Energy bills are rising, regulations are tightening, and pressure is on for industrial leaders to slash consumption, cut emissions, and keep operations running reliably and profitably.
“Five years ago, energy saving was optional. But today it’s essential – driven by stricter regulations and rising operational pressure that make efficiency a necessity rather than a choice,” says Sapan Kumar, Cognito Business Development Manager for Southeast Asia and China. “As a result, energy reduction is one of the most important things for any industry right now.”
At Cognito, we understand these evolving challenges deeply. Our Electrically Operated Double Diaphragm (EODD) pumps represent a strategic shift toward smarter, cleaner, and more cost-effective fluid transfer for a variety of industries, including ceramics, packaging, paints, and chemicals.
The Industrial Energy Challenge
For decades, pneumatic air-operated double diaphragm (AODD) pumps have been the standard across many industries. However, the hidden inefficiencies in these systems are increasingly unsustainable:
- High Energy Consumption: Generating compressed air is costly. Pneumatic pumps have significant hidden operating costs that accumulate quickly over long duty cycles, especially when compared to the efficiency of EODD systems.
- Rising Regulatory Pressure: ISO 50001 certifications, corporate ESG goals, and local decarbonization mandates require facilities to adopt more efficient systems.
- Maintenance Downtime: Pneumatic pumps are prone to leaks, pulsation-related vibrations, and component wear, leading to unplanned shutdown
Quantified Energy Savings You Can Trust
Consider a typical ceramics plant operating pumps for 12-16 hours a day. A leading global ceramic manufacturer reported a 74% reduction in energy costs after switching from AODD to Cognito’s EODD pumps, achieving payback in under a year.
Here’s why:
- Air Generation Costs Eliminated ✔ Pneumatic pumps require significant energy from compressed air.
- Higher Flow Per Cycle ✔ Cognito’s patented diaphragm design pumps more fluid with each stroke.
- Variable Speed Operation ✔ The Variable Frequency Drive (VFD) allows operators to adjust pump speeds precisely to demand.
For applications like glue transfer in corrugated packaging (18-20 hours/day operations) or paint manufacturing, where energy savings impact cost per unit produced, switching to EODD pumps yields immediate and measurable results.
What Sets Cognito’s EODD Pumps Apart
1. Smart Engineering for Rugged Performance
Cognito’s EODD pumps are designed to operate efficiently under extreme conditions. They feature bigger & robust patented diaphragms that allow for higher flow per stroke, reducing pump speed and increasing diaphragm life
2. Built for Sustainability
- 60-75% energy savings compared to pneumatic pumps.
- The VFD allows for speed modulation to ensure only necessary energy is used.
- Lower energy draw directly translates to reduced emissions and operational costs.
- Sealless pump with safety features like leak detection sensors & secondary static seals, eliminates the direct contact with process fluids.
- Designed seat & stopper cage arrangement increases the life of the manifolds.
3. Digital Control & Smart Monitoring
Our remote monitoring allows for quick decision-making and minimized downtime. Cognito’s EODD pumps are IoT-enabled and provide operators with:
- Real-time performance data
- Energy consumption tracking
- Predictive maintenance alerts
- Integration with SCADA, PLC, and DCS systems
4. Robust Construction
Backed by 60 years of design experience, Cognito pumps withstand aggressive chemicals, abrasive slurries, and harsh environments. Their sealless design eliminates leaks common in other technologies, while the built-in dampener facilitates a pulsation-free flow that reduces pipe vibrations and improves process accuracy.
Operational Advantages Beyond Energy
Cognito’s EODD pumps provide a range of operational benefits that enhance plant performance and reliability. Their sealless design reduces component failures and lowers maintenance costs, while fewer spare parts are needed compared to screw, piston, or lobe pumps, simplifying maintenance routines.
The result is shorter mean time to repair (MTTR) and higher mean time between failure (MTBF), which ensures less downtime and more consistent uptime. The pumps’ leak sensors detect and contain leaks effectively, preventing product loss and environmental harm.
With versatility across ceramics slip recirculation and casting, corrugated packaging glue transfer, paints and coatings requiring gentle transfer of shear-sensitive fluids, and pharmaceuticals and specialty chemicals needing leak-free, precise, and robust fluid transfer, Cognito’s EODD pumps deliver reliability, safety, and operational excellence in a wide range of demanding industrial applications.
“Investing in an energy efficient pump is a smart decision. If you’re still using AODD pumps, you’re not only wasting air, but bleeding cost and energy,” Kumar says.
Empowering Industrial Sustainability, One Pump at a Time
Cognito’s EODD pumps are not just an upgrade for your facility. They are a strategic investment in sustainability, operational excellence, and cost efficiency.
With robust designs, smart digital controls, and proven energy savings of up to 75%, these pumps help industries achieve their environmental and financial goals without compromising reliability.
Ready to transform your fluid transfer operations?
Explore Cognito’s EODD pump solutions here or read our case studies to see how leading manufacturers are achieving efficiency and sustainability targets with Cognito. Pump specifications may vary by region. Please contact your local sales team for more information.
