01953 609930Sanitary and Pharmaceutical Pump Skid Solutions
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Request a quote / infoDesigning the pump and fluid-control section of a sanitary or pharmaceutical skid involves more than selecting a pump that can reach the maximum flow rate.
The pump, valves, flow measurement, pulsation control, wetted materials and control interface must work together across production, dosing, transfer and cleaning.
Premier Control Technologies supports OEMs, skid builders, system integrators, engineering companies and design houses across the UK and Ireland. We help define the operating envelope, select and configure suitable components, and consider how they will interact within the finished system. Support can range from an individual component to a coordinated pump and fluid-control package, depending on the project.
From pump selection to measured process control
The final arrangement, materials, connections and control strategy depend on the application.
Design around every operating mode
A skid that performs well at its nominal duty can still be difficult to control at the bottom of its range or restrictive during cleaning. For that reason, PCT normally begins with the complete operating envelope rather than a single maximum-flow figure.
Useful design information includes:
- Minimum, normal and maximum process flow
- Clean-in-place and sterilisation-in-place flow requirements
- Available suction and discharge pressure
- Fluid composition, viscosity and temperature
- Required accuracy, repeatability and response time
- Wetted materials, connection standards and cleanability requirements
- PLC signals, communications, pneumatic supply and fail-safe behaviour
- Pulsation limits for meters, filters, columns and downstream equipment
Select the pump around the real duty
Different duties call for different pumping principles. A contamination-sensitive transfer process, a continuously metered addition and a microlitre dispensing application may all require a different approach.
Peristaltic pumps
Peristaltic pumps keep the process fluid within the tubing, which can make them useful for hygienic transfer, dosing and filling where the selected tubing and connections meet the application requirements. Pump-head design, tubing dimensions, speed range, discharge pressure and pulsation all influence achievable flow and repeatability.
Valveless piston pumps
Valveless piston pumps provide a different option for highly repeatable low-volume metering and dispensing. Their rotating and reciprocating ceramic piston design removes conventional check valves, but the wetted materials and cleaning method must still be assessed for the process.
Maximum capacity is only part of the selection. Minimum stable flow, required turndown, operating pressure, maintenance approach and available motor or PLC control can be equally important. PCT can help compare pump technologies and configure the drive, head, tubing, motor and control interface around the duty.
Manage pulsation before it affects the process
Peristaltic, diaphragm and other positive-displacement pumps can produce repeating changes in instantaneous pressure and flow even when their average output is correct. In a simple transfer line this may be acceptable. In a more sensitive skid, it can disturb flow measurement, create vibration, trigger pressure alarms or affect filtration and chromatography equipment.
The first step is to review the source of the pulsation. Pump principle, speed, the number and arrangement of pumping elements, tubing or hose characteristics and the surrounding pipework can all influence the pressure profile. PCT's guide to pulsation in peristaltic and positive-displacement pumps explains the main causes and the options available at pump and system level.
Where residual pressure pulsation must be reduced, the Equilibar PD Sanitary Pulsation Dampener can be installed downstream of a positive-displacement pump. Its air-loaded, double-sided dampening design responds to changing line pressure, while its drainable construction and sanitary Tri-Clamp connections support hygienic installations. Available configurations are rated up to 10 bar(g) and 135°C; the selected size, materials, orientation and operating conditions must be checked for each application.
Control low process flow and higher cleaning flow
Production and cleaning can create two very different valve-sizing conditions. A valve selected to pass the full CIP flow may provide poor resolution at a low dosing flow, while a valve sized for fine process control may restrict the cleaning circuit. A separate CIP bypass can solve this, but it adds pipework, valves, control logic and further areas that must be cleaned and validated.
The Equilibar FD Series sanitary back-pressure regulator uses a flexible diaphragm over multiple parallel orifices to provide precise control across a wide flow range. In suitable applications, one correctly sized FD valve can control the lower production flow and allow the higher CIP flow, potentially simplifying the process path.
For automated flow control, the FD valve can be combined with a compatible flow transmitter and an electro-pneumatic pilot regulator. The process controller compares measured flow with the setpoint and adjusts the valve's pilot pressure.
Measure actual flow and close the control loop
Changing pump speed changes expected flow, but it does not always prove what the process is receiving. Actual output can also be influenced by pump principle, discharge pressure, fluid properties, slip, tubing condition and wear.
Where verified flow matters, a suitable flow meter provides direct feedback to the skid controller. The system can then adjust pump speed, modulate a control valve, or combine both methods across a wider operating range. This turns a speed command into closed-loop flow control and provides a measured value for monitoring, totalising, batching or validation records.
PCT supplies a range of liquid flow meters and controllers, including Coriolis instruments for low-flow liquid measurement and pump control. The correct device must be selected against flow range, accuracy, pressure drop, fluid compatibility, connection type, temperature and the skid's cleaning method.
Support for skid builders and design teams
PCT's role is to complement the skid designer's process knowledge with detailed pump, pressure-control and flow-measurement expertise. Looking at the components as a connected system can expose control or sizing issues before the layout and bill of materials are fixed.
Typical areas of support include:
Pump selection and configuration
Technology, model and control selection for transfer, dosing, metering and dispensing, supported by component sizing and configuration.
Pulsation and pressure control
Pulsation reduction, back-pressure strategies and control across low production flow and higher CIP flow conditions.
Measurement and integration
Flow verification, batching, totalising and closed-loop control, together with analogue, digital, PLC and pilot-control integration.
Materials and documentation
Material compatibility, pressure, temperature, connection and drainability requirements, plus documentation and application support.
Discuss your sanitary or pharmaceutical skid
If you are developing a new skid or reviewing an existing design, send PCT the fluid, flow range, pressure, temperature, cleaning conditions and required control method. Our team can help identify suitable technologies and highlight operating conditions that need closer attention.