AODD+ Pumps: Innovation That’s a True Game-Changer

Why Flotronic^® air-operated double-diaphragm pumps are so different we had to call them AODD+.

Air-operated double-diaphragm pumps (AODD) pumps have been around since the 1950s. They are valued in a wide variety of applications because of their versatility. However, the proven, practical design of conventional AODD pumps has a significant drawback: they take too long to clean. Manually cleaning an AODD pump typically consumes two hours of labor or more.

Users just put up with this. However, Flotronic pump engineers refused to accept that long cleaning times were inevitable and set out to design a better AODD pump.

The engineers considered the problem. Disassembling an AODD pump required removing it from the line. The pumps had significant pipework that had to be taken apart before a worker could access the pump chambers. Opening the pump chambers required the removal of several bolts. They asked themselves how to improve the configuration.

Their innovations created a new type of AODD pump that was fast and easy-to-clean, compact, lower maintenance, and self-draining. For process plant operators who are dealing with labor scarcity, skilled worker retirements, and rising material costs, the design is a game-changer.

You may have tried an AODD before, but that’s nothing like a Flotronic AODD+.

It takes a unique kind of genius to look at things differently. The Flotronic engineers proposed a radical idea: turn the pump inside out. Instead of routing the process fluid through pipework on the sides of the pump, they routed the fluid through the center. This conclusion eliminated the need for pipework. Then, they proposed another radical change: redesign the pump body so the assembly was attached with one large nut. A worker could disassemble the pump by removing just one nut. The Flotronic One-Nut^® technology was born.

The One-Nut design led to additional innovations that shrank the pump footprint, reduced the need for time consuming maintenance, and minimized product loss during cleaning. Together, these improvements add up to a better type of AODD pump that we call AODD+.

What’s so great about Slimline AODD+ Pumps?

While we offer a full range of AODD pumps, the Flotronic Slimline Series are the pumps that have earned the distinction of being AODD+. The Slimline pumps have several advantages.

• As the name suggests, Flotronic Slimline pumps take up far less space than AODD pumps of comparable capacity, making them easy to integrate into existing production lines.
• The One-Nut design optimizes the piston stroke length, enabling reinforced diaphragms to be used as standard. The stronger diaphragms last longer than ordinary diaphragms … millions of cycles. Maintenance managers appreciate the less frequent need for diaphragm replacement.
• Because pump pipework is eliminated, little residual product is left in the pump at the time of maintenance or cleaning. This reduces the mess that needs to be cleaned up when a pump is serviced. In applications having high-value products, such as cosmetics or pharmaceuticals, the design avoids costly waste.
• Flotronic Slimline AODD+ Pumps — by virtue of their One-Nut design — can be manually cleaned in 15 minutes compared to the two hours it takes to clean a conventional AODD pump. The labor savings during the course of a budget year can easily recover the investment made in the pump.
• Like other AODD pumps, Flotronic Slimline pumps can be cleaned in place. However, many facilities don’t have Clean-in-Place (CIP) systems installed on every line, in which case maintenance teams like to use portable, external cleaning rigs. The Flotronic Slimline is the only AODD pump that can be used with external CIP rigs at up to 7 Bar (100 psi).

Of course, there are benefits to AODD pumps generally, and these apply to our Flotronic Slimline pumps as well. These include:

• Self-priming.
• Deadhead capable.
• Gentle on the product.
• High viscosity capable.
• Simple, reliable operation.
• Suitable for explosive environments.

Flotronic Slimline AODD+ pumps have your applications covered.

To suit different process capacities and flow rates, Flotronic Slimline Series pumps are available in four sizes based on diaphragm diameter: 7-inch, 10-inch, 12-inch, and 14-inch. The pumps are available with connections ranging from ½-inch to 3-inch, including threaded, hygienic, and flanged options. They are offered in a variety of materials to suit any application, including stainless-steel, aluminum, and special metals such as Hastelloy^®.

The pumps are engineered for hygienic applications. They have been proven particularly effective transferring viscous products where cleanliness is essential, for example, cosmetics, personal care products, and foodstuffs like yogurt and mayonnaise. The pumps are engineered with 3A guidelines in mind and manufactured from FDA-approved materials. The interior of the pump is crevice-free with no welds, for maximum cleanliness.

The 14-inch model pump is the newest member of the Flotronic Slimline family. It is a large capacity pump that offers operators a simple way to increase productivity per line. With 3-inch connections, the 14-inch Slimline pump doubles the flow rate of the 12-inch Slimline pump. In effect, the larger pump does the work of two pumps without doubling the maintenance required. Also, the 14-inch pump can handle larger particles, up to 0.787 inches, making it useful for more applications. It is the first AODD pump of its size capable of accommodating CIP processes, avoiding labor costs and the risk of pump damage during manual cleaning.

How an AODD+ solved a galling problem.

A Japanese food manufacturer transferring kimchi sauce experienced problems with metal particles in the food stream, according to detectors in the process pipework. The manufacturer had been using rotary pumps with steel-on-steel friction at the point where the shaft was secured that results in metal breaking off into the process. The pumps were the source of contamination.

Whenever metal particles were detected, operators had to halt production, strip, clean the pumps and process pipework. Every time it happened, the line lost two to three hours of production. In addition, managers had to discard significant amounts of kimchi sauce.

Managers saw the Flotronic Slimline AODD+ pump at an exhibition in Tokyo. They liked how easy it was to disassemble and clean. They liked even more the absence of steel-on-steel friction points that could wear and cause metal particles to enter the process stream.

They installed a Flotronic Slimline AODD+ pump in their process and immediately solved the metal particle problem. They also discovered that the bacteria count in the sauce had dropped to zero.

Once a week, operators clean the pumps in place at 90°C, utilizing the optional reinforced high-temperature diaphragms.

Seeing is believing.

A Flotronic AODD+ pump, because of its One-Nut design, greatly accelerates cleaning and maintenance times compared to a conventional AODD pump. A worker can disassemble, service, and reassemble an AODD+ pump in minutes rather than hours. Using the time savings, the worker is available for other maintenance tasks.

This video shows an actual head-to-head comparison of maintenance on an AODD+ pump versus an ordinary AODD pump. See how many fewer steps there are and see for yourself the impressive time savings. Watch the video now.

At every turn, AODD+ pumps are a shining example of how pump technology can transform product transfer applications. They positively impact operations on a business level by saving labor, ensuring cleanliness, simplifying cleaning, and reducing product waste.

Reach out to one of our experts to discuss your application to discover more about Flotronic AODD+ pumps and how they are different from any pump you have seen.