packaging production, wastewater handling directly affects uptime, safety, and energy use. When sumps fail, the impact moves fast, from flooded floors to damaged paper stock to lost production hours. One major corrugated packaging producer learned this the hard way after repeated pump failures turned a routine process into a daily operational risk.
By replacing conventional pump technology with Cognito’s electric double diaphragm (EODD) pump solution, the plant stabilized wastewater transfer, cut energy use dramatically, and removed safety hazards tied to flooding. The results were immediate, measurable, and sustained, reinforcing the value of modern sealless pump technology in demanding environments.
Heat, Solids, and a Sump Environment That Breaks Conventional Pumps
Corrugated packaging lines rely heavily on steam. As that steam condenses, it creates high-temperature wastewater approaching 225 degrees Fahrenheit. At the same time, routine washdowns from double backers and double facers introduce starch, glue, fibers, and oil into the system. All of this drains into industrial sumps before moving on to treatment.
Centrifugal pumps were originally installed to manage this duty. Over time, their limitations became apparent under these operating conditions.
High temperatures degraded mechanical seals. Solids caused wear and blockages. Dry running accelerated damage when sump levels dropped unexpectedly. Each failure increased the likelihood of overflows, which soaked finished paper rolls and created slip hazards on the plant floor. Material losses rose, while maintenance teams stayed in reactive mode.
AODD Pumps Solved One Problem and Created Another
To address heat and solids, the facility installed air-operated double diaphragm pumps. From a process standpoint, these industrial diaphragm pumps moved fluid reliably and tolerated harsh conditions better than centrifugal units.
The issue was how they operated.
Because the AODD pumps ran continuously, they pulled compressed air even when the sump was empty. That constant draw strained compressors and pushed energy costs higher. Around-the-clock operation also shortened pump life, which brought maintenance concerns right back into the picture.
The plant needed a solids-handling pump that could handle the application and operate only when required.
Reliable Sump Transfer Through Float-Controlled EODD Pumps
Cognito recommended a 2" stainless steel EODD pump fitted with Santoprene diaphragms and controlled by an automatic float switch. This configuration was selected specifically for high-temperature wastewater with suspended solids and a low daily duty cycle.
The float switch activates the pump only when sump levels rise. Once the water is cleared, the pump shuts off. There is no idle running and no unnecessary power draw.
This approach aligned the pump’s operation with the actual process demand, which eliminated overflows while avoiding the penalties of continuous operation.
Measurable Results That Mattered on the Plant Floor
The impact of the upgrade was clear and quantifiable:
- Energy use dropped by 80% compared to continuously running AODD pumps
- Sump overflows stopped completely after installation
- No paper rolls have been damaged by wastewater since the change
- Maintenance demands fell to near zero
- Compressor load decreased by 20 HP per pump
These outcomes delivered a strong pump upgrade ROI while stabilizing production and improving reliability.
Why the Solution Worked Across Multiple Roles
For maintenance teams, the sealless design eliminated high-temperature seal failures and removed a frequent source of leaks. Safer floor conditions followed, along with fewer emergency repairs.
For facility and operations managers, float-controlled operation meant pumps only consumed power when needed. That reduced ongoing utility costs and eased strain on compressed air systems.
For reliability engineers, the low-duty cycle extended mean time between failure and stabilized uptime in a process that had previously been unpredictable.
Each group saw value because the solution addressed root causes rather than symptoms.
A Proven Approach to Wastewater Sump Reliability
This corrugated packaging producer replaced failing centrifugal and inefficient AODD pumps with a wastewater sump pump built for heat, solids, and intermittent operation. Cognito’s electric double diaphragm pump delivered immediate ROI by reducing energy demand, preventing material losses, and supporting safer working conditions.
If your facility still relies on equipment that runs nonstop or fails under heat and solids, it may be time to reassess.
Learn directly from the experts behind Cognito. Visit the training calendar and schedule your session today.
Pump specifications may vary by region. Please contact your local sales team for more information.
