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In the fast-paced world of electronics manufacturing, safe and efficient chemical handling is a critical requirement. At the core of printed circuit board (PCB) production, especially in large-scale facilities, is the need for reliable transfer systems that can manage aggressive liquids without compromising worker safety and operational uptime.
One key example is the use of diaphragm pumps in chemical transfer operations at the world’s largest PCB copper-clad laminate and printed circuit board production base, the Kingboard Group. Ovell Pump's 2-inch polypropylene diaphragm pumps and 2-inch stainless steel diaphragm pumps have become essential tools in managing fluids like caustic soda and hydrochloric acid.
These pumps offer essential benefits: chemical resistance, safe air-powered operation, and minimal maintenance. In this case study, we explore why diaphragm pump technology is ideal for demanding chemical applications and how it enhances operational performance in the electronics industry.
When dealing with hazardous or corrosive liquids, choosing the right type of pump is more than a matter of preference—it’s a matter of safety, reliability, and regulatory compliance.
So, what is a diaphragm pump? Put simply, it's a type of positive displacement pump that uses a flexible diaphragm to move fluid. It’s a go-to choice when precision, safety, and durability are required.
Whether using an air operated diaphragm pump or an electric diaphragm pump, this design stands out because it offers:
• A sealed pumping chamber that prevents leaks and keeps operators safe from contact with dangerous liquids.
• Material compatibility with strong chemicals, making it a smart fit for tasks like transferring caustic soda or hydrochloric acid.
• Air-powered options eliminate the need for electricity, reducing fire hazards in flammable or moisture-prone environments.
In short, diaphragm pumps bring a level of safety and versatility that traditional centrifugal or rotary pumps may not match, especially in high-risk industrial settings.
1. Built for Harsh Chemical Environments
Diaphragm pumps are designed with rugged materials that can stand up to tough conditions. Whether they’re transferring acidic solutions, strong alkalis, or other aggressive liquids, these pumps are built to handle the challenge. Materials like polypropylene and stainless steel are commonly used for their chemical resistance, while PTFE diaphragms ensure long-term reliability across a wide range of applications.
2. Safe Operation with Air Power
One of the standout features of many diaphragm pumps is their ability to run on compressed air. This removes the need for electrical wiring in damp or hazardous areas, reducing the risk of sparks and making installation safer and easier. For facilities dealing with chemicals, this air-powered setup is a big plus.
3. Handles a Wide Range of Fluids
From thin, watery liquids to thick, sticky substances, diaphragm pumps can manage them all. Their flexible design allows for reliable performance across a mix of flow rates and viscosities, which is especially useful in industrial settings where fluid types can vary from task to task.
4. Easy to Maintain and Repair
Diaphragm pumps are known for their simple, practical design. With minimal moving parts and user-friendly construction, maintenance is straightforward. Diaphragm replacement is quick, and routine servicing doesn't require specialist skills or tools—saving time and reducing downtime.
In one of the busiest electronics manufacturing hubs in the world, Ovell Pump's 2-inch diaphragm pumps are critical tools for safely transporting aggressive chemicals across production lines.
At this facility, two types of pumps are used:
• The A20SSTTS pump, made of stainless steel, handles caustic soda—a highly alkaline substance used in the production process. It transfers the chemical from a bulk storage tank to a workshop environment where it's used in cleaning and surface preparation.
• The A20PPTTP pump, made with a polypropylene casing, transfers hydrochloric acid, another highly reactive chemical needed for etching and processing PCB materials.
Both pumps are installed between storage and production zones, using flexible pipework and air lines. Their job is to ensure a steady, controlled flow of chemicals without exposing workers or systems to unnecessary risk. They provide smooth operations, fewer leaks, and higher confidence in safety protocols.
1. Improved Chemical Handling Safety
The sealed, air-powered design of these diaphragm pumps minimises operator exposure to dangerous substances. This results in a safer work environment and better regulatory compliance.
2. Reduced Maintenance Demands
With long-lasting diaphragms and corrosion-resistant housings, there’s less need for frequent maintenance. This translates into lower labour costs and higher equipment uptime.
3. Enhanced System Flexibility
These pumps integrate easily with both new and existing infrastructure. Whether it's a new line or a retrofitted section of the plant, they fit in without fuss.
4. Reliable Operation in Harsh Conditions
From extreme pH levels to temperature fluctuations, diaphragm pumps continue to perform reliably. This consistency helps maintain the pace of high-volume manufacturing without chemical-related delays.
5. Cost-Effective Performance
Thanks to their long lifespan and minimal need for intervention, diaphragm pumps offer a strong return on investment. Fewer failures mean less lost product and downtime.
When it comes to moving harsh chemicals in industrial environments, the diaphragm pump stands out for its unique blend of safety, durability, and efficiency. In the case of the Kingboard Group’s PCB manufacturing facility, Ovell Pump's 2-inch models constructed with polypropylene and stainless steel are essential tools in managing caustic soda and hydrochloric acid transfer.
These pumps offer a proven, flexible, and easy-to-maintain solution that supports large-scale operations without sacrificing safety or performance. For facilities seeking to improve their chemical handling processes, diaphragm pumps are a smart, trusted investment.
Can the same pump be used for both caustic soda and hydrochloric acid?
It’s technically possible, but not advised. Using separate pumps for each chemical prevents cross-contamination and ensures each pump is matched to the fluid’s specific handling needs.
How often should diaphragm pumps be checked in a facility like a PCB plant?
Routine checks are recommended—usually weekly for high-use systems. This helps catch wear early and keeps operations running smoothly.
What happens if a diaphragm pump stops during a chemical transfer?
If the pump stops mid-transfer, it can disrupt the production line and create safety concerns. Having backup pumps or a monitoring system in place helps avoid downtime.
Why use both polypropylene and stainless steel pump casings in the same facility?
Different casings suit different chemicals. Polypropylene works well with many acids, while stainless steel offers better durability for strong bases like caustic soda.
Do diaphragm pumps need to be cleaned between uses?
Yes, especially when switching between tasks or during maintenance cycles. Cleaning helps avoid residue build-up and maintains safe, efficient performance.
