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.
At a glance
- 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
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 — Technical specifications
| Maximum operating pressure | 200 bar (2900 psi) |
|---|---|
| Pump type | Dual piston positive displacement pump |
| Wetted materials | 316L stainless steel |
04 — Other applications
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.
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