Case study · Precision pumps & injection systems

Mixing shear-sensitive fluids at 200 bar: a low-shear injection and blending pilot plant

For a leader in the manufacturing industry, Irian Mecatronics designed and built an R&D pilot unit for metering and mixing complex fluids at high pressure. The equipment injects a shear-sensitive polymer and an abrasive slurry at 200 bar (2900 psi), preserving their integrity to ensure reliable test results.

Client: A leader in the manufacturing industry
Field: Process Development
Technique: Metering, blending, precision injection

01 — The research question

How to accurately meter and mix fragile or abrasive fluids at high pressure?

Many processes in fine chemicals, pharmaceuticals, or materials science require mixing fluids with conflicting properties. Some are fragile (polymers, emulsions, cell suspensions) and degrade with the slightest mechanical shear; others are abrasive or corrosive and cause premature wear on standard equipment. Achieving a precise, repeatable mixture without altering the constituents is a challenge that off-the-shelf solutions cannot meet.

Our client needed to develop a new process by mixing a natural, shear-sensitive polymer with an abrasive slurry, all at 200 bar (2900 psi). Standard pumps consistently failed: they either degraded the polymer, which skewed test results and caused clogging, or they wore out too quickly. The turbulence they generated also made it impossible to achieve a reproducible, high-quality mixture.

Injecting and mixing fluids at high pressure with high precision while applying minimal mechanical shear to preserve their integrity.

02 — Our approach

A design focused on fluid integrity and testing flexibility

With no standard solution available, our engineering team designed a custom system focusing on the client's three key requirements: preserving the fluids, ensuring metering accuracy, and providing simple, safe operation in a lab environment.

Preserving the integrity of sensitive and abrasive fluids

The polymer degraded under shear, and the slurry wore down components. We designed a fully laminar flow path, free of the sharp bends and valves found in standard systems. This ultra-low shear approach protects the fluids, ensures the validity of the tests, and prevents any risk of clogging.
Ensuring precise and flexible metering

To explore different formulations, the client needed to vary flow rates and ratios independently and with fine control. We integrated two separate positive displacement injection lines that can be electronically synchronized. This solution offers total flexibility for R&D protocols, unlike a single pump with a flow divider, which is less accurate with such dissimilar fluids.
Integrating all functions into an ergonomic and safe unit

The equipment had to be easy to use and clean in a laboratory setting. All functions (pumping, control, HP safety) are integrated into a single mobile chassis. Access points are optimized for filling, even with paste-like products, ensuring fast and safe operation for the users.

03 — Beyond this project

Does your process also involve fragile fluids?

Pharmaceuticals / Biotechnology

Metering suspensions of active ingredients or solutions of living cells requires very low shear to avoid degradation. The principles of positive displacement injection and metering accuracy would be maintained, but adapted with pharmaceutical-grade materials and a sanitary design (CIP/SIP).

Food & Beverage

To mix textured products or those with inclusions (creams, sauces) without altering their structure, gentle pumping is essential. The principle of preserving product structure and metering accuracy would be kept, while adapting the design to food hygiene standards and often higher flow rates.

Cosmetics

Preparing emulsions or gels containing fragile active ingredients requires homogeneous mixing without breaking down the structures. The control over shear and the metering precision are directly transferable, adapting materials and surface finishes to prevent cross-contamination between batches.

04 — Specifications

The values for this project. Every system is custom-built, so they adapt to your requirements.

Show specifications · 200 bar (2900 psi) · Dual piston positive displacement pump · 316L stainless steel

Technical specifications — Mixing shear-sensitive fluids at 200 bar: a low-shear injection and blending pilot plant
Maximum operating pressure	200 bar (2900 psi)
Pump type	Dual piston positive displacement pump
Wetted materials	316L stainless steel

IRIAN Mecatronics designs and builds custom high-pressure, high-temperature equipment for research laboratories, technical centres and industry.

About the company

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05 — FAQ

Frequently asked questions

Can this low-shear injection system handle gases or supercritical fluids?

Yes, the principle of positive displacement injection is well-suited for compressible fluids. However, the implementation requires specific adaptations for seals, control algorithms, and material compatibility, especially at high pressure. For supercritical CO2, for example, we have developed dedicated demonstration cells.

Can this type of pump be adapted for very low flow rates (microfluidics) or for pilot-scale production?

Yes, the principle is scalable over a wide range. For pressure-driven microfluidics applications, we use higher-resolution actuators and smaller volumes. For industrial pilot plants, the cylinder volumes are increased, and the system can be designed for continuous operation with alternating fill and injection cycles.

How is such equipment certified for ATEX environments or to meet pharmaceutical standards (GMP)?

The design is completely revised to meet the required standards. For an ATEX zone, we select certified components and perform a specific risk analysis, as we do for our test rigs for flammable gases. For pharmaceutical grade, the design incorporates certified materials, controlled surface finishes, and cleanability in compliance with Good Manufacturing Practices (GMP).

Can the system operate in pressure control mode instead of flow control mode?

Absolutely. Our control systems can regulate either flow rate or pressure. In pressure control mode, an inline sensor provides the setpoint for the feedback loop, which adjusts the piston speed to maintain a stable pressure. This is a critical function for many process pilot plants.

Is your process limited by fragile or complex fluids?

Describe your high-pressure mixing or metering challenge. Our engineering team will analyze your project's feasibility and get back to you with a proposal for a custom approach.

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