Dual-Syringe Pump for Handling Viscous and Sensitive Fluids

The client was developing an innovative mixing process and required an upstream feeding system capable of meeting very demanding production and handling constraints.

• Complex Fluids: The system needed to simultaneously inject two products:

  • A liquid latex prone to coagulation under shear, which could cause blockages.

  • A slurry (water and carbon black mixture), a non-Newtonian, rheofluidifying paste with variable viscosity.

• High-Performance Injection: The pump had to provide a stable and precise flow rate of 0.5 to 10 L/min for each fluid, with a very short stabilization time (under one second).
• Zero-Shear Design: The pump and circuit architecture were carefully engineered to eliminate shear zones, avoid non-laminar flow, and prevent abrupt diameter changes.
• Ergonomics & Maintenance: Filling the potentially viscous slurry had to be simple and fast (“with a trowel”), and full system cleaning could be completed in under 10 minutes.
• Skid Integration: The entire system was mounted on a single mobile skid, front-accessible only, to fit within a compact production environment.

Our engineering team designed a fully custom dual-component injection skid, focusing on fluid mechanics and operator ergonomics.

• Zero-Shear Syringe Pumps: Two independent pump bodies were developed, each with a 3 L working volume. To address the challenges of handling latex, the internal design was optimized with smooth walls, full-bore fittings, and gentle geometries to ensure perfectly laminar flow and prevent coagulation.
• Design for Viscous Fluids: To simplify slurry loading, each syringe is equipped with a quarter-turn nut cover. This allows the operator to open, fill the syringe with a pasty product, and close it in under a minute, optimizing cycle times.
• Advanced Synchronization and Control: Both syringes are driven by brushless synchronous motors with servo drives, providing high responsiveness. A single HMI command initiates a coordinated injection, while independent flow setpoints for each piston ensure precise control of the mixing ratio.
• Integrated Industrial Skid: All components (pumps, electrical cabinet, HMI) are mounted on a robust 720 kg skid, movable by forklift. All operations—filling, control, and maintenance—are accessible from the front, in line with the client’s installation constraints.