Pharmaceutical Company Optimizes Efficiency with Cognito EODD Pump
In this case study, discover how a leading API pharmaceutical company in India improved energy efficiency, cut maintenance costs, and achieved seamless solvent recirculation with the Cognito EODD pumps.
Market Overview
The pharmaceutical industry is evolving rapidly, and the integration of positive displacement pumps in solvent recirculation is a key factor in enhancing operation efficiency, sustainability, and product quality in API production.
Many solvents used in API production are viscous and corrosive. The pumps should be designed to handle such challenging materials without compromising performance and should reduce the risk of leaks or spills, which can pose safety hazards in the production environment. Their role is vital in maintaining high standards of quality and safety in the pharmaceutical industry.
The Need
A prominent customer sought a robust and dependable pump for their solvent recirculation application. They faced persistent breakdowns and significant leakage issues with their existing AODD pumps. The aggressive nature of the solvent, combined with the pressure from continuous recirculation, led to frequent diaphragm ruptures, wear and tear on the discharge manifold & valve assembly failures. As a result, the customer was looking for a more reliable pumping solution for this application.
Customer Challenges with AODD Pump
Higher Energy Costs:
The pumps operated over 20 hours daily, leading to increased energy consumption of pneumatic air.
Safety Issues:
Diaphragm rupture posed a leak risk due to the absence of a leak detection system, creating safety hazards in the production environment.
Significant Downtime:
Frequent diaphragm ruptures, wear and tear on the discharge manifolds & air valve assembly failures.
Noise:
AODD pumps were quite noisy during operation, which was a concern for the pharmaceutical industry, as they preferred quieter pumping solutions.
Increased Maintenance Cost:
Frequent breakdowns resulted in higher maintenance and inventory costs.
The Right Solution
Unlike the pneumatic pumps, the EODD pumps consume less energy due to its electric operation. The EODD pump is equipped with advanced safety features that detect and address leakages promptly, preventing prolonged operational disruption.
Unique airtight diaphragm, Seal-less design & the unique "Stopper Cage Design" exceptional durability extended the lifespan of critical components and set this pump apart from the significant energy savings.
The unique features and significant energy-saving potential of the EODD pump convinced the customer to trial two units of 1.5” – PP Cognito pump, in their solvent recirculation application.
Customer Experience
Since its installation, the Cognito™ EODD pump has functioned seamlessly, showcasing its reliability and efficiency. Here are some key benefits that customers have experienced with this pump:
- Energy Savings: Up to 90%
- Improved Safety Mechanism
- Maintenance Cost Reduction: Up to 65%
- Decreased Unplanned Downtime
- ROI: Within 1.3 years
- Improved Total Cost of Ownership
Energy Consumption Comparison: AODD Pumps vs. Cognito EODD Pump
Maintenance Comparison: AODD Pumps vs. Cognito EODD Pump
The customer is happy with the performance of the Cognito™ EODD pump. They highlighted the savings and improved operational efficiency. This success story emphasizes the critical role of choosing the right pumping solution to tackle specific challenges in the pharmaceutical industry.
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