Chemical regeneration and filtration system for metal surface treatment

12/06/2026

The client located in Austria is one of the leading producers in the field of galvanising and metal surface treatment. With extensive industry experience, the company continuously invests in advanced solutions to optimise chemical treatment and media recycling technologies to improve process efficiency and sustainability. The system supports reduction of chemical waste and lower operating costs through media recovery and reuse.

CLIENT’S PROBLEM AND CHALLENGES

The application forms part of a chemical regeneration and filtration system used in flux recycling within galvanising plants. The system is responsible for maintaining a stable composition of the flux bath, which is essential for ensuring consistent coating quality and reliable surface preparation of metal components prior to galvanising.

The client introduced a flux reprocessing and filtration system designed to recover and reuse the fluxing agent. This required reliable pumping solutions for two critical stages of the process:

transfer of waste eluent from the flux baths to filter presses
return of the regenerated flux back to the flux bath

Key challenges of the project:

highly aggressive wastewater streams
safe, leak-free and mechanical seal free pumping
large project scale (96 pumps)
variable process conditions across different stages of wastewater treatment

The pumped medium consisted of a highly aggressive chemical solution based on ammonium chloride and zinc chloride. The concentration was approximately 500 g/l, with a pH level in the range of 4 to 5. This combination of high salt concentration and mildly acidic conditions created a corrosive environment that placed significant demands on pump materials and sealing solutions.

TAPFLO ACTIVITIES

Tapflo conducted a technical analysis of the flux recycling system, focusing on the chemical properties of the medium, the operating parameters and the specific roles of each pump within the process loop. Based on the assessment, two complementary pump technologies were selected to safely handle each stage of the operation:

air-operated double diaphragm pumps manufactured from HDPE,
vertical centrifugal pumps (CTV) manufactured from PP.

AODD pumps were used to transfer waste eluent from process baths to filter presses as they tolerate contaminated liquids with suspended solids and process residues. Their ability to automatically adjust to increasing backpressure typical of filter‑press cycles was also a decisive factor, since their performance is less sensitive to intermittent pressure spikes than many rotary alternatives.

APPLIED DEVICES:


air-operated diaphragm pump	vertical centrifugal pump

The AODD pump is not equipped with conventional rotary shaft seals, reducing a common leakage path. HDPE construction was chosen for its chemical compatibility with the concentrated chloride solution used in this application. The pumps also tolerates intermittent duty and short periods of dry running during transitions such as line emptying or temporary loss of suction, which can occur in batch‑operated filtration stages.

In contrast, vertical centrifugal pumps were used to circulate the regenerated flux back to the process baths. Unlike the contaminated eluent, the filtered flux requires stable hydraulic performance, which centrifugal pumps provide through smooth, non-pulsating flow under steady operating conditions. The vertical cantilever design keeps the shaft sealing area outside the process liquid, reducing a major leakage path in chloride‑rich environments and simplifying maintenance. Polypropylene (PP) construction was selected for its proven chemical compatibility with ammonium and zinc chloride solutions used in this process.

RESULT

Each flux recycling system was equipped with a Tapflo T100 PEE-3DPY11SFR air-operated diaphragm pump and a CTV25-10P-5D-07 vertical centrifugal pump, forming a fully integrated solution for both contaminated and regenerated process streams. The project included a total of 110 pumps delivered into 3 phases throughout 2019 and 2020.

AODD pump T100 PEE for chemical regeneration and filtration system

Centrifugal pump CTV25 for chemical regeneration and filtration system

The separation of pump technologies for the dirty and clean sides of the process ensured that each stage operated under optimal conditions, resulting in consistent flow behaviour and stable process parameters throughout the regeneration cycle.

As a result, the system enabled effective regeneration of the fluxing agent, leading to reduced consumption of fresh chemicals while maintaining stable bath chemistry required for high-quality galvanising.

We provide a wide selection of equipment used across all industry sectors, both in small and large enterprises. We offer professional devices for applications in:

hygienic sectors (beverages, confectionery, pharmaceuticals and cosmetics, fish processing, dairy, brewing, oils, fats, processed foods, and others),
industrial sectors (wastewater treatment plants, paper industry, surface treatment, chemical processes, mechanical industry, paint and coatings industry, leather tanning).

The bitumen industry focuses on the production, processing, and application of bitumen – including the manufacture of asphalt emulsions, modified bitumens, waterproofing masses, and more. Due to the nature of the material, the bitumen industry requires advanced technologies and specialized equipment to handle substances with high viscosity and extreme temperatures.

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At Tapflo, we provide modern industrial solutions that streamline manufacturing processes and improve chemical production efficiency. We understand that handling chemicals requires the use of the highest quality equipment, and that is exactly what we deliver. Our motorers ensure the selection of devices suitable for every type of chemical, including pumps, valves, mixers, and filters tailored to the specific medium. The highest quality of Tapflo equipment guarantees safety, accuracy, and optimization of production costs.

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The electroplating industry plays a key role in the production of various metal components. Electroplating processes require the use of equipment designed to operate in aggressive environments – with chemicals, acids, or alkalis.

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The cosmetics industry is a dynamically growing sector where production quality and efficiency are of paramount importance. Achieving these goals requires modern and reliable equipment such as pumps, mixers, valves, and homogenizers.

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Pumps and equipment for food production play a key role in ensuring efficiency, hygiene, and safety of manufacturing processes.

Investing in high-quality equipment pays off by improving product quality, increasing productivity, and reducing operational costs. By choosing the right food-grade pumps, mixers, or homogenizers from Tapflo, food industry companies can meet market challenges and deliver products of the highest quality to consumers. Every Tapflo device is characterized by compliance with strict sanitary standards such as EHEDG, 3-A, FDA, and USP VI.

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Industry Sector

We present to you the full range of products we supply. The offerings here are aimed at users of various industrial applications. We invite you to explore our extensive portfolio, which includes pumps, heat exchangers, homogenizers, hygienic valves, filters, and a wide array of other solutions.

We provide comprehensive, professional, and above all reliable diaphragm pumps, centrifugal pumps, and other equipment that ensure safe and hassle-free liquid transport. Our forty years of experience and a qualified team of top specialists guarantee that the industrial equipment we supply successfully meets the expectations of even the most demanding clients. Our diaphragm, centrifugal, vortex, gear, dosing pumps, and many others find applications across various industry sectors.

One of the most universal pumps available on the market, compressed air-operated diaphragm pumps can be used in a wide range of applications to transfer almost any medium. Their simple operating principle and robust, compact design enable these pumps to meet the high demands of various industries.

Trouble-free dry running. Smooth flow control. Self-priming up to 5 m.
No electrical installation required. Few components. Compact and robust design. Oil-free air distributor.
Compressed air supply.

Due to changes in the way we think about our impact on the environment, we are proud to present EODD – Electric Diaphragm Pumps. The product follows a modern approach but is still based on the original diaphragm pump technology, which has proven to be very effective. We consulted with our customers, who expressed a need for the features and benefits of a traditional diaphragm pump, but with the added advantage of lower operating costs. The pump is powered by a high-efficiency electric motor (IE3 class) and there is no chance of hydraulic fluid leakage, as the pump simply does not need it.

A Filter Press Pump is a specialized type of pump designed to fill a filter press with a slurry or suspension from an external storage or disposal facility, typically used in solid-liquid separation processes, typically at high pressures reaching 24 bar.

Tapflo Filter Press Pumps are known for their robust construction, reliable performance, and ability to handle high-pressure applications with ease. They are equipped with a non-return valve to prevent backflow and are available in various materials to suit different process requirements. Air operated filter press pumps have the unique feature that when the filter press is full, they stop and no additional safety systems are required to shut down the pump (like in case of electrically operated filter press pumps).

Tapflo offers a wide range of centrifugal pumps made of stainless steel and PP and PVDF plastics, including horizontal or vertical pumps, as well as magnetically driven pumps. Available in hygienic and industrial designs, Tapflo centrifugal pumps are among the most versatile pumps currently available on the market. Selected pumps can be designed for safe contact with food and are also available in ATEX explosion-proof versions.

Hose pump is a type of positive displacement pump that can be used to pump a wide variety of liquids. Tapflo industrial hose pumps use the principle of peristalsis, whereby the deformation and compression of a soft elastomer hose allows the liquid to pass through the device.

Pumps of this type are the best solution for delicate, corrosive, abrasive or dry media, including those containing solid particles. The special design, in which only the hose comes into contact with the pumped product, reduces operating costs by reducing wear on internal components and allows operation in very demanding conditions.

Tapflo submersible pumps are designed for a wide range of applications. We offer pumps for draining flat surfaces, sewage, spring water, rainwater and groundwater, as well as sludge and sediments containing solid particles. All our submersible pumps provide the performance, reliability and ease of use you need when pumping liquids consisting mainly of water. A submersible pump can be used as a permanent solution for draining water when a certain liquid level is reached, or as a mobile and easy-to-use drainage pump when unwanted water needs to be removed.

IBC containers and drums are widely used in industry – they are the simplest way to store and transport various liquids. Since many of these liquids must be mixed before use in the process, we offer a range of dedicated industrial mixers. These are simple, yet robust and safe to operate, high-quality devices. Designed and configured for common industrial applications, they enable mixing directly in the IBC container or drum. Thanks to the use of mixers, intermediate tanks can be omitted and the process becomes faster and more economical.

Tapflo hygienic valves are high-quality components made of forged 304L and 316L stainless steel. All valves in our range are serialised to ensure full traceability, even 304L valves, and are manufactured in a TÜV NORD ISO 9001:2015 approved production process. The valves are 3A and FDA certified for use in the food and dairy industries. They also meet the pharmaceutical industry’s requirements for USP Class VI elastomers.

Our offer is complemented by pump units, industrial trucks, acoustic and thermal shields, and SKID technological systems. Bearing in mind the diverse needs of our customers, we offer not only a standard range of products, but also customised solutions tailored to your requirements. Our range includes pump units of various power ratings and sizes. We are able to supply motors and gear motors for every standard pump available in our offer. If you cannot find a solution that meets your expectations in our offer, we will be happy to design and implement a customised solution.

Pumps

Other Equipment

We specialize in designing unconventional solutions tailored to the most demanding needs of our clients. We do this by introducing additional functionalities to the offered devices, increasing their mobility, adjusting their dimensions or introducing advanced safety and control systems. We offer all solutions that increase the comfort and safety of work, such as stationary and mobile systems for unloading media from tanks, barrels, IBC containers, etc.

Our mission is to provide technical solutions that guarantee proper functionality and stable operation in any environment.

Unloading drums filled with highly viscous liquids has never been easier. Our High Viscosity System (HVS) is designed to simplify this task, offering automated efficiency and exceptional product-saving capabilities. With HVS, you’ll experience a smooth unloading process, allowing you to focus on other critical tasks while achieving up to a 99% product removal rate. Say hello to effortless drum unloading with HVS.

Simplify the unloading of highly viscous liquids with our High Viscosity System Quattro-type (HVS Quattro). It is designed for high-volume applications where multiple drums (typically four) are stored on pallets. The HVS Quattro allows you to switch between the drums easily, thanks to our revolutionary articulated arm. Experience an impressive product removal rate of up to 99% which will reduce your production costs.

Unloading drums containing highly viscous liquids has become more efficient and precise with our High Viscosity System Flexi-type (HVS Flexi). This system simplifies the task, providing automation and effective product-saving features. The HVS Flexi ensures a smooth unloading experience, allowing you to concentrate on other important tasks while achieving an impressive product removal rate of up to 99%. It is suitable for applications with low to moderate volumes, such as supplying filling or packing lines directly.

Experience efficient and safe tank emptying operations with our flexible Unloading System. Designed to handle IBCs (Intermediate Bulk Containers), Mauser, Goodpack or Bag-in-Box® containers, totes, drums, barrels, and various other storage vessels, this system efficiently manages both low and high-viscosity products across a wide range of industries. Using a reliable suction lance mechanism, its innovative design and customizable control system ensure optimal performance while maintaining the highest industrial safety standards.

SLES* is an organic chemical compound with excellent cleaning and foaming properties. For this reason, it is commonly used in the production of cleaning agents, soaps, shampoos, and household chemicals. SLES is typically supplied to manufacturers of these liquids at a 70% concentration, and due to its physical properties, such a concentrated solution is difficult to process and must be diluted below 27% before being used in the production line. Our system enables continuous dilution with maximum efficiency and safety, reducing costs for the company in the long term.

Achieving precise mixing of ingredients to obtain the desired final product—while maintaining strict proportions, accuracy, and sequence—poses a major challenge for industrial manufacturers. The mixer was created specifically for this purpose. It is based on a system for diluting concentrated ingredients such as SLES. However, it has been designed in a modular way, allowing us to easily configure the system to meet actual production needs. The ingredients of the final product can be drawn from various types of tanks.

Precise and repeatable filling operations with our versatile container filler. Designed for applications requiring high accuracy and compatibility with various containers and products, from small-volume containers to large industrial drums. Filling accuracy below 0.1% ensures optimal production line performance while maintaining the highest industrial and sanitary standards. Suitable for both high- and low-viscosity products.

Responding to the individual needs of users, Tapflo offers the delivery of compact, automated process systems on a “turnkey” basis. Every demand for a non-standard pumping system is an opportunity for us to create a unique, tailor-made SKID system. Thanks to our extensive design and manufacturing capabilities, we provide solutions developed with specific functionality in mind. We offer virtually unlimited possibilities for the development of pumping units, both in terms of mechanics and automation.

Tapflo presents a series of chemical unloading systems designed for every branch of industry where liquids need to be stored, transferred, and dosed. Our solution, based on the use of a diaphragm pump, is suitable for handling viscous liquids, chemically aggressive substances, as well as those containing solid particles.

Several tank sizes can be combined with pumps in various configurations. Additional options allow the system to be tailored to specific needs. In this way, we have created the simplest and most versatile pumping solutions on the market.

saThe use of protection systems ensures not only efficient but also safe operation of diaphragm, lobe, gear, screw, and centrifugal pumps. Protection systems detect hazardous situations and respond immediately, for example by automatically shutting down the device. The pump protection solutions offered by Tapflo operate based on dedicated sensors. These include media presence sensors such as optical indicators, as well as tuning fork and capacitive sensors designed to detect the presence of a medium or to monitor its level in tanks or pipelines.

Tapflo presents a series of hygienic covers designed specifically for diaphragm pump users. The stainless steel housing is durable and sealed, effectively isolating the pump from its surroundings. Filled with a dedicated insulation mat, the hygienic covers are an ideal solution for acoustic or thermal separation of the pump. Tapflo industrial covers combine user-friendly design with high-quality materials. Built to last, they will serve reliably for years in nearly any application.

System type