Industrial Diaphragm Pump Energy Costs | Cognito

Industrial operations rely heavily on consistent, reliable fluid transfer. But for too many facilities, pump systems are quietly consuming more energy than necessary and driving up operational costs. That’s especially true with traditional pneumatic and rotary pump systems, where inefficiencies in energy use, maintenance, and downtime add up fast.

Cognito’s line of Electric-Operated Double Diaphragm (EODD) pumps offers a better way forward. Built for high-demand environments, these pumps are engineered to reduce energy consumption, support uptime, and simplify maintenance, all while helping your facility meet sustainability targets.

Outdated Pump Systems Add Up Fast

Pneumatic and gas-driven pumps are still common in many plants, but they come with a hidden energy penalty. Generating compressed air is expensive, especially when the system bleeds energy through leaks, overuse, or outdated controls. In fact, pneumatic pumps can use up to 75% more energy than EODD pumps.

Meanwhile, other technologies like rotary lobe, centrifugal, and piston pumps require expensive mechanical seals, frequent repairs, or fail under dry-run conditions. Every one of those vulnerabilities adds cost, downtime, and safety risk to your operation.

How Cognito’s EODD Pumps Cut Energy Use

Cognito’s EODD pumps are designed to address these challenges head-on.

• Fully electric — No compressed air or gas required. That alone can reduce power usage by up to 75% compared to pneumatic systems.
• Lower power draw — Up to 40–50% less energy use than piston pumps, thanks to efficient design and operation.
• Dry-run capable — The sealless construction protects the pump even when liquid isn’t present, avoiding expensive failures.
• Self-priming — Can lift fluids in suction lift applications without additional priming systems.
• Less mechanical complexity — No costly seals, packing, or flushing systems to maintain or replace. 

Real Impact in Demanding Industries

Across the industries Cognito serves, from ceramics to chemicals, these benefits translate into measurable results.

• Ceramics plants rely on Cognito pumps to move abrasive slurries without damaging the pump or the product. Less wear means longer life, less downtime, and better product quality.
  
  
• Paint and coatings operations appreciate the gentle, shear-sensitive design, which maintains product integrity while reducing energy use and maintenance demands.
  
  
• Chemical processors trust the sealless design and built-in leak detection to safely handle aggressive fluids without risking contamination or regulatory issues.

SmartInsights Means Smarter Decisions

All Cognito EODD pumps are available with SmartInsights, a remote monitoring dashboard that gives you real-time visibility into pump performance.

Monitor key metrics like flow, pressure, and temperature from anywhere. Set alerts for preventive maintenance. And compare energy use across systems or facilities to find opportunities for improvement.

With SmartInsights, you can make data-driven decisions that help reduce downtime and energy waste.

Built for Long-Term Value

Energy efficiency is just one part of the value story. Over time, Cognito’s EODD pumps deliver savings across the board:

• Lower energy bills
• Fewer maintenance interventions
• Longer pump lifespan
• Reduced downtime
• Faster ROI—typically within 12–24 months

Fewer breakdowns and simpler part replacement reduce unplanned downtime and free up resources for proactive maintenance. A lower total cost of ownership turns the switch to EODD pumps into a long-term performance gain. And the significant energy savings help support environmental targets without sacrificing output.

Start Cutting Energy Waste at the Source

Traditional pump technologies are no longer the default for industrial operations that prioritize uptime, efficiency, and sustainability.

Cognito’s EODD pumps are engineered for today's energy and environmental demands—and backed by decades of diaphragm pump innovation from Warren Rupp.

Talk to a Cognito expert today to discuss your facility’s energy goals and see how our pumps can help you achieve them.

Pump specifications may vary by region. Please contact your local sales team for more information.