The world leader for proven processing solutions. Gear ... - Suurmond

The world leader for proven processing solutions. 

Gear pumps and filtration systems for the polymer industry

op-quality products don’t just fall off trees. They are borne from ingenious, 

creative talent that never gives up scrutinizing and improving the product to make 

sure the end result is as good as it can possibly be. By the same token, increasingly 

cost-effective solutions can only be found by working in close collaboration with 

our customers. Success lies in devising solutions that balance considerations 

between the technical and commercial aspects at every stage of the process. 

Whether developing proprietary tools and programs or working to stringent safety 

and quality specifications, this passion for excellence creates top quality products 

and is the reason why Maag Pump Systems is the industry’s most trusted name 

for high performance polymer gear pumps and filter systems.

Gear pumps 

Optimizing the polymer process. Polymers are made, 

processed, and finished using a number of different techniques. During the man- 

ufacturing process, polymers exist as viscous melts or powders that react to 

different influences. Short exposure times, low energy input, and extremely low 

pulsation pumping are key factors for gentle treatment of the melt, and hence 

significantly higher product quality. Maag Pump Systems gear pumps meet all 

these criteria, making polymer processes even more cost-effective. 

Does your process require stable pumping of highly viscous substances at 

elevated temperatures? Or do you have to consider constant, controlled flows 

within a steady production rate process? Whatever the nature of your process, 

Maag Pump Systems products are designed to your needs, are versatile, and 

have been proven over the years to enhance process performance. 

cinox ® 

thermorex ® RT 

blendrex ® 

Screen 

changer 

polyrex ® 

viscorex ® 

micronex ® 

thermorex ® 

vacorex ® 

therminox ® cinox ® thermorex ®

Our dependability is the basis of your profitability.


Pumps for every process. Maag Pump Systems gear 

pumps are positive displacement pumps for high pressure applications that in- 

crease the efficiency of your process. They are commonly found in processes as 

reactor feed, reactor discharge, and booster pumps for low and high-viscosity 

applications. Our expertise, developed from our close collaboration with cus- 

tomers, is the key to our advanced product development. This greatly enhances 

our value, quality, and dependability in the polymer, chemical, and petrochemical 

industries. 

Maag Pump Systems guarantees flow stability and consistency, even at 

maximum outlet pressures. And thanks to optimized internal flow geometries, 

we routinely handle pumping from near total vacuum and other extremely low 

inlet pressure conditions. 

Maag Pump Systems has made a name for itself as a pioneer in the deve- 

lopment of gear pumps for the polymer industry. Reliability and quality are guaran- 

teed by modern manufacturing methods and state-of-the-art working pro- 

cesses. 

Permanent improvements mark the company’s research genius. Thanks 

to the introduction of various pump types, still better adjustments to the custo- 

mers’ specific application processes are facilitated: 

• GP for a wide range of applications 

• HV with a 25% higher transport volume compared to a GP model 

• HP for pressure differentials up to 300 bar 

Maag Pump Systems gear pumps are 

consistently at the leading edge of technology, 

increasing the cost-effectiveness of polymer 

processes 

• Excellent filling and feeding characteristics (especially from 

vacuum) due to optimized inlet geometries 

• Efficient flow channels 

• Full heating system 

• Extremely low shearing of polymer melts through special gearing 

with low squeeze output 

• Higher overall efficiency with minimal friction due to leading 

edge gear and bearing technology 

• Very low pulsation pumping, even at high and varying differential 

pressures 

• Compact design

Some typical pumping media 


• Acrylonitrile Butadiene Styrene [ABS] 

• Biopolymers 

• Cellulose acetate [CA] 

• Copolymeride [EPS] 

• Elastomers 

• Epoxy resins 

• Ethylene Propylene Diene Monomer [EPDM] 

• Oligomers 

• Phenolic resins 

• Polyacryl Nitrile [PAN] 

• Polyamide [PA] 

• Polybutyl Teraphthalate [PBT] 

• Polycarbonate [PC] 

• Polyethylene [PE-LD; PE-LLD, PE-HD] 

• Polyethylene Teraphthalate [PET] 

• Polymethylacrylate [PMMA] 

• Polypropylene [PP] 

• Polystyrene [PS] 

• Polysulphone 

• SBR Latex 

• Silicone 

• Special polymers 

• Styrene Acrylonitrile [SAN]


The gear pumps at a glance 

Viscosity 

Temperature 

Inlet pressure 

Outlet pressure 

Pump sizes 

Specific volumes 

Throughput range 

Housing and cover 

Gear shafts 

Bearings 

Shaft seals 

Pump heating 

Pressure pump heating 

vacorex ® 

For high pressure discharging from reactors 

and degassing equipment 

to 20,000 Pa s 

to 350 °C 

Vacuum to 10 bar 

to 300 bar, depends on pump type 

45 to 625 

47 to 148,210 cm 3 /rev 

depends on pump type 

50 to 165,000 kg/hr 

• Corrosion-resistant steel 

• Steel 

• Nitrided steel 

• Tool steel 


• Aluminium bronze 

• Special materials 

• Single heated mechanical seal 

• Double mechanical seal 

• vislip ® 

• vispac ® 

• viscoseal 

• Heat transfer medium 

• Temperature to 350 °C 

to 25 bar 

viscorex ® 

For large flow, medium pressure discharging 

from reactors and degassing equipment 

to 20,000 Pa s 

to 350 °C 


to 70 bar, higher pressures upon request 

10’’ to 54’’ 

3,199 to 199,060 cm 3 /rev 

Special sizes upon request 

3,000 to 100,000 kg/hr 


• Steel 








• vislip ® 

• vispac ® 

• viscoseal 



from 7 to 25 bar

thermorex ® 

For transfer and boosting of medium to 

high viscosity polymers 

to 20,000 Pa s 

to 350 °C 


to 350 bar, depends on pump type 

45 to 360 

46 to 25,200 cm 3 /rev 

depends on pump type 

50 to 50,000 kg/hr 


• Steel 








• vislip ® 

• vispac ® 

• viscoseal 



to 25 bar 

thermorex ® -RT 

For transfer of prepolymer or low 

viscosity polymer 

to 60 Pa s, higher viscosities upon request 

to 350 °C 


to 120 bar 

56 to 180 

46 to 3,200 cm 3 /rev 

100 to 35,000 kg/hr 


• Steel 








• vislip ® 

• vispac ® 

• viscoseal 

• Magnetic coupling 



to 25 bar 

cinox ® /therminox ® 


For transfer monomers, additives 

and catalysts 

1 to 10,000 mPa s 

to 320 °C 


to 25 bar 

22 to 180 

4.7 to 3,200 cm 3 /rev 

10 to 50,000 kg/hr 

• Extremely corrosion-resistant steel 


• Tool steel • NiAg 

• Synthetic carbon • Ceramic 

• Special materials • Coatings 



• Magnetic coupling 

• Gland 



to 25 bar 

This data for reference values only, consult Maag Pump Systems for specific applications

10 Gear pumps 

Shaft seals. As a pioneer in gear pump technology, Maag Pump 

Systems has been instrumental in shaping the technology and development of 

sealing systems for the polymer industry. Products such as vispac ® , vislip ® , and 

our proprietary mechanical seal are examples of this. After all, a gear pump’s 

dependability hinges on the reliability of its sealing system. 

Maag Pump Systems offer a broad spectrum of shaft seals for 

the polymer industry: 

• A diverse range of applications 

• Viscosities to 20,000 Pa s 

• Supply pressure from vacuum to 100 bar 

• Maximum leak tightness 

• Temperatures to 350 °C 

• Reliable and long lasting 

• Low maintenance

Maag mechanical seals 

Double mechanical seal for use in 

the polymer industry 

Supply pressure: Vacuum to 15 bar 

Viscosity: 0.001 to 3,200 Pa s 

Temperature: to 320 °C 

Single heated mechanical seal 

Supply pressure: Atmospheric to 10 bar 

Viscosity: 0.001 to 100 Pa s 


Full cartridge seal, jointly developed with a well known manufacturer, 

available 

vispac ® 

Combination of viscoseal with a packing 

gland and barrier fluid; robust and virtually 

maintenance free 


Viscosity: 50 to 20,000 Pa s 


Gland 

Gland with packing material from various 

suppliers 


Viscosity: 0.001 to 1,000 Pa s 


vislip ® 

Combination of viscoseal with a lip seal and 

barrier fluid; virtually maintenance free 




viscoseal 


11 

Close tolerance, grooved, counterrotating seal; 

tested over years, simple and maintenance free 

Supply pressure: Atmospheric to 100 bar 


Temperature: 350 °C 

Magnetic couplings 

Maintenance free over its entire service life 


Viscosity: 0.001 to 30 Pa s 

Temperature: to 300 °C

12 Compounding 

Pressure generation in the compounding process. 

Polymer pellets and flakes such as polypropylene and polyethylene are created 

over a number of steps. The compounding process that is the basis of this techno- 

logy is a continuous sequence of pumping, melting, mixing, and homogenizing 

to create a finished or semi-finished product from the various raw materials. 

To get a more processable pellet the basic polymer, together with any ad- 

ditives or fillers, will be fed into a mixer or extruder where they are melted, mixed, 

and then homogenized. The pump installed downstream of the mixer or extru- 

der transfers the melts for filtering and final pelletizing. The only conveying equip- 

ment needed is a gear pump such as the polyrex ® from Maag Pump Systems. 

Without gear pump 

∆T 1 

With gear pump 

∆T 2 

Pelletizer 

and filter 

Pelletizer 

and filter 

Extruder 

Pressure 

generation 

Pump Extruder 

Pressure 

generation 

Homo- 

genizing 

Plasticizing 

Homogenizing Plasticizing 

Pumping and 

compressing 

Pumping and 

compressing 

Pressure 

Temperature 

Pressure 

Temperature

Simple solutions for complex pumping systems are routine for Maag Pump Systems.

1 Compounding 

polyrex ® goes gentle on melts. Extruders without gear 

pumps require a certain length to generate the required pressure. This length 

depends on the rheological properties of the polymer melts and the extruder 

itself. However, the process invariably involves inefficiencies as some of the 

extruder’s mechanical energy is converted into non-useful heat. In the case of 

temperature-sensitive polymers, the permitted melt temperature cannot be ex- 

ceeded without the melt being permanently damaged. 

On compounding lines with a polyrex ® gear pump downstream, virtually all 

the pressure built up by the extruder or kneader is no longer needed since the 

more efficient pump has taken over the responsibility for pumping. This in turn 

can lower the melt temperatures in the extruder by as much as 30 °C, and yields 

an overall energy saving of as much as 25% for the extruder and pump together 

versus a line running with an extruder alone. 

A pressure regulator keeps the suction-side melt pressure of the polyrex ® 

gear pump constant by tracking the speed of the pump. What’s more, certain 

parameters such as bearing temperatures are continuously monitored. This 

guarantees an optimum running process at all times. 

Properties of polyrex ® 

• Gentle pumping of polymer melts 

• Preparation of different polymers melts with large Melt Flow 

Index ranges 

• Throughputs up to 100 tons per hour 

• Higher system throughput rates than without gear pumps 

• Constant throughputs independent of pressure 

• Lower energy requirements, with total annual energy savings 

as high as 25% 

• Long service life and durability 

• Reduced wear on the extruder barrels and screws 

• Shaft and bearing cooling possible, including retrofits, 

for increased output rates

The benefits of the gear pump system. Both shafts 

can be independently driven and synchronized by an external gear reducer, 

rather than having one gear driving the other. Within the pump, this reduces the 

friction between the tooth flanks and ensures even force distribution over the 

two gears. A set of separate drive shafts between the gear box and polyrex ® 

sets the backlash clearance between the gear teeth to prevent them from con- 

tacting each other. The following options are offered: 

• Gear couplings 

• Shaft and bearing cooling for increased output rates 

• Cooling equipment 

• Transfer and reduction gearbox that can be used 

in tandem 

• Lubrication oil gearbox supply units 

Bearing temperature 

Without cooling 

With shaft cooling 

100% throughput 

The benefits of the polyrex ® gear pump system are: 

• Extended life of the shafts 

• Gentle pumping of polymer melts 

• Increased reliability 

Compounding 

Retrofitable shaft and bearing 

cooling. The larger the gear pump, the greater the heat 

generated in the bearings. Excess temperatures reduce 

throughput by limiting the allowable pump speed. It can 

also damage the polymer that serves as a lubricant between 

bearings and shafts as it is pumped. Maag Pump Systems 

has developed a new generation of gear pumps with com- 

bined shaft and bearing cooling. This option has been 

proven to effectively dissipate internal pump heat build up, 

enabling higher pump speeds and throughputs. Installed 

gear pumps can also be field retrofitted to take advantage 

of this benefit. 

With shaft and bearing cooling 



15 

Pump speed or throughput

1 Filter systems 

Filtering is always important. Reliable filtration has be- 

come a given in the production process. It is growing in importance for product 

quality and, ultimately, end customer satisfaction. The degree to which products 

have to be filtered, and the rates at which they have to be filtered, is also 

increasing. That is why the filter technology team at Maag Pump Systems is 

committed to continuously improving and expanding the range of our large area 

filtration systems and candle screen changers. 

Maag filter systems are the best choice for any application that requires 

the highest filtering quality and the shortest possible residence times. Our engi- 

neers have developed methods to model your conditions, resulting in the optimum 

filter system design.

Maximum purity with flexible use of media.

1 Filter systems 

Robust, long term solutions. Minimal residence times and 

highly efficient heat exchange are hallmarks of Maag large area filter systems. 

A filter system with efficient filter media, hydraulically balanced candle filter bundle, 

and controller monitored switchover processes all serve to enhance your polymer 

filtering effectiveness. 

Maag Pump Systems can make a filter system to your particular require- 

ments. Heavy duty metal woven media offers effective protection against conta- 

mination while assuring a long service life. Our micronex ® filter elements offer 

filtrationratings from 0.5 to 200 microns. 

Maag Pump Systems supplies large area filtration systems as simplex or 

duplex systems with a switchover or diverter valve. With duplex filter systems, con- 

trollers regulate the valves to prevent hydraulic shocking during switchovers. 

The Maag duplex system design has benefited 

from long-standing, practical experience: 

• Simplified switchover (virtually bumpless) 

• Increased heat transfer 

• Minimized residence time 

• Improved sealing 

• Simplified draining 

• Simplified container replacement 

• Reliable operation 

• Improved access for maintenance 

• Automated controls available

Maag Pump Systems screen changers offer 

a host of benefits to enhance the quality of 

your production process: 

Filter systems 

Dramatically increased screen area. The sophisticated 

filtering technology of Maag Pump Systems is based on a proven piston design 

that works without seals. These single and dual piston screen changers for candle 

filter offer years of leak-free filtration. 

• Rheologically optimized flow channels 

• Material residence time less than 30 seconds 

• Candle changes in less than 10 minutes 

• Simple start-up and operation 

• Leak-free operation 

• Trouble-free venting 

• No seals or wearing parts to fail 

• A variety of installation positions and orientations available 

• Compact design 

For years they have been used in the fiber industry for effective protection 

against gels and contaminants in PET, PA, and similar thermoplastics. The effec- 

tive screening area of the candle filter screen changer is about 60 times larger 

than that of a flat screen. Screen areas as large as several square feet or square 

meters mean longer service life with longer intervals between back flushing or 

removal and cleaning, less pressure loss, and deeper filtration that captures soft 

particles such as gels. A screen changer fitted with candle filters can also add to 

the service life of the spin-packing on a fiber web and enable high-performance 

filtering not otherwise possible with flat screen packs. 

1

20 Total solutions 

The total is greater than the sum of individual 

parts. Maag Pump Systems manufactures its gear pumps and filter systems 

with considerable attention to detail. Equally important, however, is having the 

appropriate support equipment to make the individual parts into a practical whole. 

In the interest of offering such a solution, Maag Pump Systems also offers the 

following 

Heat exchangers 

Our blendrex ® heat exchangers can be used either 

as pre-heaters or coolers. They control polymer melt 

temperatures at viscosities as high as 10,000 Pa s. 

Alternating right- and left-hand helical elements 

that form a unique pattern of simultaneous flow 

division and radial mixing. These mixers are particularly 

effective with uneven temperature distributions 

and insufficiently mixed color concentrations. 

Diverter valves 

The divex ® diverter valve is a patented 3-way valve. 

Used in a duplex filter system, it allows filter vessels 

to be changed without interrupting the process. 

This valve is also used in pelletizing, film, and fiber 

processes as a switchover valve for activating 

pumps, extruders, pelletizers, and other equipment. 

Static mixers 

Our standard, pre-engineered thermoprofilers or 

static mixers provide cost-efficient mixing of at 

least two fluid streams. Our custom designed 

blendrex ® mixing elements continuously split the 

delivered flow, remix it, homogenize it, and symmetrically 

set the melt’s temperature gradients to 

assure even mixing, uniform additive dispersion, 

and temperature profile consistency.

1 Maag Pump Systems builds 

the viscorex ® ", still the world’s largest 

gear pump for discharging polymers 

1 0 First studies of gears and gear profiles 

by Max Maag (1 3 –1 0) 

1 13 Founding and construction of Max Maag gear 

plant in Zurich, Switzerland 

1 2 First gear pumps manufactured 

1 5 Construction of the pump plant near Zurich 

1 1 Division of Maag Zahnräder AG, formation of 

Maag Pump Systems AG, Zurich 

1 Certification to ISO 001 Quality Assurance System 

1 Integration into Textron Inc. 

1 Acquisition of the Fluid Handling Division of LCI 

2000 Acquisition of EFC Filtration Systems Inc. 

2001 Acquisition of Wil-Man Polymer Filtration GmbH 

200 Maag Pump Systems AG relocates from 

Zurich to Oberglatt, Switzerland 

200 Integration into Clyde Blowers Ltd. 

An Early Pioneer. Max Maag, who founded the subsequent 

Maag gear plant, saw the potential of gear wheels from the outset. Besides his 

engineering company he established a manufacturing plant for gear wheels, and 

in 1928 he delivered his first gear pump. Since then, his company consistently 

expanded and fabricated innumerable gear pumps that have been and are still 

being used successfully – from the smallest pump in the low-pressure range to 

huge units that can move up to 100 tons of polymer per hour. No other pump 

company in the world can lay claim to such an accomplished history or record 

of experience.

22 After Sales 

Global support. A worldwide service network of knowledgeable 

technicians are available on a 24/7 basis. These specialists understand process 

and machine technology, rheology, and materials handling, which enables them 

to analyze complex conveying problems and find technical solutions. This, cou- 

pled with locally stored spare parts, guarantees easy access and fast availability. 

Installation, commissioning, maintenance, and service activities are handled by 

our factory specialists as well. 

Maag Pump Systems also supplies the 

chemical, thermoplastics, and elastomers 

industries with quality gear pumps and 

filtration systems, controllers, and other 

accessory components. 

Maag Pump Systems offers you more: 

Gear pumps for chemical and industrial 

processes – leaders in demanding 

applications 

Any company that has made innovation a tradition 

is the right partner for meeting the challenging con- 

ditions of your chemical and industrial applications. 

Gear pumps made from modular components com- 

bine strong performance with attractive prices and 

short lead times. Whatever your requirements, when 

it comes to pressure, temperature, or viscosity, 

Maag Pump Systems has the right gear pump for 

you. 

• Worldwide service network of factory direct personnel, agents, 

and OEMs 

• Qualified technicians for installation, commissioning, 

maintenance and repairs 

• Experienced sales personnel, who can assist with your technical 

issues at any time 

• Certified Quality Management to ISO 9001 

• Internal and external training programs 

• Direct assistance with answers to problems 

• Customized viscosity measurements, flow simulations, 

and application oversight by experienced application engineers 

Gear pumps, screen changers and 

controllers for the extrusion industry – 

leaders in productivity. 

Using leading edge technology pays off. Innovative 

solutions that cut your operating costs and in- 

crease your plant’s lifespan are drawn from 

decades of experience and continuous improvement. 

Other Maag products form the ideal complement 

for gear pumps in extrusion applications. 

High-performance screen changers make your 

end products cleaner, and well-engineered control 

and measuring technology optimizes your processes.

Switzerland 

Maag Pump Systems AG 

Aspstrasse 12 

8154 Oberglatt 

Schweiz 

Phone +41 44 278 82 00 

Fax +41 44 278 82 01 

welcome@maag.com 

www.maag.com 

Singapore 

Maag Pump Systems Pte Ltd 

25 International Business Park 

No. 04-73 German Center 

609916 Singapore 

Phone +65 65 62 87 20 

Fax +65 65 62 87 29 

MaagSingapore@maag.com 

www.maag.com 

USA 

Maag Pump Systems Inc. 

1500 Continental Boulevard 

Charlotte, NC 28273 

USA 

Phone +1 704 716 9000 

Fax +1 704 716 9001 

MaagAmericas@maag.com 

www.maag.com 

France 

Maag Pump Systems SAS 

111, Rue du 1er Mars 1943 

69100 Villeurbanne 

France 

Phone +33 4 72 68 67 30 

Fax +33 4 72 68 67 31 

MaagFrance@maag.com 

www.maag.com 

Germany 

Maag Pump Systems GmbH 

August-Kümpers-Strasse 9 

48493 Wettringen 

Deutschland 

Phone +49 2557 92 80 0 

Fax +49 2557 92 80 20 

MaagGermany@maag.com 

www.maag.com 

China 

Maag Pump Systems Shanghai 

Room 1204A, Silver Tower 

218 South Xi Zang Road 

200021 Shanghai, China 

Phone +86 21 6334 3666 

Fax +86 21 6334 3336 

MaagChina@maag.com 

www.maag.com 

Italy 

Maag Pump Systems S.r.l. 

Viale Romagna 7 

20089 Rozzano (MI) 

Italia 

Phone +39 02 575 932 1 

Fax +39 02 575 932 32 

MaagItaly@maag.com 

www.maag.com 

Brugger Hüsser gestalten, Züri ch. polymer_eng_12_08_eu

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