Medium
Acids and alkalis
Container
VARIBOX and standard IBCs
Solution
5× SAFETEC pump kit
The Challenge
At its Bad Laasphe facility, EJOT galvanizes steel screws in two treatment baths, each holding 20,000 liters and featuring more than 15 processing stations. The baths, which are monitored in a laboratory, must be topped off with sulfuric acid, nitric acid, and caustic soda—a process that has so far been performed manually from canisters or disposable IBCs, involving direct contact with employees.
Direct Media Contact
When handling canisters and disposable IBCs, employees were exposed to spills, vapors, and heavy lifting in the basement—a safety risk despite the use of protective equipment.
Manual dosing errors
Manual replenishment of active baths monitored in the laboratory allows for variations in concentration—and thus for fluctuations in coating quality.
High disposal costs
Disposable IBCs incur disposal and annual inspection costs for spill containment pans—a cost factor that continues to rise with each batch.
Gallery
Dosing process
From the sealed IBC in the basement to reproducible dosing in the electroplating bath, in four steps.
The filled VARIBOX IBC is connected to the SAFETEC via a hose line with a dry coupling. The coupling reliably prevents the medium from leaking during connection and disconnection. Depending on the container type, either a conventional IBC suction lance or the suction lance integrated into the VARIBOX is used.
Using the touch panel with a plain-text display, the operator selects a preset filling quantity or enters it directly. Alternatively, the pump runs until the IBC is completely emptied. Control stations are installed both in the basement near the IBC storage areas and on the ground floor near the electroplating tanks.
The MAGSON magnetic centrifugal pump conveys fluids at temperatures up to 60 °C through pipes from the basement to the electroplating baths. Solenoid valves in the pipes act as backflow preventers when the pump is shut down. The ultrasonic flow meter measures the flow rate noncontact and without any moving parts.
The built-in dry-run monitoring system indicates an empty IBC on the display and automatically shuts off the pump. The dry coupling allows the container to be replaced without coming into contact with the fluid—the supplied VARIBOX is returned to the chemical supplier via the circulation system.
0 %
Employee exposure to corrosive substances
5
SAFETEC units for different chemicals
100 %
Automated and reproducible dosing
Products Used
SAFETEC pump ket
For emptying enclosed IBCs and drums; compatible with CDS/QC couplings
MAGSON magnetic centrifugal pumps
Leaks are impossible; the pumps operate maintenance-free
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