In industrial production processes, it is critically important for the system to be safe and sustainable as well as operating efficiently. Especially in processes using liquid chemicals, it is vital to transfer these substances to the system with precise dosages and in a controlled manner. Acids, bases, oxidizers, disinfectants, liquid fertilizers, solvents, and similar chemicals often have the potential to directly affect both equipment lifespan and personnel safety due to their aggressive nature. Therefore, the margin of error during the dosing of these substances must be kept to a minimum.
This is precisely where dosing pumps come into play as one of the fundamental pieces of equipment managing the most sensitive phase of the process. Dosing pumps ensure that chemical liquids are introduced into the system at predetermined rates and time intervals, thereby guaranteeing process safety and contributing to the consistent maintenance of product quality.
These pumps offer superior performance in chemical dosing operations, especially with their ability to integrate into automation systems, electromechanical control mechanisms, high resistance to corrosive chemicals, and precise measurement capabilities. Additionally, because they can operate with high precision even at low flow rates, they can be effectively used not only in large-scale industrial facilities but also in small and medium-sized enterprises.
The use of dosing pumps spans a wide range, from water treatment plants to food production lines, from the chemical and petrochemical industry to the pharmaceutical and cosmetics sector, from agricultural applications to pool systems. For example, in a wastewater treatment plant, a dosing pump ensures the addition of acid or base to adjust the system's pH level. Similarly, in a greenhouse, liquid fertilizers are delivered to plant roots in precise proportions. In the food sector, disinfectants need to be systematically dosed on production lines to maintain hygiene. In all these applications, the accuracy and repeatability of dosing pumps play a critical role in the continuity of process quality.
Moreover, the use of dosing pumps is not limited to process control. They also have a significant impact on reducing operating costs, minimizing chemical consumption, reducing environmental risks, and protecting employee health. Offering a much more controlled and safe system compared to manual dosing methods makes them an indispensable part of modern production facilities.
In conclusion, dosing pumps are a strategic solution aimed at ensuring quality, safety, and sustainability in industrial processes, beyond just being a device for liquid transfer. With these features, they are among the high value-added equipment that should be part of the process management system of any business that meets today's industrial standards.
Dosing pumps are specially designed types of pumps that allow liquid chemicals to be injected into the process system in a precise and repeatable manner at a specific volumetric flow rate and predefined timing intervals. These types of pumps are critically important in industrial processes for maintaining chemical balance, ensuring the sustainability of product quality, and providing system safety. Especially in applications using hazardous, corrosive, or reactive liquids, dosing pumps enhance environmental safety and minimize employees' contact with chemicals.
Dosing pumps generally operate on the principle of an electromagnetically driven diaphragm system. Within this structure, an electromagnet is activated by impulse signals, moving the diaphragm. Thanks to the forward and backward movement of the diaphragm, the liquid taken into the pump chamber is directed in a controlled manner to the discharge line. The advantage of this system is the low number of moving parts and the ability to control the pumping process with high precision.
In more advanced models, dosing pumps operate with microprocessor-supported control boards and can automatically adjust themselves according to the flow rate required by the process. For example, when the pH level changes in a water treatment plant, the dosing pump activates to deliver the appropriate amount of acid or base chemical to the system. At the same time, different control methods such as 4-20 mA analog signal, pulse signal, and Modbus communication protocols offer remote monitoring and automatic control capabilities.
One of the most notable aspects of these pumps is their degree of precision and repeatability capacity. Dosing can be done with ±1% accuracy in many models, making dosing pumps indispensable in applications requiring high accuracy, such as pharmaceuticals, laboratories, beverage production, and chemical synthesis.
Additionally, the use of chemically resistant materials is another prominent feature of dosing pumps. Pump bodies are typically made from materials resistant to corrosive chemicals like PVC, PVDF, or polypropylene, while diaphragms are made from special elastomers like long-lasting PTFE (Teflon). This ensures the safe dosing of challenging liquids such as hydrochloric acid, sodium hypochlorite, iron sulfate, and aluminum sulfate.
Dosing pumps are also equipped with features such as variable stroke length and frequency adjustment. This allows the user to adjust the amount of liquid delivered per unit time and optimize chemical usage. Additionally, their compact design allows for easy installation in limited spaces, and their low energy consumption keeps operating costs to a minimum.
In short, dosing pumps are not just liquid transfer equipment in industrial processes; they are high-tech solutions that provide precise control, automation, chemical safety, and process efficiency. These pumps play a critical role in achieving the fast, safe, and sustainable production goals needed by today's industry.
Operating Principle
The operating principle of dosing pumps is based on an electromechanical system that enables high-precision liquid transfer. The core of this system is an electromagnetically controlled diaphragm mechanism. Thanks to this structure, dosing pumps can direct liquid chemicals to a specific process with a constant flow rate and high repeatability. In this respect, they provide much more stable and safe flow control compared to manual or conventional pumping systems.
The operating cycle typically begins with impulse signals sent from a control board. These signals activate the electromagnet in the pump. With the effect of magnetization, the steel core connected to the electromagnet moves forward, and the flexible diaphragm made of PTFE (Teflon) is pushed in the same direction.
With the forward movement of the diaphragm, the liquid in the pump chamber is compressed and pushed towards the pump head. During this time, the check valve on the suction side of the system closes, and the check valve on the discharge side opens. Thus, the liquid is directed only towards the discharge line, preventing any backflow in the system. This one-way flow ensures that the dosing amount remains constant and prevents the chemical from accidentally flowing back into the system.
Later, when the impulse signal is cut, the electromagnet loses its magnetic effect. In this case, the steel core is retracted with the help of a spring mechanism or the negative pressure of the system. The diaphragm also returns to its original position, and with this backward movement, the suction valve opens, and the discharge valve closes. Thus, the pump chamber is refilled to draw in a new volume of liquid.
This cycle can be repeated dozens of times per second, depending on the needs of the system. Additionally, parameters such as stroke frequency (stroke rate) and stroke length (stroke distance) used in modern dosing pumps can be adjusted manually or automatically according to the user's preference. For example, in an application where a low amount of chemical dosing is required, the frequency can be reduced to allow the pump to operate less frequently; conversely, in cases where rapid dosing is needed, both the stroke length and frequency can be increased to meet the system's needs.
In some advanced models, diaphragm movements can be managed not only by electromagnets but also by hydraulically supported piston systems or solenoid-controlled servo motors. This is a preferred solution, especially in industrial applications requiring high pressure and flow rates.
This operating principle of dosing pumps transforms them from being merely mechanical devices transferring liquids into dynamic system elements that provide process control. This is because every cycle that occurs in the pump progresses in an integrated manner with a series of automation in the system. This gives process engineers the flexibility to precisely control, monitor, and intervene in the dosing amount when necessary.
In conclusion, although the operation of a dosing pump may seem like a simple forward-backward movement, it is a complex engineering process that combines many parameters such as precise timing, chemical resistance, flow control, and mechanical durability. This makes safe and efficient chemical dosing possible.
Technical Features of Dosing Pumps
To meet the precision, durability, and automation capabilities required by modern production processes, dosing pumps are designed and manufactured according to advanced engineering principles. These pumps, which perform not only liquid transport but also critical functions such as process control, chemical safety, and system integrity, stand out with their advanced technical features. Below, the prominent technical characteristics of dosing pumps commonly preferred in the industry are explained in detail:
• Adjustable Stroke Speed and Frequency Control
Dosing pumps allow the precise adjustment of stroke frequency (stroke speed) through potentiometers, digital displays, or signal inputs integrated into automation systems. This allows the chemical amount delivered per unit time to be easily optimized according to the user's needs. This feature provides great flexibility, especially in situations where the dosing amount needs to be increased or decreased according to the process's needs. Additionally, some models can make instant frequency updates according to process changes with automatic feedback systems.
• Electromagnetically Controlled Drive System
The electromagnetically driven system at the heart of dosing pumps provides the forward-backward movement of the diaphragm, forming the basis of the pumping function. This system, which creates a strong magnetic field to move the steel core, allows for vibration-free, quiet, and highly precise operation. Directed by an electronic circuit, this mechanism ensures that the dosing process is stable and reliable in terms of repeatability. Additionally, this structure reduces the number of mechanical parts, minimizing maintenance requirements.
• Chemically Resistant PTFE (Teflon) Diaphragm
The diaphragm region inside the dosing pump, which operates in direct contact with the liquid, is made from materials with high chemical resistance. Typically, PTFE (polytetrafluoroethylene), known as Teflon, is used. This material shows high resistance to aggressive chemicals such as hydrochloric acid, sodium hypochlorite, sulfuric acid, chlorine, and alkaline solutions. Additionally, its flexible structure reduces the risk of deformation in long-term operations. The robustness of the diaphragm structure directly affects the overall performance and lifespan of the pump.
• Fully Plastic, Corrosion-Resistant Body Structure
Dosing pumps are often operated in environments where aggressive liquids or chemical vapors are present. Therefore, pump bodies are made from high chemical resistance plastics such as PVC, PVDF, polypropylene, or polyethylene. By minimizing the use of metal parts, both the risk of corrosion is eliminated and the total weight of the pump is reduced, providing ease of installation. This structure allows the pumps to be long-lasting against external factors.
• Ceramic Ball Valve System
The check valve mechanisms located on the suction and discharge sides of dosing pumps are often supported by ceramic balls. Ceramic material has superior properties in terms of chemical resistance and wear resistance. Additionally, its high resistance to friction allows for long-term uninterrupted and leak-proof operation in the pump. This reduces maintenance frequency, increases operational continuity, and lowers the total cost of ownership of the pump.
• Easy Installation and Vertical Mounting Option
Another advantage of dosing pumps is their compact and modular designs. Most models offer the option of vertical mounting. This provides great convenience in applications where space is limited. Thanks to non-return connection equipment, quick-connect fittings, and flexible mounting kits, the installation of the pump can be completed within minutes. Additionally, many models have alternative connection points for wall, panel, or pipeline mounting.
Where Are Dosing Pumps Used?
Dosing pumps are widely used in various sectors due to their precise dosing capability, high chemical resistance structures, and control mechanisms compatible with automation systems. The most important advantage of these pumps is that they ensure reliable, measurable, and uninterrupted delivery of liquids with different viscosities, densities, and aggressiveness to the system even at low flow rates. Especially in processes where it is necessary to inject liquids in critical proportions, dosing pumps become a component that directly affects the success of the operation.
Below, the main areas of use for dosing pumps are explained in detail:
• Water and Wastewater Treatment Plants
One of the most common areas of use for dosing pumps is the water treatment sector. Chemicals such as chlorine, hypochlorite, pH regulators (acid and base solutions), coagulants, flocculants, and anti-scalants must be added to treatment systems in correct proportions. Especially for ensuring drinking water quality, performing bacteriological control, and ensuring that facilities operate in compliance with environmental regulations, precise dosing of these chemicals is essential. Thanks to dosing pumps, these substances are continuously and steadily injected into the system, ensuring continuity in water quality.
• Agriculture, Greenhouses, and Irrigation Systems
In modern agricultural applications, dosing pumps have become an integral part of liquid fertilization (fertigation) and chemical irrigation systems. Liquid fertilizers containing elements such as nitrogen, phosphorus, and potassium must be mixed with irrigation water in specific proportions according to the needs of the plants. Performing this task correctly and evenly increases product yield and prevents chemical waste. Additionally, pesticides, fungicides, pH regulators, and nutrient elements used in greenhouse environments are automatically integrated into systems with the help of dosing pumps. This minimizes human error and ensures homogeneous application.
• Food and Beverage Industry
In the food sector, where hygiene standards are at the highest level, cleaning, disinfection, and CIP (Cleaning-In-Place) processes are carried out through dosing pumps. Surface disinfectants, acid-base solutions, foam agents, or sterilization liquids are automatically injected into production equipment, lines, or tanks. Additionally, in some processes, liquid additives included in product formulations (e.g., flavoring solutions or preservatives) are precisely mixed with the help of dosing pumps. This is critical for both product standardization and food safety.
• Chemical, Petrochemical, and Industrial Production Lines
Dosing pumps are indispensable in the chemical and petrochemical sectors for the controlled transfer of aggressive, corrosive, toxic, or reactive chemicals. Liquids such as acids, solvents, polymers, surfactants, or catalysts must be safely transferred to reaction tanks or process lines. The correct and leak-proof transfer of these chemicals is a critical requirement to prevent harm to human health and the environment. Additionally, the successful completion of chemical reactions occurring in reactors depends on the precision of the dosing process.
• Power Plants and Environmental Facilities
In energy production, chemicals must be regularly added to prevent scaling, rusting, and microbiological formations in steam boilers, cooling towers, condensate systems, and similar equipment. Thanks to dosing pumps, appropriate amounts of phosphate, oxygen scavenger, pH regulator, or anti-corrosion agents are transferred to boiler feed water. Additionally, dosing pumps play an active role in environmental facilities during processes such as wastewater recovery, sludge dewatering, and chemical treatment.
• Pool and Spa Systems
In swimming pools, aquaparks, and spa systems, automatic dosing systems play a critical role in maintaining water quality. Chlorination, pH balancing, algae prevention, and flocculant applications are carried out through dosing pumps. Thus, chemicals are added to the water in amounts that will not harm user health but will be effective. Compared to manual dosing, a safer, more efficient, and user-friendly system is obtained. Additionally, automatic adjustments can be made according to parameters such as changing water flow rate or temperature.
• Textile, Paper, and Pharmaceutical Industry
Dosing pumps are also widely used in the precise control of chemicals used in dyeing, bleaching, finishing, and treatment processes. The flawless application of liquid dyes, auxiliary chemicals, or softeners used in the textile industry is vital for product quality. Similarly, dosing pumps are used in the paper industry for dosing ink additives or cellulose chemicals. In the pharmaceutical sector, liquid formulations, solvents, or additives are dosed precisely according to GMP (Good Manufacturing Practices) standards.
Considerations When Choosing a Dosing Pump
Due to their critical functions in the system, incorrect selection of dosing pumps can lead to equipment failures and significant losses in production quality. Therefore, choosing the right dosing pump is not limited to a decision-making process based on basic parameters such as capacity and price. During the selection phase, the technical requirements of the application, the characteristics of the chemical used, the operating conditions of the system, and control needs should be carefully evaluated.
Here are the main criteria to consider when selecting a dosing pump:
1. Flow Rate (Liters/Hour - L/h)
The maximum and minimum flow rate that the pump can provide should be compatible with the chemical dosing amount required by the process. The flow rate requirement may vary depending on the type of application: For example, a laboratory application may operate with very low flow rates, while a water treatment plant may demand higher capacities.
Additionally, the pump's flow rate adjustment range should be wide so that it can adapt to both low and high-volume applications. Choosing a pump that is too large can lead to control difficulties and chemical waste, while selecting a small pump can result in insufficient dosing.
2. Operating Pressure (bar or psi)
When selecting a dosing pump, a model that can withstand the operating pressure of the system should be chosen. Each pump can safely operate up to a certain maximum pressure level. For example, installing a pump with a pressure tolerance of 6 bar in a 10 bar system will reduce the system's efficiency or cause the pump to malfunction.
Additionally, since back pressure in the system directly affects the mechanical load on the pump, pressure fluctuations in the dosing line should also be considered.
3. Chemical Properties and Compatibility
The chemical composition of the liquid to be dosed directly determines the pump's body material, seal structure, valve systems, and diaphragm material.
• Pumps containing PVDF or PTFE should be preferred for acidic solutions.
• In alkaline or solvent-based liquids, polypropylene or specially alloyed materials should be used to prevent chemical interactions.
• For abrasive or crystallization-prone liquids, ceramic valve systems or special designs are recommended.
Incorrect material selection can lead to cracking in the body, seal deformation, or sealing problems. Therefore, chemical resistance tables must be reviewed.
4. Control and Automation-Compatible Operation
How the dosing pump will be controlled also plays an important role in the selection process.
• Manually controlled pumps may be suitable for systems operating at fixed flow rates.
• Models controlled by analog signals (e.g., 4-20 mA) can automatically adjust dosing according to process variables.
• In pulse signal systems, one stroke is taken for each pulse, allowing for precise control of the flow rate.
• Advanced models supporting digital communication protocols (e.g., Modbus, Profibus, CANopen) offer remote monitoring and data collection by integrating into central automation systems.
This selection should be determined according to the facility's level of digitalization and control needs.
5. Installation Area and Mounting Type
The physical dimensions of dosing pumps should be compatible with the area where the pump will be installed.
• Vertically mounted models save space in narrow areas or systems to be wall-mounted.
• Horizontally mounted models are more suitable for some floor applications.
Additionally, the pump's flow direction, hose connection points, and valve configurations should be selected to be compatible with the system. Easy accessibility of connection elements shortens installation time and provides an advantage during maintenance.
6. Energy Consumption and Efficiency
Although dosing pumps generally have low energy consumption, energy efficiency is an important criterion in continuously operating systems. Especially solenoid-driven pumps work with short-term high energy consumption, so an evaluation should be made according to the system's energy infrastructure. Energy consumption directly affects the total operating cost of the pump.
7. Service, Spare Parts, and Technical Support
The brand of the pump, its prevalence, and access to technical service should also be considered in the selection criteria. In case of a possible malfunction, quick access to spare parts and the manufacturer's ability to provide technical support are of great importance for operational continuity. Additionally, designs that are easy to maintain should be preferred.
Why Choose a Dosing Pump?
The purpose of each piece of equipment used in industrial facilities is to make production processes more efficient, safe, sustainable, and economical. In this context, dosing pumps represent much more than just ordinary pumps that transfer liquids. Especially in processes where precise dosing of chemical liquids is required, dosing pumps provide significant advantages in many areas, from occupational safety to product quality, from environmental sustainability to automation level.
Below, we explain in a multifaceted way why dosing pumps should be preferred in modern industrial processes:
• Increases Process Safety
Incorrect dosing of chemicals can lead to process imbalances, a decrease in product quality, equipment damage, and even dangerous chemical reactions. Dosing pumps help maintain the desired chemical balance within the process continuously and automatically by operating according to predetermined flow and pressure parameters. The use of dosing pumps in critical parameters such as pH balance, oxygen control, and viscosity adjustment directly increases the stability and safety of the system.
• Reduces Chemical Consumption
One of the common problems in manual dosing operations is human errors that lead to excessive chemical usage. This not only causes resource waste but also increases environmental load. Dosing pumps serve the principle of minimum consumption with maximum effect by ensuring that chemicals are delivered in the most appropriate amount according to the need. This creates significant cost advantages in the long run.
• Increases Operational Efficiency
Dosing pumps are designed to operate continuously, steadily, and without interruption, reducing the risk of interruptions in the production process. Since advanced models can work integrated with automatic control systems, processes can self-regulate without the need for human intervention. This contributes to the more efficient use of the workforce and the prevention of time losses.
• Increases Automation Level
Within the scope of Industry 4.0 and digital transformation processes, reducing the human factor in production lines and increasing machine-to-machine communication is targeted. Dosing pumps are components that directly serve this goal.
Models that can communicate with 4-20 mA analog signals, pulse inputs, Modbus, Profibus, and similar digital communication protocols allow the process to be monitored and controlled remotely at all times. Thus, a proactive rather than reactive production model can be established.
• Provides Safety for Human Health and the Environment
Many chemical substances can exhibit toxic, corrosive, or carcinogenic effects in case of direct human contact or incorrect application. Dosing pumps ensure that these chemicals are transferred to the system within a closed circuit without direct contact with the operator.
Additionally, overflow, leakage, or spillage risks are minimized with special valve systems and leak-proof bodies. This supports both employee safety and environmental protection standards.
• Ensures Standardization in Product Quality
Especially in sectors such as food, pharmaceuticals, chemicals, and cosmetics, the ratio of liquid components in product formulations directly determines product quality. While these ratios may vary in manual dosing systems, dosing pumps guarantee the use of the same chemical amount in every production cycle. This ensures the standardization of product quality and the continuity of customer satisfaction.
• Ease of Maintenance and Long Life
Advanced dosing pumps offer long-term use with low maintenance requirements. Especially ceramic ball valve systems, PTFE diaphragms, and corrosion-resistant body materials ensure that the pump operates safely for many years. Additionally, when brands with easy access to spare parts are preferred, maintenance times are further shortened, and system downtime is minimized.
• Energy Efficiency
Dosing pumps generally have low-power, high-efficiency motor and magnet systems. Especially solenoid-driven models offer high performance with low energy consumption as they consume energy only during the impulse moment. This reduces energy costs while supporting environmental sustainability.
Conclusion
In today's industrial processes, sustainability, safety, quality, and efficiency have become fundamental performance criteria. Achieving these goals is possible not only by accelerating processes but also by meticulously controlling processes and ensuring that each component performs its function with maximum accuracy. Dosing pumps are a technological solution that occupies the heart of the system, often unseen but performing vital functions in this context.
A correctly chosen dosing pump is much more than just equipment that transfers liquid. These pumps increase the controllability of production processes by ensuring that chemical substances are dosed in the desired amount, with specific timing, and in accordance with system requirements. At the same time, they ensure the continuity of product quality, support occupational safety standards, and minimize potential negative impacts on the environment.
Especially in processes involving hazardous chemicals, criteria such as reducing manual intervention, increasing dosing precision, and integration with automation systems have made dosing pumps a necessity. An incorrectly selected or insufficient pump can lead to both short-term operational problems and long-term environmental and cost-based risks.
However, it should be noted that each industrial application has different needs. The type, capacity, control method, and material structure of the pump needed by agricultural irrigation systems, water treatment plants, chemical production lines, food factories, pool systems, and power plants differ from each other. Therefore, conducting an application-specific engineering evaluation in the selection of a dosing pump is of great importance.
As Ekin Industrial, with our experience in this field and our wide product range, we offer reliable and long-lasting solutions tailored to the needs of different sectors. The dosing pumps in our product range are designed with various flow and pressure ranges, fully compatible with different chemical substances, integrable into automation systems, and user-friendly structures. Additionally, with pre-installation consultancy, technical analysis during the selection process, commissioning support, and post-installation technical services, we are committed to being with our customers at every stage.
If you want to choose the most accurate dosing pump for the safety, efficiency, and sustainability of your process, you can contact Ekin Industrial's expert engineering team and benefit from industry-specific solution proposals, product demos, and technical support services.
Remember: Correct dosing means correct performance. Choose our high-precision, reliable, and durable dosing pump solutions to ensure the success of your business.