At Langguth Chemie, pump solution optimizes filling operations while reducing noise
1963 by Rudolf Langguth. The company produces cleaners, disinfectants
and detergents for commercial and industrial applications, as well
Langguth Chemie GmbH, Konigsbrunn, Germany, was founded in
1963 by Rudolf Langguth. The company produces cleaners, disinfectants
and detergents for commercial and industrial applications, as well
as soaps, lotions, shower gels and hand sanitizers. In addition to its own
brands, it furnishes private-label brands.
The future of Langguth Chemie, however, came into question in 1993
when Rudolf Langguth passed away. Rudolf ’s son, Klaus Langguth,
stepped in and continues to operate the company.
“This company started as a one-man operation, so we had some
struggles with my father’s illness and death,” says Klaus Langguth, who is
today the company’s managing director. “We develop everything on our
own, manufacture everything on our own. We buy only raw materials and
develop the product, test the product and sell the product to our distributors
and private-label partners.”
Filled with frustration
Langguth Chemie also faced challenges in optimizing cost-effectiveness
of its production and product-transfer operations. Of concern was packaging
where finished cleaners, detergents, disinfectants, soaps, lotions,
etc., are pumped from 6,000-liter holding tanks into containers — which
generally range in size from 5 to 10 liters —before being shipped to the
end-user.
Pumps transfer exact volumes while operating reliably in demanding
start/stop conditions. Pumps inject the appropriate volume and then stop
immediately, a challenge in these operations.
For years, Langguth Chemie used plastic air-operated double-diaphragm
(AODD) pump technology. But the pumps didn’t live up to expectations in
two areas — pumping high-viscosity liquids against pressure air consumption
and noise generation.
“We needed a reliable pump system that has high suction capabilities
when pumping against pressure, with high-viscosity liquids, and that wouldn’t get dry when pumping out of containers,” explains Langguth.
“We tried other pumps, but they took too much air in order to work, and
they were loud, difficult to maintain and unreliable.”
Complete commitment
Part of PSG, a Dover Co., Almatec is a leading brand of AODD
pumps, manufactured in PSG’s Kamp-Lintfort, Germany, facility.
E-Series air-operated double-diaphragm pumps are a next-generation
technology that has replaced Almatec’s standard-setting A-Series AODD
pump line. Advances include a diaphragm-sized ring on each side of the
pump that allows a series of housing bolts to be tightened against the
housing, resulting in a more even spreading of housing-bolt force; an
optimized flow pattern that decreases resistance and increases energy efficiency;
and the use of less air to achieve the same level of flow.
Langguth Chemie employs eight E40 models in its container-filling
operation, even though they have a higher purchase price than the old
pumps. That higher price is negated by air consumption, maintenance and
downtime cost reduction.
“The mechanical parts are more stable in these pumps. They hold the
air pressure better and longer so the air consumption is lower,” Langguth
says. “It’s a theoretical level of 50% less air consumption and I think in
practical usage we are receiving, without any effect on flow rates, a 30%
to 50% increase in seal-ability. The old pumps needed too much air, about
double what the Almatec needs. With the old pumps we were probably
going to need a new compressor.”
About those pumps
E40 pumps feature solid-block polyethylene (PE) construction (as opposed
to the molded-plastic construction of the older pumps), have a 38
mm port size, dry-suction lift of up to 4 m, wet-suction lift to 9.5 m, maximum
operating pressures of 7 bar and can function with fluid temperatures
up to 70ºC. Standard diaphragms are PTFE (Teflon), but after several
months of use, Langguth Chemie has determined that the same, if not
higher, level of pump performance can be achieved with the incorporation
of EPDM diaphragms.
“When handling soaps and other cleaners, oftentimes the ingredients are surfactants that can crack plastic,
which is something we always
had to watch out for,” Langguth
says. “The EPDM diaphragms are
working well so far.”
The E40 pump advantage is apparent
when you enter the filling
room – you can comfortably carry
on a conversation.
“Everyone is happy with the
quieter pumps. The noise is 300
percent less,” says Langgueth.
“There’s about seven pumps running
at one time and just one of
the previous pumps made more
noise than the seven Almatecs all
running at once.”
Harald Vogl is a Regional Sales Manager – Germany for Almatec® and
PSG®. Mr. Vogl can be reached at harald.vogl@psgdover.com.
Almatec is a leading brand of air-operated double-diaphragm (AODD)
pumps from PSG®, a Dover Company. Headquartered in Oakbrook Terrace,
Illinois, USA, PSG is comprised of several of the world’s leading pump brands.