PuK

PROCESS TECHNOLOGY & COMPONENTS 

2026 

Water Wastewater Environmental Technology 

Energy Oil Gas Hydrogen 

Mechanical Engineering Shipbuilding Heavy Industry 

Chemistry Pharmaceutics Biotechnology 

Food and Beverage Industry 

GEA Valves: now 

also hydraulic 

SH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

NGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 




GLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


SH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLIS 


LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLI 


LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGL 


GLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENG 


NGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENG 


H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH EN 

H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLIS 

SH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH E 

ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLI 

LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH E 

gea.com/contact 

2026-GEA-coverPuk_02_ENG.indd 1 13/02/2026 08:59 

Independent magazine for Pumps, Compressors and Process Components

THE RAZORSHARP MAXIMUM 

EASY MAINTENANCE MACERATOR 

Extended service life 

up to 100 % 

The new SEEPEX Easy Maintenance Macerator meets the increasing demands of 

modern conveying processes and solid-laden media. It combines precise cutting 

technology with maximum ease of maintenance – for greater efficiency, longer 

service life, and maximum operational reliability. 

YOUR BENEFITS 

• Easy maintenance: Foldable cutting unit for quick access to shearplate and 

blades without lifting equipment 

• Superior cutting results thanks to flow-optimized geometry of the shearplate 

• Doubled service life: Reversible shearplate enables extended 

service life by up to 100% 

• Anti-blocking function: Optional reverse operation to clear blockages 

SEEPEX GmbH 

T +49 2041 996-0 

www.seepex.com

Sustainable energy savings 

with heat recovery 

When using rotary screw compressors, boosters and blowers, a considerable portion of the energy generated is lost as heat. However, this doesn’t have 

to be the case: Thanks to innovative heat recovery systems from KAESER KOMPRESSOREN, this heat can be recovered and put to effective use. 

Heat recovery – The right decision 

Energy efficiency: You can significantly reduce your energy costs by recovering recyclable heat. The recovered 

heat can be used to heat spaces, to heat water, or to support industrial processes. You are therefore able to use your 

energy twice and save money at the same time. 

Sustainability: By utilising the recyclable heat from your compressed air supply, you significantly reduce CO2 emissions. 

Heat recovery actively contributes to climate protection and helps your company operate more sustainably. 

Durability: A lower compressor operating temperature means a longer service life. Heat recovery therefore not only 

saves money but also protects your investment. 

Flexibility: Heat recovery systems from KAESER can be adapted to almost any compressor. Whether you already 

have an existing system or wish to install a new one, our innovative technology can be integrated seamlessly. 

Funding opportunities: Government subsidy programmes are available to support energy-efficiency measures. 

Find out about potential funding opportunities and start benefiting today. 

www.kaeser.com

Approx. 5 % Approx. 15 % Approx. 76 % 

Heat dissipation 

from the drive motor 

Heat energy 

recoverable through 

compressed air cooling 

Heat energy 

recoverable through 

fluid cooling 

100 % Approx. 96 % 

Total electrical power 

consumption 

Usable heat 

Approx. 2 % Approx. 2 % Approx. 4 % 

Non-usable heat 

Heat dissipated by the 

compressor into the 

ambient surroundings 

Heat remaining in the 

compressed air 

Heat recovery systems – 

Flexible for every need 

Hot air for space heating: Air-cooled rotary screw compressors, boosters and blowers from KAESER are ideal as 

complete systems to aid heat recovery for space heating and other hot air applications. Direct use of recyclable heat 

via an exhaust air ducting system enables up to 96 % of the total energy input to be recovered and reused. 

Hot water production: KAESER offers heat recovery systems with special heat exchangers for applications requiring 

hot water. Depending on the design, these systems can generate hot water up to 70°C for use as process, service and 

tap water. The indirect use of recyclable heat via heat exchanger systems can utilise up to 76 % of the electrical power 

provided to the compressed air supply. 

This is where heat recovery counts: 

● Feed into central heating systems 

● Hot water for sanitary equipment 

● Drying and sterilisation processes 

● Utility water for the food and beverage industry 

● Service water for the textile industry 

● Process water for the manufacturing industry 

Would you like to learn more about our innovative heat recovery systems? 

Then follow the QR code. 

P-119ED.19/24

Editorial 

Guest editorial 

by Stephan Brand 

Director Marketing 

Aerzener Maschinenfabrik GmbH, Germany 

Water. Energy. Future. 

Rethinking wastewater 

treatment. 

Water is precious – and scarcer 

than expected. Climate change, 

population growth and increasing 

requirements for environmental 

and health protection are increasing 

the pressure on water 

resources worldwide. Innovative 

water treatment technologies are 

therefore of central importance – 

today and in the future. 

The water and wastewater industry 

is at the centre of a decisive 

transformation. Climate 

protection, energy efficiency 

and resource conservation interact 

directly here. Wastewater 

treatment plants in particular 

offer enormous potential for 

innovation and savings. As major 

munici pal energy consumers, 

they are ideally placed to develop 

into energy producers. 

Modern aeration and control 

concepts make it possible to precisely 

adapt biological treatment 

processes to the actual and individual 

requirements of a wastewater 

treatment plant. This results 

in energy savings that not 

only reduce operating costs, but 

also sustainably improve the climate 

footprint of the systems. 

The vision of an energy self-sufficient 

wastewater treatment plant 

has long been more than just a 

vision of the future. The EU requires 

energy-neutral municipal 

wastewater treatment plants by 

2045. This goal marks a clear paradigm 

shift. Highly efficient technology, 

particularly in aeration, digester 

gas generation, waste heat 

utilisation and the use of renewable 

energies, can turn wastewater 

treatment plants into climateneutral 

energy producers. The 

technical solution concepts already 

exist today. 

requires innovative, energy-efficient 

solutions. The sustainable 

and environmentally friendly utilisation 

of sewage sludge also remains 

a central part of modern 

plant concepts. 

To summarise, one thing is clear: 

water and its treatment are crucial 

for life, health and environmental 

protection. Responsible 

use of water and targeted investment 

in modern treatment 

technologies are essential for a 

sustainable future. The transformation 

of the waste water 

treatment plant from energy 

consumer to energy producers 

has begun – visibly, measurably 

and mouldably. It will become 

clear at the latest when we look 

ahead to IFAT 2026: the future of 

water management is now. 

With this in mind, we look forward 

to an exciting and futureoriented 

IFAT 2026! 

Efficient blower and aeration systems, 

intelligent control systems 

and holistic process optimisation 

enable significant reductions 

in energy consumption and CO 2 

emissions. 

In parallel, other requirements 

are coming into focus: the fourth 

treatment stage for the removal 

of micropollutants makes a significant 

contribution to water 

protection and at the same time 

Stephan Brand 

Director Marketing 

Aerzener Maschinenfabrik GmbH 

PROCESS TECHNOLOGY & COMPONENTS 2026 

5


Editorial Advisory Board 

Editorial Advisory Board 2026 

Prof. Dr.-Ing. Andreas Brümmer, Head of Fluidics at Technical University Dortmund 

Andreas Brümmer, born in 1963, studied aerospace engineering at the Technical University of Braunschweig, where he completed 

his doctorate in the field of bird flight at the Institute of Fluid Mechanics. He began his industrial career in 1997 as head 

of the fluid dynamics at the company KÖTTER Consulting Engineers KG. Here he gained experience in the physical analysis and 

elimination of flow-induced vibrations in industrial plants. In 2005, he took over the technical management of the company. 

Since 2006, he has been Professor and Head of the Fluid Technology Department at TU Dortmund University. His research 

focuses on the theoretical and experimental analysis of screw machines both in compressor applications (e.g. refrigeration and 

air compressors, vacuum pumps) and in expander applications (e.g. waste heat utilisation). He also researches pulsating flows 

in the environment of positive displacement machines and centrifugal pumps. He was Vice Dean and Dean of the Faculty of Mechanical Engineering 

from 2008 to 2011 and Senator at TU Dortmund University from 2012 to 2014. He is a reviewer for various international journals, serves on industrial 

advisory boards and scientific committees and is the scientific director of the International Conference on Screw Machines (ICSM), which 

has been held regularly at TU Dortmund University since 1984. 

Dipl.-Ing. (FH) Gerhart Hobusch, Project Engineer, KAESER KOMPRESSOREN SE, Coburg 

Gerhart Hobusch, born in 1964, studied mechanical engineering at the University of Applied Sciences in Schweinfurt, Northern 

Bavaria. He graduated with a degree in mechanical engineering and completed postgraduate studies with a degree in industrial 

engineering. He has been working as a project engineer at KAESER KOMPRESSOREN SE, Coburg, since 1989. His responsibilities 

include the planning of compressed air stations, the development of economical, energy-saving concepts for compressed air stations 

and the worldwide training of KAESER project engineers. As part of his job, he has worked on research projects such as the 

“Compressed Air Efficiency” campaign, the EnEffAH joint project, as well as FOREnergy and Green Factory Bavaria, and is active in 

the VDMA's compressed air technology department. The standard compliant implementation of volume flow and power measurements 

on compressors, also in connection with China Energy Label efficiency requirements, as well as compressed air quality measurements according 

to ISO standards are also part of his tasks. In addition to the specialist lectures on compressed air technology held over the years, he is participating 

in the development of the KAESER blended learning concept with the design of e-learning courses and the implementation of online training courses. 

Dipl.-Ing. (FH) Johann Vetter, Head of Integrated Management Systems, NETZSCH Pumps & Systems GmbH, Waldkraiburg 

Johann Vetter, born in 1966, studied mechanical engineering at the Technical Colleage of Regensburg. His diploma thesis dealt 

with the topic “Filters and filter materials“ in Environmental and Process Engineering. Prior to his studies, Mr. Vetter had completed 

an apprenticeship as machine fitter and thus created a practical basis for his later activities in the automotive industry, 

where he worked for 16 years as a quality engineer, development engineer, project manager and department manager for airbag 

systems. Since 2013, Mr. Vetter has been responsible for special projects mainly for the oil and gas industry at NETZSCH 

Pumps & Systems, where he took over the position of Quality Manager after 3 years. Since October 2019 he has been responsible 

for the areas of integrated management systems and is also a member of the Management Board of NETZSCH Pumps & 

Systems. He is currently also the project manager responsible for sustainability at the NETZSCH Group. 

Dipl.-Ing. (FH) Sebastian Oberbeck, Global Head of Product Group Valves, Pfeiffer Vacuum+Fab Solutions, Asslar 

Sebastian Oberbeck, born 1970, graduated at the University of Applied Sciences Mittelhessen in engineering and precision 

mechanics. His career startet as project engineer and later as project manager at the Fraunhofer Institute for Microsystems 

in Mainz developing mainly micro pumps, micro valves and microsystems (MEMS) in publically funded as well as in industry 

sponsored projects. From 1998 he was responsible for nano technically manufactured Pointprobe AFM sensors at Nanosensors 

GmbH in Wetzlar. In 1999 he became founding member and partner of the startup company CPC Cellular Chemistry 

Systems GmbH where he was responsible for developing micro chemical reaction systems in Laboratory and Pilot plant applications 

in the chemical and pharmaceutical industry. 2004 he took the product management responsibility for automotive 

drive shaft components of Daimler Chrysler and Getrag at tier 1 supplier Selzer Fertigungstechnik GmbH in Driedorf. From 2009 to 2019, he was 

responsible for development and basic research for backing pumps and systems at Pfeiffer Vacuum GmbH. From 2020 to 2022, he was responsible 

for setting up and managing the Silicon Valley Innovation Center in San Jose, California for Pfeiffer Vacuum North America. From early 2023 to 

April 2025, he served as Global Energy Manager at Pfeiffer Vacuum. Since May 2025, he has been Global Head of Product Group Valves. 

6 PROCESS TECHNOLOGY & COMPONENTS 2026

PUMPS ARE THE HEART 

OF YOUR SYSTEM 

Pump technology from the innovation leader 

You can count on it: Industrial pumps from Vogelsang impress with their 

outstanding performance, exceptional durability, and ease of maintenance. 

They can also be individually adapted to meet just about any requirement. 

When it comes to pumps – Vogelsang. 

VOGELSANG – LEADING IN TECHNOLOGY 

vogelsang.info


Contents 

Title 

Control more precisely, consume less 

GEA expands its valve portfolio with water-hydraulic 

actuation, supporting more sustainable, digital beverage 

production worldwide 

With the acquisition of Denmark’s Hydract in early 2026, GEA 

expands its valve portfolio, adding water-hydraulic actuation 

alongside pneumatic technology and opening new possibilities 

for energy efficiency, digital insight, and precise regulation in 

beverage plants. (starting on page 10) 

Contents 

Guest editorial 

Water. Energy. Future. Rethinking wastewater treatment. 5 

Cover story 

Control more precisely, consume less 10 

Environmental technology 

The phosphorus resource of the future 14 

Pumps and Systems 

High-pressure plunger pumps 

Process reliability under pressure 17 

Centrifugal pumps 

Liquid tar: a dirty challenge for pumps 22 

Metering pumps 

Minimal pulsation thanks to pump synchronization: 

6-head combination pump with Smart Monitoring delivers 

water and sulfuric acid evenly into static mixer 24 

Mobile lubrication solution 

The firewood wizard from the Spessart region 26 

Rotary lobe pumps 

Compact pump technology for tankers 28 

Renovation during ongoing operation: 

Mobile pump supports mobile construction site 

in sewage treatment plant 30 

From membrane filtration to mobile pumps: 

Rotary lobe pumps in use for the highest demands 32 

Screw pumps 

Reliability meets efficiency 34 

Dosing systems 

Chemical conditioning of the steam-water cycle 

for reliable operation 36 

Macerator 

SEEPEX introduces its new generation of macerator 38 

Vacuum technology 

Vacuum technologies 

Critical roles of vacuum technology in safe and 

efficient battery recycling 40 

Vacuum pump stand 

Hyperloop – traveling through a vacuum 

at 1,000 kilometers per hour 44 

Companies – Innovations – Products 

Pumps/Vacuum technology 46 

Index of Advertisers 53 

Impressum 53 

Trade fairs and events 

IFAT Munich 2026 54 

IVS - INDUSTRIAL VALVE SUMMIT 2026 56 

FILTECH 2026 57 

VALVE WORLD EXPO 2026 58 

Compressors und Systems 

Compressed air 

The alternative for economical compressed air 60 

Breathing air compressors 

On the track with high pressure 64 

Turbo compressors 

40 years of Sweden’s heat pumps: 

from the oil crisis to the energy transition 66 

Nitrogen generators 

Nitrogen purity explained: 

How to select the right purity for each industry 70 

Compressed air production 

Compressed air for climate-neutral production 72 

Air compressors 

Air compressor troubleshooting: A comprehensive guide 

to rapid problem resolution 76 

Compressed air management 

Reducing energy costs by 50 per cent, thanks to 

efficient compressed air management 80 

Components 

Frequency converter 

Three-level technology for a new turbo compressor 82 

Condition monitoring 

From normative vibration assessment to learning-based 

condition monitoring – Condition monitoring of rotating machines 

with dynamic tolerance bands and AI 84 

Flow Solutions 

From components to integrated Flow Solutions – 

Building reliable water networks together 87 

Sensors 

Optimizing cooling tower efficiency with 

smart water quality control 90 

Valves 

Leakage problems with diaphragm valves 

in biotechnological applications 92 

Seals 

Vi 782 – A long-lasting FKM all-rounder with NFS technology 94 

Innovative filter elements 

With metal wire mesh to 90 % lower energy demand 96 


Compressors/Compressed air/Components 99 

Technical Data Purchasing 105 

8 

PROCESS TECHNOLOGY & COMPONENTS 2026

HAMPRO® HIGH-PRESSURE 

PROCESS TECHNOLOGY 

The high-pressure pumps of the HAMPRO® series are used in the Oil and Gas Industries to pump a 

very wide range of fluids, meet the stringent requirements of the relevant safety and reliability regulations 

and are characterized by a robust design and careful use of resources. 

Our experienced team of experts will be happy to help configure the 

perfect solution for your individual application. 

RECIPROCATING PUMPS 

TO API 674 

- Glycol pumps 

- Leak test pumps 

- Methanol pumps 

- Produced water injection pumps 

- Sea water injection pumps 

Pressure: 

50 – 4000 bar 

Flow rate: 0,1 – 256 m³/h 

TAILOR-MADE AND 

FULLY INTEGRATED 

Hammelmann GmbH 

(0) 25 22 / 76 - 0 

Carl-Zeiss-Straße 6-8 

pp@hammelmann.de 

D-59302 Oelde www.hammelmann-process.com

Cover story 

Control more precisely, consume less 

GEA expands its valve portfolio with water-hydraulic 

actuation, supporting more sustainable, digital beverage 

production worldwide 

With the acquisition of Denmark’s 

Hydract in early 2026, GEA expands 

its valve portfolio, adding water-hydraulic 

actuation alongside pneumatic 

technology and opening new 

possibilities for energy efficiency, 

digital insight, and precise regulation 

in beverage plants. 

It’s often the “unseen” equipment 

that decides whether a shift runs 

smoothly. In breweries and soft drink 

plants, process valves quietly do the 

hard work: separating product and 

CIP media, protecting quality, and 

keeping flow stable. 

“Water-hydraulic valve actuation 

offers more precise 

regulation, which enables new 

processing concepts such as 

late product differentiation, 

an upgrade path for existing 

installations, and the chance 

to lower CAPEX when the new 

process concept lets you do 

more with fewer tanks.” 

Bastian Tolle, Head of Business 

Development & Digitalization, GEA 

But as plants 

push for lower 

energy 

use, 

faster product 

changeovers, 

and 

better 

becomes 

less about the 

valve body and 

more 

about 

how that valve 

is actuated – 

and what that 

actuation 

enables. 

data, the question 

That’s 

why interest is rising in hydraulic 

valve technology as an alternative to 

pneumatic valve technology. 

What’s the headline for beverage 

professionals? 

Bastian Tolle: “This is about giving 

customers a real choice of actuation 

technology from one portfolio 

– the best of both worlds. GEA’s 

pneumatic valve technology already 

spans hygienic applications with 

VARIVENT and aseptic applications 

with ASEPTOMAG. By adding waterhydraulic 

actuation, GEA can offer an 

additional actuation option for singleseat, 

double-seat, and control valves, 

so engineers can select the most suitable 

approach for each application 

without changing suppliers or service 

models.” 

Why water-hydraulic actuation? 

And why now? 

Peter Espersen: “Back in 2008, hydraulic 

valve technology began as 

an energy-saving story, but the value 

proposition matured. Today, sustainability 

is back at the top of the 

agenda, digitalization is expected, 

and precise regulation can unlock 

new process concepts. Now we don’t 

have to defend that we offer an alternative. 

Plants are actively looking for 

measurable improvements.” 

Bastian Tolle: “From GEA’s perspective, 

the fit is clear: if we want to deliver 

on our promise, ‘Engineering for 

a better world,’ we can’t ignore the 

advantages that water-hydraulic actuation 

can offer. It supports sustainability, 

enables digital condition 

monitoring, and makes every valve 

capable of stable intermediate positioning, 

turning a mixproof shut-off 

valve into a regulating tool to enable 

constant inline mixing processes with 

the highest precision, allowing for 

late product differentiation. Sustainability, 

digitalization, efficiency, precision, 

and excellence – all in one technology. 

And these are concepts we 

embrace as a company.” 

In practical terms, what changes 

when you move from compressed 

air to water? 

Bastian Tolle: “Moving from compressed 

air to hydraulics changes the 

supporting system around the valve. 

You’re not only switching an actuator, 

but you’re also introducing a hydraulic 

support system that must be designed 

and sized for the application. 

You rethink the supporting system, 

so it fits the process, the maintenance 

reality, and the way a beverage site is 

run. That’s also why this technology 

needs a partner with application 

knowledge, engineering capability, 

and the confidence of an established 

supplier. The upside is that water-hy- 

When Bastian Tolle, Head of Business 

Development & Digitalization 

at GEA Pure Flow Processing, sits 

down with Peter Espersen, founder 

of Hydract, the dynamic is striking. 

They both know the valve world inside 

out, but from different angles: 

Tolle from the scale of the modular 

VARIVENT portfolio built for industry-wide 

use, Espersen from the 

stubborn reality of bringing a new 

technology to market. 

Hydraulic valve technology at a glance 

• Actuation medium: water instead of compressed air, reducing reliance 

on compressor systems. 

• Precision: stable intermediate positioning supports accurate 

regulation. 

• Digital potential: stable motion plus actuator intelligence enables 

condition monitoring (e.g., seal/gasket trends). 

• Plant fit: strongest sustainability impact when utilities are designed 

accordingly (especially greenfields and major upgrades). 

• Sustainability upgrade: easy to retrofit on existing valve solutions 

to upgrade an existing system to a sustainable, digital solution. 

10 

PROCESS TECHNOLOGY & COMPONENTS 2026

Cover story 

draulic actuators can eliminate the 

need for compressed air for valve operation. 

Air that is typically generated 

by energy-intensive compressors.” 

Peter Espersen: “Hydraulics also behaves 

differently under process forces. 

A pneumatic regulating valve can 

be influenced by changing flow and 

pressure, while a hydraulic actuator 

stays where it’s commanded and 

moves in small, controlled steps, improving 

stability around setpoints.” 

Let’s talk sustainability: how big is 

the energy-saving potential? 

Bastian Tolle: “That starts with a simple 

reality: compressed air comes 

with a footprint; water can operate 

in a closed loop. Water-hydraulic actuation 

can eliminate the need for 

compressed air for valve movement, 

which is typically generated by compressors 

in pneumatic systems. 

Replacing a large compressed-air 

supply with a compact hydraulic system 

can cut electricity demand dramatically, 

especially as you can eliminate 

losses caused by air leaks within 

the compressed air network, which 

are present in all plants and which 

you can easily hear while walking 

through these plants. 

But the real number depends on 

plant layout, compressor sizing, and 

project scope. It’s most compelling 

for greenfield projects and major upgrades 

and can also be attractive for 

extensions where compressed air capacity 

becomes a constraint. It becomes 

a meaningful lever in modernization 

projects where energy and 

CO 2 

are being optimized plant-wide, 

and where every ‘hidden consumer’ 

has to justify itself. In those projects, 

changing how valves are driven can 

be surprisingly impactful. The direction 

is clear: it helps customers get 

away from compressed air for operating 

valves.” 

What does “more digital” mean 

at valve level? 

Bastian Tolle: “Stable positioning is 

the foundation. With pneumatics, 

springs and line forces can introduce 

small deviations. Hydraulics can hold 

position with high repeatability and 

stability, which makes condition monitoring 

realistic in daily operation, 

such as tracking gasket condition and 

collecting actionable data.” 

Peter Espersen: “Hydraulic valve actuation 

controls motion digitally inside 

the actuator, not simply open/ 

close. The actuator moves from one 

position to another, records what 

happened, and can detect patterns 

such as seal wear. 

In practice, that means moving from 

‘we think the valve is fine’ to ‘we can 

see what is changing before it fails’ in 

real production conditions. 

Compare it to a CNC machine: controlled 

motion, traceable behavior, 

actionable data, while communicating 

through standard interfaces like 

IO-Link, depending on plant needs. At 

the Carlsberg brewery in Fredericia, 

Denmark, hydraulic valves enabled 

continuous inline blending and late 

product differentiation at scale. The 

principle is simple: when valves can 

regulate precisely and repeatably, 

plants can blend inline and respond 

faster to demand, rather than relying 

solely on large numbers of dedicated 

tanks and batch staging. So, instead 

of keeping 50 different beer types in 

stock, you might keep 10 or 12, as 

Carlsberg in Fredericia did.” 

Bastian Tolle: “It’s not only about 

speed. It can also reduce cleaning effort 

and resource use when processes 

and tank utilization are optimized, 

because stable regulation expands 

the set of feasible plant concepts. 

And it goes even further: if stable regulation 

lets you simplify the process 

and run with fewer tanks, it can also 

help reduce CAPEX for the plant operator.” 

What’s the rollout plan within 

GEA’s portfolio? 

Bastian Tolle: “We start where the 

impact is immediate. The first phase 

focuses on the so-called ‘high runners’ 

in the current VARIVENT system: 

N-type (shut-off), W-type (changeover), 

and R-type 

valves 

(mixproof). 

That should cover 60- 

70 % of be verage applications. 

From there, the aim 

is to broaden the offering 

across the entire 

VARIVENT system 

so hydraulic actuation 

becomes a standard choice at 

scale for hygienic valve technology. 

Aseptic valves are also on the roadmap. 

Of course, retrofit capability with the 

modular VARIVENT housing remains 

an advantage. The ambition is to add 

hydraulic actuation as an option within 

that modular logic, so customers 

can choose pneumatic or hydraulic 

actuation while keeping consistent interfaces 

to engineering, automation, 

and service for new installations or - 

and this is a key benefit - to upgrade 

“Hydraulic valve actuation 

controls motion digitally inside 

the actuator, not simply 

open/close. Compare it to 

a CNC machine: controlled 

motion, traceable behavior, 

actionable data.” 

Peter Espersen, Founder Hydract 


11

Cover story 

existing installations to this new sustainable 

technology.” 

How do you make sure the technology 

keeps its speed? 

Bastian Tolle: “We are keeping the 

Hydract team together as a focused, 

agile unit inside our Pure Flow Processing 

Division. The intent is to combine 

the expertise in hydraulic valve 

technology with GEA’s global sales, 

engineering, and service footprint.” 

as a niche, but as a credible option 

for modern production. With GEA’s 

engineers and their unmatched valve 

portfolio, we can create new customer 

solutions and make it work seamlessly.” 

Bastian Tolle: “After decades of conversations 

about what the ‘next generation’ 

of valve technology could be, 

I believe this is the rare kind of step 

The experts’ take 

that can genuinely move the needle, 

because it makes sustainability, digitalization, 

and precision regulation 

tangible in a component that sits at 

the heart of every beverage plant.” 

Learn more and discuss your application 

with GEA’s valve specialists: 

www.gea.com/contact 

And on a final, more personal note: 

what are you hoping for in the near 

future? 

Peter Espersen: “After spending years 

fighting to make a vision real, I want 

to see the technology spread into Europe, 

into the rest of the world. Not 

If I’m planning a project now, how should I proceed? 

Start with the application, not the component. Identify where stable regulation, 

sustainability KPIs, or digital monitoring could create the biggest 

plant value, and evaluate whether a hydraulic support system fits the 

project scope: greenfield, major upgrade, or extension. 

Think in outcomes: energy profile, controllability, and flexibility. 


SAFE & SUSTAINABLE 

Perfectly positioned to make your 

production processes more efficient. 

For industry, compressed air and industrial gases such as 

nitrogen and oxygen are indispensable production factors. 

They must be available at all times – in the right quality, at the right 

moment, and with maximum reliability. As true specialists, we provide our 

customers with compressed air and specialty gas solutions tailored precisely to their 

specific applications – safe, efficient, and customized. In addition, our premium 

services not only ensure continuous security of supply but also deliver significant 

cost savings through intelligent concepts such as heat recovery and digital system 

monitoring. You too can rely on … 

boge.com


The phosphorus resource of the future 

How sewage sludge ash as a raw material source is sustainably 

changing fertilizer production 

Thomas Lansdorf 

The essential element phosphorus, 

currently sourced almost exclusively 

from finite phosphate ores, is vital 

for agriculture, which accounts for 

over 80 % of its consumption. Given 

the finite nature of these sources, 

German legislation has mandated 

the recovery of phosphorus from 

sewage sludge, effective from 2029. 

Eirich presents an economical mobilization 

process that refines sewage 

sludge ash into a valuable 

phosphate fertilizer via an elegant 

digestion method. 

Significant technical efforts are underway 

to extract phosphorus from 

industrial wastewater. Traditionally, 

the procurement of phosphorus has 

been predominantly sourced from 

ores. Significant deposits of this mineral 

have been identified in Morocco, 

China, the USA, and Russia. In Europe, 

only minor deposits have been identified 

in Finland and Norway [1]. As 

with many other raw materials employed 

in industry, sources suitable 

for mining are finite. Consequently, 

the EU has classified phosphorus, 

akin to lithium, as a strategically 

significant element [2] and has advocated 

for its recovery from sewage 

sludge. This approach has been 

demonstrated to conserve resources 

and, most significantly, to ensure independence 

from sources originating 

from crisis regions. The phosphorus 

present in sewage sludge offers a 

recovery potential of 50,000 tons per 

year in Germany alone. 

Every day, humans and animals ingest 

phosphates through food and 

subsequently excrete the majority of 

them. The phosphates contained in 

food products are ultimately present 

in municipal and industrial sewage 

sludge at the end of the water treatment 

process. According to the German 

Federal Environment Agency [3], 

the phosphorus content of dried sewage 

sludge ranges from 2 to 55 grams 

per kilogram. In Germany alone, 1.8 

million tons of sewage sludge are produced 

annually (based on dry matter). 

Therefore, Germany has set itself 

the task of utilizing this phosphorus 

resource in the future. According to 

the Wastewater Sludge Ordinance, 

operators of large wastewater treatment 

plants (serving the equivalent 

of more than 100,000 inhabitants) will 

be obligated to do so from January 1, 

2029. This requirement will also apply 

to smaller plants (serving the equivalent 

of more than 50,000 inhabitants) 

by 2032 at the latest. While Germany, 

Switzerland (from 2026), and Austria 

(from 2033) are leading the way in P 

recovery, other EU member states 

are relying on voluntary regulations 

through economic incentives. The EU 

Fertilising Products Regulation (FPR) 

is the most important lever for EUwide 

distribution: Since July 2022, it 

has legalized the sale of P-recyclates 

(e. g. struvite, phosphoric acid) as fertilizers 

(CE marking) and thus creates 

essential market incentives. 

Why sewage sludge should no 

longer be used directly as fertilizer 

Just a few years ago, sewage sludge 

was mainly used in agriculture and 

was a cost-effective alternative to 

mineral fertilizers for farmers. It 

contains large amounts of nitrogen, 

phosphates, calcium, magnesium, 

and approximately 50 % organic 

matter. However, sewage sludge is a 

multi-component mixture from commercial 

and domestic sources, the 

composition of which can vary greatly 

depending on its origin and the 

season. This mixture also contains 

harmful substances such as heavy 

metals, residues from weed killers 

and pesticides, pathogens, drug residues, 

PFAS (per- and polyfluoroalkyl 

substances) and microplastics. Animal 

diseases, especially the BSE crisis, 

have further restricted its use. 

Sewage sludge also causes a considerable 

odor nuisance due to its 

biological activity. For this reason, 

sewage sludge is increasingly being 

incinerated, and its direct use as 

fertilizer is now only approved in individual 

cases. As of 2022, over 80 

percent of municipal sewage sludge 

in Germany was being thermally 

treated. [4] 

Mono-incineration plants for 

sewage sludge 

After mechanical dewatering, with 

a chamber filter press or a decanter 

centrifuge, the sewage sludge has an 

earth-moist consistency. However, 

this earth-moist material still contains 

65-75 % water. Additional thermal 

pre-drying is required to achieve 

a moisture content of 40-55 %. This 

process efficiently utilizes the waste 

heat from combustion. This is usually 

carried out in a stationary fluidized 

bed combustion system at approximately 

850°C. This ensures complete 

combustion and minimizes the formation 

of climate-damaging nitrous 

oxide (N 2 

O). The sewage sludge ash is 

completely dry after combustion and 

contains approximately 10-25 % P 2 

O 5 

. 

In very modern plants, heavy metals 

can be directly separated as filter 

dust during flue gas cleaning. 

Thermochemical removal 

of heavy metals 

Even after combustion, the ash itself 

still contains heavy metals. To 

separate these, thermochemical 

post-treatment can be carried out. 

This thermochemical depletion usually 

takes place in a rotary kiln at 

temperatures of 900–1100°C. Various 

processes exist, e. g., EuPhoRe ® , 



AshDec ® , and Pyrophos ® [5]. The addition 

of additives, such as alkaline 

earth chlorides (CaCl 2 

, MgCl 2 

), further 

promotes the formation of volatile 

heavy metal chlorides (e. g., PbCl 2 

and 

ZnCl 2 

), which simplifies their separation. 

The residence time is usually 

30–60 minutes. The addition of sodium 

carbonate instead of chlorides 

can also positively influence the solubility 

of the phosphates (e.g., in the 

Rhenania process), leading to the formation 

of citrate-soluble calcium sodium 

phosphate (CaNaPO 4 

). 

plant concepts for mixing and granulating 

can be developed fully automatically 

and cost-effectively to produce 

fertilizer granules for a wide variety of 

applications, as shown in figure 1. 

Detailed reaction process in the 

Eirich Smart Mixer 

Ash from fluidized bed combustion 

is usually sufficiently fine for use 

in the Eirich intensive mixer. If the 

ingly soluble phosphates can be almost 

completely digested within a 

few minutes. In addition, gypsum 

(CaSO 4 

2 H 2 

O, which increases 

strength) and magnesium sulfate 

(MgSO 4 

, Epsom salt) are formed from 

the calcium and magnesium components. 

After the reaction is complete, 

ammonium sulfate ((NH 4 

) 2 

SO 4 

) as a 

nitrogen source and potassium sulfate 

(K 2 

SO 4 

) as a potassium source 

could be added if required. This 

From sewage sludge ash to fertilizer 

The combustion of sewage sludge 

converts the phosphates into sparingly 

soluble minerals that are not 

plant available. These include, in particular, 

β-TCP (tricalcium phosphate) 

Ca 3 

(PO 4 

) 2 

, apatite Ca 5 

[(OH)(PO 4 

) 3 

], whitlockite 

Ca 9 

(Mg, Fe)[PO 3 

OH(PO 4 

) 6 

] and 

stanfieldite Ca 4 

Mg 5 

(PO 4 

) 6 

[6]. Ashes 

resulting from precipitation with iron 

or aluminum salts also contain sparingly 

soluble iron(III) phosphate FePO 4 

or aluminum phosphate AlPO 4 

. To improve 

plant availability, such ash can 

be treated directly in an Eirich mixer 

with dilute sulfuric acid. This leads to 

a significant improvement in nutrient 

availability; the following reactions, for 

example, take place: 

Fig. 1: Operating principle of the Eirich Smartmixer: fertilizer granules are produced from 

sewage sludge ash and diluted sulfuric acid in a single reaction step. Additional nutrients 

can optionally be added. 

1. Ca 3 

(PO 4 

) 2 

+ 2 H 2 

SO 4 

+ 4 H 2 

O → Ca(H 2 

PO 4 

) 2 

+ 2 CaSO 4·2 H 2 

O 

β-TCP + sulfuric acid → monocalcium phosphate (MCP) + gypsum 

2. Ca 5 

[(OH)(PO 4 

) 3 

] + 5 H 2 

SO 4 

+ 9 H 2 

O → 3 H 3 

PO 4 

+ 5 CaSO 4·2 H 2 

O 

hydroxyapatite + sulfuric acid → phosphoric acid + gypsum 

3. 2 FePO 4 

+ 3 H 2 

SO 4 

→ Fe 2 

(SO 4 

) 3 

+ 2 H 3 

PO 4 

iron(III)-phosphate + sulfuric acid → iron(III)-sulfate + phosphoric acid 

Another advantage of adding acid is 

the resulting pH reduction. This improves 

the release of nutrients into 

the soil, especially with highly alkaline 

ash. This combination, along with 

targeted nitrogen additions, creates a 

biologically valuable N-P-S (nitrogenphosphorus-sulfur) 

fertilizer. Additionally, 

crystallization processes during 

setting and drying increase the green 

and final strength of the granules. The 

released reaction enthalpy has a positive 

effect on the subsequent drying 

process. Thus, individual customized 

ash is too coarse after combustion 

or thermochemical post-treatment, 

pre-milling is recommended. This 

can be done, for example, in a ball 

mill or an orbit mill (Eirich Ehinger 

centrifugal mill). This ensures that 

the reaction can proceed quickly 

and completely. It also improves the 

strength of the resulting granules. 

First, the pre-weighed sewage sludge 

ash is charged in the Eirich Smart 

Mixer. Then, dilute sulfuric acid is 

added. Due to the optimal mixing in 

the Eirich intensive mixer, the sparwould 

allow for the production of a 

high-quality multi-component fertilizer 

(NPK + S + Ca + Mg) in a single 

processing step. In the Eirich Smart 

mixer, the reaction, the addition of 

further nutrient salts, and the granulation 

into spherical, free-flowing fertilizer 

granules can all be carried out 

in one process step. If necessary, a 

coating could be applied at the end 

of the granulation process by adding 

powder additives. This would further 

increase the green strength of the 

granules. The granules could also be 

colored to allow for color differentiation 

of various formulations. After 

drying and sieving, the granules can 

be separated into uniform granule 

fractions. Oversized and undersized 

fractions can be recycled by grinding 

and returned to the process and returned 

to the process, as shown in 

figure 2. 


15


Bibliography 

Fig. 2: Plant example, production of fertilizer granules with the Eirich Smartmixer: 

1 Delivery of sewage sludge ash, 2 Storage buffer (sewage sludge ash) 

3 Grinding in orbit mill, 4 Bucket elevator, 5 Intermediate buffer (ground material), 

6 Dosing and weighing of the ash, 7 Storage buffer for additive, 

8 Dosing and weighing of additive, 9 Scale for dosing sulfuric acid 

10 Eirich Smartmixer, 11 Feed to dryer, 12 Fluidized bed dryer with filter unit, 

13 Bucket elevator (feed to screening), 

14 Tumble screen, classification of good material, oversize material, 

15 Oversize material to grinding (recyclate) 

A look at Switzerland – Further 

sources for phosphate recovery 

In 2016, the Swiss government 

passed a law mandating the recovery 

of phosphates not only from sewage 

sludge but also from slaughterhouse 

waste (e. g., animal and bone meal) 

[7]. The aim is to reduce reliance on 

imports and close the national nutrient 

cycle. The use of sewage sludge 

as fertilizer has been prohibited in 

Switzerland since 2006. Transitional 

periods for recovery are in place until 

2026. Eirich has already conducted 

successful studies on phosphate mobilization 

and granulation of animal 

meal ash. This will allow for the use 

of alternative phosphate resources in 

the future. 

Outlook for the future 

By 2029 at the latest, the recovery of 

phosphorus from sewage sludge ash 

will be legally mandated in Germany, 

Switzerland, and shortly thereafter 

in Austria. It is expected that other 

EU countries will follow suit. This will 

avoid geopolitical risks such as import 

dependencies. 

Furthermore, increasingly stringent 

water protection laws (eutrophication) 

worldwide are forcing wastewater 

treatment plants to remove phosphorus 

from wastewater. In Germany 

and many other countries, approximately 

85% of the phosphorus used 

is currently employed as fertilizer. It 

is therefore logical to produce highquality 

phosphorus fertilizer from 

sewage sludge ash and other phosphate 

sources. Eirich has thus set 

itself the goal of demonstrating a 

particularly simple and economical 

process with the Eirich Smart Mixer, 

thereby offering the possibility of an 

economically viable and sustainable 

solution. The process offers the possibility 

of converting sparingly soluble 

phosphates into plant-available phosphate 

compounds in a short time. At 

the same time, the addition of nutrients, 

especially nitrogen and potassium 

compounds, can significantly 

improve the quality of the resulting 

mineral fertilizers. This makes it possible 

to produce high-quality plant 

fertilizers (NPK + S + Ca + Mg) using 

modern and future-proof process 

technology. In the medium to long 

term, it can be assumed that similar 

processes will be used in other countries 

as well, in order to become less 

dependent on imports and to integrate 

the valuable resource phosphorus 

into the circular economy. 

1. Ilina, Alexandra (10 July 2023). 

Phosphorus Occurrences in Norway: 

Significance and Potential of a Record-Breaking 

Discovery, VDI Verlag. 

https://www.ingenieur.de/technik/ 

fachbereiche/werkstoffe/norwegens- 

phosphorvorkommen-bedeutung- 

und-potenzial-eines-rekordverdaech- 

tigen-fundes/ [Accessed: 5 July 2024]. 

2. Sewage Sludge Regulation - 

AbfKlärV (27 September 2017). Regulation 

on the Utilization of Sewage 

Sludge, Sewage Sludge Mixtures, and 

Sewage Sludge Compost, Federal 

Law Gazette I No. 65, p. 3465, 2017. 

3. Roskosch, Andrea & Heidecke, Patric 

(October 2018). Sewage Sludge 

Disposal in the Federal Republic of 

Germany, Umweltbundesamt, 

Departments III 2.4 – Waste 

Technology, Waste Technology 

Transfer and III 2.5. 

4. Sichler, Theresa & Adam, Christian 

(December 2022). Estimation of Recoverable 

Materials from Wastewater 

and Sewage Sludge of Municipal 

and Industrial Origin, Umweltbundesamt, 

Dessau-Roßlau. 

5. Lodwig, Claudia (September 2020). 

Phosphorus Recovery from Sewage 

Sludge and Sewage Sludge Ash, 

Landesamt für Natur, Umwelt und 

Verbraucherschutz Nordrhein-Westfalen 

(LANUV). 

6. Okrusch, Martin & Frimmel, 

Hartwig E. (2022). Mineralogy: An Introduction 

to Special Mineralogy, Petrology, 

and Ore Deposits, 10th Edition, 

Springer Spektrum. 

7. Hartmann, Stefan (4 December 

2019). Phosphorus Recycling: 

Fertilizers from Sewage Treatment 

Plants, Swiss Federal Office for the 

Environment (BAFU). https://www. 

bafu.admin.ch [Accessed: 

4 December 2019]. 

The Author: 

Thomas Lansdorf, 

Senior Manager Fertiliser, 

Eirich Maschinenfabrik 

Gustav Eirich GmbH & Co KG, 

Hardheim, Germany 

sales@eirich.de 

www.eirich.de 




Process reliability under pressure 

Pump engineering challenges and solutions 

when handling ammonia 

Ammonia (NH 3 

) is a promising candidate 

for decarbonising industry. 

This chemical is becoming increasingly 

important, particularly in shipping 

and power-to-X processes, as 

well as for transporting hydrogen. 

However, the molecule also presents 

challenges: it is toxic and corrosive, 

and it is sensitive to low temperatures, 

which places extreme 

demands on conveyor technology. 

1. A molecule with potential — and 

risks in conveyor technology 

Not only is ammonia a basic raw 

material for fertiliser production, it 

is also becoming a key component 

of the energy transition. Known as 

‘green ammonia’, this is ammonia obtained 

from green hydrogen and can 

be produced in a CO 2 

-neutral manner. 

It can also be used as an energy 

carrier or fuel. Pilot projects in shipbuilding 

and off-grid energy systems 

are demonstrating the potential of 

this technology. 

However, handling ammonia poses 

significant technical challenges. It is 

toxic and releases harmful vapours 

in the event of leaks. When combined 

with air, it can form flammable gas 

mixtures, meaning even minor leaks 

can pose a safety risk. During transportation, 

ammonia is often in a supercooled 

liquid state, making it even 

more difficult to transport safely. 

Fig. 1: KAMAT K25000 High-pressure plunger pump for demanding ammonia applications 

This robust process pump is designed for the safe transportation and injection of liquid ammonia 

at high pressure. It has proven its worth in industrial cooling circuits, chemical process 

engineering, and energy applications. 

process-stable and explosion-proof 

(ATEX-compliant) to ensure safe operation, 

even under dynamic load 

changes or in Ex zones. 

2. Challenges when pumping 

ammonia 

a) Medium-specific properties 

Careful technical design is required 

for the pumping of ammonia, taking 

into account both the hydraulics and 

the materials. Key properties include: 

– Toxicity and chemical reactivity: 

Even the smallest leak can endanger 

people and the environment. Reacting 

with moisture leads to the formation 

of ammonium hydroxide, which 

is a highly corrosive compound that 

damages materials and seals. 

– Thermal instability: With a boiling 

point of -33°C and a vapour pressure 

of around 8.6 bar at 20°C, ammonia 

can evaporate abruptly with even a 

slight drop in pressure. This leads to 

volumetric expansion and increased 

stress on the system. 

– Cavitation tendency: Liquid ammonia 

is sensitive to pressure fluctuations 

in the inlet area of the pump. If 

the local pressure drops below the vapour 

pressure, vapour bubbles form. 

These can cause damage to valves and 

plungers when they implode. 

Challenges typically arise from the 

high vapour pressure, which is present 

even at moderate ambient temperatures, 

the low boiling point, 

and the tendency to cavitate when 

local pressure drops. Due to these 

physical properties, high requirements 

for tightness, material resistance 

and controllability of the pump 

technology used must be met. Therefore, 

pumping units must be both 

Properties of ammonia in detail 

Property 

Value 

Molecular formula NH 3 

Boiling point (1 bar) –33.3 °C 

Vapour pressure (20 °C) 

approx. 8.6 bar 

Critical temperature 132.4 °C 

Explosion limits (LFL/UFL) 

15–28 vol. 

Auto-ignition temperature approx. 651 °C 

Water solubility (20 °C) 

529 g/l (highly exothermic) 

Corrosivity 

Strongly corrosive to Cu, Zn, Al 

ATEX relevance 

Zone 2, IIA, T1–T2 


17



These physical effects necessitate 

precise design of the suction conditions. 

This includes maintaining low 

flow velocities, ensuring short pipe 

runs and sufficient net positive suction 

head (NPSHa) is available, and 

using pumps with a particularly low 

net positive suction head required 

(NPSHr). Only then can the safe, longterm, 

low-wear operation of highpressure 

systems be ensured. 

b) Choice of materials 

The chemical reactivity of ammonia, 

particularly when it is present in water, 

places high demands on all components 

of a conveyor system that 

come into contact with the medium. 

In humid environments, ammonium 

hydroxide (NH 4 

OH) is formed, creating 

a strongly alkaline solution that 

attacks various materials, including 

copper, brass, zinc, and unprotected 

aluminium alloys. Due to these corrosive 

mechanisms, many conventional 

materials are ruled out from 

the outset. 

Additionally, austenitic steels are susceptible 

to intergranular stress corrosion 

cracking (SCC), particularly at 

fluctuating temperatures and in the 

presence of chloride-containing substances. 

Therefore, long-term and safe operation 

can only be achieved with highly 

resistant materials. 

High-strength materials, such as super 

duplex or nickel-based alloys, 

Overview of suitable materials 

Material 

are preferred as they provide excellent 

protection against cracking and 

embrittlement, even when subjected 

to fluctuating pressure and temperature 

conditions. A one-piece forged 

construction without flange connections 

reduces potential leak points 

even further. 

c) Sealing technology 

When transporting ammonia, selecting 

and designing the right sealing 

technology is key to ensuring operational 

safety. Due to the medium’s 

high volatility, vapour pressure and 

toxicity, the highest standards of 

tightness must be met for environmental 

and health protection reasons, 

as well as to maintain process 

integrity. 

Corrosion behaviour in 

NH 3 

environment 

1.4404 / AISI 316L Conditionally resistant, 

susceptible to corrosion 

in SCC 

Conventional sealing solutions, such 

as stuffing boxes or simple ring seals, 

quickly reach their limits in this context. 

Instead, what is required are 

high-density, leak-free systems that 

can be relied upon to operate over 

the long term, even under changing 

operating conditions. 

One well-established solution is the 

use of cartridge sealing systems. 

These are compact, pre-assembled 

sealing units that are integrated into 

the pump head in a modular fashion. 

These systems offer the following 

technical advantages: 

– Use of chemically resistant sealing 

materials such as PTFE, FFKM or specially 

formulated elastomers, which 

exhibit high long-term resistance to 

ammonia and ammoniacal solutions. 

Suitability 

Only suitable for use in 

exceptional cases 

– No external lubrication is required, 

which reduces the risk of additional 

sources of leakage and potential 

ignition sources in potentially 

explosive atmospheres. 

– Self-adjusting sealing elements 

that mechanically readjust to maintain 

a constant sealing effect, even 

when there are changes in pressure 

or temperature. 

– Dry-running capability for shortterm 

operation without medium, 

(e. g. during start-stop pumping processes 

or commissioning). 

– Ease of maintenance: The cartridge 

seal can be replaced quickly 

without having to remove the entire 

pump head or dismantle the highpressure 

pump. 

In addition, high-quality cartridge 

sealing systems are designed to ensure 

a stable seal even under fluctuating 

pressure conditions and during 

pulsating operation. This is particularly 

relevant for plunger pumps, 

where the flow is inherently pulsating 

due to their design. 

In safety-critical applications, such as 

in potentially explosive atmospheres, 

an ATEX-compliant design (e. g., 

equipment category 2G or 3G) is also 

required. Likewise, the choice of materials 

must be 

d) Explosion protection & ATEX 

Explosion protection is a key aspect 

of safety-related plant design when 

conveying ammonia. Ammonia forms 

an ignitable gas mixture with air at 

a volume fraction of approximately 

15–28 %. Its ignition temperature is 

around 651 °C, justifying its classification 

in explosion group IIA and temperature 

class T1. Therefore, ammonia 

must be classified as a potentially 

explosive medium, particularly in systems 

with open ventilation routes or 

potential sources of leakage. 

1.4462 (duplex) Very good resistance to 

NH 4 

OH and chlorides 

1.4410 (super duplex) High strength, excellent 

pitting and SCC resistance 

Inconel 625/2.4856 

Virtually inert to ammonia, 

temperature stable 

Standard in chemical 

applications 

Recommended for 

high loads 

First choice for 

extreme conditions 

In accordance with European Directive 

2014/34/EU (ATEX), equipment 

and protective systems intended for 

use in potentially explosive atmospheres 

must be classified and designed 

accordingly. For pump technology, 

this results in a multi-stage 

safety concept: 




– Zone classification according to 

EN 60079-10-1: Classification is based 

on the probability of release, ventilation, 

and system design. Ammonia 

applications often involve Zone 2 (occasionally 

occurring explosive atmosphere), 

and in areas with potential 

leakage sources, Zone 1 as well. 

– Equipment categories: 

– Category 3G for equipment in 

Zone 2. 

– Category 2G for equipment in 

Zone 1. 

– Temperature classes: Ammonia 

is assigned to Temperature Class T1. 

Accordingly, the maximum permissible 

surface temperatures of the 

components used must not exceed 

450 °C. 

– Ignition protection types: Electrical 

components must be designed 

with appropriate protection types 

depending on the zone, for example 

Ex-e (increased safety), Ex-d (flameproof 

enclosure), or Ex-i (intrinsic 

safety). 

– Mechanical explosion protection: 

Non-electrical components such as 

pumps are also subject to the requirements 

of EN ISO 80079-36/-37. 

In particular, an ignition source analysis 

must be performed to avoid potential 

risks such as hot surfaces, 

friction, or mechanically generated 

sparks. 

In practice, this means that motors, 

sensors, control valves, frequency 

converters and cabling must all be 

supplied and documented as explosion-proof. 

Additional requirements 

must also be observed, such as those 

relating to earthing and equipotential 

bonding, the avoidance of electrostatic 

charging, and the use of conductive 

materials for housing parts 

and connections. 

The mechanical components of a 

high-pressure pump, such as seals, 

plungers and piping, must also undergo 

ATEX assessment if they are to be 

operated in hazardous areas. In these 

cases, an analysis of ignition sources 

in accordance with EN ISO 80079-36 is 

required. 

Therefore, a comprehensive explosion 

protection concept that integrates 

all relevant components and 

is documented in accordance with 

standards is an integral part of an 

ammonia-carrying conveyor system. 

e) Regulation and process control 

Precise control of pressure and volume 

flow is crucial when conveying 

ammonia – both to avoid pressure 

surges and to safely control process 

dynamics. This is important in batch 

processes, during load changes and 

in start-stop operation, for example. 

Due to ammonia's physical properties, 

particularly its tendency to 

evaporate when pressure drops, a 

smooth conveying process without 

abrupt changes in pressure or volume 

is required. 

Small but 

powerful. 

LEWA triplex G3E 

process diaphragm pump. 

With 10 kW hydraulic power and a robust monoblock design, 

the LEWA triplex G3E reaches up to 350 spm, uses 30% less 

space, and is ideal for fuel‐gas‐supply systems on ships and 

other app lications with strict space limitations. 

Learn more: www.lewa.com



One proven solution is to use frequency 

converters (FCs) to control the 

pump's speed. This enables the volume 

flow and outlet pressure to be regulated 

according to load and demand, 

elimi nating the need for additional bypass 

systems or throttling devices. 

Technical advantages 

of FC control 

– Pressure surge-free delivery: Starting 

the system up in a controlled 

manner by gently ramping up the 

speed is a significant advantage for 

media with high vapour pressure, 

such as ammonia. 

– Load-adapted operation: The delivery 

rate can be adjusted in real 

time to match variable process requirements, 

e.g. between 10 % and 

100 % of the rated speed depending 

on the pump type. 

– Reduced energy consumption: 

Operating the pump in the optimum 

efficiency range enables a significant 

reduction in power consumption in 

partial load operation. 

– Protection of mechanical components: 

Reduced acceleration and 

braking forces decrease the load on 

mechanical drive elements, thereby 

extending the service life of bearings, 

seals, and valves. 

– Interface integration: Modern 

converters offer communication interfaces, 

such as Profinet, Modbus 

and CANopen, that enable integration 

into higher-level process control 

systems. These systems offer remote 

monitoring, condition diagnostics 

and predictive maintenance. 

In potentially explosive areas, particular 

care must be taken to ensure 

that the frequency converter is either 

installed outside the Ex zone or operated 

within a certified protective enclosure. 

Additionally, suitable motor 

protection concepts must be implemented 

to ensure safe operation in 

all operating states, such as temperature 

sensors, speed monitoring and 

standstill detection. 

Frequency converter control enables 

high levels of process reliability, flexibility, 

and energy-efficient, low-wear 

operation, making it essential for 

conveying demanding media such as 

ammonia. 

To achieve almost completely pulsation-free 

pumping, resonators are 

used on the suction and/or pressure 

side as required. 

3. Conclusion and outlook 

The pumping of ammonia places 

special demands on pump technology, 

material selection, seal design 

and plant safety. Due to its high vapour 

pressure, toxic effects, thermodynamic 

instability and explosion 

hazard, ammonia is one of the most 

challenging substances in chemical 

and energy technology processes. 

The following aspects are therefore 

crucial for the safe and reliable operation 

of ammonia conveying systems: 

– Selection of corrosion-resistant 

materials such as super duplex or 

nickel-based alloys. 

– Use of leak-free sealing systems 

made from chemically resistant materials. 

– Explosion-protection compliant 

plant technology in accordance 

with the ATEX directive, including 

mechani cal ignition source assessment. 

– Process-stable control concepts 

with variable-speed drives are used 

to avoid dynamic load peaks. 

Safe, efficient and low-maintenance 

operation in an industrial environment 

can only be achieved by combining 

these measures. This is particularly 

important for continuous high-pressure 

applications or safety-critical areas, 

such as marine engineering, offshore 

supply and power-to-X systems. 

Ammonia as a key medium in the 

energy transition 

As green ammonia is increasingly 

established as a CO 2 

-free energy 

source, its applications outside the 

traditional chemical industry are becoming 

significantly more important. 

The following developments are particularly 

noteworthy: 

– Maritime propulsion systems: ammonia 

as an emission-free marine 

fuel within the framework of IMO regulations. 

– Power-to-ammonia plants: storage 

and reconversion of renew able 

energy in the form of chemically 

bound energy. 

– Fuel cell development: use of ammonia 

as a hydrogen carrier and direct 

medium in novel SOFC systems. 

– Decentralised energy storage solutions 

in regions with high renewable 

energy production. 

In demanding applications, plunger 

pumps play a central role: They enable 

the high-pressure transfer of ammonia 

and the precise, volumetrically controlled 

injection into downstream processes, 

such as combustion systems. 

Due to their design-based, pulsating 

delivery principle, flow rates can be 

precisely metered and flexibly adjusted 

via speed-controlled drives. Combined 

with media-resistant materials 

and a modular system design, plunger 

pumps are particularly well-suited 

for dynamic, safety-critical, and highperformance 

processes. 

Tailor-made plunger pump technology 

for ammonia applications 

Thanks to its flexible, modular system 

and in-depth knowledge of materials, 

KAMAT can provide robust solutions 

for the continuous conveyance and 

injection of ammonia.: 

– Pump heads made of duplex, super 

duplex, Inconel or other special 

materials 

– Cartridge sealing systems for absolute 

tightness under changing pressure 

and temperature profiles 

– ATEX-certified designs for potentially 

explosive atmospheres 

– Frequency-controlled drives for 

smooth start-up and precise pressure 

control 

– Pulsation damping through resonators 

– Engineering and manufacturing 

in Germany: modular, traceable and 

customisable 

Whether for green ammonia production, 

maritime injection technology 




or power-to-X chains, KAMAT positive 

displacement pumps are the safe 

choice. 

KAMAT positive displacement pumps 

enable sustainable, reliable processes 

under pressure, offering flexibility, 

precision and future-proofing. 

Practical example: Transporting ammonia 

safely in industrial refrigeration 

technology using a plunger 

pump 

There were repeated problems with 

the conveyance of liquid ammonia 

(NH 3 

) in an industrial refrigeration 

system for food and storage management. 

Uncontrolled flash formation, 

leakage risks, and thermally stressed 

sealing systems resulted in higher 

maintenance costs and uncertainty 

regarding continuous operation. 

The challenge 

– Pumping a highly toxic, subcooled 

medium with a high vapour pressure 

– Minimising all emissions and leaks 

– Ensuring safe operation in the 

event of thermal fluctuations during 

continuous 24/7 operation 

– Ensuring compliance with ATEX 

requirements, the Pressure Equipment 

Directive and customer-specific 

standards 

The solution 

KAMAT developed a plunger pump 

system specifically designed for the 

conveyance of ammonia: 

– Integrated suction channel for optimised 

flow and reduced cavitationrelated 

pressure fluctuations 

– Special sealing system for toxic media 

with optional leakage monitoring 

and a barrier chamber 

– Oil-air cooling to stabilise bearing 

temperature and protect seal-sensitive 

components 

– Safety monitoring with pressure/ 

temperature sensors, relief valves 

and NH 3 

gas detection 

Fig. 2: NH 3 

pump unit implemented with 

K25000. Practical example: High-pressure 

conveyance of ammonia in an industrial refrigeration 

system featuring an ATEX design 

and a pressure pulse damper. 

– Service-friendly design with clearly 

defined maintenance points and 

modular replacement systems 

Key technical data 

– Flow rate: 340 l/min 

– Suction pressure: 76 bar 

– Differential pressure: 101 bar 

– Medium: subcooled liquid ammonia 

in accordance with DIN 8949 

Result 

Since commissioning, the system has 

operated stably without any unscheduled 

downtime. It meets all safety requirements 

and the predictable maintenance 

strategy, which includes early 

leak detection and regulated temperature 

management, has led to a 

measur able reduction in service calls. 

Conclusion 

This project exemplifies how a mediacompatible 

pump design, well-considered 

suction geometry, intelligent 

sealing technology, and a monitoring 

system can ensure operational safety, 

availability, and process stability, 

even when handling demanding media 

such as ammonia, without compromising 

environmental protection 

or personal safety. 

Standards, guidelines and technical 

regulations 

1. ATEX Directive 2014/34/EU: Directive 

of the European Parliament and 

of the Council on equipment and protective 

systems intended for use in 

potentially explosive atmospheres. 

2. DIN EN ISO 80079-36:2016-12: 

Non-electrical equipment for use in 

potentially explosive atmospheres – 

Fundamentals and requirements. 

3. DIN EN 1127-1:2019-07: Explosive 

atmospheres – Fundamentals and 

methodology. 

4. API Standard 674: Positive Displacement 

Pumps – Reciprocating. 

4 th Edition. American Petroleum Institute, 

Washington D.C., 2020. 

5. DIN EN ISO 13709:2009-07 (API 

610): Process pumps – Centrifugal 

pumps for petroleum, petrochemical 

and gas industries. 

6. IEC 60079-10-1: Explosive atmospheres 

– Part 10-1: Classification of 

areas – Explosive atmospheres due 

to gases. 

7. VDMA Standard Sheet 24284: 

Pumps – Terms, parameters and definitions. 

VDMA Publishing House, 

Frankfurt am Main. 

8. TRGS 507: Technical Rules for 

Hazardous Substances – Activities involving 

ammonia. Federal Institute 

for Occupational Safety and Health 

(BAuA), 2022. 

KAMAT GmbH & Co. KG 

Witten, Germany 

www.KAMAT.de 


21



Liquid tar: a dirty challenge for pumps 

From hydrodynamic seal to dry-running magnetic coupling 

Hans-Wilhelm Möllmann 

Liquid tar is an important raw material 

in the chemical industry, even 

though its use has changed significantly 

over time. What has not 

changed over the years is the fact 

that liquid tar places particularly 

high demands on transport and, in 

particular, on the shaft seals of the 

centrifugal pumps used. Many processing 

companies have resigned 

themselves to the fact that leaks in 

the pumps are inevitable. However, 

this is not only unsanitary and hazardous 

to health, but also incompatible 

with increasing environmental 

regulations. Not to mention the 

costs incurred by the fact that leaks 

in the pumps worsen quickly and 

the pumps have to be replaced frequently. 

Fortunately, there are special 

pumps that can easily cope with 

the challenges of pumping liquid tar 

for many years. 

The problem 

Liquid tar poses such a major problem 

for conventional pumps because 

it tends to stick to surfaces, especially 

in the shaft seal area of the pump. 

It also usually contains abrasive particles 

and aggressive ingredients. In 

addition, it reaches temperatures of 

up to 380 degrees Celsius in many 

scenarios. Conventionally, pumps 

with hydrodynamic seals are used to 

convey liquid tar. In these pumps, impeller 

blades and a downstream seal 

expeller are used to relieve the shaft 

passage hydrodynamically from the 

pump and inlet pressure, thus keeping 

the medium away from the shaft 

passage. This type of pump is very 

reliable and sufficiently suited for 

transporting many media used in the 

chemical industry, fertilizer production, 

or environmental technology 

that are not subject to specific technical 

regulations on air quality. However, 

when pumping liquid tar at temperatures 

above 300 degrees Celsius, 

the limitations of this kind of pump 

are exceeded and the stationary 

seals, usually in the form of a gland 

packing, fail, resulting in the leaks described 

above, especially when the 

pumps are shut down. 

Centrifugal pump with dry-running 

magnetic coupling 

Special types of centrifugal pumps with 

magnetic couplings, on the other hand, 

can withstand the stresses involved in 

pumping hot liquid tar or, more generally, 

hot liquids containing solids. 

Centrifugal pumps with magnetic 

coup ling are essentially based on the 

principle of contactless power transmission 

via magnetic fields. The motor 

shaft carries an outer magnetic rotor, 

which transmits the magnetic forces 

to an inner magnetic rotor through a 

containment can. The containment 

can serves as a hermetic barrier, completely 

shielding the pumped medium 

from the environment. 

The core concept of Bungartz’s magnetic 

coupling technology consists 

of a strict physical separation of the 

conveying chamber from the bearing 

and sealing area. The grease-lubricated 

roller bearings run in a closed 

gas atmosphere that is independent 

of the conveying medium, typically 

using nitrogen injection. The key difference 

to conventional magnetic 

pumps lies in the use of a non-metallic, 

eddy-current-free containment 

can. This enables loss-free magnetic 

field transmission without the problematic 

heat generation and demagnetization 

risks that occur with metallic 

containment cans. Also, solids 

present in the pumped medium do 

not enter this area. 

The design features an intelligent triple 

seal consisting of hydrodynamic 

relief via impeller back blades, a lip 

seal that does not come into contact 

with the product as a secondary safety 

level, and a barrier gas inlet in the 

bearing area. This means that even if 

the containment can were to break, 

there is no risk of product leakage. 

The fundamental advantages of 

this design are considerable: since 

the bearing and magnetic coupling 

are completely separated from the 

pumped medium, almost all types of 

liquids can be pumped without any 

problems, including heavily contaminated, 

gas-laden, boiling or viscous 

media. The eddy-current-free mag- 




netic field transmission has no energy 

losses and operates completely independently 

of the pumped medium. 

The solution: 

vertical with a large gap 

A standard magnetic coupling can 

certainly be designed for higher temperatures. 

However, when combined 

with the challenging properties of 

liquid tar, conventional designs fail. 

Bungartz solves this problem in facilities, 

which convey liquid tar, by using 

vertical centrifugal pumps with dryrunning 

magnetic couplings, an extralong 

drive shaft and a heat barrier. 

This increases the distance between 

the bearing and the pumped fluid in 

the impeller to such an extent that 

the bearing temperature does not exceed 

70 degrees Celsius, even with a 

pumped medium at 380 degrees Celsius. 

This temperature is no problem 

for the robust roller bearings used. 

Because the containment can and 

the large distance between the bearing 

and the impeller form a thermal 

barrier, there is no need for cooling 

units. The ambient air alone is sufficient 

to cool the system. This reduces 

the complexity of the overall system 

and thus its susceptibility to failure. 

Pumps of the type described have 

been operating without failure or 

leakage for many years at Bungartz’ 

customers. 

Not just tar 

Special centrifugal pumps with dryrunning 

magnetic couplings offer 

many other advantages, depending 

on whether they are designed 

for horizontal or vertical installation. 

These include guaranteed dryrunning 

safety thanks to the roller 

bearing system in a gas atmosphere, 

maintenance-free operation of the 

bearing and coupling unit for at least 

three years, and high intrinsic safety 

for ATEX-compliant applications up 

to Zone 1 without additional thermal 

monitoring. Similar to scenarios 

where liquid tar is transported, these 

pumps more than compensate for 

their higher initial price due to their 

design with reliability and durability. 

In a special design, these pumps are 

also suitable for pumping boiling or 

gaseous media. 

The Author: 

Hans-Wilhelm Möllmann, 

Head of Research and Development 

at PAUL BUNGARTZ GMBH & CO. KG 

Düsseldorf, Germany 

www.bungartz.de 


23



Minimal pulsation thanks to pump 

synchronization: 6-head combination pump 

with Smart Monitoring delivers water and 

sulfuric acid evenly into static mixer 

Flexible adjustment of the recipe thanks to 

electrical stroke length setting 

Clean water, the most important 

raw product in the world, is increasingly 

becoming a luxury good. 

Water treatment is therefore becoming 

more and more important. 

A chemical company produces sulfate 

granules at its site in Sweden 

for this purpose. The plant, which 

mixes water and sulfuric acid in 

the production process, needed to 

be renovated. The previous pumps 

from Leonberg-based pump specialist 

LEWA had been running perfectly 

for 30 years. However, since 

the manufacturer no longer carries 

the old models in its product range, 

there are hardly any corresponding 

spare parts for them. To ensure 

production for the coming decades, 

the chemical company therefore decided 

to purchase a new LEWA combination 

pump with a total of six 

pump heads: three of the LDD3 M9 

type and three of the LDE3 M9 type. 

They are optimally synchronized 

with each other by an electronic 

control system at a phase shift of 

0/120/240 degrees for the process 

water and 60/180/300 degrees for 

the acid. To enable flexible adjustment 

of the mixture recipe, the 

LDD3 process water pump features 

electrical stroke length setting. In 

addition, the combination pump 

is equipped with innovative LEWA 

Smart Monitoring, which monitors 

the performance and condition of 

the units around the clock. 

the customer. During the dilution of 

concentrated sulfuric acid, it reacts 

strongly with water. In the static mixing 

installation, temperatures of up to 

300 °C can suddenly arise, while the 

aggressiveness of the acid steadily increases. 

“In the event of failures, defects 

or unplanned shutdowns of the 

plant, backflow from the mixer into 

the pumps can occur,” Moller added. 

“The units must therefore be able to 

withstand the dangerous acid and 

high temperature as well as pressure 

fluctuations and must not have vulnerable 

seals.” 

At the Swedish production site there 

had been already two combined 

LEWA pump systems in use, each 

with five pump heads, for the production 

of sulfate granules since 1989 

and 1990, respectively. The chemical 

company was extremely satisfied 

with these for more than 30 years. 

However, the Leonberg-based pump 

specialist no longer carries these 

older models in its product range, so 

the corresponding spare parts are 

no longer available. “The customer 

was convinced of the reliability and 

high functionality of the LEWA units 

based on their many years of experience, 

so I suggested replacing the discontinued 

models with new pumps 

from the same manufacturer to ensure 

production for the coming decades,” 

Moller says. “This also gave 

us the opportunity to significantly reduce 

pulsation and therefore the size 

of the pulsation dampers on the new 

pumps.” 

Optimal synchronization of the six 

pump heads over 360 degrees 

Especially for this highly sensitive application, 

the pump specialist developed 

a LEWA ecoflow combination 

“The production of sulfate granules 

for chemical water treatment in a 

continuous process is a very delicate 

matter,” says Torsten Moller, sales 

representative for LEWA in Sweden. 

Moller is managing the project with 

Fig. 1: To ensure production for the coming decades, the customer decided to purchase a 

new LEWA combination pump with a total of six pump heads: three of the LDD3 M9 type 

and three of the LDE3 M9 type. All images: LEWA 




pump with a total of six M900 pump 

heads: three each for the sulfuric 

acid and the process water. In order 

to safely pump the 85 to 98 percent 

sulfuric acid, the units have to be hermetically 

tight. The ecoflow range 

meets this requirement. For the acid 

pump, the choice was made for the 

LDE3 model, which is made of highly 

corrosion-resistant Hastelloy so that 

it can withstand the aggressive medium. 

The smaller LDD3 model is sufficient 

for the process water pump. To 

avoid problems in the event of backflow 

of diluted sulfuric acid from the 

mixer into the pumps, the customer 

chose 316L stainless steel for the material, 

since it has good acid resistance. 

In order to be able to flexibly 

dilute the sulfuric acid depending on 

the end product, the LDD3 features 

electrical stroke length setting from 0 

to 30 mm. 

To ensure that the two media are 

conveyed into the static mixer without 

a hitch and that strong chemical 

reactions do not occur, a constant 

flow rate must be ensured. “To keep 

pulsation as low as possible, we 

shifted the phases of the individual 

pump heads of a medium by 120 degrees 

each,” explains Moller. “In addition, 

the frequencies of the LDD3 

and the LDE3 differ by 60 degrees.” 

The phase shift of 0/120/240 degrees 

for the process water and 60/180/300 

degrees for the sulfuric acid results 

in nearly perfect pump synchronization 

over 360 degrees. Because of 

Fig. 2: To enable flexible adjustment of the sulfuric acid mixture recipe, the LDD3 process 

water pump features an electrical stroke length setting. 

how well the six pump heads work 

together, the new system manages 

with significantly smaller pulsation 

dampers than before. 

Smart Monitoring ensures 

continuous production 

As the heart of the plant, the new 

LEWA combination will ensure the 

continuous production of sulfate 

granules. So that nothing is left to 

chance, the units were equipped with 

innovative LEWA Smart Monitoring. 

The system not only enables precise 

control of the pump, but also automatically 

monitors all key operating 

figures around the clock and detects 

malfunctions and process deviations 

in real time. Due to the combination 

of integrated sensor technology and 

compatible evaluation software, the 

system seamlessly records changes 

in pulsations or signs of wear on 

the pump valves, for example. This 

produces up to 13,000 values per 

second, which the algorithm uses to 

calculate meaningful key figures. This 

also makes it possible to trace which 

components are causing the detected 

deviations. “For example, if a valve 

stops working properly, maintenance 

personnel immediately know which 

valve in the pump is involved,” Moller 

explains. “It is no longer necessary 

to open all twelve valves individually 

and check them manually, which 

saves a lot of working time.” 

LEWA Solutions GmbH, 

Leonberg, Germany 

https://www.lewa.com/en/pumps/ 

metering-pumps/lewa-ecoflow or 

https://www.lewa.com/en/services/ 

digital-services/lewa-smart-monitoring 


25



The firewood wizard from the Spessart region 

To keep homes pleasantly warm in 

winter, Pascal Hoh has been supplying 

households with firewood from 

the forests of the Spessart region. 

His service has become more popular 

each year. To keep up with the demand 

with a small team, the young 

entrepreneur relies on modern technology. 

Among other things, he uses 

a mobile automatic sawing and splitting 

unit as well as grease pumps from 

Lutz Pumpen that can be operated 

with a cordless screwdriver. 

For Pascal Hoh, the Spessart forests 

are home. The 35-year-old not only 

enjoys going for walks in nature to 

recharge, he also earns part of his 

livelihood here. With his small company 

Holz-Hoh, based in Altfeld—a 

district of the town of Marktheidenfeld 

in the Lower Franconian district 

of Main-Spessart in Bavaria—he has 

been offering people in the region, in 

parallel with his work as a sales technician, 

not only firewood from the 

surrounding forests for cold winter 

evenings since 2015, but he now also 

supports forest owner groups in the 

Spessart with forestry and sawing operations—a 

service that is becoming 

ever more popular. Accordingly, the 

workload has been increasing each 

year. And with it, the fleet that Pascal 

Hoh is operating is also expanding. 

This now includes a tractor with a forestry 

crane, a four-axle roll-off tipper, 

and a mobile automatic sawing and 

splitting unit. “In the first year, I sold 

around 80 cubic meters of wood,” 

recalls Pascal Hoh. “Today, sales have 

increased to around 7,000 cubic meters.” 

To dry the wood, Hoh uses the 

waste heat from four biogas plants in 

the region, allowing him to supply his 

customers year-round. In the early 

days, the wood was stored in an orchard. 

Since then, the young entrepreneur 

has purchased a commercial 

property for this purpose. 

balancing act that Pascal Hoh has to 

perform between his two jobs. He 

wants to handle as much work as possible 

on his own so that he does not 

have to bear the full risk associated 

with a larger workforce. He manages 

this thanks to the support of several 

part-time workers and technology 

that simplifies his day-to-day work. A 

major example of this is the sawing 

and splitting machine with a forestry 

crane, which automatically processes 

felled logs with diameters of up to 70 

centimeters at the roadside into furnace-ready 

firewood. A smaller-scale 

example is the maintenance of the vehicles 

and machines. “In the past, for 

example, it was incredibly laborious 

to fill the central lubrication system of 

the sawing and splitting machine with 

lubricating grease,” says Pascal Hoh. 

“Each time, we had to empty several 

400-gram cartridges using a manual 

grease gun.” The hundreds of strokes 

cost not only time, but after weeks 

of repetition, they could also cause 

strains in the hands, wrists, and forearms. 

“Therefore, we were desperately 

looking for an alternative that would 

simplify the maintenance work.” 

Instead of tiring manual pumping: 

a grease pump that can be powered 

by a cordless screwdriver 

But what would speed up the maintenance 

work? At first, Pascal Hoh 

considered pneumatic piston pumps 

that are operated with compressed 

air. They would have reduced the effort 

required, but would have been 

too inflexible, since not all machines 

and vehicles have a compressed air 

connection. The young entrepreneur 

finally found what he was looking 

for at the pump manufacturer 

Lutz Pumpen, based in Wertheim in 

Baden-Württemberg. The company 

has developed a new filling tool 

However, expansion also brings its 

own challenges. One of them is the 




called Lutz Lube Drive. What makes 

this tool unique is that it doesn't require 

any physical strength, nor a 

pneumatic connection or electric motor. 

It only requires an object that is 

part of the standard equipment in 

every workshop or business. “We 

have developed the world’s first eccentric 

screw pump tube that is powered 

by a standard cordless screwdriver,” 

says Andreas Rössler, Head 

of Sales at Lutz Pumpen. “This allows 

you to conveniently top up the 

central lubrication systems of machines 

and vehicles with lubricating 

grease, even when out in the forest, 

without physi cal strain, a power supply, 

or pneumatics.” The filling tool is 

suitable for containers with a capacity 

of 10 to 60 kg and for all standard 

NLGI 2 lubricating greases. 

The Lube Drive was designed to be as 

simple as possible to operate. When 

Pascal Hoh needs to fill a lubricating 

grease system in the forest, he 

places the lubricating grease container 

close to the vehicle or machine. 

The metal pump tube is secured in 

the container by a support. The pump 

head with the drive interface for the 

cordless screwdriver is located at the 

upper end. Hoh then connects the 

hose line to the central lubrication 

system and starts the cordless screwdriver. 

The eccentric screw pump 

tube gets to work. The eccentrically 

rotating rotor turns inside the stator. 

This creates moving chambers that 

transport the viscous grease from 

the bottom to the top, through the 

pipe directly into the central lubrication 

system. “This functional principle 

enables uniform, low-pulsation 

conveying,” emphasizes Andreas 

Rössler. The deli very rate is two kilograms 

per minute. According to Pascal 

Hoh, this is sufficient for filling the 

central lubrication systems. “Since we 

started using the Lube Drive, maintenance 

work has become significantly 

more ergonomic,” says Hoh. “By simply 

connecting the pump to a cordless 

screwdriver, the strain on your 

hands, arms, and back is noticeably 

reduced, while at the same time 

speeding up the filling process.” 

Battery-powered pump for diesel: 

like having your own fuel station in 

the forest 

Pascal Hoh has also developed a solution 

for refueling in the forest that 

makes the work easier. “In the past, 

we had to lift 30-liter diesel canisters 

up to the filler neck, which is roughly 

at hip height. It was like having to do 

some super-tiring strength training at 

the gym,” says Hoh. “We can now do 

this with the B2 Battery cordless canister 

pump from Lutz Pumpen.” The 

plastic pump tube is mounted in a 

mobile diesel tank that the team always 

has with them in the forest on 

a trailer. A battery-powered motor 

drives the pump, which draws diesel 

from the container and transfers 

it into the tank through a hose 

equipped with a nozzle. “It's as if we 

had our own gas station right in the 

middle of the forest. In the past, nobody 

wanted to take on this job. Now, 

everyone volunteers.” It is also convenient 

that the B2 Battery is modular. 

This allows Pascal Hoh to permanently 

install multiple pump tubes 

in different canisters, including one 

specifically designed for handling Ad- 

Blue. In day-to-day operations, he can 

conveniently couple and uncouple 

the motor to carry out the various 

tasks. This reduces investment costs. 

The company now also uses the B3 

Battery model to fill the saw-splitting 

machine's oil tank, so 20-liter canisters 

no longer need to be carried. 

“With a flow rate of around 50–60 

liters per minute, the canister pumps 

are powerful and far surpass most 

permanently installed diesel pumps 

in tanks. All of these were investments 

that have made our work significantly 

faster and much more ergonomic.” 

Lutz Pumpen GmbH 

Erlenstr. 5-7 

97877 Wertheim, Germany 

www.lutz-jesco.com 


27



Compact pump technology for tankers 

Reliable conveying in confined spaces 

Vanja Cobec 

The demands placed on pump technology 

in tanker construction are 

high: Conveying processes have to 

run reliably and efficiently in confined 

spaces. Pulsation-free operation 

and a stable delivery rate are 

crucial to ensure the operation of 

the tankers and at the same time 

maximise the service life of the components. 

Weight and design also 

play an important role, as tankers 

often only offer limited installation 

space. The pumps must therefore 

be able to be flexibly integrated into 

existing loading processes without 

making maintenance and operation 

more difficult. 

Against this background, many tanker 

manufacturers and logistics companies 

in the tanker sector are dependent 

on pumps that 

Fig. 1: The LoadMaster rotary lobe pump combines low weight with compact installation 

dimensions. All images: Vogelsang GmbH & Co. KG 

– are compactly constructed, 

– have the lowest possible 

tare weight, 

– pulsation-free and steady 

conveying, 

– work energy-efficiently and 

– are designed to be easy to 

maintain. 

Pump LoadMaster: Reduced tare 

weight, smooth running 

Vogelsang has developed the 

LoadMaster for these requirements. 

The newly designed rotary lobe 

pump combines a particularly compact 

design with a significantly reduced 

weight of up to 45 percent 

compared to comparable predecessor 

models. Thanks to the hydraulic 

motors that are flange-mounted directly 

in the housing, it is also up to 

25 cm shorter – a particular advantage 

when installed in tankers, where 

the available installation space is especially 

limited. The compact design 

of the pump creates additional space 

reserves for a higher drum volume 

and enables flexible integration into 

the tanker without the need for extensive 

adjustments to the existing 

loading processes. New synchronisation 

discs also ensure smooth running. 

Mechani cal loads are significantly 

reduced on seals, for example. 

The pump can be equipped for specific 

process requirements on an optional 

basis – for example with the 

InjectionSystem for improved delivery 

performance and a significantly 

longer pump service life, HiFlo rotary 

lobes for particularly low-pulsation 

delivery or a speed sensor for precise 

flow monitoring. 

An example of an industry 

application shows the 

concrete effect of the pump’s 

properties: 

The scenario: Loading and 

filling processes on a tanker 

Liquid and viscous media need to 

be loaded safely and in a controlled 

manner in order to fill tankers. In 

Designed for long service life and easy maintenance 

Ease of maintenance is a decisive factor in ensuring uninterrupted operation. 

This is made possible by the QuickService concept, which simplifies 

maintenance and reduces the time required. In addition, the pump 

is equipped with a pre-assembled quality cartridge mechani cal seal. This 

allows for easy replacement of the shaft seal and ensures safe restarting 

after maintenance work. The mo dular design of the pump also makes it 

possible to carry out targeted maintenance work on individual assemblies. 

Axial protective plates made of highly wear-resistant special steel reliably 

protect the entire pump chamber. This extends the maintenance intervals, 

reducing downtimes and operating costs. 


The LoadMaster rotary lobe pump at a glance 

– Compact design 

Small installation dimensions for easy integration into 

tankers 

– Low weight 

Facilitates installation, retrofitting and structural design 

– Smooth running 

Pulsation-free conveying reduces vibrations and ensures 

a smooth conveying process 

– Reliable conveying 

Consistent flow rate for stable processes 

– Flexible integration 

Suitable for tankers and tank trailers 

14TH INTERNATIONAL 

VALVE TRADE FAIR & 

CONFERENCE 

MAKE YOUR 

BUSINESS 

FLOW 

Fig. 2: Rendering of the LoadMaster rotary lobe pump 

this application, the LoadMaster 

pump conveys the medium 

from the tanker into a stationary 

storage tank. The pump’s 

smooth running ensures an 

even flow rate during the filling 

process, reduces pressure 

surges and vibrations and 

thus contributes to a safe, controlled 

conveying process. 

Compact pump technology 

for greater flexibility 

The LoadMaster provides 

tanker manufacturers and 

users with a rotary lobe pump 

that substantially simplifies industrial 

pumping processes. 

The combination of compact 

design, low weight and smooth 

running creates greater flexibility 

– precisely where space 

is limited and stable, smooth 

opera tion is important. 

The Author: Vanja Cobec, 

Director Product Management 

at Vogelsang GmbH & Co. KG 

Essen/Oldb., Germany 

www.vogelsang-info/en/ 

DÜSSELDORF 

valveworldexpo.com 

Good Company



Renovation during ongoing operation: 

Mobile pump supports mobile construction 

site in sewage treatment plant 

Urgent repairs were needed on the 

primary clarifier and pipes at the 

Bad Reichenhall sewage treatment 

plant – but shutdown was not an 

option. With the TORNADO ® Mobil 

from NETZSCH, it was possible to 

reliably divert the raw wastewater 

over a distance of 200 metres. The 

mobile pump can be used flexibly at 

different sections of the construction 

site. This meant that all repair 

work could be carried out without 

interrupting operations. 

the supply and discharge pipes had 

to be renovated as well. ‘You can’t just 

“switch off” a sewage treatment plant 

to gain access to the affected areas,’ 

explains Peter Wohlschlager, electrician 

at the Bad Reichenhall sewage 

treatment plant. To make matters 

worse, different sections had to be 

repaired, which meant that the construction 

site kept changing location. 

‘We needed a solution that would allow 

repairs to be carried out as quickly 

and easily as possible without interrupting 

operations,’ Wohlschlager 

continues. 

Pump on wheels for flexible use 

NEMO ® progressing cavity pumps 

have been successfully used in Bad 

Reichenhall for several years. In 2021, 

the Bad Reichenhall sewage treat- 

With an annual wastewater flow 

of approximately 3,500,000 cubic 

metres, the Bad Reichenhall wastewater 

treatment plant is an important 

part of the municipal infrastructure. 

It is operated entirely by the local authority, 

which attaches great importance 

to local control and sustainable 

management. 

Recently, however, the plant faced a 

real test. As part of a concrete renovation 

project for the primary clarifier, 

Fig. 2: The TORNADO ® Mobil is mounted on a trailer, making it ideal for temporary redirection 

and challenging renovation projects. 

Fig. 1: Renovation during ongoing operation: The Bad Reichenhall sewage treatment plant 

was looking for an innovative solution. 

ment plant decided to purchase a 

TORNADO ® Mobil as a flood protection 

pump to bridge any possible failure 

of the three flood pump stations. 

The pump is equipped with an electric 

motor and allows for sensitive 

adjustments to ensure reliable and 

accurate conveying, even with low 

wastewater volumes. The sewage 

treatment plant also planned to use 

the TORNADO ® Mobil for the concrete 

renovation project. After consulting 

with Pitt Mair, Area Sales Manager at 

NETZSCH, nothing stood in the way 

of this application. ‘The TORNADO ® 

Mobil was developed specifically for 

applications like this,’ reports Mair. 

The powerful TORNADO ® XLB-8/2 rotary 

lobe pump is mounted on a trailer, 

making it quick and easy to deploy 

exactly where it is needed. 




In Bad Reichenhall, the TORNADO ® 

Mobil was positioned close to the 

basin to ensure a short suction side. 

Three suction hoses fed the raw 

wastewater directly into the pump, 

which reliably transported it approximately 

200 metres to another part 

of the plant. There, the cleaning process 

could continue as usual, while 

the damage to the pumped-out basin 

and the drained pipes was repaired 

and sealed using an inliner. 

Fig. 3: In Bad Reichenhall, the TORNADO ® 

Mobil was positioned next to the primary 

clarifier, where it pumped raw wastewater 

from a depth of 7 m. 

Reliable pumping of liquids 

containing solids 

With a constant flow rate of up to 905 

cubic metres per hour at a maximum 

pressure of 3 bar, the TORNADO ® 

XLB-8/2 is specially designed to convey 

large volumes – for example, the 

contents of the 1,500 cubic metre 

primary clarifier in Bad Reichenhall. 

‘Solids with a grain size of up to seven 

centimetres do not affect the delivery 

rate in any way,’ adds Pitt Mair. ‘The 

pump can also easily cope with the 

typical contaminants found in raw 

wastewater, such as sand, wood residues, 

toilet paper residues or faeces. 

Inside the pump, two three-wing 

helical lobes rotate and mesh closely 

with each other. This rotary motion 

creates a vacuum on the suction 

side, which automatically draws raw 

wastewater directly from the primary 

clarifier to depths of up to seven 

Fig. 4: The TORNADO ® XLB-8/2 is designed 

for large flow rates. Viscous media and 

solids up to 70 mm in size pose no problem 

for this robust pump. 

metres. This means the TORNADO ® 

can restart immediately, even with 

fluctuating water levels, air in the suction 

area, or interruptions. 

Easy handling and maintenance 

In addition to mobility, the ease of 

handling the pump was a decisive 

factor for the sewage treatment plant 

operator, also with regard to future 

applications. Thanks to the patented 

Full Service in Place (FSIP ® ) design, the 

TORNADO ® can be maintained directly 

at the site of operation without the 

need for time-consuming removal or 

dismantling. For many tasks, it is sufficient 

to open the housing cover to 

access the lobes, seals and other essential 

components. ‘The design is 

geared towards making transport, 

flexible operation and maintenance 

as simple and intuitive as possible,’ 

Fig. 5: Two intermeshing rotary lobes generate 

negative pressure on the suction side, 

which draws in the pumped medium. 

explains Pitt Mair. ‘Even replacing 

wear parts or quick cleaning can be 

done in just a few steps.’ 

Proven excellence, 

good partnership 

The cooperation between the Bad 

Reichenhall sewage treatment plant 

and NETZSCH was goal-oriented and 

cooperative throughout the entire 

project. Thanks to the existing experience 

with NETZSCH pumps on site, 

the contact persons were quickly 

found. From the initial presentation 

of the TORNADO® Mobil to the successful 

completion of the renovation 

measures, it became clear how valuable 

close cooperation and personal 

support are in everyday technical 

work. 

‘With the TORNADO ® Mobil, we were 

able to quickly establish a solution 

for repairing the primary clarifier and 

pipelines. The expert advice provided 

by the experts at NETZSCH made 

the project a complete success,’ says 

Wohlschlager. 

TORNADO ® Mobil – rotary lobe 

pump on wheels 

The TORNADO ® Mobil combines 

the power and tolerance to solids 

of a rotary lobe pump with maximum 

flexibility in mobile use – 

ideal for temporary diversions, 

renovations, and demanding applications 

directly on site. 

Flow rate: Up to 1400 m³/h, 

depending on the model 

Max. pressure: Up to 6 bar, 

depending on model, higher 

pressures on request 

Pumped media: Resistant to 

solids with a grain size of up to 

70 mm 

Drive: Diesel or electric 

Assembly: Mobile on trailer 

Maintenance: Full Service in 

Place (FSIP ® ) 

NETZSCH Pumpen & Systeme GmbH 

Waldkraiburg, Germany 

https://pumps-systems.netzsch.com/en 


31



From membrane filtration to mobile pumps: 

Rotary lobe pumps in use 

for the highest demands 

You can recognize them immediately, 

even from a distance: their water 

blue color and characteristic pump 

cover. These two features have 

long since become a trademark and 

stand for rotary lobe pumps “Made 

in Müns terland” that have proven 

themselves in the most demanding 

applications worldwide. Whether in 

industry, in the marine and offshore 

sectors, or in wastewater treatment 

for municipalities and industrial 

companies – wherever fluids need to 

be pumped reliably, gently, and efficiently, 

these robust displacement 

pumps are at home. 

In wastewater treatment, the pumps 

are used for conveying a wide range 

of different fluids and sludges: primary 

sludge, surplus sludge, grease sludges, 

elastomers, and permeate, but the 

solids-resistant positive displacement 

pumps can also be found in digestion 

tower convection. But how is this possible? 

Why can the Börger rotary lobe 

pumps convey so many different fluids? 

lows for several million possible combinations 

in practice. Each pump is 

configured and manufactured from 

25 pump sizes with flow rates of up to 

1,440 m³/h precisely for its specific application. 

Each component is selected 

to optimally suit the respective operating 

conditions. The result is a very long 

service life, minimum failure rates, 

and maximum operational reliability. 

Or, to quote a well-known advertising 

slogan: It runs and runs and runs. 

Mobile use 

The pumps also demonstrate their 

strengths in mobile applications. The 

compact, low-on-space design, unproblematic 

pumping in slurp operation 

and the ability to react flexibly to 

changing flow rates by operating at 

different speeds are reasons why our 

pump is the ideal mobile pump. 

Thanks to this combination of individuality, 

robust design, and maintenance-friendly 

construction, Börger 

Rotary Lobe Pumps can be used for 

almost any pumping task. Here are 

some examples: 

Example 1 

Pumps in membrane filtration 

A wastewater treatment plant was 

looking for pumps for conveying per- 

Individual configuration 

The key to versatility lies in exceptional 

adaptability. Börger consistently relies 

on a modular design principle that al- 

meate. The operator of the plant had 

only gained experience with centrifugal 

pumps in this area before. However, 

he was dissatisfied with the 

complex and failure-prone piping 

construction required for backwashing 

the membranes. 

Today, four Börger BLUEline rotary 

lobe pumps are used in membrane 

filtration. They suck the water 

through the membranes and can be 

operated in reverse by simply changing 

the direction of rotation. This allows 

backwashing with filtered water 




to be carried out without a complicated 

valve and pipe system, 

making the system much simpler 

and more reliable. 

vice life of the hydraulic motor, 

the customer had a pressureless 

leakage oil line retrofitted on the 

wheel loader. 

Since different flow rates are required 

for filtration and backwashing, 

the pumps are speedcontrolled 

via a frequency 

converter. This way, the flow 

rate can be adjusted directly and 

flexibly. 

During operation, the Börger rotary 

lobe pumps impress with their 

stable running and low wear. In 

addition to the high quality, customers 

are particularly impressed 

by the ease of maintenance of the 

pumps (MIP ® = Maintenance in 

Place). The pumps can be maintained 

by the customer's personnel 

in a very short time. This keeps 

downtime and maintenance costs 

to a minimum. 

Example 2 

Particularly useful: hose storage 

compartments are integrated 

into the mobile unit. Suction and 

pressure hoses can be carried 

along directly, so that the pump 

is immediately ready for operation 

at the point of use. This saves 

time and makes the solution even 

more efficient in everyday use. 

With the help of the manufacturer’s 

own control technology, 

the pump can also be operated 

unattended. A level sensor monitors 

the fill level in the respective 

basin or sewer, and the control 

system automatically switches 

off the pump as soon as the minimum 

fill level is reached. This ensures 

maximum safety and reduces 

the workload for operating 

personnel. 

ATEX-compliant pump for 

pumping chemical wastewater 

A large chemical company uses 

a Börger BLUEline Nova rotary 

lobe pump to empty two process 

water tanks. The contaminated 

process water from different 

plants on site is collected in two 

1,000 m³ basins. The basins are 

located in a potentially explosive 

atmosphere. Two submersible 

motor pumps are used to empty 

the basins. Since these pumps 

are not ATEX-compliant, they 

only empty the basins to 70 % so 

that they do not run dry. The remaining 

30 % are emptied by the 

Börger BLUEline Nova. The pump 

is ideally suited for this application, 

since it is capable to pump 

in slurp operation and is insensitive 

to dry running. 

It is installed on a platform above 

the basins and sucks in the medium 

with a pumping height of 

up to 4 m. The stainless-steel 

rotary lobe pump has an ATEXcompliant 

design for use in the 

Ex-zone and also meets the requirements 

of TA-Luft. 

The casing protection made of 

stainless steel protects the pump 

casing against wear caused by 

the abrasive components in the 

pumped medium. A Variocap is 

an effective, space-saving and inexpensive 

device to protect the 

pump from uncontrolled pressure 

surges. The overpressure 

protection is simply installed on 

the pump instead of the quick-release 

cover. Reversibility is maintained 

thanks to the purely mechanical 

process. 

Example 3 

Mobile pump for a 

telescopic loader 

A wastewater engineer was 

looking for a powerful mobile 

pump that could be used flexibly 

both at the sewage treatment 

plant and in the sewer network. 

The requirements were clear: 

robust, quickly available, and 

easy to handle. Since the sewage 

treatment plant had purchased 

a new telescopic loader 

for sewage sludge loading a 

few months earlier, a simple 

and clever idea arose: Why not 

operate the mobile pump directly 

via a hydraulic motor on 

the telescopic loader? 

The idea was convincing across 

the board. A BLUEline rotary lobe 

pump was mounted on a specially 

designed mobile unit that can 

be easily attached to the telescopic 

loader via an adapter. This 

allows the pump to be conveniently 

transported to the respective 

location – whether on the 

company premises or for use in 

the sewer. 

The pump is driven by a hydraulic 

motor. To ensure a long ser- 

The wastewater engineer is correspondingly 

impressed. With 

the custom-made mobile solution, 

he now has flexible, powerful, 

and practical pump technology 

that makes everyday work 

noticeably easier. 

At the IFAT, you can find Börger 

in hall B1 booth 439. 

Börger GmbH, 

Borken-Weseke, Germany 

www.boerger.com 


33


Screw pumps 

Reliability meets efficiency 

SEW-Eurodrive modernizes screw pumps in the Daun 

sewage treatment plant 

Christian Rüttling 

When it comes to durable and 

ener gy efficient drive solutions, 

SEW-Eurodrive is a sought after 

partner – including in the water and 

wastewater sector. At the wastewater 

treatment plant of the Daun 

municipal association, two central 

screw pumps were equipped with 

new drive technology. With the retrofit 

carried out by SEW-Eurodrive, 

the operator not only received a 

technically advanced solution, but 

also a complete package consisting 

of delivery, installation, and commissioning. 

Everything from a single 

source and consistently geared toward 

maximum operational reliability 

and energy efficiency. 

The two identical screw pumps at the 

Daun sewage treatment plant inlet 

are essential for their operation: They 

raise the incoming waste water to the 

required ground level to enable the 

further cleaning process. The sewage 

treatment plant is located in the Vulkaneifel, 

between the cities of Trier 

and Koblenz, about 60 kilometers 

south of Bonn, and has a treatment 

capacity of 22.500 population equivalents 

(PE). The originally installed 

drive technology for the screw pumps 

consisted of a helical gear unit with a 

free input shaft, which was connected 

to a separate motor via a belt. This 

solution was functional but had typical 

disadvantages such as increased 

maintenance and energy losses due 

to the belt drive. 

With increasing operation time, it became 

apparent that the aging drive 

technology no longer met the requirements 

for reliable and efficient 

operation. Damage to the roll- 

Fig. 1: SEW Collage Screw pump, photos: SEW, association municipality of Daun 

Legend of the collage 

1. The original drive of the worm pump consisted of a helical gear unit with an upstream belt 

2. The existing drive technology no longer met the requirements in terms of reliability and efficiency 

3. The new DRU.. Is directly connected to the helical gear unit 

4. The two screw pumps of the Daun sewage treatment plant are fit for the future with the new drives 

5. Different drive concepts are available for the operation of worm pumps – in this example, the design with motor adapter and 

the variant with belt drive 



Screw pumps 

ing bearing on one of the two gear 

units also necessitated rapid action. 

The operator of the system was faced 

with a decision: Repair of the existing 

drive or complete replacement. The 

choice was for a future-proof solution 

– the replacement of both drive units 

with modern, energy-efficient gearmotors 

from SEW-Eurodrive. 

Direct drive instead of belt: Energyefficient 

and maintenance-friendly 

The new drives are also designed as 

helical gear units, but differ from the 

previous solution in one crucial way: 

The motor is connected directly to 

the gear unit via a pinion shaft. Direct 

coupling offers several advantages. 

By eliminating the belt drive, transmission 

losses are reduced, which 

noticeably improves energy efficiency. 

At the same time, there is no need 

for a maintenance-intensive wear 

part – an advantage that both reduces 

operating costs and improves the 

availability of the system. 

The gear units of the R.. series achieve 

a maximum output torque of 4.300 

Nm and are filled with SEW’s own 

premium lubricant GearOil by SEW- 

Eurodrive. This lubricant offers a service 

life of up to 50% longer than conventional 

oils and reliably protects 

against gearing wear, fretting and pitting 

damage. This extends the service 

life of the drive unit and sustainably 

increases its operational reliability. 

The newly installed DRU type motors 

meet the requirements of energy efficiency 

class IE4 and provide a power 

rating of 11 kW each. Due to their 

high efficiency – especially in comparison 

to the original motors – they 

make an important contribution to 

reducing operating costs. As a result, 

the investment usually pays off after 

just a few years. 

At the same time, the environmental 

objectives of the municipality are effectively 

supported. Another technical 

detail is the backstop integrated 

in the motor. It prevents the screw 

Fig. 2: SEW Screw pump: Screw pump drives can be implemented both with belt drive and in 

direct design. 

from rotating backwards when the 

motor is switched off due to the 

weight of the water in the conveying 

chambers, thereby avoiding damage 

to the system. 

Complete solution from 

a single source 

SEW‐Eurodrive not only supplied the 

new drive components but also carried 

out their proper installation. This 

“all-in-one” solution minimizes interface 

problems and reduces the risk 

for the operator. The close coordination 

between SEW and the municipality 

ensured smooth implementation 

and rapid re-startup of the 

system. 

The replacement of the drive technology 

at the Daun wastewater treatment 

plant is part of a wide range of 

retrofit projects that SEW‐Eurodrive 

has successfully implemented worldwide. 

In these projects, not only 

SEW’s own products are replaced, 

but also drive technology from other 

manufacturers – including custom‐designed 

steel substructures, 

adapter solutions, and additional mechanical 

interfaces. The company's 

many years of experience and technical 

expertise enable tailor-made concepts 

that optimally take into account 

aspects such as service life, serviceability 

and energy efficiency. 

Conclusion: Sustainability and 

future readiness 

With the installation of the new drive 

units, Daun has received a futureproof 

solution that will work reliably 

for years to come. The combination 

of an energy-efficient motor, robust 

gear unit and high-quality lubricant 

ensures that the screw pumps perform 

reliably even under demanding 

conditions. 

With this project, SEW-Eurodrive is 

once again demonstrating how sophisticated 

retrofit measures can not 

only replace existing technology, but 

also create real added value for operators 

and the environment. The 

Daun wastewater treatment plant is 

therefore perfectly prepared for the 

challenges of the future – efficient, 

low‐maintenance, and sustainable. 

The Author: Christian Rüttling, 

market manager for industrial gear 

units at SEW-EURODRIVE in 

Bruchsal, Germany 

www.sew-eurodrive.de 


35


Dosing systems 

Chemical conditioning of the steam-water 

cycle for reliable operation 

In Hamburg-Bahrenfeld, the Center 

for Resources & Energy (ZRE) is a 

facility that not only sorts waste 

streams but also converts them 

into energy. What used to end up as 

waste is now systematically separated, 

processed, and converted into 

electricity and heat. The site demonstrates 

how modern recycling and 

energy management can work in an 

urban environment. 

Sorting, processing, recovering 

The heart of the ZRE is a sorting plant 

that is unique in Germany. As soon as 

the waste arrives, it is separated into 

Fig. 1: Dosing station for caustic soda: Removal 

of the medium from the on-site IBC 

and dosing into the high-pressure area 

three categories: high-calorific, lowcalorific, 

and residual waste. In the 

residual waste stream, sensors, magnetic 

technology, wind sifters, and 

near-infrared detection ensure the 

precise recovery of ferrous and nonferrous 

metals, plastics, and glass. 

Only materials that cannot be recycled 

economically are used thermally—with 

the aim of maximizing the 

yield of recyclable materials. 

Energy production with 

measurable output 

Energy recovery enables up to 

75 MW of district heating in winter 

and around 23 MW of electrical power 

in summer. In addition, approximately 

five MW of heat from exhaust 

gas streams is used annually. Once 

fully operational, this will supply over 

40,000 households with electricity 

and around 39,000 households with 

heat. A plant that shows that the energy 

transition has long been taking 

place in the heart of the city. 

sera solutions as the backbone of 

water processes 

Stable water chemistry is essential 

for the energy-related processes in 

the ZRE. In the water-steam cycle, 

the pH value, conductivity, and hardness 

must be kept within narrow tolerances 

to prevent corrosion, deposits, 

and efficiency losses. 

For this purpose, a combination of 

ammonia and caustic soda dosing 

systems was designed: 

• Ammonia in the low-pressure range 

Ammonia ensures the volatile alkalization 

of feed water and condensate. 

It raises the pH value in the wet pipe 

areas and reliably protects carbon 

steel from acid-induced corrosion. Its 

volatile properties also ensure even 

distribution in the branched pipe network. 

• Caustic soda in the high-pressure 

range 

Caustic soda is used for non-volatile 

alkalization. It stabilizes the pH value 

in feed and boiler water, protects 

evaporator and superheater surfaces 

from deposits, and prevents corrosive 

attacks in the high-pressure section. 

Both media are dosed by sera using 

robust piston diaphragm pumps – designed 

for high operating pressures, 

low-pulsation delivery, and precise, 

reproducible dosing quantities. The 

modular system concepts (DAV) offer 

maximum operational reliability and 

enable reliable control of water chemistry 

in 24/7 operation. The result: a 

stable, efficient water-steam cycle that 

protects the entire plant and ensures 

consistently high energy yields. 

Proven technology – flexible 

application 

The solutions used come from the 

sera standard portfolio for water 

treatment: softening, alkalization, 

and pH correction are among the 

globally proven processes in power 

plant and energy technology. The vertical 

DAV dosing systems are modular 

systems that guarantee high operational 

reliability, long service life, 

and energy-efficient processes – precisely 

tailored to the requirements of 

the ZRE. 

Fig. 2: Rear of the dosing station for caustic soda 

sera GmbH 

Immenhausen, Germany 

www.sera-web.com 



Macerator 

Easy Maintenance Macerator – the Razor-sharp Maximum 

SEEPEX introduces its new generation 

of macerators 

For decades, SEEPEX has optimized 

the performance of its globally 

sought-after progressive cavity 

pumps by using razor-sharp macerators 

to reliably shred solids and 

fibrous materials into the smallest 

particles. This prevents pipeline 

blockages and ensures reliable protection 

of downstream system components. 

With a completely new 

generation of macerators, SEEPEX is 

now taking its shredding technology 

to the next level. 

The new Easy Maintenance Macerator 

stands for maximum service convenience, 

optimized cutting performance, 

and increased system availability. 

Starting January 1, 2026, the company 

ushers in a new phase of its Easy 

Maintenance strategy. 

“Our new macerator generation offers 

our demanding customers a 

range of benefits in terms of handling, 

maintenance, and cost-efficiency, 

as they benefit from reduced wear 

and significantly longer service life. At 

the same time, SEEPEX strengthens 

its market position with this new solution”, 

concludes Guntram Schulz, 

Global Market and Product Manager 

at SEEPEX. 

Small parts – big impact 

in wastewater flow 

Cotton swabs and wet wipes in wastewater, 

bones and fishbones as well as 

shells, pits, and fibers in food production 

– many industrial waste processes 

end in a liquid, pumpable suspension 

that still contains solids and 

Fig. 2: The macerator’s upward folding 

cutting unit of SEEPEX MACM simplifies 

maintenance. 

disruptive materials. These can significantly 

impair subsequent processes. 

The Easy Maintenance Macerator 

homogenizes sludge through an efficient 

shredding process, ensuring 

smooth transport of the medium 

through the pump. This increases 

oper ational safety and minimizes the 

risk of disruptions throughout the entire 

plant process 

Technical Highlights 

Key technical highlights of the latest 

SEEPEX product include: Flow-optimized 

shear plate geometry, durable, 

replaceable knives made of highly 

wear-resistant tool steel, and a 

reversible shearplate. The design allows 

easy and quick access to the cutting 

unit – both for maintenance and 

for removing foreign objects – without 

lifting equipment. The macerator 

achieves a throughput of up to 

100 m 3 /h with motor ratings of 1.5 kW 

(standard), 2.2 kW and 3 kW. 

Fig. 1: The macerator will be showcased for the first time at IFAT in Munich in May, where it 

will be presented to a wider professional audience. 

The optimized cutting performance 

ensures extremely fine shredding of 

solids and fibers. Entanglements are 

significantly reduced, enabling longterm 

trouble-free pump operation. 

The new macerator thus increases 



Macerator 

the reliability and service life not only 

of SEEPEX pumps but also of other 

connected process installations such 

as centrifuges or screw presses. 

Quick access and predictive 

maintenance 

The Easy Maintenance Macerator 

meets customer requirements with 

quick access and simple servicing. 

The foldable cutting unit allows convenient 

opening of the machine from 

above. The shearplate is easily accessible 

and quickly replaceable. Blades 

can also be mechanically adjusted 

from the outside. Cleaning and removal 

of foreign objects can be up to 

80 % faster. An optional reverse operation 

is available: the knife rotation direction 

can be changed during operation. 

Blockages can thus be cleared 

without opening the macerator. Additional 

operational safety is provided 

by an integrated debris separator. A 

separate cleaning flap allows direct 

access to the housing, enabling quick 

and easy removal of disruptive solids. 

SEEPEX expects the new macerator 

to achieve double the service life and 

significantly reduce spare part costs 

– thanks to the reversible shear plate 

and bidirectional operation. 

Modern machines for modern 

waste management 

SEEPEX has been an innovation 

leader in pump technology for over 

50 years – and more recently in the 

development of complementary digital 

solutions. To reliably meet the 

requirements of modern customer 

projects far above average, SEEPEX 

focuses on products precisely tailored 

to user needs. SEEPEX has extensive 

expertise in the use of its 

proven progressive cavity pumps 

and macerators. They operate reliably 

in many applications in municipal 

and industrial wastewater treatment. 

Other key process applications 

for macerators and pumps include 

agriculture (especially biogas production), 

the food and beverage industry, 

fish processing, paper and pulp 

production, and sugar refineries – in 

short, wherever coarse and fibrous 

materials must be shredded before 

the pumping process. 

Smooth pumping – easy maintenance: 

With the Easy Maintenance 

Macerator, SEEPEX once again meets 

the growing demands of modern industry. 

With this latest generation 

of macerators, the pump specialist 

Fig. 3: The flow optimized cutting plate is 

reversible, and the adjacent blades made of 

hardened material are easy to replace – 

ensuring an exceptionally long service life. 

brings a product to market that, in 

combination with a SEEPEX progressive 

cavity pump, ensures sustainable, 

trouble-free operation when 

transporting media containing solids. 

SEEPEX GmbH 

Bottrop, Germany 

www.seepex.com 

Safe drinking water networks 

require reliable disinfection 

From precise chlorine gas dosing to on-site 

sodium hypochlorite production, Lutz-Jesco 

solutions keep your drinking water treatment 

safe, efficient, and future-proof. 

www.lutz-jesco.com 

Visit us at 

IFAT 2026 and 

experience our 

technologies live: 

Hall 3A, 

Stand 222.



Critical roles of vacuum technology in safe 

and efficient battery recycling 

As the global demand for lithiumion 

batteries grows – driven by electric 

mobility and renewable energy 

– so does the need for advanced battery 

recycling technologies. Among 

the most critical enablers of safe 

and efficient recycling is vacuum 

technology. Vacuum technologies 

play an essential role across several 

key process steps, from material 

preparation to solvent recovery and 

quality assurance. 

In this article, we examine how different 

types of vacuum technology 

contribute to the performance, 

safety, and environmental integrity 

of modern battery recycling. Rather 

than proposing a one-size-fits-all solution, 

we highlight the specific vacuum 

requirements of five different 

process stages and discuss the advantages 

and limitations of available 

solutions. 

1. Enhanced safety in shredding 

After the used battery has been fully 

discharged, it is shredded to break 

down the components. Shredding 

used batteries can be hazardous 

due to the volatile nature of materials 

like the liquid electrolyte. Sparks 

during shredding can ignite the electrolyte, 

leading to potentially explosive 

conditions. 

Dry vacuum pumps: claw and screw 

technologies 

Dry vacuum pumps, such as claw and 

screw vacuum pumps, are often the 

first choice for creating an inert and 

contaminant-free atmosphere in the 

shredding process. They effectively 

evacuate ambient air to allow the 

injection of inert gases like nitrogen, 

which drastically reduces the risk of 

ignition. Due to their oil-free operation, 

they are insensitive to contamination 

of the operating fluid by process 

gases, depending on the gases 

introduced. It makes them ideal 

where cleanliness and gas purity are 

essential. 

Additionally, dry vacuum pumps are 

energy-efficient, especially in continuous 

operation, due to the absence of 

sealing liquids or oils. However, they 

come with certain limitations: exposure 

to corrosive vapors or particulates 

released during shredding may 

lead to wear unless corrosion-resistant 

coatings or materials are used. 

Furthermore, the initial investment 

is typically higher than for vacuum 

pumps running with an operating fluid, 

such as oil-lubricated or liquid ring 

vacuum pumps. 

Liquid ring vacuum pumps: robust 

handling of wet gases 

Transitioning from dry gas to vapor 

handling, liquid ring vacuum pumps 

become relevant. These vacuum 

pumps are excellent at managing the 

wet gases that emerge during the 

shredding process. Their lack of small 

gaps and therefore mechanical friction 

makes them easier to assess in 

terms of ignition risk. 

While liquid ring vacuum pumps generally 

consume more energy than 

dry vacuum pumps of comparable 

size when handling non-condensable 

gases, they can be more energy efficient 

when pumping condensable vapors, 

as the condensation within the 

liquid reduces the gas volume to be 

evacuated – allowing for smaller vacuum 

pump sizing and lower energy 

consumption. However, they require 

the management of operating fluids, 

which can be a drawback in terms of 




can reach a lower ultimate pressure, 

but these versions encounter more 

problems with condensation because 

there is less oil per chamber. 

Liquid ring vacuum pumps: vaportolerant 

and chemically robust 

Limited by the vapor pressure of the 

sealing liquid (typically water), liquid 

ring vacuum pumps achieve ultimate 

pressures around 30 hPa (mbar), depending 

on operating temperature 

and fluid management. This makes 

them suitable for pre-drying or bulk 

vapor removal. 

operational efficiency and environmental 

impact. 

Oil-lubricated rotary vane pumps: 

a compromise solution 

Positioned between dry and liquidbased 

technologies, oil-lubricated 

rotary vane vacuum pumps present 

a pragmatic solution for the shredding 

process. They are mechanically 

simple, cost-effective, and capable of 

handling moderate vapor loads while 

delivering stable vacuum levels. 

However, their reliance on oil introduces 

risk of contamination and necessitates 

additional components 

like oil mist filters and regular maintenance 

routines. Moreover, they are 

less suited for explosive atmospheres 

or applications demanding absolute 

cleanliness, limiting their use in direct 

contact with volatile shredding environments. 

Consideration of ATEX requirements 

In potentially explosive shredding environments, 

the use of ATEX-certified 

vacuum systems or vacuum pumps 

may be required to mitigate ignition 

risks and ensure compliance with 

Euro pean safety directives. However, 

ATEX certification is not mandatory 

per se. The responsibility to perform 

a comprehensive risk assessment 

and decide on the necessity of certified 

equipment rests with the operator. 

Depending on process-specific 

hazards – such as the concentration 

of flammable gases or the potential 

for spark generation – ATEX-certified 

solutions can offer an additional layer 

of safety and legal assurance. 

The choice of vacuum pump must 

align with the specific operational and 

safety requirements of the shredding 

step – factoring in gas composition, 

flammability risk, environmental controls, 

and cost structure. 

2. Efficient electrolyte removal 

during drying 

The drying phase is crucial for removing 

the electrolyte following the 

shredding process. Vacuum drying 

lowers the boiling points of volatile 

components, facilitating evaporation 

at lower temperatures. The achievable 

base pressure of a vacuum system 

is fundamentally limited by the 

pumping principle of the technology 

used; to reach deeper vacuum 

levels – especially for removing solvents 

with low vapor pressure – it is 

often necessary to combine different 

vacuum technologies, as individual 

vacuum pumps tend to lose suction 

performance near their ultimate 

pressure. 

Oil-lubricated rotary vane pumps: 

cost-effective solution 

Rotary vane vacuum pumps can typically 

reach ultimate pressures between 

0.1 and 1 hPa (mbar), offering a 

good balance between performance 

and cost for moderate drying requirements. 

Rotary vane vacuum pumps 

are available in single-stage or multistage 

versions. Multi-stage versions 

Dry screw and claw vacuum pumps: 

clean and high performance 

Among all vacuum technologies considered 

(except dual-stage rotary 

vane vacuum pumps), dry screw 

vacu um pumps achieve the deepest 

vacuum levels, capable of reaching 

pressures below 0.01 hPa (mbar). 

Due to their relatively high ultimate 

pressure (10-60 hPa (mbar)) 

and limited tolerance for condensable 

vapors, single-stage claw vacuum 

pumps can be ruled out for drying 

applications where deep vacuum 

and solvent handling are critical. 

However, a two-stage version of the 

claw vacuum pumps allows for pressures 

lower than 10 hPa (mbar) and 

can therefore be considered. 

Vacuum boosters: extending 

vacuum performance 

To overcome pressure limitations of 

the primary vacuum pumps mentioned 

and to maintain a defined 

pressure, vacuum boosters can be 

added upstream of the main vacuum 

stage. Vacuum boosters are dry, positive 

displacement vacuum pumps. 

Their main task is to increase the 

pumping speed at working pressure. 

They increase the available pumping 

speed in lower pressure ranges 

where the efficiency of the backing 

pumps is already decreasing. When 

properly configured, the combination 

of vacuum booster and backing 

pumps can significantly enhance 

pumping speed and enable the system 

to reach much lower pressures 

than the backing pump alone – often 

by an order of magnitude. However, 


41



the achievable performance strongly 

depends on the specific ratio between 

the booster and backing pump, which 

must be carefully matched to process 

parameters such as gas composition, 

expected throughput, operating temperatures, 

and pressure setpoints. 

The design of the booster separates 

the gearbox and bearings from the 

suction chamber, allowing oil-free, 

contactless operation. Single-stage 

vacuum boosters cannot be used directly 

against atmospheric pressure, 

as too-high pressure differences can 

cause overheating and lobe expansion. 

To prevent this, booster systems 

require a bypass control during 

startup to prevent overload and ensure 

system protection. 

Consideration of ATEX 

requirements 

As with other steps in battery recyc ling, 

compliance with ATEX directives is not 

automatically required but depends 

on a risk analysis performed by the 

operator. If ATEX is required, the system 

must be considered as a whole. 

3. Improved purity through vacuum 

distillation 

Following the drying process, the 

vaporized electrolyte must be condensed 

and purified for reuse. Vacuum 

distillation enables this by separating 

electrolyte components based 

on differences in their boiling points 

– without requiring extreme temperatures 

that might degrade sensitive 

substances. This process step 

requires stable, deep vacuum levels 

and high chemical resistance, especially 

when dealing with complex 

electrolyte mixtures. 

Both dry and wet vacuum technologies 

play critical roles in enabling efficient 

and precise separation – depending 

on the specific system design, 

required vacuum depth, and tolerance 

to chemical or thermal stresses. 

Oil-lubricated rotary vane 

vacuum pumps 

Rotary vane vacuum pumps can be 

a viable option for vacuum distillation, 

offering stable performance and 

competitive acquisition costs. However, 

their use is limited by the sensitivity 

of the operating fluid (oil) to 

contamination from process media. 

Chemical compatibility must be carefully 

evaluated, as exposure to aggressive 

or condensable vapors can 

degrade the oil, increase maintenance 

needs, and compromise vacuum 

performance. Therefore, their applicability 

is restricted to media that 

do not adversely interact with the lubrication 

system. 

Dry screw and claw vacuum pumps: 

clean and controlled separation 

Dry screw vacuum pumps are the 

most effective dry technology for vacuum 

distillation. They achieve deep, 

stable vacuum levels critical for lowering 

boiling points and enabling precise 

separation without thermal decomposition. 

Their oil-free operation 

eliminates the risk of contamination, 

making them ideal for high-purity recovery 

of valu able electrolyte components. 

Dry claw pumps, while also oil-free 

and low-maintenance, cannot reach 

the same vacuum depths as screw 

vacuum pumps. As such, they are 

better suited for preliminary vacuum 

generation or systems where ultimate 

pressures of around 20 hPa 

(mbar) are sufficient. Their simplicity 

and energy efficiency make them 

a viable option where deep vacuum 

is not essential, and they still provide 

contaminant-free operation that supports 

high process purity. 

Liquid ring vacuum pumps: thermal 

buffering and vapor tolerance 

The general advantages and limitations 

of liquid ring vacuum pumps 

have been discussed in the context 

of shredding and drying. In distillation, 

their strengths remain relevant 

– particularly in condensation stages 

with high solvent content or chemically 

aggressive media. Their abili ty 

to tolerate liquid carryover and stabilize 

volatile mixtures makes them a 

practical choice in systems with fluctuating 

process loads. However, for 

applications requiring deeper vacuum 

or higher energy efficiency, their 

use should be carefully evaluated. 

The performance advantages of vacuum 

boosters – particularly in achieving 

deeper vacuum levels and faster 

evacuation – have been outlined earlier. 

These benefits also apply to distillation, 

where system throughput 

and pressure stability are critical. 

4. Advanced process monitoring in 

battery recycling 

Process monitoring is a critical aspect 

of refining battery recycling methods 

to ensure efficiency and sustainability 

– particularly when handling complex 

chemical reactions within thermal 

treatment processes such as 

pyrolysis. One of the key tools in this 

monitoring is the residual gas analysis 

(RGA). RGA is a method used to determine 

which gases are present in a system 

and in what quantities. It relies on 

mass spectrometry, where molecules 

are ionized, and the resulting ions are 

sorted by their mass-to-charge ratio 

(m/z) using a quadrupole mass filter. 

In battery recycling it is employed to 

analyze the gas phases emitted during 

the recyc ling process. This technology 

enables real-time surveillance 

and control by identifying and quantifying 

the gases released, which are 

indicators of the chemical reactions 

occurring within the system. Through 

this analysis, it is possible to gain a 

deep understanding of the process 

dynamics, which aids in the optimization 

of the recycling method and 

equipment. Mass spectrometry supports 

the identification of hazardous 

or corrosive subs tances, ensuring environmental 

compliance and worker 

safety. It also helps in adjusting process 

parameters to improve efficiency 

and throughput, leading to a more refined 

and controlled recycling operation 

that maximizes material recovery 

and minimizes harmful emissions. 

5. Ensuring system integrity 

through leak detection 

Ensuring high process integrity plays 

an important role to prevent hazardous 

conditions and ensure optimal 

recovery rates. A key component of 

maintaining high integrity is rigorous 

leak testing to confirm the tightness 

of recycling chambers and equipment. 

The process begins with pres- 




sure decay testing, which serves as 

an initial indicator for potential leaks. 

This method involves pressurizing a 

system, then measuring the pressure 

decrease over time. If the pressure 

drops beyond a pre-defined threshold, 

it indicates a potential leak. For 

pressure decay testing, vacuum 

gauges provide accurate and reliable 

measurements to detect any drops in 

pressure that could signal a leak. 

Following a pressure decay test, 

tracer gas leak detection is employed 

to precisely quantify the leak. Tracer 

gas leak detection is highly sensitive 

and suitable for detecting even 

smallest leaks. A tracer gas such as 

helium or hydrogen is introduced 

into the system, and a leak detector 

with an integrated mass spectrometer 

analyzer cell identifies and quantifies 

any escaping gas. The use of helium 

is particularly effective due to 

its small molecular size and inert nature, 

which allows it to quickly pass 

through leaks without reacting with 

the materials involved. 

Together, these methods provide a 

comprehensive approach to maintaining 

high process integrity in battery 

recycling facilities. 

Conclusion 

The integration of vacuum technology 

in battery recycling processes 

addresses multiple challenges associated 

with safety, efficiency, and 

environmental impact. By enhancing 

process safety through inert atmospheres, 

enab ling efficient material 

separation via controlled vacuum 

levels, and ensuring system integrity 

through advanced leak detection, vacuum 

technology is at the forefront of 

driving sustainable practices in bat- 

tery recycling. As the industry continues 

to evolve, the role of vacuum 

technology will expand, further embedding 

its significance in the sustainable 

life cycle management of battery 

technologies. 

Busch Vacuum Solutions 

Maulburg, Germany 

www.buschvacuum.com 

www.buschgroup.com 

High-Pressure Technology for Process-Critical Applications 

KAMAT high-pressure plunger pumps 

Modular. Powerful. Easy to maintain. 

Up to 4,000 bar. Flow rates of up to 600 m3/h. 

Material options: Stainless steel: Duplex. Inconel. 

ATEX-compliant. Designed for continuous-duty operation. 

Engineered and manufactured in Germany. 

Reliable flow. Precise control. Seamless integration. 

More information: www.KAMAT.de Scan the QR code or contact us directly.



Hyperloop – traveling through a vacuum 

at 1,000 kilometers per hour 

Leybold supports the EuroTube Foundation 

with expertise and technology 

Admittedly, the EuroTube Foundation’s 

vision sounds particularly appealing 

in times of delayed trains 

and congested roads: Swiss researchers 

want nothing less than to 

transport people and goods from A 

to B safely, environmentally friendly, 

and, above all, extremely quickly 

with the Hyperloop. The technology 

is currently still in the testing phase, 

but its success depends not least on 

the quality of the vacuum technology. 

Only in a vacuum tunnel is air resistance 

low enough to enable energy-saving 

gliding at speeds of up to 

1,000 kilometers per hour through 

a tube. Vacuum pioneer Leybold is 

therefore involved in the project, 

providing advice and support as well 

as its vacuum pumps. 

Proven cooperation between 

Leybold and EuroTube 

The cooperation between Leybold 

and the non-profit foundation 

has proven successful and has 

grown over the years. EuroTube was 

founded in 2019 by a group of former 

students from ETH Zurich and 

EPF Lausanne who successfully participated 

in the SpaceX Hyperloop 

Competitions. It has since developed 

into a research center with 15 employees, 

an office, and a laboratory 

in Dübendorf near Zurich. Leybold 

supports the Hyperloop project with 

its products and immense application 

knowledge. “We are confident 

that our commitment will make the 

Hyperloop project a success,” emphasizes 

physicist Dr. Tom Kammermeier, 

who has been involved in the 

project at Leybold since 2017. 

Swissloop concept has accelerated 

Hyperloop development 

The two partners first met in August 

2017 at the SpaceX Hyperloop Pod 

Contest in Hawthorne, California, on 

the SpaceX premises. This was after 

the ETH Zurich students had beaten 

thousands of teams with their Swissloop 

concept at Elon Musk’s SpaceX 

competition. The student Swissloop 

initiative has certainly accelerated 

Hyperloop development. “That’s why 

we immediately offered Leybold’s 

support,” reports Tom Kammermeier 

enthusiastically. “Five colleagues immediately 

traveled from Cologne to 

Zurich to visit two students in rented 

university rooms and learn about their 

visionary ideas,” adds Kammermeier. 

These ideas were so well-founded 

that other specialists from Leybold 

have since joined the project: In addition 

to Dr. Tom Kammermeier, 

Sebastian Rosensträter has also been 

supporting the EuroTube team in a 

management role for four years. 

Fig. 2: Leybold is involved in the project – 

providing advice and support as well as its 

vacuum pumps. 

Vacuum pump stand consisting of 

RUVAC WH4400 and DRYVAC DV650 

Fig. 1: The vacuum tunnel enables energy-efficient gliding at speeds of up to 1,000 kilometers 

per hour. 

Among other things, Leybold regularly 

performed calculations and simulations 

for EuroTube during this time 

because the framework conditions 

were developing dynamically. The 

designs therefore had to be repeatedly 

adjusted and recalculated. The 

result was positive, because in July 

2024, EuroTube was able to celebrate 

the kick-off of the first construction 

phase of the Hyperloop test facility 

“DemoTube” in the Zurich Innovation 

Park. EuroTube currently has a vacuum 

pump station from Leybold run- 




ning on this demonstrator, consisting 

of RUVAC WH4400 series 

Roots pumps and the DRYVAC 

fluence the exact positioning and 

distribution of the suction capacity 

along the route. “However, this 

Hyperloop as a future replacement 

for medium-haul flights 

than expanding the conventional 

network. According to Sebastian 

Rosensträter, the existing rail- 

DV650 dry-compressing screw 

vacuum pump. “These are typically 

volumetric pumps that reach 

down to the fine vacuum range,” 

explains Tom Kammermeier. The 

pump stand container also has 

space for another system so that 

the pumping capacity can be increased 

further as needed during 

test operation once completion. 

Pump-down time and leak rate 

are crucial 

How long and how often evacuation 

is required, and at which section 

of the route – these are the 

crucial questions that needed to 

be answered from a technological 

perspective. “And that is precisely 

the input that Leybold was 

able to provide. There are two 

important variables here,” Tom 

Kammermeier continues: the 

pump-down time and the leak 

rate. The pumping time determines 

how quickly a Hyperloop 

can resume opera tion after the 

tube has been ventilated, and 

the leak rate determines how 

many pumps of what size need to 

be running in order to maintain 

the operating pressure. Various 

pressure gradients can then in- 

only really becomes relevant for 

large dimensions that have not 

yet been realized today,” reveals 

Kammermeier. 

Maintaining negative pressure 

in the tubes, minimizing energy 

consumption 

Leybold can rely on its proven 

vacuum technologies to achieve 

the target values. The two big 

players, Virgin Hyperloop One, 

owned by investor Richard 

Branson, and Hyperloop Transportation 

Technologies (HTT), 

have already ordered pumping 

systems consisting of up to eight 

DRYVAC and eight WH Roots 

pumps from Leybold. In addition, 

the HTT system has been 

designed in a container so that 

the vacuum technology can then 

be offered as a mobile solution. 

The HTT unit fits into a standard 

shipping container, offering a 

complete plug-and-play solution. 

The entire system is designed to 

achieve and maintain the vacuum 

in the tubes with minimal energy 

consumption and maximum 

uptime. The containers will be set 

up at intervals of ten kilometers 

along the route. 

The broad practicality of this futuristic-looking 

transport system 

has yet to be proven. In addition, 

structural change is underway: 

Virgin Hyperloop One, a 

major player in the Hyperloop 

universe, has already withdrawn. 

According to Sebastian Rosensträter, 

apart from the Euro- 

Tube research institute, almost 

all of the companies currently active 

are start-ups that are banking 

on the growth potential but 

pursuing different approaches: 

“Some see the Hyperloop as a 

future replacement for mediumhaul 

flights. This would require 

the construction of new vacuum 

tube routes from airport to airport. 

The Hyperloop capsules 

would cover the distances just 

as quickly as airplanes – but with 

significantly reduced CO 2 

emissions,” 

explains Sebastian Rosensträter. 

The second group sees 

the Hyperloop more as an alternative 

to high-speed trains. The 

reason: all train routes are already 

at their capacity limit, and 

due to the speed and braking 

distance, the frequency of highspeed 

trains is so low that the 

construction of a new Hyperloop 

route could be cheaper overall 

ways could then be reserved primarily 

for freight transport. 

Transportation at 

the Olympic Games 

So, it remains exciting, and there 

are many ideas. Whether the Hyperloop 

will replace or supplement 

other modes of transportation 

in the future remains to be 

seen. “The fact is that, not least 

thanks to the support of Leybold, 

test tracks have been successfully 

planned and implemented, 

making the Hyperloop concept 

technically suitable for transporting 

people and goods,” concludes 

Sebastian Rosensträter. 

Technically and in terms of vacuum 

technology, there are currently 

no insurmountable hurdles. 

According to Sebastian 

Rosensträter, the projects should 

ideally be implemented through 

government tenders. In his opinion, 

it would also be conceivable 

to implement prestigious projects 

in the Middle East or at major 

sporting events such as the 

Olympic Games. 

Leybold GmbH, Köln, Germany 

www.leybold.com 

THAT’S 

WHAT 

SOLID? 

BUNGARTZ 

CENTRIFUGAL PUMPS 

Standard pumps can hardly cope with adverse pumping media. 

Particularly with solids, they bite their teeth out. This is where 

professionals like the MPCH DryRun come in. Thanks to 

innovative technology, the substances never reach the bearing and 

magnetic coupling area. The pump also scores highly with viscous, 

toxic and hot products. The advantages: 

– highly intrinsically safe 

– maintenance-free 

– even with media containing solids without the addition 

of coolant and lubricating fluid 

– no thermal monitoring of the containment shroud necessary 

THEN 

BRING IT ON! 

The MPCH DryRun – 

a strong example from the Bungartz master workshop. 

More under +49 -211 57 79 05 - 0 

and online: www.bungartz.de/mpchdryrun 


45

Pumps/Vacuum technology 


Smaller dimensions, low maintenance 

Progressing cavity pumps redefined: 

Expanding application ranges and improving 

cost efficiency 

Progressive cavity pumps are considered a reliable and cost-effective 

pumping technology for challenging processes involving abrasive, 

corrosive, and solids-laden media. The drawbacks of this technology 

have traditionally been the high space requirements and maintenance 

costs. The newly developed Scion progressive cavity pumps address 

precisely these aspects, delivering uncompromising performance with 

small dimensions and simplified maintenance. 

AxFlow introduces the new Scion progressing cavity pumps from 

manu facturer NOV to the German and European markets. NOV is 

widely known for its Mono technology and can draw on decades of experience 

in the field of Mono progressive cavity pumps. With the development 

of the new Scion series, the classic disadvantages of progressive 

cavity pumps have been systematically addressed. The new 

generation is up to 25 % shorter than comparable models, allowing 

progressive cavity pumps to be integrated even into installations with 

very limited available space. In addition, maintenance has been further 

simplified through a modular design, while spare-parts costs have 

been reduced for many applications. 

Fig. 2: Reduced overall length: the new Scion models are up to 25% shorter without 

any loss of performance 

unit from suction to discharge port is up to 25 % shorter than the previous 

generation. For plant designers, this translates into greater flexibility, 

particularly where installation space is limited. 

“Maintenance in Place” consistently implemented 

To ensure easy access for maintenance, Scion progressive cavity 

pumps are equipped with a fully split housing. The entire drive train— 

including rotor, stator, shaft, coupling and sealing—can be removed 

within minutes while the pump remains connected to the piping system 

(“Maintenance in Place”). The housing can be opened by loosening 

only a few bolts and does not use tie rods that would unnecessarily 

complicate maintenance. As a result, blockages and material build-ups 

can be removed quickly and safely without the need to disconnect the 

suction or discharge lines. 

Fig. 1: Compact footprint: NOV Scion progressing cavity pumps with 

fully split housing 

Typical applications for Scion progressive cavity pumps include the 

transfer of corrosive and particle-laden chemicals, abrasive slurries, industrial 

wastewater, ceramic slips, as well as paper and pulp suspensions. 

In these applications, the robust pumps can fully demonstrate 

their advantages, particularly their virtually pulsation-free conveying 

characteristics. 

Up to 25 % smaller with uncompromising performance 

The new rotor/stator assembly now employs a 2:3 lobe geometry, 

offering new possibilities in the design of the pumping unit. The increased 

lobe depth of the new design allows for a large displacement 

volume without requiring high rotational speeds that would otherwise 

lead to increased wear. At the same time, the new geometry ensures 

full pressure capability up to 12 bar and flow rates of up to 410 m³/h 

while maintaining a high solids-handling capacity. The efficiency gains 

associated with this geometry enable high performance within a reduced 

installation space. Depending on the model, the complete pump 

Free-molded stator: reduced spare-parts costs and easy handling 

Unlike many progressive cavity pumps, the stator housing is also split, 

allowing the stator elastomer to be replaced individually. This significantly 

simplifies maintenance operations. Operators no longer need to 

handle the total weight of the complete rotor/stator assembly, which 

can amount to around 67 kg for a model in size 13. Once the casing 

is removed, the corresponding stator core weighs only 12 kg—representing 

a clear improvement in occupational safety and a reduction in 

service time. 

For many operators, spare-parts costs are an equally important consideration. 

By replacing the free-molded stator, operating costs are 

significantly lower than when replacing the complete assembly. The 

metallic housing is reused and therefore does not add to spare-parts 

expenditure. 

Available on the German market since February 2026 

AxFlow will exclusively launch the new Scion series to the market in 

Germany. Since February 2026, the ten most important Scion models 

will be available from AxFlow. Additional sizes covering the full flow 

range at pressures up to 6 bar will follow later in the year. Subsequently, 

two-stage pump models capable of delivering pressures of up to 

12 bar will also be available. Worth noting: The two-stage Scion progressive 

cavity pumps contain two stator cores arranged one behind 

the other, each of which is identical to the stator core of the singlestage 

pumps. If only one of them is worn, only one stator core needs 

to be replaced. The already reduced spare parts costs are thus cut in 

half again. Stator elastomers for Scion progressing cavity pumps are 




available in NBR, EPDM, NBR-FDA, FKM and PU, covering a wide range 

of chemical compatibility requirements. The housing is made of protective-coated 

gray cast iron or corrosion-resistant stainless steel. The 

hollow rotor made of stainless steel or, optionally, hard chrome-plated 

steel saves further weight and reduces vibration inside the pump. 

The new Scion series replaces the Mono EZStrip and Mono 2000 product 

lines. Spare parts for previous series will continue to be available 

from AxFlow on a long-term basis. Existing pumps can also be easily replaced 

by new Scion models. AxFlow offers standardized solutions that 

are easy to integrate into existing installations. 

Fig. 1: Compact battery-powered motor, ideal for emptying IBCs or drums independently 

of the mains supply (All images: FLUX) 

Fig. 3: Saves space and material while simplifying handling: the stator elastomer 

can be replaced separately. 

The new Scion progressing cavity pumps demonstrate that proven 

pumping technology can be systematically further developed. The significantly 

more compact design, improved efficiency and well-engineered 

maintenance concept reduce footprint, downtime and operating 

costs alike. As a result, the Scion series opens up new application 

possibilities for progressing cavity pumps—particularly in installations 

where plant designers and operators have previously been constrained 

by limited space or maintenance requirements. 

new FBM 4100 battery motor from FLUX covers all areas of application 

of its mains-powered counterpart, and this with a total weight of 

only 2.8 kg including batteries. With pumps for a wide variety of fluids, 

the motor is suitable for areas without a power outlet, e. g. in sectors 

such as construction, industry, food or agriculture, and is also resistant 

to corrosive media in chemistry or electroplating. Intelligent, patent-pending 

functions such as Dry-run protection and programmable 

batch filling for metering predefined delivery quantities without a flowmeter 

expand the range of applications. An LCD display control allows 

the speed to be selected in 10 % increments and up to 6 filling quantities 

to be programmed and called up as often as required. The motor 

can be used with FLUX drum and container pumps of the F 400 series 

in various material designs, for example for fluids such as AdBlue, 

plant protection concentrate, concrete additives, cooking oils or chemicals 

such as Hydrochloric acid, etc. For more viscous media, it can be 

combined with progressive cavity pumps of the F 570 series. 

AxFlow GmbH 

Theodorstr. 105 

40472 Düsseldorf, Germany 

Tel +49 (211) 238060 

info@axflow.de 

www.axflow.de/nov 

Wirelessly fill, transfer and meter liquids and easily measure 

delivery quantities 

Powerful and smart battery motor for 

drum pumps 

Drum pumps are a practical solution for quickly and cleanly filling fluids 

from drums, IBCs, canisters, etc. With a rated power of 420 W, the 

Fig. 2: The clear LCD display shows all essential functions and performance values. 

Ready for various applications 

With an optional adapter, the motor is compatible with pump units 

from other manufacturers, expanding their range of applications. The 

brushless, maintenance-free and highly efficient FBM 4100 motor 

achieves a delivery rate of up to 84 l/min in a typical drum pump configuration. 

In practical use with a hose and hand nozzle at 80 % speed, 

one battery charge allows eleven 200-litre drums or 2.2 1000-litre IBCs 


47



conventional solids handling pumps—especially when handling sewage 

sludge—were directly incorporated into the development of the 

new system. 

The SDS pump system includes a robust piston diaphragm pump 

whose configuration has been optimized for extreme loads. Valves, 

materials, and design details have been carefully adapted to typical 

solids media to ensure smooth and long-lasting pump operation. The 

diaphragm separates the pumped medium from the hydraulic area, so 

that only a few components actually come into contact with the medium. 

This significantly reduces wear and tear and noticeably extends 

the service life of the system. 

Fig. 3: The FBM 4100 battery motor pumps up to 2,200 litres per battery charge at 

80 % power and allows adjustable batch filling. 

to be emptied. Depending on the model, the scope of delivery includes 

the motor, two 18V, 4Ah Einhell PXC batteries, a twin charger and, optionally, 

an adapter for connecting drum pumps from other manufacturers. 

Special covers protect the batteries from splashing water and 

aggressive vapours. The portfolio also offers preconfigured sets with a 

pump, 2 m long delivery hose and hand nozzle. The Battery Motor is 

available in IP24 with open cooling by ambient air and in a closed IP44 

version with reduced performance. This also works under harsh conditions, 

e. g. when pumping Hydrochloric acid. In addition to the core 

version, both models are also available in a Pro version, which offers 

a 5-pin plug connection for external start/stop and a 24 V power supply 

for direct connection of peripheral devices such as level sensors or 

flowmeters. 

FLUX-GERÄTE GMBH 

Talweg 12 

75433 Maulbronn, Germany 

Tel +49 (7043) 101-0 

info@flux-pumpen.de 

www.flux-pumpen.de 

ABEL presents new Solids Diaphragm 

Solution (SDS) 

ABEL GmbH, a leading international manufacturer of robust pump 

technologies for wastewater and sewage sludge conveyance, has been 

setting standards in the conveyance of demanding media for decades. 

With the new SDS Solids Diaphragm Solution, ABEL is further expanding 

this expertise and offering a powerful solution for the efficient and 

reliable transport of sewage sludge and other media with a high solids 

content. 

As an established supplier of high-quality positive displacement pumps, 

ABEL is expanding its portfolio with a technology that is specially designed 

for media with a solids content of up to 30 %. The SDS (Solids 

Diaphragm Solution) represents a new generation of solids handling 

pumps that combines state-of-the-art technology, long service life, and 

high cost-effectiveness. It is based on more than 40 years of practical 

experience in solids handling. Findings from the daily operation of 

A key highlight of the new SDS pump solution is the ABEL Smart Pump 

Assistant, an integrated AI-supported monitoring system that enables 

predictive maintenance of pumps. Users receive continuous, upto-date 

information on the status of their pumps as well as specific 

recommendations for action to ensure reliable and efficient operation. 

The monitoring system provides both an overview of the general condition 

of the pump and detailed information on the remaining safe service 

life of wear parts, detected fault patterns, and their exact location 

– either via an app or by email. This data greatly facilitates targeted 

maintenance of the pump and also allows conclusions to be drawn 

about connected system components. Through continuous operation, 

the system monitors the plant around the clock and detects poten- 




tial deviations at an early stage. It continuously records operating data 

such as pressure, flow, or wear indicators and evaluates them automatically. 

The Smart Pump Assistant thus detects potential malfunctions 

weeks in advance and enables predictive maintenance planning. 

Plant operators benefit from increased process reliability, optimized 

maintenance intervals, and significantly higher plant availability—without 

any manual intervention. 

Another advantage of the SDS is its mechanical drive, which operates 

without a hydraulic unit and therefore requires significantly fewer components 

compared to hydraulic systems. This not only makes the pump 

easy to maintain, but also significantly reduces operating costs – by up 

to 80 % in many applications. Thanks to its clear, straightforward design, 

maintenance work can be carried out quickly and without special expertise. 

Inspection openings facilitate access to relevant wear parts, while 

the reduced need for spare parts further improves cost-effectiveness. 

Overall, the SDS pump solution combines high technical performance 

with user-friendliness and digital intelligence. It offers a particularly 

reliable, durable, and economical solution for operators who need to 

convey media with a high solids content safely and efficiently. ABEL 

is once again setting a clear example for innovative and sustainable 

pump technologies in wastewater and sewage sludge management. 

ABEL GmbH 

Abel-Twiete 1 

21514 Büchen, Germany 

Tel +49 (4155) 818-0 

abel-mail@idexcorp.com 

www.abelpumps.com 

TORNADO ® T1 XXLB-F: 

Engineering Excellence sets a new 

standard in high-capacity rotary lobe 

pump technology 

In the ever-evolving world of fluid handling, NETZSCH Pumps & 

Systems has once again raised the bar with the launch of its largest 

rotary lobe pump to date: the TORNADO ® T1 XXLB-F. Unveiled at IFAT 

Brasil 2025, this engineering powerhouse redefines the limits of the 

NETZSCH pump portfolio and pushes the boundaries of what’s possible 

in performance and size. The TORNADO ® T1 family has grown – bigger, 

stronger, and unstoppable – welcome to the new era of complex 

fluid handling. 

The TORNADO ® T1 XXLB-F is the latest addition to the TORNADO ® 

family, which has long been recognized for its robust construction, reli- 

ability, and adaptability to complex fluids. With this new model, NETZSCH 

introduces a pump capable of handling flow rates up to 1,400m³/h and 

differential pressures up to 12bar, making it ideal for high-volume, highpressure 

applications across a wide range of industries. 

Engineering excellence meets application versatility 

What sets the TORNADO ® T1 XXLB-F apart is not just its impressive size, 

but its thoughtful engineering, designed for maximum performance in 

the most demanding environments. 

Sealing system – Innovative sealing concepts, from single mechanical 

seals to double mechanical seals for highly challenging media, ensure 

optimal process safety and long-term durability. NETZSCH’s proven 

GSS-Technology (Gearbox Security System) prevents cross-contamination 

between the pump chamber and gearbox, protecting critical components 

and enhancing operational safety. Combined with the FSIP ® 

(Full Service in Place) concept, all maintenance tasks can be carried out 

without removing the pump from the pipeline — saving time, reducing 

downtime, and lowering maintenance costs. 

Helical lobe design – Flow-optimized, three-wing helical lobes are individually 

adapted to the conveyed medium. Both the lobe material and 

geometry are specifically engineered to meet the exact requirements 

of each application, ensuring superior wear resistance and extended 

service life. Special geometries are available for viscous, abrasive, or 

solids-containing media, guaranteeing reliable performance even under 

the harshest operating conditions. This tailored approach not only 

enhances hydraulic efficiency but also reduces energy consumption 

and maintenance intervals. 

Wear plates – To further extend service life, the XXLB-F is equipped with 

axial wear plates as standard. These highly wear-resistant plates protect 

critical pump surfaces and significantly reduce wear in demanding 

applications. For extremely abrasive media, radial wear plates are 

available as an optional upgrade, providing additional housing protection. 

Together, these wear protection measures maximize resistance 

to abrasion, minimize unplanned downtime, and maintain consistent 

pumping efficiency over time. 

Heavy-duty bearing system – Engineered for 24/7 continuous operation, 

the XXLB-F’s heavy-duty bearing arrangement ensures precise 

shaft alignment, minimizing mechanical stress and maximizing service 

life. Designed to withstand high loads, the bearing system delivers the 

durability needed for solids-laden or highly viscous media. The result 

is a robust, low maintenance bearing solution that ensures smooth operation 

and long-term reliability in even the harshest industrial environments. 

Ideal choice in demanding applications 

When it comes to challenging conveying tasks, the NETZSCH TORNADO ® 

T1 XXLB-F is the solution customers can rely on. It is perfectly designed 


49



for all tasks in wastewater treatment. With its high flow capability and 

efficiency, the XXLB-F is ideal for MBR (membrane filtration) applications. 

Also, because of its reverse operation ability to handle both filtration 

and backwashing in one single unit, it saves space, time, and 

maintenance effort. MBR plants with centrifugal pumps require two 

pumps (one for filtration and one for backwashing). 

NETZSCH Pumps & Systems at 

IFAT 2026 in Munich 

Your global partner for conveying 

complex media 

For wellpoint dewatering, the XXLB-F offers unmatched reliability in 

controlling or lowering groundwater levels, making excavation and 

construction projects for foundations, tunnels, trenches, and pipelines 

both safe and efficient. 

Our lifting systems, equipped with the FSIP ® (Full Service in Place) concept, 

provide a very compact, service-friendly solution for sewage and 

drainage systems, minimizing downtime and maximizing productivity. 

In the mining sector, the XXLB-F proves its strength by effortlessly 

removing unwanted water accumulations from mines and pits, ensuring 

uninterrupted operations. Especially when you consider the 

space restrictions underground, the XXLB-F, with its extremely tiny 

footprint, is the best choice, and the full service in place concept is 

mandatory. 

For the oil & gas industry, whether in tank depots, seaport terminals, or 

petrochemical plants, the XXLB-F stands for robust performance and 

reliability, features the necessary material properties/variations and 

complies with the needed standards and certifications such as API. 

Even in the most demanding food industry applications, such as conveying 

highly viscous magma and molasses in sugar production, the 

XXLB-F demonstrates its endurance — operating at low speeds with 

high displacement volumes to ensure gentle, efficient conveying without 

damaging the sugar crystals. 

NETZSCH Pumps & Systems will be presenting its current product range 

at IFAT 2026 – with a focus on state-of-the-art pump technologies for 

environmental and energy applications, including the PERIPRO ® peristaltic 

pump in its largest size, 10/66, and the new size of the proven 

TORNADO ® XXLB-F rotary lobe pump. 

As a global specialist in the development, production and distribution 

of pumps and systems, NETZSCH has been offering solutions tailored 

to the requirements of the environmental and energy industries for 

over 70 years. Whether in wastewater treatment, lubricating oil and 

sludge conveyance, or biogas plants, our patented technologies provide 

you with reliable, efficient, and sustainable support. 

At IFAT 2026, Christian Alt, Business Field Manager Environmental & 

Energy/EMENA, and his team will welcome you in Hall B1 at Booth 251. 

Our experts will present the entire portfolio of pump technologies: 

progressing cavity pumps, rotary lobe pumps, multi screw pumps, peristaltic 

pumps and versatile grinding systems for a wide range of applications. 

Another highlight: technical presentations on the PERIPRO ® peristaltic 

pump in the largest size 10/66 and on the new TORNADO ® XXLB-F 

rotary lobe pump, which impressively demonstrate how NETZSCH 

combines innovation, energy efficiency and practicality. 

And when it comes to replacing centrifugal pumps, in particular submersible 

centrifugal pumps, the XXLB-F shows significant advantages: 

easy service and maintenance thanks to dry installation outside the pit 

due to self-priming capability. It performs consistently at its high efficiency 

across a broad flow range and can be maintained without taking 

the pump out of the sump or the pipeline. Submersible centrifugal 

pumps, on the other hand, require costly substructures to remove or 

lift the pump and only reach peak efficiency at one specific operating 

point. With its full service in place concept, all maintenance parts are 

front-loading and can be inspected while the pump is still installed in 

the plant and connected to the pipeline. 

The TORNADO ® T1 XXLB-F is more than just a pump—it’s a statement 

of NETZSCH’s commitment to innovation, customer-centric design, and 

engineering excellence. With NETZSCH, you’re choosing a partner dedicated 

to delivering the most reliable, efficient, and tailor-made solution 

for your application. The XXLB-F is built to handle your toughest challenges 

with confidence, efficiency, and NETZSCH quality. 


Geretsrieder Str. 1 

84478 Waldkraiburg, Germany 

Tel +49 (8638) 63-0 

info.nps@netzsch.com 

www.pumps-systems.netzsch.com 

“NETZSCH is known worldwide for customised solutions in wastewater 

and biogas applications. With the PERIPRO ® peristaltic pump in the 

largest size 10/66 and the TORNADO ® XXLB-F rotary lobe pump, we 

demonstrate how robust technology and simple maintenance work together 

in demanding processes. Visit us at IFAT – we will give you concrete 

insights into how our technologies can measurably advance your 

operations.”– Christian Alt, Business Field Manager Environmental & 

Energy/EMENA 




Our claim ‘Proven Excellence’ – outstanding quality and reliability – has 

shaped our actions and the success of our customers worldwide since 

1873. 

We look forward to welcoming you to our stand at IFAT from 4 to 7 

May 2026! 



84478 Waldkraiburg, Germany 

Tel +49 (8638) 63-0 

info.nps@netzsch.com 

www.pumps-systems.netzsch.com 

Launch of the new 

Packo MFP3/125-315 pump 

Innovation focused on low total cost of ownership across the entire 

operating range 

400 m³/h and a head of 25 to 50 meters, measured with water at 1.450 

rpm. In this way, Packo offers a solution that performs across a wide 

range of applications, without compromise. 

Packo introduces the MFP3/125-315: a new standard in energy 

efficiency and user-friendliness 

Packo, part of the Verder Group, is proud to announce the launch of 

the MFP3/125-315, the latest addition to the successful MFP3 pump 

series. This innovative pump has been developed with maximum efficiency 

and minimal total cost of ownership (TCO) in mind for the user. 

With this, Packo remains true to its philosophy: creating industrial 

pump solutions that not only excel technically, but are also sustainable 

and cost-saving in the long term. 

Low TCO as a starting point 

As with all MFP3 pumps, achieving the lowest possible TCO is central 

to the MFP3/125-315. This is realized through the use of standardized 

interchangeable parts and extensive standardization of components 

across different pump types. As a result, maintenance and repairs are 

simplified, leading to lower operating costs and higher system availability. 

Packo demonstrates that innovation and cost control can go 

hand in hand. 

Technical innovation: wide and high energy efficiency 

During the development of the MFP3/125-315, Packo consciously went 

beyond the classic goal of achieving peak efficiency at the BEP (best 

efficiency point). In practice, many pumps rarely operate exactly at 

their BEP. They often function under varying process conditions and 

at different operating points, for example during different phases in 

the brewing process. Additionally, only a limited number of pumps are 

supplied with a full impeller diameter. 

Therefore, the MFP3/125-315 was designed to achieve a hydraulic efficiency 

of nearly 80 % over an exceptionally wide operating range: from 

60 % to 120 % of the flow at the BEP. This results in stable and efficient 

energy consumption, regardless of varying process conditions. 

Unique features and performance 

A major advantage of the MFP3/125-315 is that its high efficiency is 

maintained even with trimmed impellers. This provides maximum 

flexi bility without compromising efficiency. Specifically, the pump 

achieves an efficiency of almost 80 % at flow rates between 150 and 

Packo’s vision: sustainable progress for the industry 

With the launch of the MFP3/125-315, Packo underlines its commitment 

to developing pumps that not only excel at the BEP but guarantee 

the lowest possible TCO across the entire operating range. Packo 

continues to focus on technological innovation and sustainable solutions, 

so that customers can rely on reliable and cost-efficient pumps 

both today and in the future. 

Packo Inox NV (A Verder Company) 

Industriepark Heernisse, Cardijnlaan 10 

8600 Diksmuide, Belgium 

pumps.packo.be@verder.com 

www.packo.com 

www.verderliquids.com 

Pfeiffer Vacuum+Fab Solutions introduces 

COMBI WVD vacuum booster 

pump unit 

Pfeiffer Vacuum+Fab Solutions – a member of the global Busch Group 

– announces the launch of the COMBI WVD vacuum booster pump 

unit. This compact unit offers high performance and a small footprint. 

It is an expansion to the existing COMBI series and consists of a PANDA 

vacuum booster and a DuoVane two-stage oil-lubricated rotary vane 

vacuum pump. 

The COMBI WVD vacuum booster pump unit features high pumping 

speed and low ultimate pressure, from atmosphere down to the 

10 -3 hPa (mbar) range. This makes it ideal for both stand-alone operation 

and use as backing pump for high vacuum pumps, such as turbomolecular 

vacuum pumps. The COMBI WVD pump unit is the successor 

to the CombiLine WD. 

COMBI WVD vacuum booster pump units are particularly ideal for 

vacu um coating or drying applications and are also well suited for use 


51



Reliable vacuum generation with low maintenance 

The COMBI WVD series ensures reliable vacuum generation, making it 

also well suited for applications in R&D or the chemical and pharmaceutical 

industries. This is made possible by the contact-free operation 

of the PANDA vacuum boosters in the process chamber. In addition, 

certain configurations can utilize optional magnetic couplings for 

both vacuum pump and booster, eliminating the need for conventional 

shaft seals. This design also minimizes maintenance needs and contributes 

to overall cost efficiency. 

Additionally, the PANDA vacuum booster is equipped with an integrated 

bypass valve that protects the vacuum pump unit against 

overloading and overheating, enhancing the reliability and safety of 

the COMBI WVD. 

The new COMBI WVD vacuum booster pump unit is an expansion to the existing 

COMBI series and consists of a PANDA vacuum booster and DuoVane two-stage 

oil-lubricated rotary vane vacuum pump. Source: Pfeiffer Vacuum+Fab Solutions. 

Pfeiffer Vacuum+Fab Solutions 

Berliner Str. 43 

35614 Asslar, Germany 

Tel +49 (6441) 802-0 

www.pfeiffer-vacuum.com 

www.buschgroup.com 

in metallurgy, Research & Development, and other industries. They are 

available with various configurations of PANDA vacuum boosters and 

DuoVane rotary vane vacuum pumps. To ensure optimal adaptability 

to each customer’s process as well as long-term operational reliability 

of each individual setup, customized configuration options are supported. 

Pfeiffer also provides a variety of accessories, including control 

units for the vacuum booster and the rotary vane vacuum pump, oil 

mist separators, gas-ballast valve kits and spare parts. 



Index of Advertisers 

Index of Advertisers 

Aerzener Maschinenfabrik GmbH Inside cover page 59 

BAUER KOMPRESSOREN GmbH page 75 

BOGE KOMPRESSOREN Otto Boge GmbH & Co. KG page 13 

EIRICH Maschinen- und Anlagenbau GmbH page 79 

Filtech Exhibitions Germany page 97 

GEA Tuchenhagen GmbH 

Cover page 

Getriebebau NORD GmbH & Co. KG page 69 

GF Georg Fischer GmbH, Piping Systems page 95 

Goetze KG Armaturen page 55 

Hammelmann GmbH page 9 

JESSBERGER GmbH 

3. Cover page 

JUMO GmbH & Co. KG page 83 

Kaeser Kompressoren SE 

Insert 

KAMAT GmbH & Co. KG page 43 

LEWA GmbH page 19 

Lutz-Jesco GmbH page 39 

Messe Düsseldorf GmbH page 29 


4. Cover page 

Paul Bungartz GmbH & Co. KG page 45 

Promoberg Srl page 37 

SEEPEX GmbH 

2. Cover page 

SMC Deutschland GmbH page 85 

Vogelsang GmbH & Co. KG page 7 

Watson-Marlow GmbH page 23 

Zwick Armaturen GmbH page 63 

Your media contact 

D-A-CH 

Thomas Mlynarik 

Tel.: +49 (0) 911 2018 165 

Mobile: +49 (0) 151 5481 8181 

mlynarik@harnisch.com 

INTERNATIONAL 


Benjamin Costemend 

Mobile: +33 (0) 6 75 64 29 730 

benjamin.costemend@gmail.com 

Impressum 

Publisher 

Dr. Harnisch Verlags GmbH in cooperation 

with the Editorial Advisory Board 

© 

2026, Dr. Harnisch Verlags GmbH 

Publishing company and reader service 

Dr. Harnisch Verlags GmbH 

Eschenstr. 25 

90441 Nuremberg, Germany 

Phone (911) 2018-0 

Fax (911) 2018-100 

E-Mail puk@harnisch.com 

www.harnisch.com 

Technical Director 

Armin König 

Editorial coordination 

Silke Watkins 

Thomas Mlynarik 

Advertisements/Suppliers source 

Silke Watkins/ Matti Schneider 

Editorial Advisory Board 2026 

Prof. Dr.-Ing. Andreas Brümmer, 

TU Dortmund 

Dipl.-Ing. (FH) Gerhart Hobusch, 

KAESER KOMPRESSOREN SE 

Dipl.-Ing. (FH) Johann Vetter, 


Dipl.-Ing. (FH) Sebastian Oberbeck, 

Pfeiffer Vacuum+Fab Solutions 

Disclaimer 

The named authors are responsible for 

the content of the individual articles and 

do not necessarily reflect the opinion of 

the editorial team. Despite careful checking, 

the publisher cannot accept any liability 

for the accuracy of the content. The 

contents of the magazine and the website 

are protected by copyright and may 

not be reproduced or otherwise used or 

published without the prior written consent 

of the publisher. 

ISSN 2364-723X 

Printed by 

AKONTEXT s.r.o. 

Prag/Tschechien 

www.akontext.cz 


53


IFAT 

PFAS, UWWTD, phosphorus: 

focus on municipal water at IFAT Munich 2026 

– How cities and municipalities are 

coping with PFAS, climate impacts 

and new EU regulations 

– Expert panels, solution tours and 

special areas at IFAT Munich 2026 

– World-leading trade fair as a must-- 

attend event for municipal 

decision-makers and practitioners 

Cities and municipalities are under 

major pressure to act when it comes 

to water and wastewater management: 

Stricter regulations, climate 

impacts and increasing investment 

requirements are coming up against 

limited resources. IFAT Munich 2026 

will show which technical, regulatory 

and organizational solutions municipalities 

need now. From May 4 to 

7, 2026, over 3,000 exhibitors from 

more than 60 countries will present 

their solutions for water, recycling 

and circularity at the world’s 

leading trade fair for environmental 

technolo gies. A key focus is traditionally 

on water management. Municipalities 

in particular are faced 

with the task of future-proofing the 

drinking water supply and wastewater 

treatment, implementing new 

legal requirements, and expanding 

their infrastructures to make them 

climate-resilient. 

Forever chemicals present new 

challenges for municipalities 

The discussion about per- and polyfluoroalkyl 

substances (PFAS) has 

developed from a specialist topic 

into a socially relevant debate. Local 

authorities must comply for the first 

time with binding PFAS limit values in 

drinking water. That requires investments 

in monitoring, analytics and 

processing technologies. At the same 

time, there is an increased focus on 

site remediation, as the high mobility 

of these substances, also known as 

“forever chemicals”, poses risks to the 

drinking water supply. 

The panel “PFAS in focus: challenges 

and solutions for dealing with the poison 

of the century” organized by figawa 

e. V. on May 6, 2026 on the Blue 

Stage will discuss how PFAS can be 

handled in technical and economic 

terms. In addition, a presentation by 

the German Association for Waste 

Management (DGAW) on May 4 will 

show how PFAS can be removed from 

water streams and destroyed using 

activated carbon. 

UWWTD: Stricter requirements for 

urban water management 

All images: Messe München GmbH 

With the revised Urban Wastewater 

Treatment Directive (UWWTD), the 

EU redefined the framework conditions 

for urban water management at 

the end of 2024. “A milestone for water 

protection, but also a huge challenge 

for wastewater management 



IFAT 

and municipalities,” says Dr. Lisa 

Irwin-Broß, member of the DWA 

Management Board. According 

to its specifications, a fourth purification 

stage will need to be added 

to several hundred wastewater 

treatment plants in Germany 

alone by 2045. In addition, wastewater 

treatment is to be energyneutral 

in the future. 

The DWA is addressing the topic 

with a solutions tour on May 5 

and a session on the Water Stage 

on May 7. The Association of Municipal 

Enterprises (VKU) will be 

discussing the financing of the 

fourth purification stage on the 

Blue Stage on May 4 in the presentation 

“UWWTD: status of financing 

the fourth purification 

stage through extended producer 

responsibility”. 

Phosphorus recycling: 

planning security required 

for municipalities 

From 2029, municipal wastewater 

treatment plant operators in 

Germany will be obliged to recover 

phosphorus if the phosphorus 

content of the sewage 

sludge dry matter is at least two 

percent. While the regulatory requirements 

are clear, many municipalities 

are now faced with 

operational questions regarding 

the economic implementation. 

“Phosphorus recycling should 

be integrated into the planning 

of sewage sludge recycling at an 

early stage and in the long term. 

An open dialog between all parties 

involved is crucial,” says 

Tabea Knickel, Managing Director 

of the German Phosphorus 

Platform (DPP). The DPP will 

be hosting the discussion panel 

“Phosphorus recovery in dialog: 

challenges and prospects” 

on May 7 on the Blue Stage. The 

DWA and DVGW will already be 

using the stage on May 6 for their 

joint innovation forum “Regional 

Phosphorus Recycling”. 

Protecting critical water infrastructure 

is becoming increasingly 

important 

In view of geopolitical risks, hybrid 

threats, and new legal requirements, 

protecting critical 

infrastructures is becoming increasingly 

important. The drinking 

water supply and waste water 

disposal are affected directly. 

The NIS2 Implementation Act 

and the planned KRITIS Umbrella 

Act form the legal framework for 

this. “The acts give the industry a 

clear legal framework for necessary 

investments and for implementing 

measures,” says Peter 

Frenz from the DVGW. “The resilience 

of critical infrastructures in 

Germany can only be increased 

through a comprehensive approach 

that holistically considers 

risks from the cyber, information 

and physical space.” At IFAT 

Munich, the “Day of resilient municipalities” 

on May 7, will focus 

on this topic with presentations 

on the Blue Stage and accompanying 

solution tours. 

Making municipalities waterconscious 

Climate change, heavy rain, dry 

spells and heat pose additional 

challenges for municipalities. 

Water-conscious urban planning 

can reduce the risk of flooding, 

safeguard urban greenery, and 

reduce heat stress. “The knowledge 

is available, and many pilot 

projects demonstrate its effectiveness. 

We now need to 

implement this on a broad scale 

in order to create livable settlement 

areas,” says Dr. Friedrich 

Hetzel, Head of the DWA Water- 

Conscious Space and Settlement 

Development department. DWA 

and DVGW will be presenting the 

Spotlight Area “The water-wise 

city of the future” as well as several 

forums and sessions on the 

Blue Stage. 

Using warm wastewater as an 

energy source 

The heat contained in wastewater 

can cover five to ten percent 

of the heating requirements of 

buildings in Germany. “This potential 

is particularly interesting 

for operators of district and local 

heating networks. Not least because 

the Municipal Heat Planning 

Act, which came into force 

at the start of 2024, stipulates 

that all heating networks must 

be climate-neutral by 2045,” explains 

Reinhard Reifenstuhl, 

DWA spokesperson for the main 

committee on the circular economy, 

energy, and sewage sludge. 

The heat can be extracted via 

heat exchangers directly in the 

sewage system or in the effluent 

of wastewater treatment plants. 

Both have advantages and disadvantages. 

These will be discussed 

on May 6 on the Blue Stage at the 

DWA session “Waste heat utilization/hydrothermal 

energy”. 

You will find more information 

about IFAT Munich at https:// 

ifat.de 

Want to find out more? 

Full details of our diaphragm valves


IVS – Industrial Valve Summit 

The countdown to IVS– 

Industrial Valve Summit 2026 

has officially begun 

The sixth edition of IVS is just around 

the corner – Industrial Valve Summit, 

the leading global gathering for exhibitors, 

industry thought leaders, 

decision-makers and buyers across 

the industrial valve and flow control 

supply chain. Scheduled to take place 

from 19 to 21 May 2026 at the Bergamo 

Exhibition Centre, in Italy, the 

Summit will represent another significant 

milestone in IVS’s continued 

growth and evolution. 

The exhibition area will expand with 

two new halls, bringing the total to 

four, while the programme will feature 

three full days open to the public, 

evolving into a true Valve Week. Starting 

on Tuesday 19 May, the scientific 

sessions will begin alongside the official 

opening of the exhibition to the 

global valve community. This development 

reflects the commitment to 

meeting the growing demand for advanced 

content, networking opportunities 

and expert discussion. 

Visitors can get the free pass to join 

the event through the official IVS 

– Industrial Valve Summit website. 

Early registrations confirm a very 

positive trend, showing growth compared 

to previous editions. 

Thanks to the scientific contribution of 

VALVEcampus – the Association dedicated 

to training industrial valve manufacturers 

and a long-standing partner of 

the Summit – IVS 2026 will offer a technical 

programme at the forefront of innovation, 

designed to address the most 

pressing challenges facing the industry. 

Special focus will be placed on emerging 

technologies and on opportunities 

offered by new application markets 

such as hydrogen, water management, 

CCUS (carbon capture, utilisation and 

storage) and LNG, all key strategic drivers 

for industrial development. 

The programme will be structured 

around six main thematic areas: standardisation 

and standard development; 

digital technologies applied to valves, 

actuations and control; valve design 

and materials for severe services; advanced 

sealing solutions for industrial 

valves; AI applied to mechanical design, 

procurement and manufacturing; 

additive manufacturing. 

Alongside these sessions, four highly 

specialised round tables will address 

complex topics, including subsea 

valve actuation in deepwater environments, 

the use of choke valves in highpressure 

systems, the performance 

and safety of control valves in critical 

applications, and surface treatment 

technologies to enhance component 

resistance to erosion and corrosion. 

Additional broader conferences are 

also currently being defined, focusing 

on applications and market trends in 

the industrial valve sector. 

The previous edition, held from 14 to 

16 May 2024, achieved record results, 

welcoming 15,000 visitors (+25 % 

compared to 2022) from 69 countries 

and 325 exhibitors (+13 %) from 

14 nations. The international component 

was particularly dynamic, doubling 

compared to the fourth edition. 

www.industrialvalvesummit.com 



FILTECH 

Filtration is the key to quality and 

efficiency in production 

Without separation technology, 

there can be no purity – this principle 

applies to countless processes and 

virtually every sector of industrial 

production. Whether it's purified air, 

cleanroom technology, or liquid media 

free of contaminants: filtration 

and separation are the key to safety 

and quality. 

At FILTECH, exhibitors offer insights into all areas of filtration and separation. Source for all 

images: FILTECH 

Research and development are constantly 

producing optimisations and 

new technologies that increase efficiency 

and lead to even better results. 

It is therefore always worthwhile for 

those responsible in production companies 

to keep an eye on current 

trends and check which new materials 

and processes can improve their 

processes. With 600 exhibitors and 

over 160 scientific presentations at 

the conference, FILTECH 2026 will 

once again provide the platform for 

industry and science. 

FILTECH 2026: Focus on filtration 

and separation 

Whether it be gases, liquids or solids 

separation: FILTECH is the world‘s 

leading event for all aspects of filtration 

and separation. It takes place 

every 18 months in Cologne and offers 

industry professionals a unique 

platform to learn about the latest developments 

and innovations in this 

field and to make the right choice 

when it comes to filter systems. 

The event is divided into two main areas: 

the exhibition area and the accompanying 

conference. In the exhibition 

area of FILTECH 2026, 600 

exhibitors from over 40 countries 

will present their latest products 

and technologies. Here, participants 

will have the opportunity to learn all 

about the latest trends and developments 

in filtration and separation 

technology. From innovative filter 

materials to modern separation processes, 

all topics of relevance to the 

industry will be covered. 

The accompanying conference is the 

second highlight of FILTECH. It provides 

a platform for scientific exchange 

and discussion of current 

challenges and solutions in filtration 

and separation technology. Experts 

from science and industry will present 

their latest research results and 

discuss forward-looking approaches. 

For industry professionals, this is an 

ideal opportunity to learn about the 

latest technologies and make valuable 

contacts. 

The meeting place for industry 

experts and decision-makers 

FILTECH is the world‘s most important 

meeting place for discerning, 

quality-conscious companies. Here 

they can find all the relevant information 

and solutions they need for their 

production processes. The event not 

only offers a comprehensive overview 

of the latest technologies, but 

also the opportunity to make direct 

contact with suppliers and find specific 

solutions for their own production 

requirements. 

FILTECH is the platform for anyone 

who wants to optimise their production 

processes using modern filtration 

and separation technologies. The 

combination of trade fair and conference 

offers a unique opportunity to 

obtain comprehensive information 

and bring your own production processes 

up to date. 

www.filtech.de 


57


VALVE WORLD EXPO 

VALVE WORLD EXPO 2026: 

News and trends relating to industrial 

transformation at the world's leading trade 

fair for industrial valves in Düsseldorf 

The latest key technologies for 

industrial transformation – VALVE 

WORLD EXPO will be showcasing 

technological innovations in the field 

of industrial valves in halls 1 and 3 at 

Düsseldorf Fairgrounds from 1 to 3 

December 2026. 

VALVE WORLD EXPO presents intelligent 

products and solutions for fossil 

and alternative applications. As an 

international meeting place for manufacturers, 

developers, users and decision-makers 

from the process industry, 

it is a high-calibre platform for 

professional exchange, knowledge 

transfer and business development. 

Four key topics reflect the central 

themes of the industry and form the 

guiding principles of VALVE WORLD 

EXPO 2026: Global Energy, Process 

Industries & Safety, Digitalisation & 

Automation and Valve Value Chain. 

Global Energy highlights the entire 

spectrum of the energy landscape – 

from oil and gas to LNG and district 

heating to renewable energies and hydrogen 

– and demonstrates the role of 

valves as enablers in all energy sectors. 

Process Industries & Safety emphasises 

the importance of safe, efficient 

valve technologies, which are primarily 

used in the chemical, petrochemical 

and pharmaceutical industries. 

Digitalisation & Automation focuses 

on intelligent valve solutions, digital 

twins and automated systems that 

enable predictive maintenance and 

can be seamlessly integrated into 

networked plant landscapes. 

The fourth key topic, Valve Value 

Chain, highlights the entire value 

Image: Messe Düsseldorf GmbH/C. Tillmann 

chain – from advanced materials and 

components to engineering and manufacturing 

to service and logistics solutions 

– all across the entire life cycle. 

From fossil fuels to renewable energy 

sources – solutions for current 

and future industrial requirements 

The challenges of the energy transition 

and the increasing demands on 

efficiency, safety and sustainability 

require high-performance, reliable 

valve technologies. This applies not 

only to fossil fuels, but also to alternative 

and renewable energies such 

as hydrogen infrastructures, carbon 

capture and storage processes, 

power-to-X plants and offshore energy 

projects. 

The latest developments in the fields 

of hydrogen-resistant materials, cryogenic 

valve solutions for LNG and 

green hydrogen, automated components 

for decentralised energy systems 

and high-pressure valves for 

modern energy storage solutions will 

also be discussed in Düsseldorf. 

The processes in the chemical and 

petrochemical industries place very 

specific demands on materials, safety 

and durability: the focus is on PTFE 

and metal-insulated shut-off and control 

valves, TA-Luft-compliant lowemission 

solutions, SIL-certified safety 

valves and intelligent monitoring 

systems for precise process control. 

International conference and the 

new PUMP WORLD complement the 

trade fair 

Traditionally, the high-calibre Valve 

World Conference, organised and run 

by KCI, complements the events at the 

fairground. An extensive programme 

of presentations with exciting keynotes 

and best cases, which specifically 

promotes the transfer of knowledge 

between research, engineering 

and practice, awaits trade visitors in 

hall 1. 

With a new name and a compact offering, 

Pump World presents itself as 

a special show for pumps in hall 3. 

It is dedicated to highly specialised 

pumps for a wide range of industrial 

applications – in particular pumps 

that can be precisely integrated into 

the industrial valves and systems on 

display. 

Initiatives such as the High Potential 

Day complement the compact range 

of products on offer in the exhibition 

halls. 

www.valveworldexpo.com 






Mechanical Engineering Shipbuilding Heavy Industry 



SH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 






GLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 



SH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLIS 


LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLI 


LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGL 


GLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENG 


NGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENG 


H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH EN 

H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLIS 

SH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH E 

ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLI 

LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH E 


Compressors and Systems 


The alternative for economical 

compressed air 

Maximum energy efficiency with unrestricted reliability 

AERZEN is significantly expanding its 

product portfolio in the higher-pressure 

range and has added innovative 

compressors from the standard 

segment for differential pressures 

of up to 13 bar. The packages consistently 

meet customer and market 

requirements and offer new, 

economical perspectives for conveying 

and compressing air and special 

gases. Energy savings of more than 

10 per cent are possible. 

Compressed air is omnipresent in industry 

and has become an integral 

part of many applications. However, 

it is also a very cost-intensive medium 

- and therefore one which offers an 

important lever for energy savings. 

This is precisely where the new compressed 

air packages from AERZEN 

come in. The compressors combine 

excellent performance with maximal 

energy efficiency and set new 

standards in compressed air technology. 

Thanks to their high-power 

density and reliability, they keep life 

cycle costs low and ensure significant 

cost reductions - an ideal solution for 

making processes even more cost-effective, 

sustainable and efficient. 

Tradition meets innovation: compressed 

air taken further 

For more than 160 years, AERZEN 

compressor technologies have been 

considered pioneering in the conveying 

and compression of gases. In the 

compressed air sector, the innovation 

and technology leader has up until 

now made a name for itself primarily 

as a supplier of stages and special 

packages. By adding the oil-free and 

oil-injected screw compressor series 

up to 13 bar, the company is positioning 

itself in the compressed air technology 

sector and is significantly expanding 

its expertise. 

Fig. 1: With the DS series, AERZEN offers a highly energy efficient solution for oil-free compression 

from 4 to 10.5 bar. All images: AERZEN 

The new packages complete the 

portfolio in the higher pressure 

range and open up additional fields 

of application - be it in food technology 

the beverage industry, chemical 

and process engineering, the textile 

industry, medical and pharmaceutical 

technolo gy, electronics and 

semi conductor production or in the 

cement and lime industry. They 

have been developed to meet the 

highest demands and can be used 

wherever working air, instrument air, 

workshop air, process air or control 

air for pneumatic control systems is 

required. 

DS series: double-stage, oil-free 

screw compressors 

The purity of compressed air is often 

crucial, as it influences the quality of 

the processes used to manufacture 

high-quality products. Oil-free operations 

are therefore vital for many 

processes and a must in terms of 

safety, reliability and availability in 

particularly sensitive areas. The new 

double stage screw compressors of 

the DS series compress absolutely 

oil-free in accordance with ISO 8573- 

1, class 0 and reliably provide 100 % 

clean process air. This ensures 100 % 

product purity. 

The directly-driven compressed air 

packages were designed for maximum 

energy efficiency, minimum maintenance 

effort/costs and extreme durability 

in mind and they ensure outstanding 

performance in almost all 

application areas at differential pressures 

of between 4 and 10.5 bar. Energy 

savings of up to 12 % are possible 

compared with other compressor 

models available in the market. This 

leap forward in efficiency is achieved 

through innovative compressor stages 

with new, highly efficient 4+6 rotor 

profiles in the low and high pressure 

stages as well as motors with energy 

efficiency class IE4 or IE5. A VFD is integrated 

and ensures optimum operation 

with a large turndown. 




The compact DS compressors are 

available in numerous sizes for drive 

powers from 55 to 355 kW and volume 

flows from 259 to 3,636 m³/h 

and are also suitable for sensitive 

scopes of application in the food and 

beverage industry, chemical and process 

engineering as well as medical 

and pharmaceutical technology. The 

process air generation is of course 

PFAS-free, without compromising on 

performance and durability. 

SI series: oil-injected compressors 

with permanent magnet motor 

The SI series are new single stage, 

oil-injected air compressors. Thanks 

to an innovative screw compressor 

stage and a highly efficient IE5 class 

permanent magnet motor (PM motor), 

they achieve a very high efficiency 

of 96 % which enables significant 

energy savings to be made even in 

partial load operation. 

Fig. 3: The new AERZEN compressors and screw compressors set new standards in compressed 

air technology. 

nates the need for lubrication and 

the usual bearing replacement. The 

anti-friction bearings of the compressor 

stages are designed for a service 

life of at least 30,000 hours, further 

reducing maintenance and service 

costs. 

The new screw compressors are 

available in sizes from 7.5 to 90 kW 

and are used in numerous, sometimes 

demanding applications with 

differential pressures from 5.5 to 

13 bar and volume flows from 24.6 

to 915 m³/h. Pressure and operating 

temperatures are continuously 

monitored. This ensures stable and 

safe production processes. Other 

advantages of the SI series include 

its unique reliability, reduced maintenance 

requirements, compact design 

and low sound emission values 

with a sound pressure level of 

around 70 dB(A). 

The optimal solution for every 

requirement 

Every location, every company, every 

process has its own special features. 

AERZEN therefore offers a wide selection 

of finely graduated sizes and 

an enormous variety of customised 

accessories and spare parts components. 

The comprehensive range of 

options and modifications - including 

coolers, dryers, special motors, 

special materials, special oils and 

customised heat recovery systems - 

allows targeted adaptation to individual 

customer process requirements 

and particularly challenging climatic 

Fig. 2: The single stage, oil-injected air compressors 

in the SI series achieve a very high 

efficiency of approx. 96 % - even under partial 

load. 

The rotor is connected directly to the 

compressor shaft, so that additional 

losses in the drive train are avoided. 

The required quantity of compressed 

air is adjusted as needed by means of 

a VFD. The ideally harmonised combination 

of a high-quality drive train 

and the highly efficient compressor 

stage results in particularly efficient 

operation of the entire package. The 

PM motor technology works entirely 

without roller bearings. This elimi- 

Fig. 4: The wide range of options and auxiliary parts enables targeted customisation to individual 

customer process requirements. 


61



conditions and ensures the greatest 

possible flexibility in the design of 

machines and plants. 

Optimum compressed air quality 

thanks to perfect air conditioning 

One focus is the area of compressed 

air treatment. Compressors work 

with the ambient air. However, this 

contains impurities of various types, 

such as steam, dust or liquids. If 

these are not removed, problems 

are inevitable. Condensing water vapours, 

for example, can cause corrosion, 

which can damage components 

of the compressed air installation 

and lead to production interruptions. 

The result: increased operating costs 

due to failures. AERZEN’s wide range 

of products for filtering, cleaning and 

drying the compressed air produced 

in the compressor leaves nothing 

to be desired and ensures high and 

cons tant compressed air quality in 

every process. 

Safe, efficient and environmentally 

friendly compressed air generation 

AERZEN air compressors represent 

the highest level of engineering, unrivalled 

innovative strength, uncompromising 

quality and technological 

sophistication. They have been 

developed to increase productivity 

and reduce operating costs. Thanks 

to the extremely compact design of 

the DS and SI compressors, the ma- 

Fig. 5: The water-injected packages of the SW series ensure oil-free 

compression up to 13 bar. 

chine footprint is also reduced. The 

smart package concept even enables 

side-by-side installation, as operation 

and maintenance can be carried 

out from both the operating and rear 

sides. Transport by pallet truck, forklift 

truck or crane is possible without 

any problems. 

In addition to the new DS and SI 

series, AERZEN also offers water-injected 

compressed air stages. The 

SW series packages with screw rotors 

made of high-alloy, corrosion-resistant 

stainless steel offer increased energy 

efficiency, reduced maintenance 

requirements and a unique water 

puri fication concept, and ensure oilfree 

compression up to 13 bar. 

“Our declared aim is to offer our customers 

a full range of products, solutions 

and services. Our air compressors 

are state of the art and support 

you on your way to greater efficiency 

and process reliability. They therefore 

make an important contribution 

to sustainability and economic efficiency,” 

emphasises Stephan Brand, 

Director of Marketing at AERZEN. 


Aerzen, Germany 

info@aerzen.com 

www.aerzen.com 


www.zwick-aRmatuRen.de 

tRi-SHaRk 

zeRO leakage* 

cOntROl ValVe 

*acc. to EN12266 Leckage A


Breathing air compressor 

On the track with high pressure 

Julius Nasch 

Why would a student racing team 

need the support of a compressor 

manufacturer? The obvious 

answer: “To fill the tyres.” However, 

the partnership between 

BAUER KOMPRESSOREN and the 

TUfast Racing Team revolves around 

a technology that, at first glance, 

doesn’t seem related to compressed 

air: autonomous driving. 

But let’s start at the beginning: 

Formula Student is an international 

engineering competition in which student 

teams develop, build and test a 

racing car within one season, and 

compete against teams from around 

the world. Speed itself is not the only 

thing that counts. Design, efficiency, 

an understanding of costs and the 

overall technical concept are all considered 

in the assessment. 

the Suspension, Chassis, Aerodynamics 

and Structural Mechanics departments. 

Electrical systems including 

software are developed by the High 

and Low Voltage departments along 

with the teams for Vehicle Dynamics 

and Autonomous Driving. 

Reliable braking with high pressure 

In autonomous driving, the vehicle 

has integrated sensors used to detect 

the route as well as its own position 

and movement. An on-board 

computer calculates possible racing 

lines and optimises them to minimise 

the lap time. Since the racing car accelerates, 

brakes and steers autonomously 

in this operating mode, the 

Formula Student rules prescribe extensive 

safety measures. Among 

these is the Electronic Braking System 

(EBS), which is where compressed air 

comes into the picture. 

The EBS reliably brings the vehicle to a 

standstill when needed. While electric 

motor regenerative braking is all you 

need for racing, a redundant mechanical 

braking mechanism always has 

to be provided in case of emergency. 

Since there is no driver in the vehicle 

during autonomous driving who 

could provide the necessary brake 

pressure, the braking force is applied 

using compressed air instead. 

Technical University of Munich’s 

TUfast Racing Team – a success story! 

In this competition, the Technical 

University of Munich is represented 

by the TUfast Racing Team. As a student 

association, the team has been 

developing its own Formula Student 

vehicles since 2003, bringing together 

students from a wide range of disciplines. 

While racing cars with combustion 

engines were built in the early 

days, the development of electric 

vehicles gained importance starting 

in 2011. The team has built electric 

vehicles exclusively since 2017 and 

now, they are also capable of fully 

autonomous driving. 

The team members, around 100 in total, 

are organised in a structure similar 

to a business: different departments 

each work on particular aspects of the 

project under the supervision of team 

management. The Management, Costing 

and Business Plan departments 

are responsible for events, sponsor 

contacts, and financial and business 

planning. The vehicle’s mechanical 

components are the responsibility of 

Fig. 1.0+1.1: CAD renderings of the EBS components (compressed air tanks, lines and valves, 

brake pedal and cylinders) 




Fig. 2: xb025 racing car on the racecourse 

A consistent, reliable supply of compressed 

air was a key requirement, 

ultimately determining success or 

failure in competitions. It was therefore 

reassuring for the team to know 

that, since it’s market launch in 1995, 

the JUNIOR II has earned a downright 

legendary reputation as the 

most successful and top-selling portable 

breathing air compressor in the 

last three decades thanks to its reliability. 

Portability was also of fundamental 

importance for the TUfast 

Racing Team because a lot of equipment 

needs to be hauled from one 

competition to the next: with its compact 

dimensions, it fits in the boot of 

any vehicle and, with a weight of less 

than 44 kilograms, it’s easy to move 

around on site by two people using 

its ergonomic handle. 

With the compressor and two carbon 

helmets provided in addition, the 

team was ready to compete. 

Geared for success thanks to 

technical excellence 

Fig. 3: Bauer Kompressoren and the TUfast Racing Team at the Formula Student Germany 

competition 2025 on the Hockenheimring 

Two compressed air tanks are filled 

for this purpose before setting off. 

When needed, a transmitter operated 

by a team member opens valves that 

deliver compressed air to the brake 

cylinders. The hydraulic cylinders of 

the conventional brake system are 

then actuated by the pneumatic cylinders 

of the EBS. This safely brings 

the vehicle to a stop. 

High pressure is required when filling 

the compressed air tanks. When 

the existing compressed air solution 

failed in the summer of 2025, shortly 

before the competition in Spain, 

the situation was therefore critical. 

That’s when BAUER KOMPRESSOREN 

pitched in and provided a BAUER 

JUNIOR II high-pressure compressor. 

JUNIOR II – the portable and highly 

reliable filling solution 

The JUNIOR II was chosen since it 

can compress the required air up to 

300 bar. Since contaminants or oil 

in the system can cause dangerous 

brake system failures, the purity of 

the compressed air is even more important. 

The integrated Triplex filter 

system delivers such high purity that 

the air even conforms to the DIN EN 

12021: 2014 standard, meaning it can 

be used as breathable air for divers 

or fire-fighters. 

The support paid off: in Spain, the 

TUfast Racing Team celebrated its 

second overall victory for the season. 

They also won in the purely autonomous 

driving category for the first 

time in the association’s history. This 

likely wouldn’t have been possible 

without the quick response of BAUER 

KOMPRESSOREN. 

The team has set ambitious goals for 

the 2026 season, planning to make 

the new xb026 racing car even lighter 

and more competitive than its predecessor. 

Another overall victory in 

August 2026 at the Formula Student 

Germany competition on the Hockenheimring 

is the objective. A lot of 

work remains to be done before that: 

all components are currently in fabrication. 

The test phase starts in April 

2026, after which the team has to assert 

itself in a total of four competitions 

across Europe starting in July. 

The Author: Julius Nasch 

Team Manager xb026 

TUfast Racing Team 

München, Germany 

https://tufast-racingteam.de/de/ 


65



40 years of Sweden’s heat pumps: from the oil 

crisis to the energy transition 

Rasmus Sinnige 

A technology multiple decades old is 

not usually seen as the most exciting 

piece of machinery on the market. 

But the humble heat pump is a 

piece of industrial equipment that is 

increasingly at the forefront of the 

ongoing energy transition. In fact, 

in some countries it is becoming intrinsic 

to the way towns and cities 

heat their homes, businesses and 

factories. While countries are now, 

be latedly, recognizing the value of 

heat pumps, in Scandinavia they 

have been a key element in providing 

climate-neutral district heating 

for decades. 

These two machines are named after 

royals from Sweden’s history, 

„Katarina“ and „Gustav-Adolf“, and 

are the centerpieces of two world-record 

breaking heat pumps that have 

been providing climate-neutral district 

heating to the city since 1985. As 

this article shows, Göteborg Energi is 

again investing in a new generation 

of heat-pump technology, which will 

set a new world record in terms of its 

thermal power. At the same time, it 

will set the world record for the largest 

heat pump with the natural refrigerant 

isobutane. 

Evolution rather than revolution 

Long-term thinking is important in the 

business world, and it is even more 

valuable in today’s climate when every 

company is searching for ways to 

cut costs and save energy. After recognizing 

the precariousness of relying 

on oil imports, Sweden long ago 

had the foresight to appreciate that 

heat-pump systems were cost-efficient, 

sustainable heating solutions. 

In the 1960s the Swedish government 

provided the legal framework that 

enabled heavy investments in the expansion 

of district heating systems. 

Sweden’s embrace of heat pumps 

goes back to the 1980s, in the aftermath 

of the oil crises of the previous 

decade. Visible testaments to 

this can be seen at Göteborg Energi 

Ryaverket, a large heat-pump plant 

co-located with a wastewater treatment 

plant in Gothenburg, on Sweden’s 

south-west coast. 

Here, the eagle-eyed might spot two 

shiny, well-polished plaques attached 

to two Atlas Copco Gas and Processor 

turbocompressors. 

Fig. 2: Name plate of the large turbocompressor, 

the heart of the heat pump 

In the aftermath of the oil crises in 

the 1970s, the government then put 

new laws into place that supported 

the transition away from fossil fuels 

to power these networks. In their 

place, the country invested substantially 

in domestic non-fossil-fuel 

energy sources, such as hydropower 

and nuclear power for electricity, and 

waste incineration and biomass to 

power district heating. 

Just after large quantities of lowcarbon-intensity 

electricity became 

available in the early 1980s from 

the aforementioned hydropower 

and nuclear power plants, large 

heat pumps such as „Katarina“ and 

„Gustav-Adolf“ entered the story. 

Once commissioned, these two machines 

became the world’s largest 

heat-pump modules, both with an 

output of 65 MW from a single large 

turbocompressor per module. 

Fig. 1: Birds-eye view on the Ryaverket Plant and the adjacent sewage water treatment plant 

Since then, the technology has 

evolved, but without “moonshot” 

leaps forward. Why? Simply, this was 

already proven, efficient technology. 

Evolution rather than revolution 

is the theme. What did happen was 

that Atlas Copco Gas and Process advanced 

the machine at the heart of 

the heat-pump system, the turbo- 




compressor. Powerful FEM-computer 

software has helped optimized impeller 

design, for example. And the latest 

AI tools have improved the thermodynamic 

performance, which increases 

the efficiency of the heat-pump cycle. 

Then there is their ease of maintenance, 

which recently encouraged 

Jonas Strandberg, plant manager for 

the Ryaverket heat pumps at Göteborg 

Energi, to describe maintaining 

them as quite “boring”. He points out 

that along with good maintenance, 

partly provided by the Atlas Copco 

Gas and Process aftermarket service 

team, key is having the right spare 

parts in stock. Learning these lessons 

over the four decades of operation 

has taught Göteborg Energi how 

to do preventive maintenance in a 

way that nearly eliminates unplanned 

downtimes. 

Fig. 3: Large heat pump compressor GT098R3G1 for RYA heat pump at the time of delivery 1985 

The maintenance program is underpinned 

by a diagnostic system that 

includes refrigerant sensors in the 

source and district heating networks 

that can detect the smallest trace of 

refrigerant in the “parts-per-billion” 

order of magnitude. This is an important 

feature that detects even the 

smallest leakage of the refrigerant 

into the water circuits. The additional 

vibration monitoring systems detect 

imbalances in the finely manufactured 

internal parts of the turbocompressor, 

preventing severe damage. 

After 40 years providing sustainable 

district heating, Göteborg Energi recently 

decided to extend the working 

lives of „Katarina“ and „Gustav-Adolf“ 

for another 15 years. 

to service this high demand reduces 

the system efficiency. 

It is much better to orchestrate the 

heat sources in a sensible way: recovered, 

unavoidable industrialwaste 

heat might be the baseload 

throughout the year, supported by 

waste incineration. The heat-pump 

system would then provide an intermediate 

heat load, supported by biomass 

or a gas power plant as peak 

load and backup. 

Nonetheless, heat pumps have the 

advantage of being highly flexible, 

Heat pumps as intermediate 

systems 

Of course, heat pumps are not an 

elixir, a fix-all solution, and they have 

limitations. They ideally work hand 

in hand with other heat sources in a 

network, like instruments in an orchestra. 

Moreover, heat pumps are 

usually not the largest generator in 

a district heating system. In winter, 

many heating systems require higher 

peak-load power and temperatures 

that are well above normal summer 

conditions. Oversizing a heat pump 

Fig. 4: Still in good shape and fit for at least 15 years to come – the entire heat pumps at 

Ryaverket including the Atlas Copco Turbocompressor 


67



meaning they are quicker to react 

than other heating sources. The 

Ryaverket heat pumps can be cold 

started and ramped up to full power 

in under 15 minutes, far ahead of 

all the other heating systems. This 

means they are ideal at delivering 

heat on demand, and they work well 

in conjunction with more fluctuating 

wind and solar systems that are rapidly 

gaining power market share in 

most countries. 

Record breaking 

Testament to the success of the fourdecade-old 

Gothenburg heat pumps 

is that Göteborg Energi went back to 

Atlas Copco Gas and Process to design 

another compressor. Soon to be 

deployed, this new module can generate 

up to 58 MW and will replace 

the plant’s two oldest existing heat 

pumps. It will use wastewater from 

a nearby waste treatment plant (of 

at least 10°C) and produce 3.5 times 

more district heat at 90°C for every 

megawatt of electricity the heat 

pump uses. The system is due to begin 

operating in 2027, and it will take 

the total installed heating capacity 

to 158 MW across three heat-pump 

modules (including the 50 MW apiece 

from „Katarina“ and „Gustav-Adolf“). 

Fig. 6: The use of large heat pumps is not limited to district heating generation 

The rediscovery of the utility of heat pumps. Each will have a thermal 

capacity of 82.5 MW, and they 

large heat pumps continues apace, 

reflected in the southern Germany will become the largest heat-pump 

city of Mannheim, which has ordered 

two Atlas Copco Gas and the newly installed 58 MW unit in 

modules in the world, surpassing 

Process turbocompressors for two Gothenburg. 

Fig. 5: Overview different refrigerant classes and their future fitness 




Modern refrigerants for modern 

heat pumps 

The choice of refrigerant determines 

the design of any new heat pump, 

and the history of the Gothenburg’s 

„Katarina“ and „Gustav-Adolf“ provides 

an instructive example of how 

critical this is: both had to change 

their refrigerant, R12, a chlorofluorocarbon 

(CFC), due to its contribution 

to ozone depletion. The Montreal 

Protocol of 1987 started the process 

of banning CFCs, which in the 1990s 

meant that heat-pump manufacturers 

needed to come up with an alternative. 

The answer appeared to be 

hydrofluorocarbons (HFCs), but they 

also have a significant impact on the 

greenhouse effect, and they are now 

also subject to a global phase out 

(with the EU aiming for 2050). 

With this in mind, Göteborg Energi 

stipulated that they wanted a heat 

pump design that employed a future-proof, 

natural refrigerant. The 

choice was isobutane R600a, which 

though flammable, achieves a balance 

between efficiency, cost and not 

being harmful to the environment. 

The Atlas Copco Gas and Process 

turbocompressor was consequently 

designed specifically for isobutane 

R600, a future-proof refrigerant commonly 

used in every modern refrigerator 

at home. 

Sweden’s 40-year embrace 

Unspectacular, proven technology 

that has been running for decades is 

rarely in the limelight. But the humble 

heat pump is nevertheless increasingly 

recognized as a vital industrial 

equipment in the energy transition. 

While this technology largely fell out 

of fashion as fossil fuels predominated, 

Sweden embraced it, underpinned 

by governmental investment 

decisions in the 1970s and 1980s. 

Gothenburg’s „Katarina“ and 

„Gustav-Adolf“ have stood the test of 

time, and their design, efficiency, and 

aftermarket maintenance programs 

have enabled their lifespan to be expanded 

another 15 years. They will 

soon be accompanied at Ryaverket 

by a new heat pump with isobutane 

R600a refrigerant, replete with an Atlas 

Copco Gas and Process turbocompressor 

that benefits from decades of 

evolutionary advancements. Just like 

its older siblings have been doing for 

the past 40 years, it will provide the 

city’s inhabitants with climate-neutral 

district heating for de cades to come. 

The Author: Rasmus Sinnige 

Market Manager New Energy 

Atlas Copco Energas GmbH, Köln 

rasmus.sinnige@atlascopco.com 

https://www.atlascopco.com/gasand-process/en 

Proven Reliability. 

NORD drive solutions for 

environmental processes. 

4–7 May 

Hall B1, Booth 117 

Getriebebau NORD GmbH & Co. KG | T: +49 4532 289-0 | info@nord.com | www.nord.com



Nitrogen purity explained: How to select 

the right purity for each industry 

For businesses that utilize nitrogen, 

understanding the nuances of 

nitrogen purity is not just a technical 

detail. Nitrogen purity is a critical 

factor that can significantly impact 

operational efficiency, product 

quality and ensure the safety of the 

process and its operators. While you 

may already be familiar with the basics 

of nitrogen production, choosing 

the optimal purity level for your 

specific application is key to unlocking 

the full benefits of on-site nitrogen 

generation. 

As nitrogen solutions provider, our 

goal is to ensure you're not paying for 

purity you don't need or compromising 

your products with purity that's 

too low. 

The importance of purity levels 

Nitrogen purity is typically expressed 

as the percentage of nitrogen in the 

gas, with the remainder being mostly 

oxygen and trace amounts of 

other gases. The required purity level 

is dictated by the sensitivity of your 

application to oxygen. For some processes, 

a small amount of oxygen is 

acceptable, while for others, even 

trace amounts can be detrimental. 

Here is a breakdown of common nitrogen 

purity levels and their typical 

applications: 

95 % to 98 % N 2 

purity 

This purity range is often sufficient for 

applications where the primary goal is 

to displace oxygen to prevent oxidation 

or combustion of the end product. 

– tire inflation: Using nitrogen of this 

purity can help maintain tire pressure 

for longer periods and prevent oxidation 

of the rubber. 

– fire prevention: In environments 

where there is a risk of fire, such as 

in coal mines or chemical plants, this 

purity level can be used to create an 

inert atmosphere. 

99 % to 99,99 % N 2 

purity 

At this level of nitrogen, the main 

goals are to extend shelf life of products 

in the food and beverage industry, 

where we want to maintain the 

end product quality: taste, colour, 

smell. This process can also be called 

Blanketing. The other application is to 

inert material in contact with dangerous 

gases or liquids (Inertization). 

– modified atmosphere packaging: 

by reducing the contact with oxygen 

hence slowing oxidation and 

microbial growth, the end product's 

integrity is preserved (meat, precooked 

food, cheese/butter or even 

pharmaceutical products). 

– beverage dispensing: In the beverage 

industry, it is used maintain the 

flavor profile of beer, wine, milk, soft 

drinks (juice, mineral water, soda) or 

oils (olive, soybean, etc). 

– controlled atmosphere storage 

(fruits and vegetables). 

– inertization (Oil & Gas plants, natural 

gas purging, boiler layups, etc). 

99.9 % to 99.999 % N 2 

purity 

Higher purity levels are required for 

more sensitive applications where 

even small amounts of oxygen can 

have a negative impact on the product 

quality and directly threaten the 

process safety. 

– laser cutting: In laser cutting, highpurity 

nitrogen is used as an assist 

gas to prevent oxidation and ensure 

a clean cut. 

– electronics manufacturing: This 

purity is essential for creating an inert 

atmosphere during soldering and 

other manufacturing processes to 

prevent defects. 

– gas-assisted injection molding 

(gaim): In this industry, nitrogen is 

used to safely displace raw material, 

helping to create clear channels and 

reduce defects. 

– protective atmosphere in exlposive 

area (atex): as an inert gas, nitrogen 

is used to create a non-flammable 

atmosphere, especially for maintenance 

purpose. 

99.999 % and higher 

(UHP - Ultra High Purity) 

The most demanding applications require 

ultra-high purity nitrogen to ensure 

the integrity of the final product. 

– chemical industry: UHP nitrogen is 

used in various chemical processes to 




prevent unwanted reactions and ensure 

product purity. 

– pharmaceuticals: In the pharmaceutical 

industry, it is used to create 

a sterile and inert environment for 

manufacturing and packaging. 

The cost of “too pure” 

In many technical and industrial applications, 

striving for the highest 

possible purity seems like a safe bet. 

However, when it comes to on-site nitrogen 

generation, this mindset can 

lead to significant and unnecessary 

expenses. The truth is, the relationship 

between nitrogen purity and the 

cost of production is not linear — it's 

exponential. Understanding this principle 

is key to optimizing your operational 

budget without compromising 

quality. 

The primary cost associated with nitrogen 

generation is the energy required 

to run the air compressor that 

feeds the system. This is because as 

the oxygen concentration decreases, 

it becomes harder to isolate and remove 

the remaining oxygen molecules. 

The system must work harder, 

process more air, or run longer cycles 

to capture those last few parts per 

million (PPM). This increased workload 

directly translates to a higher 

electricity bill. 

Example: laser cutting — mild steel 

components 

Application requirement: A metal 

fabrication shop uses nitrogen as 

an assist gas for laser cutting 5mmthick 

mild steel plates. The nitrogen’s 

role is to prevent oxidation on the 

cut edge, leaving a clean, paint-ready 

surface. 

Sufficient purity 

99.95 % nitrogen is the industry 

standard for this task. It provides a 

high-quality, oxide-free cut edge at 

high speeds. 

The “too pure” scenario 

The shop invests in a nitrogen generation 

system rated for 99.999% (often 

called Ultra High Purity or UHP), typically 

reserved for cutting exotic materials 

like titanium or very thick stainless 

steel. 

The financial impact 

Capital expense 

A UHP nitrogen generator is significantly 

more complex and therefore 

more expensive upfront than a 

standard 99.95 % system. The initial 

investment could be 40-60 % higher. 

Operational expense 

The energy cost to produce 99.999 % 

nitrogen can be over 30 % higher 

than producing 99.95 %. For a busy 

shop, this can mean an extra 2,000- 

5,000 EUR in annual electricity costs. 

The result 

The shop has spent more on the initial 

equipment and continues to pay 

a premium on its monthly utility bills, 

all for a cut quality on mild steel that 

is indistinguishable from one made 

with the more economical 99.95% 

purity gas. 

How to determine the right purity 

To determine the right nitrogen purity 

for your application, consider the 

following: 

Application requirements 

What is the maximum allowable oxygen 

content for your process? 

Industry standards 

Are there any industry-specific standards 

or regulations that dictate the 

required purity level? 

Cost-benefit analysis 

What is the trade-off between the 

cost of higher purity and the potential 

benefits of improved product quality 

or process efficiency? 

Conclusion 

Selecting the right nitrogen purity is 

a critical decision that can have a significant 

impact on your business. By 

carefully evaluating your application’s 

requirements and consulting with 

experts in the field, you can ensure 

that you are using the most appropriate 

and cost-effective nitrogen purity 

for your needs. This will not only 

help you to optimize your processes 

and improve product quality but also 

to achieve significant savings in the 

long run. 

OMEGA AIR d.o.o. Ljubljana 

Ljubljana, Slovenia 

info@omega-air.si 

www.omega-air.si 


71



Green Smart Factory 

Compressed air for climate-neutral 

production 

Dipl. Betriebswirtin, MA Daniela Koehler, Dipl.-Ing. (FH) Gerhart Hobusch 

Completely climate-neutral production 

is no longer a utopian vision. 

The Green Smart Factory demonstrates 

how cost-efficiency, quality 

and environmental responsibility 

can successfully go hand in hand. At 

the core of this transformation lies 

highly intelligent compressed air 

generation, which plays a key role in 

ensuring sustainable, future-ready 

manufacturing. 

Heizomat’s managing directors are 

more than visionaries – they are 

doers who pursue their goals with 

unwavering determination. No matter 

how “impossible” an idea may initially 

seem, how great the challenges 

or how long the journey, they see it 

through. Their success speaks for itself: 

within a single generation, the 

company has grown into a leading 

provider of heating technology and 

energy solutions. Now comes another 

milestone with pioneering potential. 

Since September 2025, the new 

“Green Smart Factory” has been in 

operation – a production facility designed 

from the ground up to integrate 

environmentally friendly technologies 

to enable climate-neutral 

production. 

At the Green Smart Factory, Heizomat 

also manufactures its own proprietary 

pallet shredder. The system 

turns used pallets and wood off-cuts, 

by-products of almost every production 

operation that would otherwise 

require disposal, into high-quality 

woodchips. In turn, these chips are 

used to provide heating that is essentially 

climate- and cost-neutral. 

Renewable energy forms the backbone 

of production. Plans include 

the construction of the company’s 

own wind turbine, while the roof is 

already equipped with a photovoltaic 

system. Together with an in-house 

wood gasifier, these systems enable 

electrici ty to be generated as sustainably 

as possible. The concept is further 

strengthened by electricity and 

heat storage, supported by numerous 

additional innovations within 

the production hall that help drive 

the plant’s energy footprint towards 

Fig. 1: The ultra-modern and innovative compressed air station lies at the heart 

of the Green Smart Factory. 

zero. This unwavering commitment 

to renew able energy is more than an 

ecological statement – it is a core element 

of the company’s production 

strategy. Energy is not viewed as an 

external cost factor, but as a controllable 

resource within a closed, intelligently 

managed system. 

Energy-oriented production control 

A defining feature of the Green Smart 

Factory is the close alignment of production 

processes with energy availability. 

Manufacturing generally runs 

on a single-shift basis – a model that 

benefits employees while also optimising 

the use of renewable energy. 

During the summer months, production 

hours are deliberately extended 

to coincide with peak photovoltaic 

output. Slightly longer daytime 

shifts ensure that the solar installation’s 

full potential is harnessed. Energy-intensive 

processes, such as nitrogen 

generation, are activated only 

when sufficient “green” electricity is 

available. 

This logic is fully automated. Compressed 

air and nitrogen generation 

are integrated into the Manufacturing 

Execution System (MES) and directly 

linked to the ERP (Enterprise 

Resource Planning) system used for 

machine and plant engineering. The 

result is seamless, end-to-end production 

control – from order processing 

and manufacturing through to 

warehouse logistics – creating a truly 

smart operation. Automated feedback 

and inventory reconciliation 

ensure that production progress remains 

transparent and traceable at 

all times. Extensive storage areas, 

including facilities in the production 

basement, make it possible to purchase 

and stockpile raw materials in 

advance. This enables larger quan- 




tities to be secured when market 

prices are favourable. The raw materials 

are then delivered into production 

just in time via “lifts” as part of 

the manufacturing process. 

Smart machines and connected 

processes 

At the heart of the Green Smart Factory 

are highly integrated, intelligent 

production systems. These “smart 

machines” enable flexible, efficient 

and resource-conscious manufacturing 

by autonomously adjusting 

production parameters and detecting 

deviations or faults in real time. 

This performance depends on seamless 

IT integration. Using IoT-enabled 

systems, machines, production lines 

and the entire factory infrastructure 

communicate continuously with one 

another. The resulting data streams 

provide full transparency and enable 

those responsible to optimise 

processes on an ongoing basis. Production 

planning, material flows and 

energy consumption are not only automated, 

but also dynamically adapted 

to current conditions. This intelligent 

responsiveness is a crucial 

foundation for achieving both maximum 

efficiency and genuine sustainability. 

Compressed air – a key energy 

source 

The intelligent compressed air station 

incorporates the latest innovations 

and advanced technologies, reliably 

meeting the entire compressed 

air demand for production with maximum 

efficiency and cost-effectiveness. 

Compressed air is required 

both as plant air for modern manufacturing 

systems and as the basis 

for on-site nitrogen generation. Highpurity 

nitrogen is produced via pressure 

swing adsorption (PSA) and is 

used for sensitive applications such 

as laser material processing. Depending 

on demand, the nitrogen is either 

used directly or further compressed 

downstream and stored in nitrogen 

gas cylinder bundles for later use. 

A connected compressed air station 

for smart energy management 

The compressed air station is seamlessly 

integrated into the factory’s 

digital system landscape. At its heart 

is a master compressed air management 

system – in this case the Sigma 

Air Manager – which serves as both 

the central control unit and the interface 

to the company’s overarching 

control technology. Compressed air 

generation is carried out by multiple 

components. A variable-speed rotary 

screw compressor covers the base 

load, continuously adjusting its output 

to match demand and supplying 

Fig. 3: The Sigma Air Manager is the intelligent 

“brain” that connects all components 

and ensures an optimal compressed air 

supply. 

the required flow rate at the necessary 

operating pressure to the compressed 

air network. When demand 

peaks, two smaller fixed-speed units 

can be brought online. They primarily 

provide redundancy but can also 

support higher load requirements 

whenever needed. Compressed air 

treatment is likewise designed with 

built-in redundancy. Two parallel 

treatment lines, each equipped with 

refrigeration dryers and downstream 

coalescence microfilters, ensure consistently 

high compressed air quality. 

Within this highly integrated production 

environment, the compressed 

air supply plays a vital role. In industrial 

manufacturing, compressed air 

is every bit as essential as electricity: 

if the power fails, production stops 

– and the same applies if the compressed 

air supply is interrupted. Accordingly, 

requirements for efficiency, 

availability and quality are high. 

Heizomat’s managing directors were 

fully aware of this critical dependency. 

For the Green Smart Factory, 

they therefore partnered with a 

compressed air systems specialist 

renowned for its expertise. Kaeser 

Kompressoren was entrusted with 

the planning and implementation of 

a tailor-made compressed air station 

designed precisely to meet the factory’s 

needs. 

Fig. 2: Manufactured in the Green Smart Factory, the pallet shredder turns used pallets and 

wood off-cuts into valuable wood chips for sustainable reuse. 


73



Fig. 4: Air-main charging systems, numerous sensors and decentralised safety stages ensure 

an optimal compressed air supply at all times. 

measurement system. Sensors for 

pressure, temperature, humidity 

and pressure dew point are installed 

both upstream and downstream of 

the centralised compressed air treatment 

stage. The system is further 

complemented by thermal mass flow 

sensors capable of detecting even 

the smallest flow rates – for example, 

those caused by leaks. In practice, 

intake and ambient conditions 

within the compressed air station are 

continuously monitored by an ambient 

sensor that records air pressure, 

temperature and relative humidity. 

These data provide valuable insight 

into operating conditions and allow 

conclusions to be drawn regarding 

cooling requirements. All measured 

values are transmitted in real time via 

the network to the master controller. 

This information can subsequently be 

used, for example, to automatically 

control the ventilation system. 

Heat recovery and circular thinking 

Fig. 5: Exhaust heat from the compressors is recovered and utilised for heating and climate 

control in the production halls. 

This is particularly critical for sensitive 

applications such as fully automated 

laser cutting, where purity and reliability 

are essential. 

Compressed air quality in accordance 

with ISO 8573-1 

The required compressed air quality 

is defined in accordance with ISO 

8573-1 (2010). For applications within 

the Green Smart Factory, a classification 

of 1: 4: 2 (Particulates: Water: 

Oil) was specified. In some respects, 

these requirements even exceed the 

purity criteria of ISO cleanroom class 

5 as per ISO 14644-1, underscoring 

the exceptionally high-quality standards 

of the production operation. 

Compliance with these strict limit values 

is ensured by a carefully coordinated 

system comprising centralised 

air treatment, air-main charging systems 

and decentralised safety stages. 

For supply lines serving particularly 

sensitive equipment, additional filter 

combinations – microfilters and activated 

carbon filters – are installed. 

This reduces the total hydrocarbon 

content locally to class 1 (0.01 mg/m³), 

ensuring maximum process reliability 

and product quality. 

Monitoring, measuring technology 

and quality assurance 

Compressed air quality is safeguarded 

by a comprehensive multi-sensor 

Integrated heat recovery is another 

key pillar of the factory’s efficiency 

concept. The exhaust heat generated 

during compressed air production 

is fed into a 50 m³ stratified thermal 

storage tank and used to heat both 

the production and office areas via 

ceiling radiant panels. In summer, with 

an alternative water supply, the same 

panels can also be used for cooling, 

ensuring a comfortable indoor climate 

all year round. In principle, the system 

could even be expanded to include adsorption 

cooling, converting heat into 

cooling during the warmer months. 

However, this would require a largely 

constant heat flow over extended 

periods, as well as defined minimum 

water temperatures. 

Sustainable condensate treatment 

Like heat, condensate is an unavoidable 

by-product of compressed air 

generation. It forms from the moisture 

contained in the intake air, which 

fluctuates with the seasons and prevailing 

weather conditions. As the 

compressed air cools after generation, 

condensate collects in the aftercooler 

and, to a lesser extent, in the 

downstream refrigeration dryer. An 




Fig. 6: The large air receiver provides ample 

storage capacity, and the AQUAMAT unit installed 

in front of it ensures environmentally 

friendly condensate treatment. 

efficient separation system removes 

the condensate from the compressed 

air flow and routes it to a dedicated 

condensate treatment unit. 

As in all other areas, the Green Smart 

Factory relies on modern, networked 

technology for condensate treatment. 

An AQUAMAT i.CF system is 

used as an active solution, with sensors 

monitoring filter utilisation. This 

ensures reliable, efficient condensate 

treatment while making optimum use 

of filter capacity. Sensors continuously 

track the condition and loading of 

the closed filter cartridges, while process 

data and system messages are 

transmitted via the compressed air 

station network. Servicing is consequently 

predictable, safe, hygienic 

and ergonomic. If required, the system 

can be expanded on a modular 

basis, allowing it to be adapted retrospectively 

to accommodate changing 

capacity requirements. 

Conclusion 

Heizomat’s Green Smart Factory provides 

an impressive example of how 

carbon-neutral industrial production 

can be achieved through the intelligent 

integration of renewable energy 

generation, digitalisation and highly 

efficient compressed air technology. 

In this concept, the networked compressed 

air supply is far more than 

a supporting utility – it is a central element 

of a holistic energy and production 

strategy: smart, efficient and 

consistently sustainable. A vision has 

become reality – one designed not 

only to set new standards, but also to 

inspire others. And, incidentally, the 

Green Smart Factory is open to visitors. 

The Authors: Daniela Koehler, 

Graduate Business Economist (MA), 

Press Officer; 

Dipl-Ing. (FH) Gerhart Hobusch, 

Head of Application Engineering 

Germany - 

both KAESER Kompressoren SE, 

Coburg, Germany 

EFFICIENT POWER BEAST 

IK 22 SERIES | DIRECT-COUPLED 

FOR MAXIMUM EFFICIENCY AND 

UNCOMPROMISING RELIABILITY 

› Maximum efficiency thanks to direct-coupled drive 

› Horizontal design saves space and enables fast and 

easy maintenance 

› Uncompromising BAUER quality for maximum 

reliability and operational safety in continuous duty 

› B-CLOUD ready as standard for remote access, 

remote monitoring and B-APP connectivity 

› 22 – 37 kW 

› 600 – 4.200 l/min 

› 55 – 525 bar 

› Air, Nitrogen, Helium, Heliox, 

Argon and Neon 

www.bauer-kompressoren.de 

Discover 

product details 

NEW!



Air compressor troubleshooting: 

A comprehensive guide 

to rapid problem resolution 

Rodrigo Varela 

In modern industrial operations, 

compressed air systems function 

as critical utilities that power numerous 

processes. When these systems 

malfunction, the ripple effects 

can quickly cascade throughout an 

entire facility, potentially resulting 

in costly downtime and production 

losses. Understanding effective 

troubleshooting techniques is, 

therefore, essential knowledge for 

maintenance teams and operational 

staff who rely on these systems. 

This article explores the fundamentals 

of air compressor troubleshooting, 

examining not only the technical 

aspects of diagnostic procedures 

but also the methodical approach required 

to identify and resolve issues 

efficiently. By implementing a structured 

troubleshooting process, organisations 

can significantly reduce 

the impact of compressed air system 

failures and maintain optimal operational 

performance. 

What does troubleshooting mean? 

Troubleshooting is the systematic 

process of identifying, analysing, and 

resolving problems within a system 

or machine. Rather than employing 

guesswork, proper troubleshooting 

follows a methodical approach that 

isolates variables and tests hypotheses 

in a logical sequence. The fundamental 

purpose is to determine 

the root cause of a malfunction and 

restore normal operation as quickly 

and efficiently as possible, minimising 

downtime and preventing recurring 

issues. 

In the context of compressed air systems, 

effective troubleshooting requires 

both technical knowledge 

of the equipment and a structured 

problem-solving methodology. This 

dual approach ensures that maintenance 

teams can address a wide 

range of potential issues, from simple 

filter blockages to complex control 

system failures. 

How can a breakdown impact your 

operation? 

When a compressed air system fails, 

the consequences extend far beyond 

the immediate mechanical issue. 

Consider the following impacts: 

1. Production standstill: 

For many manufacturing processes, 

compressed air is an indispensable 

utility. Without it, production lines can 

come to a complete halt, creating bottlenecks 

throughout the operation. 




2. Financial losses: 

Downtime directly translates to financial 

losses through missed production 

targets and idle labour costs. Industry 

estimates suggest that downtime can 

cost between € 11,500 and € 58,000 

per hour for medium to large manufacturing 

operations. 

3. Delivery delays: 

Production interruptions often lead 

to delivery shortages to customers, 

which can damage business relationships 

and result in reputation losses, 

particularly in just-in-time manufacturing 

environments. 

4. Quality issues: 

Intermittent compressed air system 

problems might not cause complete 

shutdowns but can lead to quality defects 

in products that rely on precise 

pneumatic operations. 

5. Additional stress: 

System failures create pressure on 

maintenance teams and production 

managers to resolve issues quickly, 

potentially leading to rushed decisions 

and incomplete fixes. 

Given these significant impacts, a systematic 

approach to troubleshooting 

becomes not merely helpful but essential 

to operational resilience. 

How to conduct troubleshooting 

effectively (step-by-step) 

1. The detective's first rule: 

Listen carefully 

Begin by interviewing operators 

about symptoms, timing, and changes 

before the problem occurred. Ask 

about unusual sounds, performance 

changes, or warning indicators. Questions 

like “Is the compressor making 

unusual noises?” or “Did it stop suddenly?” 

can yield crucial insights, establishing 

a baseline understanding 

before physical inspection. 

2. The power of observation: 

Visual assessment 

Conduct a thorough visual inspection 

for obvious issues. Look for oil 

leaks, cracked hoses, loose wires, 

or blocked vents. Check pressure 

gauges, temperature indicators, and 

warning lights. Examine belt tension, 

coupling alignment, and signs 

of overheating or vibration. These 

checks can identify safety hazards 

that require immediate attention before 

deeper troubleshooting. 

3. Back to basics: 

Power and airflow verification 

Verify fundamental operational requirements. 

Ensure proper electrical 

power supply with correct voltage. 

Check that emergency stops are reset 

properly. Examine intake filters 

for blockages and cooling systems 

for proper function. Confirm circuit 

breakers and fuses are intact. These 

basic checks often resolve seemingly 

complex problems quickly. 

4. The methodical mind: 

Structured diagnosis 

Use troubleshooting checklists that 

match symptoms to likely causes. 

Follow a logical elimination process, 

working from most to least likely 

problems based on symptoms. Consult 

manufacturer documentation 

and maintenance history for context. 

Consider both mechanical components 

and control systems as potential 

problem sources. 

5. The scientific method: 

Isolate variables 

Test one component at a time to 

clearly identify cause-and-effect relationships. 

If you suspect a clogged filter, 

replace it and test before making 

other changes. Document each test 

and result. Isolate sections of piping 

to locate leaks or bypass control 

components to identify faults. Resist 

making multiple changes simultaneously, 

which obscures which action 

resolved the issue. 

6. The expert’s solution: 

Precise intervention 

Implement appropriate solutions with 

precision. Replace components with 

manufacturer-specified parts. Use 

proper techniques for repairs to prevent 

introducing new problems. Adjust 

control parameters carefully to 

match operational requirements. Ensure 

fixes address root causes rather 

than merely treating symptoms. 


77



7. The proof in practice: 

Verification testing 

Restart the system and observe operation 

through a complete cycle. Monitor 

pressure, temperature, and power 

consumption. Listen for unusual 

noises or vibrations. Test under normal 

load conditions to ensure repairs 

hold up under typical demands. This 

verification prevents premature assumptions 

of success. 

warnings. Develop operator inspection 

checklists to catch developing 

problems. Consider service agreements 

for regular professional maintenance. 

This transition from reactive 

to preventive approaches improves 

reliabili ty and reduces ownership 

costs. 

Advanced troubleshooting 

techniques 

Beyond the basic steps, several advanced 

techniques can enhance troubleshooting 

effectiveness: 

1. Data analysis: 

Utilise trend data from monitoring 

systems to identify patterns that precede 

failures, allowing for predictive 

maintenance. 

2. Thermal imaging: 

Common compressed air system issues and solutions 

Employ infrared cameras to detect 

hotspots in electrical components 

or mechanical systems before they 

cause failures. 

3. Ultrasonic detection: 

Use ultrasonic equipment to locate 

air leaks that are otherwise impossible 

to detect visually or audibly. 

4. Vibration analysis: 

Monitor vibration signatures to identify 

bearing wear, misalignment, or 

imbalance before catastrophic failure 

occurs. 

5. Oil analysis: 

Test compressor lubricant to detect 

metal particles that indicate internal 

component wear. 

While each breakdown has unique characteristics, certain issues occur 

frequently in compressed air systems: 

Problem Potential causes Troubleshooting steps 

8. The knowledge transfer: 

Educational opportunity 

Explain to operators and maintenance 

staff what went wrong and 

why. Provide guidance on warning 

signs that could help identify similar 

issues earlier. Discuss maintenance 

procedures that might have prevented 

the breakdown. This knowledge 

sharing helps prevent recurrence and 

builds system understanding. 

Low pressure 

Excessive energy consumption 

Air leaks, inadequate 

compressor size, 

clogged filters, control 

system issues 

Inefficient control system, 

leaks, operating at 

higher pressure than 

necessary 

Check system for leaks, 

verify compressor capacity 

against demand, 

inspect and clean filters, 

check pressure 

switch settings 

Conduct leak audit, 

optimise pressure settings, 

consider VSD 

technology, evaluate 

control strategy 

9. The historical record: 

Comprehensive documentation 

Record symptoms, diagnostic steps, 

and resolution in your maintenance 

system. Document parts replaced, 

adjustments made, and settings 

changed. Note environmental or operational 

factors that contributed to the 

failure. This documentation becomes 

valuable for future troubleshooting 

and reveals patterns over time. 

Moisture in air lines 

Compressor will not 

start 

Failed or undersized 

dryer, excessive ambient 

humidity, improper 

draining 

Electrical issues, safety 

circuits engaged, control 

system faults 

Check dryer operation, 

verify dryer sizing, 

ensure automatic 

drains are functioning, 

consider dew point 

monitoring 

Check power supply, 

verify emergency stop 

status, inspect control 

circuit, test motor 

starter 

10. The prevention strategy: 

Proactive maintenance planning 

Recommend preventive maintenance 

schedules based on the identified 

issue. Suggest condition monitoring 

tools that could provide early 

Excessive noise 

Worn bearings, 

coupling misalignment, 

loose components, improper 

installation 

Inspect bearings 

and couplings, check 

mounting and isolation, 

tighten loose components, 

verify proper 

foundation 




These advanced techniques can 

transform troubleshooting from 

a reactive process to a predictive 

one, significantly reducing unplanned 

downtime. 

Familiarity with these common 

issues accelerates the troubleshooting 

process by providing 

likely starting points for investigation. 

Conclusion 

Effective air compressor troubleshooting 

requires a balance 

of technical knowledge and methodical 

approach. By following 

the structured process outlined 

in this article, maintenance 

teams can identify and resolve 

compressed air system issues efficiently, 

minimising the operational 

impact of breakdowns. 

Key takeaways for improving 

your troubleshooting process include: 

3. Train personnel on both the 

technical aspects of compressed 

air systems and structured problem-solving 

methodologies 

4. Transition from reactive to 

preventive strategies by incorporating 

lessons learned from each 

breakdown 

5. Partner with compressed air 

specialists who can provide expertise 

and support for complex 

issues 

Remember that the most effective 

troubleshooting is the 

kind you rarely need to perform 

because preventive and 

predictive maintenance practices 

have already addressed potential 

issues before they cause 

breakdowns. Working with a 

knowledgeable compressed air 

service partner can help develop 

comprehensive maintenance 

plans that significantly reduce 

the need for emergency troubleshooting 

while improving overall 

system reliability and efficiency. 

By implementing these approaches, 

organisations can 

transform compressed air system 

maintenance from a reactive 

emergency response to a strategic 

asset management practice, 

delivering improved uptime, reduced 

operating costs, and enhanced 

production reliability. 

The Author: Rodrigo Varela, 

Senior Director Aftermarket, 

ELGi Europe 

ELGi Compressors s.r.l. 

Dreve Richelle 167 

1410 Waterloo, Belgium 

euenquiry@elgi.com 

www.elgi.com/eu 

1. Adopt a systematic approach 

rather than relying on guesswork 

or trial-and-error methods 

2. Document thoroughly to build 

an institutional knowledge base 

that supports future troubleshooting 

The multi-talent 

for all consistencies 

The unique Eirich mixing principle opens up the 

world of process technology to you. We invented 

and refined it to improve our customers and their 

products. 

Day after day. 

eirich.com 


79



Smart maintenance tools 

Reducing energy costs by 50 per cent, thanks 

to efficient compressed air management 

About 86 per cent of a company’s 

operating costs are energy costs. 

Compressed air is a very expensive, 

yet indispensable type of energy. 

Considering rising energy prices 

and the increasing political pressure 

to reduce CO 2 

emissions, companies 

should pay special attention to 

these “energy gobblers”. Half of all 

energy costs can be saved with efficient 

solutions provided by BOGE, 

compressor manufacturer. 

Fig. 2: The airtelligence provis 3 continuously optimises energy consumption: a reduction by 

merely 1 bar saves as much as 10 per cent in energy costs. 

Protecting budgets and the environment 

with sustainable compressed 

air generation: If industrial companies 

adjust the right elements, they 

will be rewarded with high savings 

potential and improved economy. 

This is how companies can halve their 

required energy requirements for 

compressed air generation, for example. 

This protects resources and lowers 

operating costs. Using smart tools 

provided by BOGE, companies can 

identify and use this potential. 

Regular maintenance is indispensable 

for the efficient use of compressed 

air. After all, wear on seals 

and hoses can have significant financial 

consequences. Leaks are among 

the major and most common causes 

of energy losses in compressed 

air systems. Without regular maintenance, 

they will often remain undetected, 

wasting up to 50 per cent of 

a system’s energy. To prevent this, 

BOGE has integrated a leak monitor 

in the control of its compressors. “The 

monitor records leaks during downtimes, 

thus allowing precise identification 

and rapid elimination of energy 

losses. This means that significant 

costs can be saved with minimal effort”, 

explains Frank Hilbrink, BOGE 

Product Manager. 

Another important area where companies 

can lower energy costs, and 

can therefore be more economical, 

is heat recovery. Up to 94 per cent of 

energy used during compressed air 

generation can be re-used as heat. In 

this process, BOGE diverts the waste 

heat from the compression process, 

specific to each compressor. It can 

then be used to heat rooms or water, 

for example. Compressors manufactured 

by others can also be retrofitted 

with BOGE’s heath recovery system. 

The average payback period is 

merely four months. 

Smart control optimises 

compressor utilization 

Fig. 1: With extensive measures, BOGE not only helps its partners to lower operating costs 

but also makes an active contribution to better sustainability and climate protection. 

An interlocking control, such as the 

BOGE airtelligence provis 3, makes 

the entire compressed air management 

efficient and adaptable. The 

intelligent control solution ensures 

the ideal utilisation of compressed 

air systems. The software integrates 

an unlimited number of components 




Fig. 3: Up to 94 per cent of energy used during compressed air generation can be 

re-used as heat. 

and, based on requirement, works 

out the perfect compressor configuration 

for a specific time during operation. 

The smart tool is therefore particularly 

suitable for highly fluctuating 

compressed air requirements and 

mixed compressor combinations. Additionally, 

the airtelligence provis 3 

continuously optimises energy consumption: 

a reduction by merely 1 

bar saves as much as 10 per cent in 

energy costs. 

Furthermore, the interlocking control 

helps with energy audits. Since 2015, 

the German Federal Government has 

obliged companies to perform regular 

energy audits or to introduce an energy 

management system in accordance 

with ISO 50001. Smart software solutions, 

like those provided by BOGE, 

allow the integration of relevant data 

sources without recording actual usage 

data. The analysis of this data 

helps to identify energy savings potential 

and to meet the requirements 

of the certification process. If a company 

receives its certification, it will 

benefit from certain tax relief. With 

these measures, BOGE not only helps 

its partners to lower operating costs 

but also makes an active contribution 

with them to better sustainability and 

climate protection. 

BOGE KOMPRESSOREN 

Otto Boge GmbH & Co. KG 

Bielefeld, Germany 

www.boge.com 

Come and see for yourself: 

www.harnisch.com 

Perfectly positioned. 

The international specialist magazines from Dr. Harnisch Publications 

You can now explore our newly designed website, with a 

clear focus on responsive design and easily usable applications. 

Alongside the free-to-use digital magazine editions, you will 

fi nd bonus news coverage, events, subscription and 

general information on all our magazines. Take a look at 

www.harnisch.com for all relevant content. 

Our publications include: 

- Technology & Marketing -



Efficient driving of high-speed motors 

Three-level technology for a 

new turbo compressor 

In the new turbo compressors by 

BOGE, the three-level technology 

of frequency converter SD2M by 

SIEB & MEYER can fully show its 

advantages. It ensures low rotor 

losses preventing excessive heating 

of the motor, which is extremely 

problematic in high-speed applications. 

Thanks to several, individual 

adaptations – for example a Modbus 

interface and optimized water cooling 

– the innovative frequency converter 

by SIEB & MEYER is the ideal solution 

for this sophisticated application. 

Fig. 1: The frequency converters operate one or two DC motors in the compressors that 

provide the different compressing stages. Image: BOGE 

BOGE is one of the leading global 

players in the field of compressors 

and compressed air systems. From 

food and plastics sector to steel and 

even pharmaceutical industry, numerous 

companies appreciate the high 

reliability, efficiency and economic 

viability of the various compressed 

air solutions. The portfolio ranges 

from individual compressors or compressed 

air components to complete 

system and service solutions. In the 

latter case, BOGE not only takes over 

the complete installation but also the 

inspection and maintenance of the 

system. 

Three-stage compression 

The BOGE product range of turbo 

compressors will shortly be extended 

by a 230 kW device. “Our turbo compressors 

save resources and energy. 

They can do without a drop of oil and 

reduce the noise level to a minimum 

despite the high speeds involved,” described 

Peter Boldt, head of the turbo 

development at BOGE. “The low-wear 

turbo technology sets entirely new 

standards regarding efficiency and 

cost savings.” 

In the new 3-stage turbo compressors 

BOGE uses multilevel converters by 

Fig. 2: BOGE extends its product range 

of turbo compressors with a 230 kW device 

that is equipped with the frequency 

converter SD2M by SIEB & MEYER. 

Image: BOGE 

SIEB & MEYER – specifically, the series 

SD2M with 150 kW and 75 kW. These 

frequency converters operate one or 

two permanent magnet DC motors in 

the compressors. Converter number 

one drives the compressor stages 1 

and 2, converter number two drives 

the compressor stage 3. “The motors 

work with different speeds of about 

35,000 or 55,000 revolutions each,” 

said Peter Boldt. “By means of the 

interface to the compressor control, 

the speeds of the motors are synchronized 

to each other.” 

Efficient and cost-saving 

The used drive technology is also 

highly efficient in other areas. Owing 

to the SIEB & MEYER frequency 

converters, the turbo compressors 

come with particularly compact dimensions. 

In contrast to competitive 

products, devices by SIEB & MEYER 

can do without motor LC filters or 

motor chokes, which are very large 

and heavy as well as costly and wiring-intensive. 

This reduces the footprint 

of the overall system. In addition, 

the supplier integrated water 

cooling in the devices on the request 

of the compressor manufacturer. 

Particularly important: thanks to the 

forward-looking converter technology, 

the overall efficiency of the turbo 

compressors was enhanced, resulting 

in lower energy costs. “We 

talk about savings of 3 to 5 percent,” 

confirmed Peter Boldt. “That doesn't 

sound like much at first – but considering 

that the turbo compressor 

draws about 230 kW electrical power 

per hour, the users save a lot of money 

over the time.” 

For BOGE, however, the most important 

advantage of the SIEB & MEYER 

products is that these frequency converters 

were specially designed for 




high speeds. “Competitive devices 

may perform significantly worse in 

terms of efficiency and require more 

peripheral devices such as motor 

LC filters,” emphasized Peter Boldt. 

“With this supplier, our experience 

regarding converter efficiency has 

been very good, especially concerning 

the prevention of rotor losses, 

which is a crucial factor in high-speed 

applications.” 

higher switching frequencies. In addition, 

the motor is loaded with only 

50 % of the voltage jumps compared 

to two-level technology. Three-level 

technolo gy alone can reduce the losses 

generated in the rotor by about 

75 %. If the switching frequency is 

also doubled, the losses in the rotor 

can be reduced by up to 90 %. Therefore, 

LC filters are often not required 

anymore – as in this application. 

Reducing motor losses 

New technology on the horizon 

“This is exactly what our solutions 

are tailored to,” confirmed Markus 

Finselberger, director sales drive 

electronics at SIEB & MEYER. “With 

our products, converter-based motor 

losses are significantly reduced 

compared to competitive products. 

Beside the lower motor heating, the 

system efficiency is increased and 

power consumption is reduced. This 

in turn saves costs – a win-win for 

the user.” The background: about 

90 % of all losses caused by the converter 

occur in the rotor. These losses 

result in heat that can damage the 

motor. Taking into account the small 

rotor volume as a design-specific 

factor of high-speed motors, further 

temperature problems are the outcome. 

The SD2x frequency converter 

family comes with control techniques 

that ensure a much smaller 

proportion of harmonic frequencies 

in the motor current. 

Fig. 3: The three-level technology used in the 

frequency converter SD2M can reduce the 

losses generated in the rotor by about 75 %. 

Image: SIEB & MEYER AG 

In comparison with the conventional 

two-level converter technology, the 

three-level technology used in the 

frequency converter SD2M goes even 

further: only half the voltage is supplied 

to the power semiconductors of 

the output stages. This makes the use 

of power semiconductor designed 

for much lower voltages possible. 

Better yet, these semiconductors 

can switch faster. The result: there 

are fewer switching losses in the output 

stage, which enables significantly 

So far so good – and it gets even better: 

BOGE plans additional turbo 

compressors for their product range 

that could be operated by devices 

from the new SD4x product family 

by SIEB & MEYER. The latter ensure 

operation of high-speed motors with 

even fewer losses. They also support 

PWM switching frequencies of 24 and 

32 kHz. For an even finer modulation 

of the sine-wave signal, a commutation 

angle control for 32, 48 and 

64 kHz is also integrated now. The 

result is an almost optimal sine with 

nearly no harmonic currents. Moreover, 

the power loss caused by the 

PWM can be reduced even further. 

SIEB & MEYER AG, 

Lüneburg, Germany 

info@sieb-meyer.de 

www.sieb-meyer.com 

PRECISION DOESN’T HAPPEN 

BY CHANCE ... 

... it’s something you can calibrate 

DAkkS, ISO, AMS, and CQI: We offer a wide range 

of calibration services. Experience the advantages 

of reliable, traceable, and audit-ready measuring 

chain – so you can focus on your core business. 

↘ https://jmo.to/calibrate


Condition Monitoring 

From normative vibration assessment to 

learning-based condition monitoring – 

Condition monitoring of rotating machines 

with dynamic tolerance bands and AI 

Frank Ringsdorf 

Monitoring rotating machines for 

vibrations and bearing damage has 

been a central element of industrial 

maintenance strategies for decades. 

Vibration monitoring in particular 

has established itself as a proven 

means of detecting mechanical 

damage at an early stage and avoiding 

unplanned downtime. Classic 

concepts are predominantly based 

on normatively defined evaluation 

parameters and static limit values. 

However, with increasing plant complexity, 

variable operating conditions 

and rising demands on availability 

and efficiency, these methods 

are reaching their limits. Today’s 

modern condition monitoring systems 

must not only measure, but 

also understand correlations. This is 

where learning-based, data-driven 

approaches come in, which evaluate 

vibration and process data in context 

and assess it dynamically. 

Normative basis for vibration and 

condition monitoring 

Machine vibrations are now assessed 

on the basis of DIN ISO 20816, which 

has completely replaced the previous 

ISO 10816 standard. The standard 

describes how to assess the vibration 

condition based on the vibration velocity 

and classifies machine conditions 

into four assessment zones – 

from unremarkable to critical. 

In addition, DIN ISO 17359 describes 

the systematic development of condition-based 

maintenance strategies. It 

explicitly requires the consideration 

of several condition variables, trend 

analyses and continuous adaptation 

of the evaluation logic to real operating 

conditions. 

Both standards provide an important 

framework, but deliberately do 

not define specific algorithms for 

anomaly detection. Practical implementation 

is left to the user – and this 

is precisely where the limitations of 

static limit values become apparent. 

State of the art: Vibration and roller 

bearing diagnostics 

In industrial practice, vibrations in 

motors, pumps, fans and compressors 

are mainly detected using acceleration 

or vibration velocity sensors. 

Measuring vibration acceleration is 

considered particularly useful for 

bearing damage analysis. 

Special bearing damage parameters 

that evaluate high-frequency shock 

pulses have become established for 

condition monitoring of roller bearings. 

Parameters such as k(t), BCU 

or kurtosis values allow early detection 

of incipient bearing damage. In 

a more advanced diagnostic stage, 

the time signal is converted into an 

envelope frequency spectrum in order 

to identify damage symptom frequencies 

of individual bearing components. 

These methods are technically mature 

and deliver reliable results under 

constant operating conditions. 

However, their significance decreases 

significantly as soon as the speed, 

load or process conditions change dynamically. 

Limits of static thresholds in realworld 

operation 

Fig. 1: Modern condition monitoring systems for pumps must understand correlations and 

generate the right value-added information for maintenance. Image: Shutterstock/Doin 

Traditional monitoring systems work 

with fixed thresholds that are set 

for a defined operating point. In real-world 

plants, however, operating 

conditions change continuously. 




Fig. 2: Dynamic tolerance bands take variable operating conditions into account 

Speeds vary, flow rates change, and in isolation. Interactions between mechanical 

behaviour and process sta- 

media conditions fluctuate. This variability 

inevitably leads to greater dispersion 

of measured values – even though they are crucial for evaluating 

tus are not taken into account, even 

when there are no faults. In such cases, 

static thresholds either generate 

the plant status. 

false alarms or must be widened to Learning-based condition monitoring 

and industrial analytics 

such an extent that relevant anomalies 

are detected too late. 

Learning-based monitoring systems 

In addition, classic systems often consider 

vibration and process variables proach. They record the typical 

take a fundamentally different ap- 

operating 

behaviour of a machine in 

fault-free condition and model this 

behaviour in a data-driven manner. 

Instead of individual limit values, dynamic 

tolerance bands are created 

that continuously adapt depending 

on the current operating point. Vibration 

characteristics are analysed 

together with process variables and 

placed in a functional context. 

Modern probabilistic AI models learn 

probability distributions rather than 

individual target values. This allows 

deviations to be quantitatively evaluated 

and risks to be made transparent. 

The sensitivity of the monitoring 

can be adjusted depending on the application 

without the need for manual 

limit definitions. 

CONDInet as an IoT and AI system 

solution 

CONDInet implements this approach 

in the form of a modular, learningbased 

condition monitoring system.



Benefits for maintenance and 

operation 

The combination of standard-compliant 

vibration monitoring and learning-based 

analysis provides significantly 

more information than 

traditional systems. Changes in plant 

behaviour are detected earlier, better 

classified and presented in a comprehensible 

manner. 

Fig. 3: CONDInet provides clear status information and everything remains in the local network 

without a cloud connection. 

The solution combines classic vibration 

diagnostics with AI-supported 

analysis of vibration and process data. 

Sensors record vibration parameters, 

bearing condition indicators and optional 

process variables. Monitoring 

devices calculate standard-compliant 

parameters and make them available 

in a standardised form via an 

IoT gateway. The subsequent analysis 

takes place in a web-based AI platform 

that automatically learns typical 

plant behaviour. 

It is particularly interesting that 

CONDInet’s AI is on-premise, meaning 

that the data does not have to be 

transferred from the company network 

to the cloud. 

The central element is the creation of 

dynamic tolerance bands for all monitored 

metrics. Deviations are not 

evaluated as mere limit violations, 

but as context-dependent anomalies. 

An aggregated AI index summarises 

the current plant status as a dimensionless 

characteristic value and enables 

intuitive status evaluation. 

Visualisation, alerting and 

operation 

The results of the analysis are visualised 

via web-based dashboards. In 

addition to trends for individual metrics, 

status indicators, heat maps and 

time series of tolerance bands are 

also available. 

The system clearly distinguishes 

between training and monitoring 

modes. During the training phase, 

the reference behaviour is established, 

while in the monitoring phase, 

continuous evaluation takes place in 

real time. Alarms are only triggered in 

the event of persistent, significant deviations, 

which significantly reduces 

false alarms. 

The solution can be used both cloudbased 

and on-premise and can be integrated 

into existing control systems 

via standardised interfaces. 

Maintenance personnel receive a 

sound basis for decision-making regarding 

condition-based measures, 

operators benefit from higher availability 

and reduced downtime costs, 

and plant manufacturers can monitor 

their machines throughout their 

entire life cycle using data. 

Conclusion 

Simply monitoring vibration parameters 

against fixed limits is increasingly 

insufficient for the requirements 

of modern industrial plants. Learning-based 

systems with dynamic 

tolerance bands represent a logical 

further development that meets normative 

requirements while also doing 

justice to real operating conditions. 

CONDInet shows how classic vibration 

diagnostics, IoT architecture and 

artificial intelligence can be combined 

to form a holistic condition monitoring 

system – from measurement to 

well-founded condition assessment. 

The Author: 

Frank Ringsdorf 

AVIBIA GmbH 

Engelskirchen, Germany 

www.avibia.de 




From components to integrated 

Flow Solutions – Building reliable 

water networks together 

Florian Albrecht 

The effects of climate change are 

putting significant stress on municipal 

infrastructure, and water networks 

in particular. Integrated Flow 

Solutions that combine a wide range 

of materials and components with 

modularity and prefabrication, are 

ideally suited to increase network 

resilience. Leveraging their expertise 

in municipal infrastructure, GF 

and VAG are already delivering a 

measurable impact in the field with 

NeoFlow Plug-and-Play Chambers. 

The urgency of this transformation 

is evident. Water as an essential resource 

is impacted by three major 

trends: Climate change, urbanization 

and aging infrastructure are putting 

unprecedented pressure on municipal 

water networks worldwide. 

On the one hand, extreme weather 

events have become more frequent. 

The IPCC (Intergovernmental Panel 

on Climate Change) estimates that 

for every additional degree of global 

warming, the atmosphere can 

absorb 7 % more moisture, which 

significantly increases the likelihood 

of heavy rainfall. 1 This puts infrastructure 

such as drainage and sewer systems 

under significant stress. 

At the same time, water scarcity is 

intensifying due to the effects of climate 

change. Northern Europe’s historic 

precipitation deficit between 

February and April 2025 is only one 

example of many. 2 Water scarcity is 

further exacerbated by population 

growth, leading experts to predict 

that water demand will exceed supply 

by 40 % by the year 2030. 3 

Lastly, many water networks are 

struggling due to the combination 

of increasing urbanization and aging 

water infrastructure. In many countries, 

a significant portion of potable 

water is lost through leakages before 

it ever reaches an outlet. Across 

the EU, estimates are as high 25 %. 4 

This issue is compounded by a lack of 

skilled labour experienced across the 

municipal water sector. 

So how can these three major challenges 

be met? While they have complex 

and varied causes, it has become 

clear that strengthening water infrastructure 

is the key to a more resilient 

water supply. But in order to achieve 

this goal efficiently and cost-effectively, 

it is crucial to rethink the way water 

infrastructure is designed, installed, 

and operated. 

From material diversity to system 

compatibility 

Water networks are rarely homogeneous. 

Decades of incremental 

expansion, varying standards and 

codes, as well as conservative planning 

mean that mixed-material water 

networks, where iron, steel, concrete 

and polymers coexist, are standard. 

This adds complexity while operating 

and maintaining these networks: Mismatched 

components, incompatible 

materials, or installation errors can 

impact performance and increase the 

probability of leakages, failure or an 

inefficient operation. 

Integrated Flow Solutions address 

this challenge at the system level. 

Rather than treating pipes, valves, 

and sensors as separate items, they 

are engineered to function as a unified 

system. This ensures material 

compatibility and reduced installation 

complexity, while leveraging 

connection methods specifically designed 

for mixed-material piping simplifies 

the integration in existing networks. 

Overall, this approach greatly 

lowers the risk of leakages which in 

turn minimizes maintenance costs. 

Pressure management as a key 

lever against water loss 

Fig. 1: Following a plug-and-play approach, integrated Flow Solutions ensure compatibility, 

speed up the installation, and simplify logistics. All images GF 

Especially in ever-expanding cities, 

water networks are frequently overpressurized 

to meet growing demands, 

shortening the lifespan 


87



site to controlled manufacturing environments, 

utilities can compensate 

for workforce constraints while maintaining 

high quality and safety standards. 

Crucially, pre-fabrication also 

provides a high degree of flexibility, 

allowing utilities tailor Flow Solutions 

to their individual needs. 

Integrated Flow Solutions 

Fig. 2: Crucial for longevity: In today’s complex water networks, couplers need to able to deal 

with a wide variety of materials and diameters. GF addresses this with its MULTI/JOINT system 

for quick, safe and simple connections. 

Swiss company GF is reshaping itself 

to become the global leader for 

Flow Solutions for Buildings, Industry 

and Infrastructure. With the acquisition 

of the German VAG-Group in 

October 2025, GF now benefits from 

VAG’s globally recognized metal valve 

technologies. By combining GF’s polymer 

piping systems and connection 

of pipes and fittings and causing 

leakages. One of the most effective 

tools for reducing non-revenue water 

is therefore pressure management. 

Pressure reducing valves (PRVs) are 

widely considered an ideal solution 

as they reduce the flow rates of existing 

leaks and limit unnecessary mechanical 

stress on the infrastructure, 

resulting in lower burst rates and 

prolonged asset life. Studies have 

shown that lowering the pressure of 

water networks by 25 % can reduce 

the occurrence of pipe bursts by up 

to 75 %. 5 Combined with hydraulic 

modelling and optional instrumentation 

such as sensors and flow meters, 

pressure reducing valves are an 

efficient solution for district metering 

areas (DMAs). 

Streamlined installation thanks to 

pre-fabrication 

In order for integrated Flow Solutions 

to have a lasting impact on water networks, 

it is not enough to focus on 

the seamless interaction of pipes, 

valves and sensors. The ability to 

quickly implement them whenever 

and wherever they are needed is crucial 

for operators and installers. However, 

across the EU, labour and skills 

shortages have reached critical levels, 

particularly in infrastructure‐intensive 

sectors such as construction, 

utili ties, and mechanical installation. 

Fig. 3: Pressure management is one of the most effective tools to get the most out of water 

networks. Pictured here is GF’s NeoFlow Pressure Reducing Valve. 

For utilities, this shortage translates 

directly into longer project timelines, 

higher execution risk, and increased 

dependence on external contractors. 

As a result, utilities are increasingly 

prioritizing speed, predictability, and 

simplicity of execution over bespoke 

designs that demand high labour intensity. 

Pre‐fabricated and factory‐tested solutions 

reduce on‐site installation 

time, minimize specialized labour 

requirements, and lower the risk 

of assembly errors, enabling utilities 

to deploy infrastructure with a 

plug‐and‐play approach. By transferring 

complexity from the construction 

technologies and VAG’s high-performance 

metal valves — including gate, 

knife-gate, butterfly, penstock, control, 

check and air valves used in critical 

infrastructure such as water networks, 

dams, desalination and power 

plants — GF can now deliver end-toend 

Flow Solutions for the water sector. 

The goal of the acquisition is to 

improve compatibility across components, 

simplify sourcing and logistics, 

strengthen local support, and provide 

solutions designed to reduce leakages, 

lower maintenance costs and increase 

network longevity. This is supported 

by VAG’s ability to supply both 

commodity standards and customized 

solutions for a huge variety of valves. 




Renewing aging water networks 

efficiently 

In the wake of increasingly strained 

infrastructure, which loses significant 

volumes of treated water before 

reaching consumers, many utilities 

are modernizing their networks with 

the goal of improving performance 

and reducing losses. 

Sabesp, the largest sanitation company 

in Brazil, provides water supply 

and wastewater services to 375 municipalities 

in the state of São Paulo. 

To support its renewal program, GF 

supplied a NeoFlow Plug-and-Play 

Chamber that integrates multiple 

GF technologies (GF, Uponor, VAG) 

into one compact, high-performance 

unit. GF's solution reduces water 

loss, increases operational efficiency, 

and provides a future-ready platform 

that accelerates the network's 

modernization efforts. 

wide, integrated Flow Solutions provide 

a practical and scalable pathway 

to greater network resilience. The 

example of Sabesp in Brazil demonstrates 

that measurable results (significant 

reductions in water loss, operating 

costs and non-revenue water) 

can be achieved without large-scale 

reconstruction. When engineering 

expertise, high-performance components 

and smart design converge, 

water infrastructure becomes more 

efficient, durable and adaptable. 

References 

1 

https://www.ipcc.ch/report/ar6/wg1/ 

chapter/chapter-11/ 

2 

https://www.dwd.de/DE/presse/ 

pressemitteilungen/DE/2025/ 

20250415_pm_trockenheit_news. 

html#:~:text=April%202025%20 

nur%20rund%2040,Jahr%201976%20 

am%20trockensten%20gewesen 

3 

UNEP IRP - Policy Options for Decoupling 

Economic Growth from Water 

Use and Water Pollution. Urama, 

Kevin & Bjornsen, Peter & Riegels, 

Niels & Vairavamoorthy, Kalanithy & 

Herrick, Jeffrey & Kauppi, Lea & Mcneely, 

Jeffrey & McGlade, Jacqueline 

& Eboh, Eric & Smith, Michael. (2016). 

4 

European Commission – Water Resilience 

Strategy 

5 

EU Reference document “Good Practices 

on Leakage Management WFD 

CIS WG PoM” 

The Author: 

Florian Albrecht, 

Business Development Manager 

Infrastructure Solutions at GF 

www.gfps.com 

Because the chamber arrives fully 

assembled, the installation required 

only half a day — limited to excavation, 

positioning and connection. 

Sabesp now benefits from a measurable 

sustainability impact, as the 

plug-and play solution saves approximately 

130 million litres of water 

per year, which is enough to supply 

around 3,000 people. By stabilizing 

pressure, it also lowers energy consumption 

and protects the piping 

system from bursting. With a chamber 

designed for up to 100 years and 

internal components lasting up to 50 

years, it further enhances the environmental 

footprint, lowers maintenance 

requirements, and total lifecycle 

costs for Sabesp. 

Conclusion 

As climate change, urbanization 

and aging infrastructure continue 

to strain water networks world- 

Visit GF & VAG at IFAT from 4-7 May in Munich, Germany: 

• GF booth: B3.351 

• VAG booth: C2.451 

NeoFlow Plug-and-Play Chamber 

In order to offer utilities around 

the world an efficient solution for 

reducing leakages and non-revenue 

water, GF developed a plugand-play 

pressure management 

solution. Housed in a pre-fabricated 

High-Density Polyethy lene 

(HDPE) chamber, the system 

combines GF’s polymer NeoFlow 

pressure reducing valve, a range 

of VAG’s metal components including 

the EKOplus gate valve 

and a DUOJET air valve, as well as 

a restrainer and measurement 

technology. The chamber is integrated 

in the existing network 

with the help of flexible MULTI/ 

JOINT couplers, ensuring a quick 

and easy installation. The chamber 

is also designed for rapid deployment 

across water networks, 

which provides utilities with an 

efficient way to scale their pressure 

management. 


89


Sensors 

Optimizing cooling tower efficiency with 

smart water quality control 

Water is at the heart of every industrial 

process from maintaining 

system temperature to ensuring 

energy efficiency. At a leading 

food producer in India, the cooling 

tower played a critical role in keeping 

operations stable. However, despite 

regular maintenance and water 

treatment, the company began 

facing recurring issues that impacted 

both performance and cost-efficiency. 

The challenge: corrosion and 

chemical imbalance 

Over time, the food manufacturer’s 

maintenance team noticed accelerated 

corrosion of condenser fins within 

the cooling tower. The fins, made 

from galvanized coated material, 

were deteriorating far sooner than 

expected. This corrosion not only affected 

the cooling tower’s efficiency 

but also increased energy consumption 

and maintenance downtime. 

A closer inspection revealed that the 

root cause lay in imbalanced chemical 

dosing during water treatment. Variations 

in the dosing concentration disrupted 

the water’s pH, conductivity, 

and dissolved oxygen (DO) levels so 

that higher corrosion rates were the 

result. In the absence of continuous 

monitoring or an automated control 

mechanism, maintaining stable water 

chemistry became increasingly difficult, 

which ultimately lead to unpredictable 

performance and frequent 

system maintenance. 

The challenge for the company was to 

find a solution that could monitor key 

water quality parameters in real time, 

ensure optimal dosing levels, and automate 

corrective actions while simplifying 

system operation. 

The JUMO solution: intelligent 

monitoring and control 

To address the issue, the food manufacturer 

partnered with JUMO, which 

is known for its expertise in smart 

measurement and automation technology. 

JUMO’s engineering team 

conducted a detailed evaluation of 

the cooling tower water system and 

proposed a fully integrated control 

solution tailored to the company’s 

needs. 

The solution involved deploying a set 

of high-precision JUMO sensors to 

continuously measure pH, conductivity, 

and DO levels in the cooling 

tower water. These sensors provided 

real-time, accurate readings that 

were fed into a programmable logic 

controller (PLC). 

JUMO’s engineers then developed a 

custom PLC program that analyzed 

sensor data and automatically controlled 

the chemical dosing pumps. 

As a result, the system continuously 

maintained the ideal chemical balance 

by regulating the dosing frequency 

and concentration. Any deviation 

from the defined limits triggered 

automatic adjustments, thereby eliminating 

manual intervention and ensuring 

consistent water quality 24/7. 

The installation also included data 

logging and visualization so that the 

food manufacturer’s technical team 

could monitor trends, review performance 

reports, and carry out predictive 

maintenance with ease. 

Results: stable operation and sustainable 

performance 

Fig. 1+2: Site installation 

Implementing JUMO’s intelligent 

monitoring system brought immediate 

improvements. The rate of corrosion 

dropped significantly and the 

condenser fins maintained their integrity 

much longer. This optimized 

dosing process reduced the consumption 

of treatment chemicals, 

which results in both cost savings 

and environmental benefits. Additionally, 

the automated control sys- 



Sensors 

tem enhanced operational reliability 

and minimized downtime. The cooling 

tower now functioned at peak efficiency, 

as a result of which it provided 

stable temperature regulation and 

consistent process performance. 

JUMO’s solution also empowered the 

food producer with actionable insights 

through precise data recording. 

By shifting from a reactive to a 

proactive maintenance approach, the 

company achieved long-term stability 

and improved decision-making related 

to water management. 

This successful collaboration stands 

as a testament to how JUMO’s advanced 

water quality control solutions 

can help industries overcome 

complex operational challenges. By 

combining cutting-edge sensors, intelligent 

control, and robust engineering 

design, JUMO transformed 

the cooling tower into a self-regulating, 

data-driven system. 

Consequently, the food manufacturer 

not only achieved better equipment 

protection and efficiency but also reinforced 

its commitment to sustainable 

and reliable water management 

practices. Precision in measurement. 

Intelligence in control. Reliability in 

performance − powered by JUMO 

JUMO GmbH && Co. KG 

Fulda, Germany 

mail@jumo.net 

www.jumo.group 

GREEN EFFICIENT TECHNOLOGIES 

The independent media platform for 

energy supply, efficiency enhancement and 

alternative energy sources and storage 

Sustainable opportunities in process 

technology 

Circular economy in the industrial 

production process 

Topics H 2 

, Synthetic Fuels, Water, 

Solar & Photovoltaics, Wind Power, 

Bioenergy, Geothermal Energy, Battery 

Technology, System Integration and 

other alternative options 

Dr. Harnisch Verlags GmbH · Eschenstr. 25 · 90441 Nuremberg · Tel.: +49 (0) 911 - 2018 0 · info@harnisch.com · www.harnisch.com


Valves 

Leakage problems with diaphragm valves 

in biotechnological applications 

Causes, risks and constructive solutions 

for compensating the pressure 

deformation residue in elastomere 

diaphragms 

Sealing systems under aseptic 

operating conditions 

Diaphragm valves are a central functional 

element in biotechnological 

production plants and play an essential 

role in the safety separation 

and control of aseptic processes. 

Their sealing function is crucial 

for maintaining sterile conditions. 

Against this background, sealing systems 

are increasingly coming into 

focus, especially when they are used 

under recurring thermal and mechanical 

loads. 

Leakage problems observed during 

plant operation 

Recently, Goetze KG Armaturen, a 

manufacturer of diaphragm valves, 

has received an increasing number of 

reports of leakage problems with diaphragm 

valves from various manufacturers 

that are currently in use. 

These occur in particular after repeated 

sterilisation in the SIP process with 

saturated steam and manifest themselves 

as leaks in the transition area 

between the valve body and the diaphragm. 

The cause of these leaks lies 

in the setting behaviour of the Elastomere 

diaphragms used. 

As a result of this settling behaviour, 

the originally set sealing pressure between 

the diaphragm and valve body 

is reduced with increasing operating 

time. This can initially result in minor 

leaks, which later become increasingly 

pronounced. 

Effects on sterility, product quality 

and plant operation 

Leaking diaphragm valves can lead 

to contamination of the environment, 

cause sterility problems and 

favour cross-contamination within 

the production facilities. In sensitive 

biotechnological processes, there 

is a risk of losing entire production 

batches. Regardless of the specific 

extent of the damage, such leaks 

always pose a considerable risk to 

micro biological safety and the validation 

of the system. 

Plant operator requirements and 

regulatory framework 

Against this backdrop, plant operators 

are increasingly looking for practical 

solutions to sustainably manage 

this problem. The focus is increasingly 

shifting from the diaphragm as an 

individual component to the interaction 

between the diaphragm, valve 

body and actuator. What is required 

is a coordinated sealing system that 

takes into account the material-related 

changes in the elastomer seals 

over the entire service life. 

It is clear that users are prepared to 

abandon their previous reticence towards 

new, optimised technologies if 

they make a significant contribution 

to avoiding batch losses that threaten 

the existence of the company. 

At the same time, plant operators are 

pursuing the goal of not jeopardising 

existing qualifications and certifications, 

for example in accordance with 

FDA requirements, due to technically 

avoidable leakage problems. 

Constructive compensation of the 

settling behaviour 

A sealing system that minimises the 

effects of the settling behaviour of 

elastomer seals must therefore compensate 

for this with suitable design 

compensation elements. It is crucial 

The so-called compression set describes 

the permanent deformation 

of an elastomer seal under longterm 

mechanical and thermal stress. 

This material-typical behaviour is a 

fundamental property of elastomer 

seals. In addition to classic Elastomere 

diaphragms, multi-layer sealing 

systems are also affected by this, 

for example combinations of PTFE 

and EPDM. 

Fig. 1: Goetze KG Armaturen: patented stainless steel pressure sleeve 



Valves 

The basis for a sustainable solution 

is a qualified root cause analysis 

in which both the material used 

and the specific operating conditions 

and sterilisation cycles are taken 

into account. In addition, application-related 

technical advice from 

the manufacturer in each case is required 

to ensure long-term stability 

and process reliability when sizing 

the sealing system. 

Conclusion 

Fig. 2: Goetze KG Armaturen: position of the patented pressure sleeve in the actuator 

(highlighted in red) 

that the pressing force required for 

the sealing function is maintained 

permanently regardless of thermal 

cycles, pressure loads and material 

fatigue. This is the only way to ensure 

a stable and reliable seal between the 

diaphragm and valve body. 

This design from Goetze eliminates 

the need to retighten the diaphragm 

after the first steam sterilisation, 

which is otherwise often necessary. 

Sustainable problem solving 

through system customisation 

Leakage problems due to the settling 

behaviour of Elastomere diaphragms 

pose a relevant risk to sterility, 

product quality and system 

availability in biotechnological applications. 

A purely component-based 

approach falls short of the mark. 

Only a systemic approach that takes 

into account the diaphragm, Actuator 

and design compensation elements 

makes it possible to permanently 

ensure the required sealing 

pressure. Suitable technical solutions 

can reduce leakage risks, minimise 

maintenance costs and stabilise 

the operational safety of aseptic 

systems in the long term. 

Patented solution with mechanical 

equalisation 

The patented design of Goetze KG 

Armaturen offers a possible solution 

in which the residual pressure 

deformation of the Elastomere diaphragms 

is specifically compensated. 

A stainless steel pressure sleeve 

integrated into the Actuator takes on 

the function of a mechanical equalising 

element and ensures constant 

compression of the Diaphragms. 

In practical applications, the leakage 

problem can be permanently solved 

by replacing the diaphragm in combination 

with a suitable Actuator. 

Various Diaphragm materials and 

actuator designs are available for 

this purpose, which can be adapted 

to the process conditions in each 

case. In many cases, it is not necessary 

to replace the entire valve, but 

it may make sense to do so depending 

on the system concept and life 

cycle strategy. 

Goetze KG Armaturen 

Ludwigsburg, Germany 

info@goetze.de 

www.goetze-group.com 


93


Seals 

Vi 782 – A long-lasting FKM all-rounder with 

NFS technology 

Dipl.-Ing. (FH) Michael Krüger 

In many industrial plants, seals face 

exacting demands for chemical and 

thermal resistance. Under challenging 

process conditions, conventional 

elastomers frequently reach their 

limits, leading to shorter service 

life, rising maintenance costs and 

a greater risk of unplanned plant 

downtime. 

At the same time, per- and polyfluoroalkyl 

substances (PFAS) are coming 

under increasing regulatory scrutiny. 

Restrictions are currently being discussed 

at European level, with the 

aim of minimising potential risks to 

the environment and human health. 

For users and design engineers, this 

means sealing solutions must be selected 

not only on technical merit but 

with evolving legal requirements in 

mind. 

Fig. 1: COG FKM Vi 78, All images: COG 

Vi 782 - a durable FKM all-rounder 

with non-fluorinated surfactants 

Based on this, C. Otto Gehrckens 

(COG) has developed Vi 782, a peroxide-cured 

FKM compound, whose 

base polymer is manufactured using 

non-fluorinated surfactants (NFS technology). 

aqueous media — including acidic 

environments such as sulphuric acid, 

as well as applications involving alcohols. 

Conventional FKM types do 

not offer this breadth of chemical 

compatibility. It is the result of targeted 

compound and additive development, 

with chemical range, cure 

system and media compatibility precisely 

coordinated. Where aqueous 

media or acidic cleaning agents are 

present — at pipework, valves and fit- 

The material offers the proven chemical 

and thermal performance expected 

of an FKM compound and covers 

an operating temperature range from 

-10 °C to +200 °C in air. All of which 

makes it suitable for wide-ranging industrial 

environments. It also exhibits 

excellent resistance to mineral oils as 

well as aliphatic and aromatic hydrocarbons. 

Extended media resistance 

What sets Vi 782 apart is its carefully 

targeted formulation: Unlike many 

other FKM compounds, Vi 782 is also 

suitable for prolonged contact with 

Fig. 2: Aseptic fitting 



Seals 

tings along the process line, for 

example — this broad compatibility 

simplifies material selection 

and supports reliable, consistent 

plant operation. 

Suitability for CIP and SIP cleaning 

processes 

Vi 782 is also specifically designed 

for cleaning cycles with 

aggressive CIP and SIP media (CIP 

= Cleaning in Place; SIP = Sterilisation 

in Place), and demonstrates 

excellent resistance to WFI water 

as commonly used in the pharmaceutical 

industry. It also performs 

reliably in contact with 

the flavouring agents commonly 

found in the food and beverage 

industry. A low volume swell 

ensures consistent sealing performance 

and means the compound 

is readily accommodated 

even in demanding installation 

conditions, such as aseptic fittings 

compliant with DIN 11864. 

Vi 782 in use: wide range of 

applications 

Beyond its outstanding material 

properties, Vi 782 meets a wide 

range of approvals and regulatory 

requirements for the food and 

pharmaceutical industries. These 

include FDA § 177.2600, USP 

chapter 87 and 88, USP chapter 

381 and 3-A Sanitary Standard 

Class I. The compound also 

complies with relevant European 

frameworks, including Regulation 

(EC) 1935/2004, Regulation 

(EU) 2024/3190 (BPA), REACH and 

RoHS — making it suitable both 

for highly sensitive applications 

and for broader industrial use. 

Vi 782 is particularly well suited to 

process and chemical engineering 

applications where chemically 

and thermally demanding conditions 

must be managed reliably 

over the long term. Its combination 

of broad chemical compatibility 

and well-balanced sealing 

properties makes it easier to design 

for recurring cleaning cycles, 

supporting stable process operations 

throughout. In mechanical 

and plant engineering, it offers a 

compelling solution for components 

in contact with mineral oils, 

hydrocarbons, moderate acids or 

weak alkalis. In food and pharmaceutical 

applications, the balanced 

properties of Vi 782 lend 

themselves well to structured 

qualification and validation. The 

compound has also proven itself 

in chemical processing environments 

where diverse media and 

thermal stresses converge. 

Optimized material selection 

for reliable sealing performance 

Ultimately, however, the right 

material is only part of the equation 

— what counts is how well it 

is matched to the specific application. 

Drawing on deep expertise 

in both materials and processes, 

COG provides guidance 

on selection and seal design, 

from assessing operating conditions 

through to accounting 

for typical installation scenarios, 

with the aim of delivering technically 

robust, longterm reliable solutions. 

Elastomeric seal design should 

always reflect both the temperature 

and the media conditions involved, 

supported by competent 

application engineering advice. 

Cleaning media — types, concentrations 

and cycle durations — 

should also be factored into material 

selection at an early stage. 

Appropriate groove and gland 

design is critical to long-term reliable 

performance. Existing approvals 

can support the qualification 

process but should always 

be verified on a project-specific 

basis against actual temperature 

and service limits. 

Conclusion: Vi 782 as a versatile 

FKM solution 

In Vi 782, COG has developed a 

compound that brings together 

key practical requirements across 

both regulated and industrial en- 

Properties of Vi 782 

• Operating temperature range (air): -10 °C to +200 °C 

• Excellent chemical resistance 

• Excellent resistance in CIP/SIP processes 

• Suitable for aseptic fittings (including hygienic design 

compliance) 

• Resistant to flavouring agents and wide-ranging solvents 

• Approvals: FDA § 177.2600, USP chapter 87, USP chapter 88, 

USP chapter 381, 3-A Sanitary Class I, VO (EC) No. 1935/2004 

vironments: broad chemical resistance 

— including to aqueous 

media, acids (e. g. sulphuric acid) 

and alcoholic environments — 

along with temperature stability 

and process reliability in CIP/SIP 

media. The use of PFAS-free additives 

in the base polymer also 

provides additional regulatory 

certainty for forward planning. 

The key lies in the finely tuned interplay 

between polymer, cure 

system and a purpose-built formulation. 

This gives users and 

design engineers a versatile compound 

that simplifies material selection 

in complex, mixed-media 

environments and supports predictable 

maintenance intervals. 

The Author: 

Dipl.-Ing (FH) Michael Krüger, 

Head of Operational Application 

Engineering, 

C. Otto Gehrckens GmbH & Co. KG, 

Pinneberg, Germany 

www.cog.de 

Control 

Building reliable 

water networks together 

Visit us at IFAT, Munich 

4 – 7 May 2026, 

Booth GF: B3.351 / VAG: C2.451 


IFAT26_PUK_Print-Ad_Control_92x62mm.indd 1 02.03.2026 13:07:48 

95


Innovative filter elements 

With metal wire mesh to 90 % 

lower energy demand 

Innovative filter elements for seawater desalination 

Seawater desalination using SWRO 

(Seawater Reverse Osmosis) provides 

reliable water sources for 

households, agriculture, and industries 

in water-scarce regions. It has 

become a key pillar of global water 

strategies. However, the process is 

highly energy-intensive, so the key 

challenge is: How can these processes 

be made more economical 

and sustainable? One often underestimated 

factor is the final pre-filtration 

stage before the RO membranes, 

where automatic filters with 

innovative metal wire mesh from 

Haver & Boecker deliver decisive advantages. 

In reverse osmosis (RO), seawater is 

forced under high pressure through 

a semi-permeable membrane. Salts 

and other substances such as bacteria, 

viruses, lime, or heavy metals 

are retained, while pure water passes 

through. To ensure this principle works 

reliably over time, membrane fouling 

must be minimized – because deposits 

lead to rising operating pressures and 

directly increase energy demand. 

Therefore, typical RO pretreatment 

consists of several stages: 

– Coarse and fine particle prefiltration 

– UF/MMF filtration to reduce 

SDI value to < 5 

– Final protection against suspended 

solids immediately before the RO 

membrane 

Cartridge filters – an underestimated 

cost factor 

In many plants, disposable filter cartridges 

with nominal ratings of 1–20 µm 

handle the final filtration stage. They 

are considered a simple standard solution 

but have major drawbacks: 

1. Downtime and 

maintenance effort 

Replacing cartridges is a fully manual 

process that can take several hours 

depending on plant size and filter 

count. During this time, system performance 

drops until all spent cartridges 

are removed and new ones 

installed. This means high labor costs 

and recurring downtime, reducing 

overall plant efficiency. 

2. Pressure loss 

To minimize maintenance, cartridges 

are often used longer than technically 

optimal. As particles accumulate, differential 

pressure rises steadily. Biofilm 

growth is also promoted, and if 

these films detach, they can reach 

the RO membrane, causing fouling or 

even irreversible damage. 

3. Energy demand and costs 

Increasing blockage directly impacts 

the high-pressure pump, which must 

maintain flow. Differential pressure 

rises from an initial 0.2 bar to 1 bar or 

more before cartridge replacement. 

According to Filtersafe, an international 

manufacturer of filter systems, 

the average pressure loss for filter 

cartridges is 0.5-0.7 bar. 

4. Material consumption 

and disposal 

Depending on the size of the plant 

and the water quality, a seawater 

desalination plant consumes tens of 

thousands of filter cartridges annually, 

creating significant procurement 

and storage costs and complex disposal 

logistics. Spent cartridges are 

often classified as hazardous waste, 

making disposal costly and environmentally 

burdensome. These factors 

have a negative impact on both the 

operating costs (OPEX) and the CO 2 

balance of the plant. 

Automatic filters with metal wire 

mesh – the smart alternative 

To eliminate these weaknesses, more 

operators are switching to self-cleaning 

automatic filters. Filtersafe, for example, 

relies on filter elements made 

of metal wire mesh from Haver & 

Boecker as the core of its automatic 

filters. 

These elements – constructed from 

multi-layer mesh or mesh laminates 

– form the heart of the filter, ensuring 

precise filtration, long service life, and 

reliable cleaning. They enable significant 

efficiency gains and cost savings 

across multiple categories: 

1. Downtime and maintenance 

effort 

Unlike cartridges, metal mesh elements 

are designed for years of reliable 

operation with minimal maintenance. 

Their multi-layer structure 

maintains dirt-holding capacity and 

flow performance far longer than 

Fig. 1: Possible construction of a filter element 

for water treatment (from above): 

Protection layer, filtration layer, protection 

layer, support layer. 


FILTECH 

other media. No consumable replacement is 

needed, the system runs continuously, and filtration 

capacity remains stable. 

2. Pressure loss 

The precise pore structure of the filter elements 

ensures a consistently low differential 

pressure of just 0.05 bar on average – compared 

to 0.5–0.7 bar for cartridges. Excellent 

cleanability prevents biofilm buildup and guarantees 

high filtrate quality. The multi-layer 

construction ensures a stable flow rate even 

under high loads – an advantage that can be 

veri fied during the design phase using simulations 

(burst pressure calculation and flow rate). 

In addition, automatic filters operate cyclically: 

as soon as a layer of particles forms on the 

filter element and the differential pressure 

reaches a threshold value (e. g., 0.2 bar), a 

short cleaning cycle starts automatically (see 

Fig. 2). A rotating scanner cleans the mesh 

surface while a small amount of the already 

filtered water rinses out the deposited particles. 

Operators benefit from increased operational 

reliability: filtration continues without 

interruption, the risk of biofilm deposits is significantly 

reduced, and consistently high filtrate 

quality is ensured. 

up to 75 % and CO 2 

emissions by more than 

3,000 tons per year. 

4. Material consumption and disposal 

Multi-layer stainless steel elements last for 

years, even under high mechanical loads and 

corrosive conditions. Sintered POROSTAR ® 

laminates, where layers are bonded, further 

increase burst strength by up to 25 % compared 

to non-sintered designs. With the series 

production of mesh laminates made of 

Avesta 254 SMO, Haver & Boecker is also setting 

a new standard for seawater-resistant filter 

elements – currently the only supplier offering 

this solution. Custom configurations 

enable optimal adaptation to the respective 

system – for maximum efficiency and sustainability. 

Consumables and disposal costs are 

almost completely eliminated. 

The core: metal wire mesh filter elements 

The performance of self-cleaning automatic 

filters depends on the quality of their filter 

elements. Multi-layer meshes and laminates 

from Haver & Boecker are specially engineered 

for the demanding conditions of 

seawater desalination. They deliver precise, 

repeatable filtration at cut points down to 

June 30 – July 02, 2026 

Cologne – Germany 

The Filtration Event 

www.Filtech.de 

Platform 

for your 

success 

600+ Exhibitors 

Fig. 2: Schematic diagram of the average differential pressure of different filter types. 

3. Energy demand and costs 

5 µm, setting benchmarks for accuracy, stability, 

Calculations from Filtersafe show: In a sample 

and durability. 

plant with 32,000 m³/h RO protection filtration, 

cartridges caused annual energy consumption 

Field insights 

of 4,900 MWh, while metal mesh 

elements in combination with the self-cleaning 

Pilot projects confirm significant savings. A 

automatic filter required only 490 MWh joint study by Filtersafe and plant operators 

– a 90 % reduction. Since the filter elements showed OPEX reductions of 80–92 %, with 

ensure extremely low pressure loss over the consistent filtrate quality and reduced energy 

long term, operating costs are reduced by and labor costs: 


Delivers 

solutions for 

current 

and future 

challenges 

Your Contact: Suzanne Abetz 

E-mail: info@filtech.de 

Phone: +49 (0)2132 93 57 60

App App away! 

The Dr. Harnisch Publications App 

including free online issues 

of our magazines. 

Fig. 3: In addition to their precisely definable pore structure, high mechanical stability, 

and corrosion resistance, HAVER POROSTAR ® filter elements offer individual 

customization options. 

“Our pilot projects in an SWRO 

plant in West Asia show that an 

auto matic 20 µm screen filter 

achieves the required filtrate 

quality while cutting operating 

costs by over 80 % compared 

to cartridges. The self-cleaning 

screen technology is a full replacement 

for disposable filters, 

delivering major savings in energy, 

labor, and consumables 

without compromising reliability.” 

Ben Gido, Head of R&D, 

Filtersafe. 

Self-cleaning automatic filters 

with metal wire mesh elements 

outperform cartridge filters in 

every key area. They enable 

energy-efficient, sustainable, and 

cost-effective seawater desalination 

– transforming RO pre-filtration 

from a cost driver into an efficiency 

booster. 

Haver & Boecker OHG, 

Drahtweberei 

Oelde, Germany 

www.haverboecker.com 

The Dr. Harnisch Publications App 

is available for mobile devices for free 

in the following App Stores: 

www.harnisch.com

Compressors/Compressed air/Components 


AERZEN at IFAT 2026 

Innovative blower technologies, digital 

intelligence and system solutions for 

integrated aeration concepts 

AERZEN, the expert in blower technology for aeration tanks, will be presenting 

the next generation of energy-efficient blowers at IFAT 2026 

and will also be showcasing the intelligent combination of aeration 

technologies. New screw and turbo blowers, as well as fully integrated 

system solutions comprising blower, aeration and control technology 

raise the biological treatment stage to a new level of efficiency and 

significantly reduce the CO 2 

footprint of wastewater treatment plants. 

The result: stable processes, optimised operating costs and maximal 

energy efficiency. 

AERZEN solutions for the aeration of aeration tanks are technologically 

leading and set the standard regarding energy and resource efficiency. 

At IFAT 2026 in Munich, the company is looking ahead to the next stage 

of development. Under the slogan “Efficient by Nature - Sustainable by 

Design. It's in our DNA,” the application specialist will be showcasing pioneering 

innovations, integrated system solutions and digital services 

for energy-efficient aeration systems at stand 351 in Hall A3. 

reduces energy consumption, optimises long-term operating costs and 

makes wastewater treatment plants economically and ecologically sustainable. 

Energy savings of up to 55% and a reduction in the CO2 footprint 

of up to 65% are possible. 

Unrivalled product diversity in blower and aeration technology 

With its wide portfolio of premium technologies, AERZEN covers the 

entire spectrum of aeration technology and enables customised solutions. 

In the blower range, the portfolio includes rotary piston, screw 

and turbo blowers. AERZEN offers plate, disc and tube aerators for aeration 

technology. This technological diversity creates maximal flexibility 

in the design and allows optimal adaptation to the process, load profile 

and efficiency targets. 

Technology and system expertise from a single source 

Whether in customised machine and technology design, smart control 

and regulation technology, individual ROI calculations, flexible rental 

solutions (Aerzen Rental), innovative concepts for heat recovery and 

machine room aeration, digital services or support with subsidy applications: 

AERZEN accompanies customers from the technical design 

stage through to economic optimisation and provides compelling answers 

to the sector’s most important questions. The individual modules 

interlock seamlessly and are geared to each other as required. 

This allows efficiency potential to be fully exploited. 

Premiere of the new AERZEN screw and turbo blowers 

New sizes of “Delta Hybrid” screw blowers and “Aerzen Turbo” turbo 

blowers will have their premiere. The screw blowers achieve potential 

savings of up to 37% compared to conventional positive displacement 

blowers and impress with their extremely low sound pressure levels. 

The low-maintenance turbo blowers with air bearings open up additional 

performance ranges with maximal energy efficiency, the smallest 

footprint and an exceptionally large turndown. The result: demandorientated 

oxygen supply through precise load control with reduced 

energy demand. 

Holistic optimisation of the aeration system 

AERZEN takes a holistic approach to wastewater treatment - with an 

intelligent combination of highly efficient blower and aeration technology 

and smart control technology in the biological treatment process. 

Each solution is individually designed and optimally harmonises efficiency, 

performance, costs and operational reliability. This significantly 

System solutions are the key to maximal resource efficiency 

Many wastewater treatment plants consume unnecessary amounts of 

energy and tie up valuable resources due to outdated or oversized machine 

technologies. IFAT 2026 offers a unique opportunity to explore innovative 

blower and aerator technology as well as holistic solution concepts 

from a technology mix of rotary piston, screw and turbo blowers. 

You will find AERZEN at IFAT 2026 in Hall A3, stand 351. 


Reherweg 28 

31855 Aerzen, Germany 

Tel +49 (5154) 81-0 


Hygienic container valve for bulk 

goods 

WAREX VALVE develops DKZ 105 SKV container valve for IBC 

containers in the pharmaceutical industry. This is a tightly sealing 

shut-off valve that has been specially developed for installation under 

containers or silos 

WAREX VALVE GmbH, a specialist in industrial valves based in Senden, 

is expanding its product portfolio with the DKZ 105 SKV DN 250 container 

valve in a special design. The newly developed valve was specifically 

designed for hygienically demanding applications and is particularly 

suitable for use in the pharmaceutical industry. 

AERZEN will be presenting the next generation of energy-efficient blowers and the 

intelligent combination of aeration technologies at IFAT 2026. Image: AERZEN 

The container valve serves as a discharge closure for IBC bulk containers 

and meets high standards of hygiene, tightness, and ease of maintenance. 

With over 60 years of experience in the development and 

manufacture of industrial valves, WAREX VALVE consistently relies on 


99



Certified and FDA compliant 

WAREX VALVE is ISO 9001 certified. The sealing materials used in the 

DKZ 105 SKV container valve comply with FDA requirements and EU 

Regulation 1935/2004. The valve therefore meets international quality 

and safety standards and is ideal for regulated markets with high documentation 

and compliance requirements. 

Warex Valve GmbH 

Stauverbrink 2 

48308 Senden, Germany 

Tel +49 (2536) 99 58-0 

info@warex-valve.com 

www.warex-valve.com 

3D filter mesh for efficient water 

treatment 

MINIMESH ® RPD HIFLO-S for double flow capacity 

in-house production, high-quality materials, and customer-specific solutions 

for the DKZ 105 as well. 

Designed for hygiene and durability 

The DKZ 105 SKV container valve is made entirely of 1.4404 stainless 

steel and has a low dead space design. This minimizes product deposits 

and significantly simplifies cleaning processes – a decisive advantage 

for sensitive areas of application such as pharmaceutical and food 

applications. 

A special design feature is the specially designed seal without interfering 

edges, which enables a controlled material flow while ensuring a 

high level of tightness. At the customer’s request, the inner diameters 

of the DKZ 105 SKV shut-off valve were individually adjusted. This requires 

a specially designed seal sleeve and valve disc that are precisely 

matched to each other. 

Ground and polished surfaces not only enhance the hygienic properties, 

but also contribute to the high quality and durability of the valve. 

The demands on modern water treatment are continuously increasing. 

Microplastics, fine particles, and organic contaminants pose complex 

challenges for operators. At the same time, pressure is growing 

to reduce energy consumption and the use of chemicals. Mechanical 

filtration plays a key role here: the more solids, including the finest 

micro plastics, can be separated directly, the lower the need for additional 

treatment processes. Filter elements made of metal wire mesh 

offer a durable and adaptable solution. Compared to conventional filter 

meshes, high-performance meshes from Haver & Boecker even 

double the throughput – with the same pore size. 

Metal wire mesh for reliable high-performance filtration 

Filter elements made of wire mesh ensure high process reliability even 

under extreme conditions. Thanks to different mesh types, they can be 

precisely tailored to the specific application. Basically, a distinction is 

made between open square or rectangular mesh and visually closed 

filter mesh. In various water treatment systems where particles down 

to the micrometer range from 5 μm need to be filtered precisely and 

economically, the use of MINIMESH ® S filter meshes (see Fig. 1) as a filter 

layer has proven effective. 

RPD HIFLO-S: efficiency boost through 3D mesh structure 

Within the MINIMESH ® S specifications, MINIMESH ® RPD HIFLO-S 

(see Fig. 2) offers enormous efficiency gains for fine filtration. While 

Low maintenance, sustainable, and customized 

A key feature of the DKZ 105 is its low-maintenance design. Wear-critical 

components such as the shaft bearings are protected by the use of 

wear-resistant PEEK bushings. This significantly increases the service 

life of the valve and reduces downtime – a clear advantage in terms of 

the cost-effectiveness and sustainability of the entire plant. 

In addition, WAREX VALVE offers container valve designs tailored to 

customer requirements. Container geometry, process conditions, and 

industry-specific standards are already taken into account in the design. 

This provides purchasers and plant operators with a tailor-made 

solution instead of a compromise product. 

Fig. 1: The independent testing institute Whitehouse Scientific confirms the outstanding 

filtration properties of MINIMESH® S filter meshes with “precision pores.” 




Fig. 2: MINIMESH ® RPD HIFLO-S – corrosion- and temperature-resistant highperformance 

filter mesh in new weaving technology with pore sizes < 40 μm. 

standard filter meshes with small pore sizes typically lead to reduced 

flow rates and significant pressure drops in mechanical filtration, RPD 

HIFLO-S achieves more than double the flow at the same pore size – a 

decisive advantage for energy-efficient processes. This resolves a longstanding 

contradiction, as high flow capacity and fine pore size were 

once thought to be mutually exclusive. 

The distinctive feature is the three-dimensional mesh structure, which 

increases the number of pores and significantly enlarges porosity within 

the same space. As a result, dirt-holding capacity and flow performance 

remain consistent far longer than with conventional filter mesh. 

Thanks to optimized cleaning capability – for example, with rotating 

suction devices or backwashing – differential pressure remains consistently 

low. This reduces energy demand and extends the service life 

of filter systems. The outcome: lower operating costs (OPEX) and improved 

process stability. 

Material variety and customized configuration 

The properties of filter candles, screen mesh, or filter plates can be 

precisely tailored to the respective application by selecting suitable 

materials, weave types, and support or drainage layers. Particularly 

noteworthy: thanks to the innovative weaving technique of 

MINIMESH ® RPD HIFLO-S, special materials such as Hastelloy, Inconel, 

Superduplex, Avesta 254 SMO, or titanium can also be woven in the 

small pore range. This makes highly corrosion- and temperature- 

resistant filter meshes available in pore sizes smaller than 40 μm. 

Recyclability is also ensured: MINIMESH ® RPD HIFLO-S is made exclusively 

from pure stainless steels and thus meets the criteria of the 

circular economy. Using modern simulation software, new and innovative 

mesh specifications can be modeled and flow behavior and filtration 

efficiency simulated before physical implementation. This eliminates 

costly and time-consuming test phases. 

Benefits at a glance 

- Pore size range from 5-40 μm, precisely calibratable 

- Double flow rate at the same pore size 

- Excellent separation efficiency and stability 

- Corrosion- and temperature-resistant special materials 

- Optimized dirt-holding capacity and cleaning performance 

- Fully recyclable – contributing to the circular economy 

Global application examples 

Whether in the development of an autonomous energy system in Namibia, 

wastewater treatment in Norway, or seawater desalination in 

drought regions – Haver & Boecker filter meshes are already setting 

new standards in mechanical water treatment: 

• In Namibia, the funded development project HygO is supported by 

modern hydrogen technology. The aim is to develop an autonomous 

energy system in the form of so-called microgrids. In an additional cycle 

for biological-mechanical water treatment, intermediate MINIMESH ® 

RPD HIFLO 5-S filter cartridges retain particles as small as 5 μm. 

• Our strategic partnership with Norwegian company renasys enables 

the development of innovative filtration systems that significantly reduce 

the energy consumption of wastewater treatment plants. By using 

MINIMESH ® RPD HIFLO 5-S filters, up to 99 % of dirt particles are removed 

before the actual treatment process. 

• In seawater desalination in drought regions, the use of corrosion-resistant 

MINIMESH ® S filter meshes in automatic filters for pre-filtration 

leads to extended service life and minimized maintenance requirements 

for RO membranes, thus reducing operating costs. 

MINIMESH ® RPD HIFLO-S is a future-ready solution for advanced water 

treatment systems: durable, designed to save chemicals and energy, 

regenerable, and fully recyclable – an ideal component for circular 

value chains. 

HAVER & BOECKER OHG 

Drahtweberei 

Ennigerloher Str. 64 

59302 Oelde, Germany 

www.haverboecker.com 

Measuring technology 

Making the invisible visible 

How many compressed air station operators have complete visibility 

into their machines' exact condition and compressed air quality? For 

many manufacturing companies, insufficient monitoring of this critical 

data is a common challenge. The result? Unplanned downtime, decreased 

efficiency, and unnecessarily high energy costs. 

Kaeser’s cutting-edge measuring technology delivers the ideal solution. 

With advanced process data acquisition, businesses can lower 

energy costs and sustainably enhance compressed air quality. Highprecision 

sensors track all key process and energy metrics, including 

leakage currents, voltage quality, pressures, temperatures, and flow 

rates. Additionally, leaks, pressure dew points, differential pressures, 

and internal machine conditions are fully transparent – providing 

operators with invaluable insights and significant operational 

advantages. 

Continuous monitoring 

Advanced measuring technology enables continuous monitoring of 

the entire compressed air system. Data can be captured, analysed, and 

visu alised in real time. Kaeser multi-sensors transmit key measurements 

directly to central control units, such as the Sigma Air Manager, 

providing the foundation for future predictive maintenance. This proactive 

approach cannot only reduce costs but also significantly lowers 

the risk of unplanned downtime. 


101



VEGA at IFAT 2026 

Stably measured values for a resilient 

water industry 

Extreme weather events, rising demands on drinking water quality and 

ever more complex wastewater processes are putting operators under 

increasing pressure. A sustainable and resilient water and wastewater 

infrastructure therefore needs one thing above all else: reliable measurement 

data, even under difficult conditions. 

From 4 to 7 May 2026, at IFAT in Munich, booth C1.239, VEGA will be 

showing how state-of-the-art level and pressure instrumentation helps 

to keep processes stable and efficient over the long term. Interactive 

demonstrations at the exhibition stand illustrate the capabilities of the 

sensors under realistic operating conditions. 

One focus is on wastewater treatment. Precise and stable measured 

values are indispensable in all process stages: from inflow via pumping 

stations to sedimentation and aeration to sludge dewatering and effluent 

control. Even in the presence of foam, vapours, buildup or changing 

media conditions, VEGA sensors deliver reliable, reproducible results 

– also in situations where other measuring methods reach their 

limits. This helps to prevent overflows, optimise energy consumption, 

reduce downtime and stabilise processes over long periods. 

Strategically placed sensors in a compressed air system enhance safety, efficiency, 

and sustainability. 

Placing the right sensors in the right locations is essential. Intelligent 

sensors capture multiple data points at each measuring location and 

integrate seamlessly via the secure Kaeser Sigma Network. This advanced 

process data acquisition enables real-time monitoring, detailed 

analysis, and valuable system insights for fault prevention and process 

optimisation. Operators can fine-tune their compressed air systems independently 

or benefit from real-time monitoring by external experts. 

With state-of-the-art sensor technology, modern measuring devices 

are compact, powerful, and energy-efficient, ensuring reliable operation 

even in hard-to-reach places. They are also easy to install and 

ready for immediate use. 

VEGA is also presenting solutions for safe and efficient water management 

– from drinking water supply and flood defence to the monitoring 

of critical infrastructures. Precise level and pressure measurement 

technology ensures reliable operation of basins, reservoirs, pipeline 

networks and open channels. Intelligent level switches support automated 

alarms and control processes, thus increasing operational safety 

even under extreme environmental conditions and stresses. 

Maximum efficiency and sustainable savings 

Reliable compressed air supply is essential for seamless production. 

Kaeser’s advanced measuring technology delivers precise data to optimise 

system settings, detect leaks, and efficiently manage compressed 

air distribution. This enables compressed air station operators to reduce 

energy costs, prevent unnecessary downtime and maximise overall 

production efficiency. 


P.O. Box 2143 

96410 Coburg, Germany 

Tel +49 (9561) 640-0 

productinfo@kaeser.com 

www.kaeser.com 

Another topic VEGA is focusing on is digitalisation: Modern IIoT connectivity 

enables simple integration of sensors into existing control systems 

and ensures reliable monitoring of all critical process conditions 

during continuous operation. The acquired measurement data becomes 

decision-relevant information, enabling predictive maintenance 




and increasing plant availability. The combination of robust measurement 

technology and intelligent data utilisation makes water and 

wastewater treatment plants efficient, reliable and fit for the future. 

VEGA Grieshaber KG 

Am Hohenstein 113 

77761 Schiltach, Germany 

Tel +49 (7836) 50-0 

info.de@vega.com 

www.vega.com 

Moisture in compressed air networks 

– an invisible challenge with 

far-reaching consequences 

Compressed air systems are an essential part of modern beverage 

production. They power valves, cylinders and other pneumatic components, 

ensuring smooth and reliable operation. However, particularly 

in complex production environments with varying temperature zones 

and frequent system expansions or modifications, a frequently underestimated 

problem can occur: moisture accumulation in compressed 

air networks. 

Various dryer technologies are available, each suited to different requirements: 

• Membrane dryers offer compact design and low maintenance but 

reach their limits at high flow rates. 

• Adsorption dryers deliver excellent drying performance but involve 

higher maintenance costs. 

• Refrigerated dryers are considered highly economical and suitable 

for a wide range of applications. 

SMC’s IDFA Refrigerated Air Dryer combines strong performance with 

high efficiency. It is compliant with F Gas regulations and supports a 

wide range of operating capacities — making it suitable for everything 

from small production setups to large scale industrial environments. 

SMC Deutschland GmbH 

Boschring 13-15 

63329 Egelsbach, Germany 

Tel +49 (6103) 402-0 

info@smc.de 

www.smc.eu.de 

Less compressed air, more savings: 

Efficient drying solutions for bottles 

In beverage production, reliable drying of bottles prior to certain processing 

steps is essential—such as before labeling, capping, or inkjet 

printing. Conventional methods such as open compressed air pipes 

or fan nozzles are inefficient and result in high energy consumption. 

SMC relies here on modern air amplifiers and special nozzles with a focused 

blow angle. These utilize the physical principle of ambient air induction: 

By precisely directing the compressed air, additional ambient 

air is drawn in, thereby multiplying the airflow—while simultaneously 

reducing compressed air consumption. 

This moisture is caused by condensation when warm, humid air cools 

— for example, in long pipework or when air flows between zones 

with different temperatures. The consequences are severe: corrosion 

inside pipes, the release of rust particles, increased wear on components, 

and even unexpected production downtime. 

Practical experience shows that replacing outdated components with 

modern compressed air solutions—such as the KNH High Efficiency 

Air Nozzle—leads to substantial savings. Moreover, the system operates 

particularly efficiently at low operating pressure. Such optimizations 

are not only environmentally beneficial but also highly attractive 

from a business perspective. Targeted drying also contributes to greater 

process reliability: labels adhere more consistently, prints appear 

clearer, and the risk of product defects is reduced. 

Modern monitoring and drying technologies offer effective solutions. 

SMC’s PSH Condensation Checker provides precise real time monitoring 

of relative humidity and temperature in compressed air lines. It 

identifies conditions that may lead to harmful condensation and issues 

early warnings, enabling predictive maintenance and reducing 

unplanned system interruptions. 




Tel +49 (6103) 402-0 

info@smc.de 

www.smc.eu.de 


103



Flexible carton handling through intelligent 

gripper technology 

In addition to bottle handling, the handling of beverage cartons is a key 

component of production logistics. Efficient and space saving solutions 

are particularly important for palletizing and depalletizing. While traditional 

palletizers deliver strong performance, they require significant 

floor space and often lack flexibility. 

Robotic solutions offer a more dynamic alternative. They support the 

use of various end of arm tools and can be programmed for a wide 

range of tasks. However, conventional grippers quickly reach their limits: 

they may damage cartons, create gaps in layer patterns, or be incompatible 

with varying packaging formats. 

All images: XENIA Srl. 

The ZGS Series vacuum area grippers from SMC address these issues 

by relying on advanced vacuum technology for exceptionally gentle 

handling. The foam type suction surface allows the gripper to pick 

cartons from above without leaving pressure marks and enables 

precise, secure placement. The system integrates essential components—ejector 

unit, valves, silencer, and pressure switch—into one 

compact unit, providing integrated vacuum generation and streamlined 

installation. 

Thanks to IO Link compatibility and easy connectivity, the grippers can 

be seamlessly integrated into existing automation environments and 

flexibly controlled. Another advantage: The ZGS Series is compatible 

with major industrial and collaborative robot brands. SMC already provides 

plug and play integration options, enabling rapid deployment 

and simplified setup. As a result, new opportunities emerge for compact, 

modular, and scalable automation solutions—ideal for facilities 

with limited space or frequently changing production requirements. 

The company specializes in reinforced materials based on high-performance 

matrices such as HDPE, PP, PVDF and other specialty polymers. 

These compounds are specifically designed to withstand chemically 

aggressive environments exposed to acids, solvents and other process 

fluids, while maintaining structural integrity, high electrical conductivity 

and mechanical strength over time. 

Typical applications include pump housings and impellers, valve 

bodies and internal components, flanges, fittings, connectors, sealing 

elements and structural supports for processing equipment. In these 

applications, Xenia compounds provide a high stiffness-to-weight ratio 

and enhanced fatigue resistance compared to unfilled polymers, 

while their intrinsic electrical conductivity enables effective dissipation 

of electrostatic charges, supporting safe operation in ATEX-classified 

environments. 




Tel +49 (6103) 402-0 

info@smc.de 

www.smc.eu.de 

Advanced thermoplastic composites 

for pumps, valves and critical 

components in the Chemical Process 

Industry 

In the Chemical Process Industry (CPI), components operate under extreme 

conditions: aggressive chemicals, elevated temperatures, continuous 

mechanical loads and demanding safety requirements. Reliability 

and long-term stability are critical to ensuring plant efficiency and 

minimizing downtime. 

Xenia Materials, global developer of fibre-reinforced thermoplastic 

compounds, engineers advanced solutions for injection moulding and 

3D printing applications where unreinforced polymers or metallic components 

may no longer meet performance expectations. 

As CPI systems evolve toward higher efficiency, extended service life 

and sustainability targets, advanced thermoplastic composites represent 

a strategic alternative to conventional materials. Through continuous 

research and application-driven development, Xenia Materials 

positions itself as a technical partner for manufacturers seeking corrosion-resistant, 

electrically conductive and high-performance solutions 

for next-generation chemical processing equipment. 

XENIA Srl 

Via Dante Alighieri 23/A 

36065 Mussolente (VI), Italy 

info@xeniamaterials.com 

www.xeniamaterials.com 


H ENG 

ENGLISH ENGLISH E 

H ENGLISH ENGLISH ENGLISH ENG 

H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 






GLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


NGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 






H ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


SH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 




LISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

ISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 



GLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 




NGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 


ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

NGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 

ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 



Automotive 

GEA Valves: now 

also hydraulic 


Shipbuilding Heavy Industry 




Technical Data Purchasing >>> 

gea.com/contact 

105 

2026-GEA-coverPuk_02_ENG.indd 1 13/02/2026 08:59 


Pumps 

Range of applications/Applications 

Manufacturers/Suppliers 

Agricultural technology 

Automation solutions 

Automobile industry 

Beverage industry 

Biochemistry 

Breweries 

Building services engineering 

Chemical industry 

Construction industry 

Cosmetics industry 

Dairy farming 

Dosing technology 

Drainage 

Electrical industry/Information industry 

Emptying 

Energy industry 

Environmental engineering 

Filling technology 

Fire extinguishing/foaming agent dosing technlogy 

Food technology and bioprocess engineering 

Fountains/Sprinkler systems/Irrigation 

Gas drying 

Gas scrubber 

Geothermics 

Groundwater technology/Wells 

Heat transfer systems 

Heating and house technology 

High-pressure cleaning and descaling 

High-temperature engineering 

Atlas Copco Gas and Process 

Schlehenweg 15, 50999 Köln/Germany 

Phone: +49 (0)2236 9650 0 

E-mail: atlascopco.energas@de.atlascopco.com 

Website: www.atlascopco-gap.com 

Paul Bungartz GmbH & Co. KG 

Düsseldorfer Str. 79, D-40545 Düsseldorf/Germany 

Phone: +49 (0)211 577905-0, Fax: +49 (0)211 577905-12 

E-mail: pumpen@bungartz.de 

Website: www.bungartz.de 


Am Industriepark 2-10, 21514 Büchen/Germany 

Phone: +49 (0)4155 49-0, Fax: +49 (0)4155 49-2423 

E-mail: flowcomponents@gea.com 

Website: www.gea.com 

GRUNDFOS GmbH 

Schlüterstr. 33, 40699 Erkrath/Germany 

Phone: +49 (0)211 92969-0, Fax: +49 (0)211 92969-3799 

E-mail: infoservice@grundfos.de 

Website: www.grundfos.com 


Carl-Zeiss-Str. 6-8, 59302 Oelde/Germany 

Phone: +49 (0)2522 76-0, Fax: +49 (0)2522 76-140 

E-mail: mail@hammelmann.de 

Website: www.hammelmann.de 


Jägerweg 5-7, 85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 

E-mail: info@jesspumpen.de 

Website: www.jesspumpen.de 


Salinger Feld 10, 58454 Witten-Annen/Germany 

Phone: +49 (0)2302 8903-0, Fax: +49 (0)2302 801917 

E-mail: info@KAMAT.de 

Website: www.KAMAT.de 

• 

• • • • • • • • 

• • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • 

• • • • • • • • • • • • • • • • • 

• • • • • • • • • 

106

Horticulture 

Industrial technology 

Injection 

Laboratory technology 

Machine and plant engineering 

Metallurgical plants and Rolling mills 

Mineral oil industry 

Mining, pit and quarry 

Multiphase fluids 

Nuclear and reactor technology 

Odorizers 

Offshore installations 

Oil hydraulics and presses 

Oil production technology 

Osmosis technology 

Paper and pulp industry 

Petrochemical industry 

Pharmaceutical industry 

Pipeline 

Power plant technology 

Precision mechanics and optical industry 

Pressure rise 

Pressure test 

Process engineering 

Process technology 

Public services 

Refrigeration and air conditioning technology 

Renewable energies 

Seawater desalination 

Sewage technology/Canalisation 

Ship technology/Shipyard 

Steel industry 

Sterile technology 

Swimming pool technology 

Tank systems 

Technical universities 

Textile industry 

Tunnel construction 

Vehicle construction/Aircraft construction 

Viscose and adhesives 

Wastewater treatment plants 

Waterjet cutting 

Water supply/Water technology 

Water treatment 

Woodworking and wood processing 

• • • • • 

• • • • • • • • • • • • • • • • • 

• • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • 

107

Pumps 







Biochemistry 

Breweries 

Building services engineering 



Cosmetics industry 

Dairy farming 

Dosing technology 

Drainage 


Emptying 


Environmental engineering 


Fire extinguishing/foaming agent dosing technlogy 

Food technology and bioprocess engineering 

Fountains/Sprinkler systems/Irrigation 

Gas drying 

Gas scrubber 

Geothermics 

Groundwater technology/Wells 

Heat transfer systems 

Heating and house technology 

High-pressure cleaning and descaling 

High-temperature engineering 

LEWA Solutions GmbH 

Ulmer Str. 10, 71229 Leonberg/Germany 

Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 

Website: www.lewa.com 

• • • • • • • • 


Erlenstr. 5–7, 97877 Wertheim/Germany 

Phone: +49 (0)9342 879-0 

E-mail: info@lutz-pumpen.de 

Website: www.lutz-pumpen.de 


Geretsrieder Str. 1, 84478 Waldkraiburg/Germany 

Phone: +49 (0)8638 63-0 

E-mail: info.nps@netzsch.com 

Website: www.pumps-systems.netzsch.com 

SEEPEX GmbH 

Scharnhölzstr. 344, 46240 Bottrop/Germany 

Phone: +49 (0)2041 996-0 

E-mail: info@seepex.com 

Website: www.seepex.com 

Vogelsang GmbH & Co. KG 

Holthoege 10-14, 49632 Essen (Oldenburg)/Germany 

Phone: +49 (0)5434 83-0, Fax: +49 (0)5434 83-10 

E-mail: contact@vogelsang.info 

Website: www.vogelsang.info 

Watson-Marlow Limited 

Bickland Water Road, Falmouth Cornwall, TR11 4RU, United Kingdom 

Tel +44 (1326) 370 370 

E-mail: info@wmfts.com 

Website: www.wmfts.com 

• • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • 

• • • • • • • • • • • • • • 

108

Horticulture 

Industrial technology 

Injection 


Machine and plant engineering 




Multiphase fluids 

Nuclear and reactor technology 

Odorizers 


Oil hydraulics and presses 

Oil production technology 

Osmosis technology 




Pipeline 

Power plant technology 


Pressure rise 

Pressure test 

Process engineering 

Process technology 


Refrigeration and air conditioning technology 


Seawater desalination 




Sterile technology 

Swimming pool technology 

Tank systems 



Tunnel construction 


Viscose and adhesives 


Waterjet cutting 

Water supply/Water technology 

Water treatment 


• • • • • • • • • • 

• • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • 

109

Pumps 

Type of pumps 



Axial flow pumps 

Block pumps 

Channel impeller pumps 

Inline pumps 

Mixed flow pumps 

Pitot tube pumps 

Propeller pumps 

Radial flow pumps 

Side channel pumps 

Standardized pumps 

Vortex pumps 

Rotary positive displacement pumps 

Progressive cavity pumps 

Gear pumps 

Peristaltic pumps 


Screw pumps 

Vane pumps 

Oscillating displacement pumps 

Disposable design 

Hose diaphragm piston pumps 

Hydraulic diaphragm pumps 

Mechanical diaphragm pumps 

Piston/Plunger pumps 



Phone: +49 (0)2236 9650 0 





Phone: +49 (0)211 577905-0, Fax: +49 (0)211 577905-12 





Phone: +49 (0)4155 49-0, Fax: +49 (0)4155 49-2423 



GRUNDFOS GmbH 


Phone: +49 (0)211 92969-0, Fax: +49 (0)211 92969-3799 



• • • 

• • • • • 

• • • • • • • • • • • • • 



Phone: +49 (0)2522 76-0, Fax: +49 (0)2522 76-140 



• 



Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 



• • • • • • • • 



Phone: +49 (0)2302 8903-0, Fax: +49 (0)2302 801917 



• 

110

Drive concept Design features Conveyed media Service 

Canned motor 

Combustion engine 

Hydraulic drive 

Linear motor 

Magnetic rotor 

Pneumatic drive 

Stepper motor 

Submersible motor 

Three-phase asynchronous motor 

Abrasion resistant 

Hermetically/Leakage-free 

High-temperature applications 

Hygienic design 

Nickel-based materials 

Plastic/Plastic lining 

Rubberized 

Self-priming 

Special materials 

Stainless steels 

Suction aid (Priming aid) 

Biomaterials/Foodstuffs 

Boiler feed water 

Brackish water 

Chemicals/Acids/Alkaline solutions 

Concrete/Mortar/Cement 

Condensate 

Coolant 

Faeces/Liquid manure 

Fish 

Fuel 

Heating oil 

Oils/Greases/Lubricants 

Water/Waste water 

Installation and commissioning 

Maintenance, service and repair 

Status and demand analysis 

Support and project engineering 

Training and instruction 

• • 

• • • • • • • • 

• • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • 

111

Pumps 

Type of pumps 




Block pumps 


Inline pumps 







Vortex pumps 



Gear pumps 



Screw pumps 

Vane pumps 









Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 

Website: www.lewa.de 

• • • 



Phone: +49 (0)9342 879-0 





Phone: +49 (0)8638 63-0 



SEEPEX GmbH 


Phone: +49 (0)2041 996-0 





Phone: +49 (0)5434 83-0, Fax: +49 (0)5434 83-10 





Tel +44 (1326) 370 370 



• • • • • 

• • • • • • • 

• • 

• • 

• • 

112

Drive concept Design features Conveyed media Service 

Canned motor 

Combustion engine 

Hydraulic drive 

Linear motor 

Magnetic rotor 

Pneumatic drive 

Stepper motor 

Submersible motor 

Three-phase asynchronous motor 

Abrasion resistant 

Hermetically/Leakage-free 

High-temperature applications 

Hygienic design 

Nickel-based materials 

Plastic/Plastic lining 

Rubberized 

Self-priming 

Special materials 

Stainless steels 

Suction aid (Priming aid) 

Biomaterials/Foodstuffs 

Boiler feed water 

Brackish water 

Chemicals/Acids/Alkaline solutions 

Concrete/Mortar/Cement 

Condensate 

Coolant 

Faeces/Liquid manure 

Fish 

Fuel 

Heating oil 

Oils/Greases/Lubricants 

Water/Waste water 






• • • • • • • • • • • • 

• • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • 

113

Pumps 

Matrix Power ratings 

Head p [MPa] 

(1 MPa = 10 bar = 

100 mWS) 

< 0,5 < 2,0 < 6,3 < 25,0 > 25,0 

Capacity Q [m3 / h] 

< 1 A F K P V 

< 10 B G L R W 

< 100 C H M S X 

< 500 D I N T Y 

> 500 E J O U Z 




Block pumps 


Inline pumps 







Phone: +49 (0)2236 9650 0 



API 610 

centrifugal 

pumps 



Phone: +49 (0)211 577905-0, Fax: +49 (0)211 577905-12 



A , B, C, D, 

E, F, G, H, 

I, J, K, L, M, 

N, O, P, R, 

S, T, U 

A , B, C, 

D, F, G, H, 

I, K, L, 

M,N, P, 

R, S, T 

A , B, C, D, 

E, F, G, H, 

I, J, K, L, M, 

N, O, P, R, 

S, T, U 

A , B, C, 

D, E, F, 

G, H, I, J, 

K, L, M, 

N, O 



Phone: +49 (0)4155 49-0, Fax: +49 (0)4155 49-2423 



J 

J 

GRUNDFOS GmbH 


Phone: +49 (0)211 92969-0, Fax: +49 (0)211 92969-3799 



0.25 - 630 

kW 

11 - 700 

kW 

0.25 - 200 

kW 

1.1 - 11 

kW 

0.12 - 630 

kW 

11 - 700 

kW 

0.25 - 630 

kW 



Phone: +49 (0)2522 76-0, Fax: +49 (0)2522 76-140 





Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 



A, B, C A, B, C 



Phone: +49 (0)2302 8903-0, Fax: +49 (0)2302 801917 



114



Vortex pumps 



Gear pumps 



Screw pumps 

Vane pumps 







A, B, C, on 

F, G, request 

H, K, L, M, 

P, R, S, V, 

W, X 

A to Z A, B, C, 

F, G, 

A, B, C, 

F, G, 

H, K, L, M, H, K, L, M, 

P, R, S, V, P, R, S 

W, X 

A to Z 

H H N 

0.25 - 630 

kW 

0.25 - 75 

kW 

1.5 - 90 

kW 

0.09 - 2.2 

kW 

0.09 - 1.1 

kW 

0.09 - 2.2 

kW 

on request 

A, B, F, 

G 

A, B, C, 

F, G 

A, B, F, G A, B, C, F, 

G, H 

K, L, M, 

N, P, R, 

S, T, V, 

W, X, Y 

115

Pumps 

Matrix Power ratings 

Head p [MPa] 

(1 MPa = 10 bar = 

100 mWS) 

< 0,5 < 2,0 < 6,3 < 25,0 > 25,0 

Capacity Q [m3 / h] 

< 1 A F K P V 

< 10 B G L R W 

< 100 C H M S X 

< 500 D I N T Y 

> 500 E J O U Z 




Block pumps 


Inline pumps 







Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 




Phone: +49 (0)9342 879-0 





Phone: +49 (0)8638 63-0 



Up to 

300 m 3 /h 

up to 

24 bar 

Up to 

2.700 

m 3 /h 

up to 

40 bar 

SEEPEX GmbH 


Phone: +49 (0)2041 996-0 





Phone: +49 (0)5434 83-0, Fax: +49 (0)5434 83-10 





Tel +44 (1326) 370 370 



116



Vortex pumps 



Gear pumps 



Screw pumps 

Vane pumps 







A, B, C, 

F, G, H, 

K, L, M, 

P, R, S, 

V, W, X 

A, B, F, 

G 

A, B, C, D, 

F, G, H, I, 

K, L, M,N, 

P, R, S, T, 

V, W, X, Y 

Up to 

2.700 

m 3 /h 

up to 

40 bar 

Up to 

1.000 

m 3 /h 

up to 

240 bar 

Up to 

21 m 3 /h 

up to 

10 bar 

Up to 

1.000 

m 3 /h 

up to 

10 bar 

Up to 

3.000 

m 3 /h 

up to 

160 bar 

on 

request 

U 

U 

A, B, C A, B, C, 

D, F, G, 

H, I 

117







Beam conducting systems 


Biotechnology 

Ceramic industry 


Clamping devices 

Coating 

Conveying/Materials handling 

Distillation in the fine vacuum range 

Distillation in the low vacuum range 

Distilling 

Dry freezing 

Drying technology 


Electronics 

Electron microscopy 

Energy technology 


Food preservation and packing 

Foodstuffs, drinks and tobacco industry 

Foundry technology 

Heat treatment 

Hoisting 


Laser technology 

Aerzen Maschinenfabrik GmbH 

Reherweg 28, 31855 Aerzen/Germany 

Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 

E-mail: info@aerzen.com 

Website: www.aerzen.com 


POB 2143, 96410 Coburg/Germany 

Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 

E-mail: produktinfo@kaeser.com 

Website: www.kaeser.com 


Boschring 13–15, 63229 Egelsbach/Germany 

Phone: +49 (0) 6103 / 402-0 

Email: info.de@smc.com 

Internet: www.smc.de 

• • • • • • • • • • • • 

• • • • • • • • • • • • • • 

• • • • • 

Vacuum pumps and systems 


Claw-type vacuum pumps 

Cryo-vacuum pumps 

Diaphragm vacuum pumps 

Diffusion vacuum pumps 

Fuel jet vacuum pumps 

Gas ring vacuum pumps (Side channel blower) 

Getter pumps 

Liquid ring vacuum pumps 

Pressure vacuum pumps 

Reciprocating vacuum pumps 

Roots vacuum pumps 

Rotary piston vacuum pumps 

Screw vacuum pumps (Helicoidal gear vacuum pumps) 

Scroll vacuum pumps 


Steam ejectors 

Turbomolecular vacuum pumps 

Vacuum systems 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 





Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 



• 

• • 

118

Vacuum accessories 

Leak detection 

Low-pressure plasma treatment 

Materials technology 

Mechanical engineering 

Medical technology 

Metal finishing 

Packaging technology 



Plastics industry 

Printing and paper industry 

Refrigeration/Air conditioning technology 


Research institutions 

Space simulation technology 

Space travel 

Spectrometry/Spectroscopy 

Sputtering 


Suction/Exhausting 


Thin layer technology 

Universities 

Vaporising 

Vapour sterilisation 

Ventilating 

Accessories, other 

Analysis devices 

Ball valves 

Chambers 

Cold traps 

Component parts 


Condensers 

Container 

Custom-made devices 

Filters 

Flange components (flanges, seals, cables) 

Leak detectors 

Measurement devices 

Separators/Traps 

Service 

Sound enclosures 

Special components 

Valves 

• • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • 

• • • • • • 

Vacuum pumping stations 

Service 

Diffusion pumping stations 

Roots vacuum pumping stations with dry-running backing pump 

Roots vacuum pumping stations with fluisealed backing pump 

Special pumping stations chemical applications 

Special pumping stations customer-specific designs 

Special pumping stations helium leak detection 

Special pumping stations HV and UHV design 

Turbomolecular pumping stations with dry-running backing pump 

Turbomolecular pumping stations with fluisealed backing pump 






• • • 

119


Power Ratings 

Key for pressure range 

Coarse vacuum 1000 mbar – 1 mbar A 

Fine vacuum 1 mbar – 10 -3 mbar B 

High vacuum 10 -3 mbar – 10 -7 mbar C 

Ultra-high vacuum < 10 -7 mbar D 


Claw-type vacuum pumps 

Cryo-vacuum pumps 

Diaphragm vacuum pumps 

Diffusion vacuum pumps 

Fuel jet vacuum pumps 

Gas ring vacuum pumps (Side channel blower) 

Getter pumps 

Liquid ring vacuum pumps 

Pressure vacuum pumps 

Reciprocating vacuum pumps 

Roots vacuum pumps 

Rotary piston vacuum pumps 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 



A, B, C 



Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 



A 

120

Screw vacuum pumps (Helicoidal gear vacuum pumps) 

Scroll vacuum pumps 


Steam ejectors 

Turbomolecular vacuum pumps 

Vacuum systems 

Diffusion pumping stations 

Roots vacuum pumping stations with dry-running backing pump 

Roots vacuum pumping stations with fluisealed backing pump 

Special pumping stations chemical applications 

Special pumping stations customer-specific designs 

Special pumping stations helium leak detection 

Special pumping stations HV and UHV design 

Turbomolecular pumping stations with dry-running backing pump 

Turbomolecular pumping stations with fluisealed backing pump 

Chambers 


Leak detectors 

Measurement devices 

A 

121

Compressors 






Biogas 

Biotechnology 

Blast-furnace blowers 

Blasting technology 

Brewery technology 

Bulk transport 


Cleaning (blowing out) 

Coke oven technology 

Compensating air 

Compressed air tools 


Control air 

Conveying air 

Drying 



Fertiliser industry 


Foodstuffs, drinks and tobacco industry 

Foundries 

Garage equipment/Tool drive 

Garage technology 

Gas compressor helium 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 





Phone: +49 (0)2236 9650 0 



BAUER KOMPRESSOREN GmbH 

Stäblistr. 8, 81477 München/Germany 

Phone: +49 (0)89 78049-0, Fax: +49 (0)89 78049-167 

E-mail: industrie@bauer-kompressoren.de 

Website: www.bauer-kompressoren.de 

BOGE KOMPRESSOREN Otto Boge GmbH & Co. KG 

Otto-Boge-Straße 1-7, 33739 Bielefeld/Germany 

Phone: +49 (0)5206 601-0, Fax +49 (0)5206 601-200 

E-mail: info@boge.com 

Website: www.boge.com 



Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 



• • • • • • • • • • • • • • • • • • • • • 

• • • • 

• • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • 

122

Gas compressor nitrogen 

Gas transport 

General factory air 

Harbour basins 

Heat recovery 


Lifting/Clamping 

Machinery and plant engineering 

Manual operation 

Medical technology 




Natural gas industry 


Oil field 

Oil firing blowers 

Packaging (exclusive foodstuffs) 

Paint coating units 

Paint spraying technology 



Petrol stations 


Pneumatic delivery blowers 

Powder coating 


Printing industry 


Refinery 


Sand blasting 



Silo technology 

Starting of motors/Engines 

Switchgears 



Trade 


Ventilation of instruments 


Wind tunnel 


• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 

123

Compressors 

Type of compressors 


Axial compressors 

Booster, dry-running 

Booster, fluilubricated 


Construction compressors 

Dental compressors 

Diaphragm compressors 

Gas compressors 

Liquid ring compressors 

Piston compressors, dry-running 

Piston compressors, fluilubricated 

Portable screw compressors, fluicooled 

Portable screw compressors, fluifree compression 

Roots compressors 

Rotary gear compressor 

Rotary piston blowers 

Rotary vane compressors 

Rotary vane compressors, dry-running 

Rotary vane compressors, fluilubricated 

Screw compressors, dry-running 

Screw compressors, fluilubricated 



Phone: +49 (0)5154-81-0, Fax: +49 (0)5154-81-9191 



• • • • • • • • 



Phone: +49 (0)2236 9650 0 





Phone: +49 (0)89 78049-0, Fax: +49 (0)89 78049-167 



• • • • • 



Phone: +49 (0)5206 601-0, Fax +49 (0)5206 601-200 





Phone: +49 (0)9561-640-0, Fax: +49 (0)9561-640-130 



• • • • • • • • • • 

124

Conveyed media 

Service 

Scroll compressors 

Side channel compressors 

Small and very small compressors 

Turbines/Expander 

Turbo chargers 

Turbo compressors, axial 

Turbo compressors, radial 

Turbo compressors, radial/axial 

Acetylene 

Ammonia 

Breathing air 

Carbonic acid 

Chloric gas 


Ethylene 

Gases, other 

Helium 

Hydrogen 

Natural gas 

Nitrogen 

Oxygen 

Synthesis gas 

Vapour 






• • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • 

• • • • • • • • 

• • • • • • • • • • 

125

Compressors 

Power Ratings 

Key for volume flow and pressure 

Volume V 

m 

[ ] 

3 

min 

 

Pressure [in bar] 0–0,2 0,2–5 5–20 20–100 > 100 

0 – 2 A B C D E 

2 – 10 F G H I J 

10 – 25 K L M N O 

25 – 50 P Q R S T 

> 50 U V W X Y 


Axial compressors 




Construction compressors 

Dental compressors 


Gas compressors 

Liquid ring compressors 



Portable screw compressors, fluicooled 



Phone: +49 (0)5154-81-0 

Fax: +49 (0)5154-81-9191 



E, J, O, 

T 

G 



Phone: +49 (0)2236 9650 0 





Phone: +49 (0)89 78049-0 

Fax: +49 (0)89 78049-167 



25-500 

bar 

1,1-315 

kW 

Motorpower 

25-500 

bar 

1,1-315 

kW 

Motorpower 

25-500 

bar 

1,1-315 

kW 

Motorpower 

25-500 

bar 

1,1-315 

kW 

Motorpower 



Phone: +49 (0)5206 601-0 

Fax +49 (0)5206 601-200 



5.5 

up to 

11 kW 

5.5 

up to 

18.5 kW 

0.75 

up to 

30 kW 

0.75 

up to 

30 kW 

5.5 

up to 

18.5 kW 

0.75 

up to 

11 kW 

0.65 

up to 

18.5 kW 



Phone: +49 (0)9561-640-0 

Fax: +49 (0)9561-640-130 



G, H, L, 

M, Q, R 

G, H, I, 

L, M, N 

F, G F, G, K, 

L, P, Q 

G, H, I, 

L, M, N 

126

Portable screw compressors, fluifree compression 

Roots compressors 


Rotary piston blowers 

Rotary vane compressors 






Side channel compressors 

Small and very small compressors 

Turbo chargers 

Turbo compressors, axial 

Turbo compressors, radial 

Turbo compressors, radial/axial 

B, C, D, 

E 

B, C, D, 

E 

B, C, D, 

E, G, H, 

I, J, M, 

N, O 

G, H, I, 

J, L, M, 

N, O, T 

I, J, N, 

O, S, T, 

X, Y 

900 kW Air up to 

30 MW, 

500,000 

m 3 /h; 

PP/PE: 

10 MW, 

65,000 

m 3 /h 

up to 

35 MW, 

208 bar, 

500,000 

m 3 /h 

on 

request 

on 

request 

45 

up to 

355 kW 

2.2 

up to 

315 kW 

4 up to 

30 kW 

0.65 

up to 

1.5 kW 

150 + 

220 kW 

on B, C, D, 

request E 

B, C, D, 

E 

H, I G, H, I, 

L, M, N 

D, E 

127

Compressed air technology 


Compressed air treatment 







Roots compressors/Rotary piston blowers 








Adsorber (hydrocarbon) 

Adsorption dryer 

Combination dryer (Refrigeration/adsorption dryer) 

Compressed air filter 

Condensation drain and treatment 

Emulsion separator 

Maintenance unit 

Membrane dryer 


Oil-water separator 

Pressure maintaining systems 

Pressure vessels 

Refrigeration dryer 

Water separator 



Phone: +49 (0)5154 81-0, Fax: +49 (0)5154 81-9191 





Phone: +49 (0)89 78049-0, Fax: +49 (0)89 78049-167 





Phone: +49 (0)5206 601-0, Fax +49 (0)5206 601-200 





Phone: +49 (0)9561 640-0, Fax: +49 (0)9561 640-130 





Phone: +49 (0) 6103 / 402-0 



• • • • • • • • • • • • • • 

• • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • 

128

Pressure 

distribution 

Compressed air tools Other Service 

Connection technology 

Hoses 

Pipes/Pipe systems 

Valves 

Workshop equipment 

Clamping/Nailing/Riveting 

Drilling/Screwing 

Grinding/Polishing/Brushing 

Hammering/Chiselling 

Milling/Thread 

Painting/Spraying 

Planing/Filing 

Sandblasting/Purging 

Sawing/Cutting/Separating 

Other Compressed air tools 

Controllers and management systems 

Heat exchangers and aftercoolers 

Heat recovery systems 

Measurement devices (volume flow, pressure, dew point) 

Residual oil content measurement 

Suction filters 






• • • • • • • • 

• • • • • • 

• • • • • • • • • • • • • • • • • • • • • 

• • • • • • • • • • 

• • • 

129


Range of applications 




Biotechnology 

Chemical and process technology 

Containers and tanks 

Conveyor technology 

District heating 

Fluid technology 

Food and beverage industry 

Gas distribution 

Marine and sea engineering 

Pharmaceutical industry and cosmetics 

Pipeline systems and offshore technology 

Power plant technology and energy supply 

Refrigeration and cryo technology 


Solids 

Water extraction, treatment, supply and wastewater disposal 

Other industrial applications 



Phone: +49 (0)4155 49-0, Fax: +49 (0)4155 49-2423 



Georg Fischer Piping Systems Ltd 

Ebnatstrasse 111 

8201 Schaffhausen/Switzerland 

E-mail: info.de.ps@georgfischer.com 

Website: www.gfps.com 


Robert-Mayer-Str. 21, 71636 Ludwigsburg/Germany 

Phone: +49 (0)7141 48894-60, Fax: +49 (0)7141 48894-88 

E-mail: info@goetze-armaturen.de 

Website: www.goetze-group.com 


Jaegerweg 5, 85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 



JUMO GmbH & Co. KG 

Moritz-Juchheim-Straße 1, 36039 Fulda/Germany 

Phone: +49 (0)661 6003-0, Fax: +49 (0)661 6003-881-2346 

E-mail: info@jumo.net 

Website: www.jumo.net 



Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 


• • • • • 

• • • • • 

• • • • • • • • • 

• • • • • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • • • • 

• • • • • • • • • 



Phone: +49 (0)9342 879-0 





Phone: +49 (0) 6103 / 402-0 



• • • • • • • 

• • • • 



Tel +44 (1326) 370 370 



Zwick Armaturen GmbH 

Egerstr. 1 & 25, 58256 Ennepetal/Germany 

Phone: +49 (0)2333 9856-5, Fax: +49 (0)2333 9856-6 

E-mail: info@zwick-armaturen.de, 

Website: www.zwick-armaturen.de 

• • • • • • • • 

130

Industrial valves 

Valves 

Automatic valves 

Check valves, lift type 

Heavy duty valves 

Outlet valves for vessels 

Plastic valves 

Regulators and control valves 

Shut-off valves 

Special valves 

Stainless steel valves 

Angle seat valves 

Bellow-type valves 

Check valves, lift type 

Compressed air valves 

Control valves 

Cryogenic valves 

Diaphragm valves 

Drain and vent valves 

Float valves 

Hydraulic valves 

Magnetic valves 

Monoflange valves 

Multiway valves 

Needle valves 

Pinch valves 

Piston valves 

Pressure control valves 

Pressure reducing valves 

Safety valves 

Sampling valves 

Shut-off valves 

Special valves 

Steam valves 

Other valves 

• • • • • • • • • • 

• • • 

• • • • • • • • • • • • • 

• • • • • • • • • • • • • • • • 

• • • 

• • • • • • 

131


Components and assemblies 

Butterfly/Gate valves 


Compensators 

Condensate separators 

Couplings 

Filters 

Gear drives 

Pipelines and hoses 

Pipe fittings 

Pressure vessels 

Seals and seals systems, dynamic 

Seals and seals systems, static 

Separators 

Sight glasses 

Other accessories 

Backflow flaps 

Butterfly control valves 

Butterfly valves, shut-off 

Check valves, swing type 

Gate valves, shut-off 

Knife-gate valves 

Slide valves 



Phone: +49 (0)4155 49-0, Fax: +49 (0)4155 49-2423 








• • • • • 

• • • 


Robert-Mayer-Str. 21, 71636 Ludwigsburg/Germany 

Phone: +49 (0)7141 48894-60, Fax: +49 (0)7141 48894-88 

E-mail: info@goetze-armaturen.de 



Jaegerweg 5, 85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400, Fax: +49 (0)89 666633-411 




Moritz-Juchheim-Straße 1, 36039 Fulda/Germany 

Phone: +49 (0)661 6003-0, Fax: +49 (0)661 6003-881-2346 



• 



Phone: +49 (0)7152 14-0, Fax: +49 (0)7152 14-1303 




Phone: +49 (0)9342 879-0 





Phone: +49 (0) 6103 / 402-0 





Tel +44 (1326) 370 370 



• • • 

• 


Egerstr. 1 & 25, 58256 Ennepetal/Germany 

Phone: +49 (0)2333 9856-5, Fax: +49 (0)2333 9856-6 

E-mail: info@zwick-armaturen.de, 


• • • 

132

Ball and plug valves Actuators and positioners Measuring-Control technology/Sensors Other 

Ball valves 

Cylindrical plug valves 

Floor drain ball valves 

Multiway ball valves 

Plug valves 

Sampling ball valves 

Actuator accessories 

Actuators 

Control actuators 

Electrical actuators 

Electropneumatically and electrohydraulically positioners 

Hydraulic actuators 

Manual actuators 

Pneumatic actuators 

Underwater actuators 

Other actuators 

Analysis 

Condition monitoring 

Electronic monitoring and control 

Fill level 

Flow 

Function monitoring 

Gas leakage 

Humidity 

Pressure 

Residual oil vapour 

Temperature 

Commissioning 

Planning/Engineering 

Services/Maintenance 

Training/Instruction 

• • • • • • • • 

• • • • • • • • • • 

• 

• • • • • • • • • • • 

• • • • • • • • • • 

• 

133

Brand name register 

ABEL GmbH 

Abel-Twiete 1 

21514 Büchen/Germany 

Phone: +49 (0)4155 818-0 

E-mail: abel-mail@idexcorp.com 

Website: www.abelpumps.com 

As a leading global pump manufacturer, 

ABEL supplies robust and AI-powered pump systems 

for abrasive, aggressive, and shear-sensitive media. 

The main areas of pump application include mine 

backfilling, the transfer of mine tailings, dewatered 

sewage sludge and other sludges from various 

industrial processes, as well as filter press feeding. 

For exhibition-participation 

please visit our homepage: 

https://abelpumps.com/en/ 


Reherweg 28 

31855 Aerzen/Germany 

Phone: +49 (0)5154 81-0 

Fax: +49 (0)5154 81-9191 



Positive displacement blowers 

Rotary piston compressors 

Screw compressors 

Turbo blowers 

Rotary piston gas meters 


please visit our homepage 


AF Compressors 

Ateliers François S.A. 

Rue côte d‘Or 274 

4000 Liège/Belgium 

Phone: +43 (0)664 9207 944 

E-mail: opc@afcompressors.com 

Website: www.afcompressors.com 

AF offers a complete range of oil-free compressors 

“high and low” pressure. 

20-40 bar oil-free piston PET compressors for PET 

bottling or other applications. 

8 and 10 bar oil-free OPC range of piston 

compressors for any industrial applications 

(possibilities from 6-15 bar). 

- Compressor management systems 

- Smart Inverter Starter 

- Variable speed drive 

- Separate cooling systems 

For our presence on international 

exhibitions, please visit our website: 

www.afcompressors.com 


Schlehenweg 15 

50999 Köln/Germany 

Phone: +49 (0)2236 9650 0 

E-mail: 

atlascopco.energas@de.atlascopco.com 

Website: 

www.atlascopco-gap.com 

Industrial heat pumps and heat pumps systems 

using turbocompressors, integrally-geared 

turbocompressors, direct-driven turbocompressors, 

turboexpanders (integrally-geared and direct-driven), 

Companders, oil-free gas screw compressors, 

API 610 centrifugal pumps, as well as corresponding 

services. Markets served: Energy (conventional + 

renewable), hydrocarbon processing, chemical/ 

petrochemical, new markets (i.e., hydrogen, CCUS 

etc.), industrial gases. 


please visit our homepage 

www.atlascopco-gap.com 

AVIBIA GmbH 

Büchlerhausen 22 

51766 Engelskirchen/Germany 

Phone: +49 (0)2263 96 907 33 

E-mail: info@avibia.de 

AVIBIA is your expert partner for condition 

monitoring of rotating machines. We implement 

modern condition monitoring solutions. Our product 

range extends from sensors to IoT systems. 

We monitor vibrations, rotational speeds, and 

bearing conditions. Our consulting services are 

independent and practical. Our solutions are based 

on the latest technology. We combine our own 

products with those of strong partners to create 

added value for our customers. 

MEORGA 

May 6 2026, Bochum 

Kraftwerkstechnisches Kolloquium 

Oktober 6–7, 2026, Dresden 

134



Stäblistr. 8 

81477 München/Germany 

Phone: +49 (0)89 78049-0 

Fax: +49 (0)89 78049-167 



BAUER KOMPRESSOREN is one of the leading 

manufacturers of medium and high-pressure system 

for the compression of air and gases worldwide. 

- Medium and high-pressure compressors 

- 25 – 500 bar, 2.2 – 315 kW 

- Air and gas treatment 

- Storage systems 

- Air and gas distribution 

- Gas measurement systems 

- Controls 

For current trade fairs please visit: 

www.bauer-kompressoren.de/ 

news-events/trade-show-dates/ 

BOGE KOMPRESSOREN 

Otto Boge GmbH & Co. KG 

Otto-Boge-Straße 1–7 

33739 Bielefeld/Germany 

Phone: +49 (0)5206 601-0 

Fax: +49 (0)5206 601-200 



BOGE AIR. THE AIR TO WORK. 

Customers in over 120 countries worldwide trust the 

BOGE brand. 

The product range includes screw compressors and 

piston compressors in oil-lubricated and oil-free 

versions, scroll and turbo compressors, compressed 

air treatment systems, controls and heat recovery, 

as well as customised special solutions. Since 2023, 

the BOGE product portfolio has been expanded to 

include nitrogen and oxygen generators, offering 

complete solutions from a single source – 

efficient, safe and sustainable. 

For up-to-date exhibition activities 

please visit our website: 

www.boge.com 

BRINKMANN PUMPEN 

K.H. Brinkmann GmbH & Co. KG 

Friedrichstr. 2 

58791 Werdohl/Germany 

Phone: +49 (0)2392 5006-0 

Fax: +49 (0)2392 5006-180 

E-mail: sales@brinkmannpumps.de 

Website: www.brinkmannpumps.de 

BRINKMANN PUMPS offers a complete range 

of powerful pump solutions based on centrifugal 

pumps or screw spindle pumps for various 

applications: 

- Multiphase conveyance 

- Plastic recycling 

- Mechanical engineering 

- Electric mobility 

- Optical machines 

- Dosing technology 

- Pump control 

- Drive technology 

- Renewable energies 

For current trade fairs, please visit 

our website: 

www.brinkmannpumps.de 


Düsseldorfer Str. 79 

D-40545 Düsseldorf/Germany 

Phone: +49 (0)211 577905-0 

Fax: +49 (0)211 577905-12 



- Horizontal pumps with hydrodynamic shaft seal 

- Vertical pumps for wet and dry installations, without 

bearings in the liquid, also for Zone 0 use 

- Options of hydrodynamic sealing downstream: 

Stuffing box, mechanical seal, dry running magnet 

coupling 

- All castable and weldable stainless steel qualities 

- Special materials such as titanium, zirconium, etc. 

Please visit our homepage 

www.bungartz.de 

Maschinenfabrik Gustav Eirich 

GmbH & Co KG 

Walldürner Str. 50 

74736 Hardheim/Germany 

Phone: +49 6283 51-0 

Fax: +49 6283 51-325 

E-mail: eirich@eirich.de 

Website: www.eirich.de 

Delivery program: 

As a leading manufacturer of machines and systems, 

Eirich has been pioneering advanced technologies 

for mixing, granulating, dispersing and more since 

1863. “Eirich digital” also offers numerous services, 

from smart spare parts systems to AI-based process 

analysis. 


our homepage: 

www.eirich.de/de/ 

135


FELUWA Pumpen GmbH 

Beulertweg 10 

54570 Mürlenbach/Germany 

Phone: +49 (0)6594 10-0 

Fax: +49 (0)6594 10-200 

E-mail: info@feluwa.de 

Website: www.feluwa.com 

FELUWA MULTISAFE ® double hose-diaphragm 

pumps are hermetically sealed, oscillating positive 

displacement pumps and the ideal solution for 

pumping abrasive, aggressive and toxic media. Their 

exceptional suitability for heterogeneous mixtures 

with a high solids content and for extreme pumping 

temperatures make them the choice for demanding 

applications. In addition, FELUWA Wastewater 

Technology offers high-quality pumps and systems 

for efficient wastewater disposal in industrial plants 

as well as in private and public buildings. 


our website: 

www.feluwa.com 


Am Industriepark 2–10 

21514 Büchen/Germany 

Phone: +49 (0)4155 49-0 

Fax: +49 (0)4155 49-2423 



Hygienic Pumps 

Hygienic valves 

Aseptic valves 

Cleaning technology 

Further information are available 

on our website: 

www.gea.com 






• Ball Valves 

• Smart Actuators 

• Measurement 

• Valves 

• Industrial Ethernet Connectivity 

• Butterfly Valve 565 

The plastic Butterfly Valve 565 ensures reliable fluid 

control in water and water treatment applications. 

As a fully compatible and lightweight valve, it is 

available in wafer and lug style versions, versatile for 

different applications. 

Data Center World 

June 4–5, Frankfurt 

Hydrogen Technology Expo 

October 21–23, Hamburg 

Semicon 

November 18–21, München 

Further information are available on 

our website: 

www.gfps.com 


Robert-Mayer-Str. 21 

71636 Ludwigsburg/Germany 

Phone: +49 (0)7141 48894 60 

E-mail: info@goetze.de 


For more than 75 years, Goetze KG Armaturen has 

been manufacturing high-performance fittings 

and valves. The family-run company with its 

Headquarters in Ludwigsburg, has made a name 

for itself worldwide with its quality level (“Made 

in Germany”) - meanwhile more than half of its 

production now goes to foreign markets. 


our website: 

www.goetze-group.com/en/company/ 

exhibitions 

GRUNDFOS GmbH 

Schlüterstr. 33 

40699 Erkrath/Germany 

Phone: +49 (0)211 92969-0 

Fax: +49 (0)211 92969-3799 



Intelligent pumps and solutions for building services, 

industry and water utility, including circulator pumps, 

endsuction pumps, multistage pumps, pressure 

boosting systems, immersible pumps, inline pumps, 

dosing pumps, lifting stations, submersible ground 

and wastewater pumps 

For current trade fairs, 

please visit your local Grundfos 

website 

136



Carl-Zeiss-Str. 6–8 

59302 Oelde/Germany 

Phone: +49 (0)2522 76-0 

Fax: +49 (0)2522 76-140 




Process pumps 

Sewer cleaning pumps 

Mining pumps (deep mining industry) 

Hot water appliances 

Operating pressure up to 4,500 bar 

Flow rate up to 4,250 l/min 

Applications systems for cleaning, removing, 

cutting, coating removal, decorning, deburring 

with high pressure water 

Worldwide participations in trade 

fairs,for current trade fairs, please 

visit our homepage: 

www.hammelmann.com 

We are looking forward to your visit! 


Jägerweg 5–7 

85521 Ottobrunn/Germany 

Phone: +49 (0)89 666633-400 

Fax: +49 (0)89 666633-411 



The family-run company JESSBERGER headquartered 

in Ottobrunn near Munich is manufacturer of electric 

and pneumatic driven drum- and container pumps, 

vertical and horizontal progressive cavity pumps, 

dosing pumps for high viscous media, hand operated 

pumps and a comprehensive range of accessories 

like flowmeters, nozzles etc. Air operated diaphragm 

pumps, horizontal centifugal pumps (also available 

as magnetically coupled seal-less centrifugal pumps) 

and vertical centrifugal pumps complete the delivery 

program beside further industrial pumps. 


www.jesspumpen.de 



Moritz-Juchheim-Straße 1 

36039 Fulda/Germany 

Phone: +49 (0)661 6003-0 

Fax: +49 (0)661 6003-881-2346 



Delivery program 

• Temperature sensors and heat meters 

• Transmitters and controllers 

• Automation system and digital indicators 

• Hygro transducers and hygrothermal transducers 

• Measuring devices and flow sensors 

• Level probes and float switches 

• Level sensors and level switches 

• Solid state relays and power controllers 

Current trade fairs: 

messen.jumo.info 


Postfach 21 43 

96410 Coburg/Germany 

Phone: +49 (0)9561 640-0 

Fax: +49 (0)9561 640-130 



Screw compressors oil-cooled/dry-running, 

compressor controllers, reciprocating compressors, 

oil-lubricated and dry, high pressure compressors, 

boosters, portable compressors, screw vacuum 

pumps, compressed air treatment components, 

pneumatic accessories, refrigeration dryers, rotary 

blowers, screw blowers, magnetic, bearing turbo 

blower, services around compressed air (analyse, 

services, contracting) 


www.kaeser.com 


Salinger Feld 10 

58454 Witten/Germany 

Phone: +49 (0)2302 8903-0 

Fax: +49 (0)2302 801917 



High pressure plunger pumps + systems 

Mining pumps + systems 

Process pumps + Systems 

Water hydraulic pumps + Systems 

Operating pressures up to 4000 bar 

Flow rates up to 10,000 l/min 

Systems in mobile and stationary design 

KAMAT valve technology and water tools 

For KAMAT‘S current global trade fair 

partipcipations, visit 

www.KAMAT.de/en/innovations-and - 

exhibitions.html 


137


KRACHT GmbH 

Gewerbestr. 20 

58791 Werdohl/Germany 

Phone: +49 (0)2392 935-0 

Fax: +49 (0)2392 935-209 

E-mail: info@kracht.eu 

Website: www.kracht.eu 

We are a leading German technology provider for 

pumps, fluid measurement, valves, hydraulic drives, 

and customized system solutions. 

Our modular gear pumps are used as transfer and 

lubrication pumps, as process pumps for abrasive 

or poorly lubricating fluids, as high-precision dosing 

pumps, and as hydraulic pumps for pressures up to 

315 bar. In addition, we develop customized special 

pumps for specific applications in close collaboration 

with our customers. 

Current trade fair dates: 

www.kracht.eu 


KRAL GmbH 

Bildgasse 40, Industrie Nord 

6890 Lustenau/Austria 

Phone: +43 (0)5577 86644-0 

E-mail: kral@kral.at 

Website: www.kral.at 

KRAL GmbH is an internationally established 

manufacturer of screw pumps and high-precision 

flowmeters for demanding industrial applications. 

Its products are recognized worldwide for reliability, 

precision, and long service life. 

KRAL screw pumps provide high flow rates with 

a compact design and are also suitable for high 

differential pressures. Oils and other lubricating, 

non-aggressive fluids are conveyed almost pulsationfree 

and with very low noise. A special solution is 

the hermetically sealed magnetic-coupled pump 

designed for operating temperatures of up to 300 °C. 

The robustly engineered KRAL flowmeters deliver 

laboratory-level measurement accuracy even under 

harsh operating conditions. 

Current trade fair dates and details 

can be found at 

www.kral.at 


Ulmer Str. 10 

71229 Leonberg/Germany 

Phone: +49 (0)7152 14-0 

Fax: +49 (0)7152 14-1303 


- Metering Pumps 

- Process Diaphragm Pumps 

- Metering Systems 

- Packages 

- After sales service 

Current trade fair dates 

can be found at: 

www.lewa.com/en/ 

lewa-group/exhibitions-and-events 


Erlenstr. 5–7 

97877 Wertheim/Germany 

Phone: +49 (0)9342 879-0 



Lutz Pumpen GmbH is a leading manufacturer of 

industrial pumps with a focus on work safety and the 

highest demands. 

The product range includes drum pumps, container 

pumps, air-operated diaphragm pumps, flow meters, 

centrifugal pumps as well as system solutions. 

Current trade fair dates can be found 

on our website: 

www.lutz-pumpen.de 



84478 Waldkraiburg/Germany 

Phone: +49 (0)8638 63-0 


Website: 

https://pumps-systems.netzsch.com/en 

As a specialist for conveying complex media, 

NETZSCH develops customised and sophisticated 

pump solutions on a global level. The product 

spectrum ranges from the industry’s smallest 

metering pumps to high-volume pumps for 

applications in the oil & gas or mining industries. 

NETZSCH offers NEMO ® progressing cavity pumps, 

TORNADO ® rotary lobe pumps, NOTOS ® multi 

screw pumps, PERIPRO ® peristaltic pumps, grinders, 

macerators, dosing technology and barrel emptying 

units, accessories and service. 

For current trade fairs, please visit: 

https://pumps-systems.netzsch.com/ 

en/events 

138


ProMinent GmbH 

Im Schuhmachergewann 5–11 

69123 Heidelberg/Germany 

Phone: +49 (0)6221 842-0 

E-mail: info@prominent.com 

Website: www.prominent.com 

The ProMinent Group is a manufacturer of 

components and systems for metering technology 

and a reliable solution partner for water treatment. 

Product portfolio: metering and process pumps, 

peristaltic pumps, measuring and control devices, 

sensors for controlling and metering liquids, and 

metering systems for water treatment such as 

chlorine dioxide systems, electrolysis systems, 

UV systems and ozone systems. 

You can find trade fair participations at: 

www.prominent.com/en/Company/ 

Company/Exhibitions-and-Events/ 

Exhibitions-and-Events.html 

J.P. Sauer & Sohn 

Maschinenbau GmbH 

Brauner Berg 15 

24159 Kiel/Germany 

Phone: +49 (0)431 3940-0 

Fax: +49 (0)431 3940-24 

E-mail: info@sauercompressors.de 

Website: www.sauercompressors.com 

Sauer Compressors offers medium- and 

high-pressure compressors for applications in the 

general industry, offshore, commercial shipping and 

defence sectors. The modern reciprocating piston 

compressors for compressing air as well as all kinds 

of gases reach pressures of 20 bar to 500 bar. 

The SAUER product brand comprises high-pressure 

compressors, while HAUG stands for oil-free, dryrunning 

and hermetically gas-tight compressors. 

Please visit our website for upcoming 

trade shows 

www.sauercompressors.com 

SEEPEX GmbH 

Scharnhölzstr. 344 

46240 Bottrop/Germany 

Phone: +49 (0)2041 996-0 



SEEPEX is one of the leading worldwide specialists in 

the field of pump technology. 

Our portfolio comprises progressive cavity pumps, 

pump systems, and digital solutions. 

Our pumps are used wherever low to highly viscous, 

aggresive or abrasive media must be conveyed at 

low pulsation rates. 

Please visit our website for 

upcoming exhibitions 

www.seepex.com 


Boschring 13–15 

63329 Egelsbach/Germany 

Phone: +49 (0) 6103 / 402-0 


Website: www.smc.de 

SMC is a world-leading manufacturer, partner and 

solution provider in the field of pneumatic and 

electrical automation technology. Our product 

portfolio includes sensors, actuators, communication 

modules, valves and valve manifolds, components 

for fluid control and temperature regulation, as well 

as pneumatic connectors for industrial automation. 

We drive innovation across all relevant technologies – 

with a particular focus on energy efficiency. 

You can find information about our 

trade fair participation on our homepage 

www.smc.eu/de-de/ 

presse-messen/messen 

Vogelsang GmbH &Co. KG 

Holthoege 10–14 

49632 Essen (Oldenburg)/Germany 

Phone: +49 (0)5434 83-0 

Fax: +49 (0)5434 83-10 

E-mail: germany@vogelsang.info 


- Rotary lobe pumps 

- Macerators 

- Shredder 

- Vacuum pumps 

- Biogas technology 

- Agricultural technology 

Further trade shows at 

www.vogelsang.info 

139



Bickland Water Road, Falmouth 

Cornwall, TR11 4RU, United Kingdom 

Tel +44 (0)1326 370 370 



Watson-Marlow Pumps: accurate and repeatable 

peristaltic tube pumps for food, pharmaceuticals 

and industry 

Watson-Marlow Tubing: precision tubing for 

pumping and other purposes, in a range of materials 

Bredel Hose Pumps: heavy duty hose pumps for 

viscous and abrasive slurries and sludge 

Alitea: unique peristaltic panel-mount pumps and 

pumphead solutions for OEM customers 

Flexicon Liquid Filling: benchtop filling, semiautomatic 

systems and fully automatic filling, 

stoppering and capping machines 

MasoSine Process Pumps: low shear sinusoidal 

pumps for high viscosity food, beverage and 

cosmetics application 

BioPure Technology: advanced single-use tubing 

connector systems with LOT traceability on every 

component 

ASEPCO: Weirless Radial diaphragm in-line and tankbottom 

valves for pharmaceutical industries 

FlowSmart: reinforced platinum-cured silicone 

hoses and high performance sanitary gasket 

products 

Aflex Hose: specialist in the design and manufacture 

of PTFE-lined flexible hoses 

For trade fairs please visit 

www.watson-marlow.com/ 

gb-en/about/exhibitions/ 

WOMA GmbH I Kärcher Group 

Werthauser Str. 77–79 

47226 Duisburg/Germany 

Phone: +49 (0)2065 304-0 

Fax: +49 (0)20650 304-200 

E-mail: info@woma.karcher.com 

Website: www.woma-group.com 

WATER AS A TOOL 

• High-pressure plunger pumps for industrial 

cleaning and process applications 

• Ultra-high-pressure water jetting units 

• High-pressure hot water units 

• Water tools and accessories for various water 

blasting applications in industry and construction 

• Industrial Jetting Solutions 

• Service, maintenance and training 

Current Trade show dates events 

are listed on our website 

www.woma-group.com 



Egerstr. 1 & 25 

58256 Ennepetal/Germany 

Phone: +49 (0)2333 98565 

Fax: +49 (0)2333 98566 

E-mail: info@zwick-armaturen.de 


Zwick Armaturen GmbH, a family-owned company 

for over 40 years, manufactures shut-off valves that 

meet the highest requirements. The product range 

includes metal-seated butterfly valves in the TRI-CON 

series, check valves in the TRI-CHECK series and 

double block and bleed designs in the TRI-BLOCK 

series. Also part of our product portfolio are the new 

TRI-TOP and TRI- ENTRY series for LNG applications, 

as well as other well-known series such as the 

TRI-SHARK control valve. The modular design, 

special technical features and wide range of 

valve series, which can be produced in various 

materials, make the valves suitable for a wide range 

of applications. 

Please visit 

www.zwick-valves.com 

for further information 

140

Your Global Partner for 

Complex Fluid Handling 

Find the optimum conveying solution for your application and select from 

four pump technologies, complemented by grinding systems and accessories. 

Benefit from our expertise - from initial consultation to service and spare parts. 

> 70 

YEARS OF 

EXPERIENCE 

INDIVIDUAL 

CONSULTING 

5 

TECHNOLOGIES 

SERVICE 

& SPARE 

PARTS 

Visit us at the trade fairs: 

IFAT, 4-7 May 

Munich, Hall B1, Booth 251 

6 6 

The Battery Show Europe, 9-11 June 

Stuttgart, Hall 1, Booth K46 

www.pumps-systems.netzsch.com

PuK - Process Technology & Components 2026

Transform your PDFs into Flipbooks and boost your revenue!

PuK - Process Technology & Components 2026

Transform your PDFs into Flipbooks and boost your revenue!

Delete template?

Save as template ?