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Home Wastewater & Exhaust Gas Treatment AAL Electroplating Pickling Case Study-2
Electroplating Pickling India Completed: November 2025

Zero-Leakage Vertical Pickling Pump:
450 L/min, 7+ Months of Continuous Operation


How an Indian electroplating facility reduced downtime and acid-related corrosion by switching to PPH vertical pumps for mixed-acid pickling circulation.

β€œMeibao pumps provide stable corrosion resistance and rarely leak during continuous operation. Compared with other brands, they need much less maintenance and have significantly reduced production downtime.”

NV
Patel
Director
AAL

The Challenge

Acid Fumes, Corrosion, and Repeated Pump Failures

AAL is an electroplating company in India. Its pickling process uses a 20% hydrochloric acid and sulfuric acid mixture at 60Β°C to remove oxide from metal surfaces.

The pickling tanks continuously circulate the acid solution through filter machines to keep the bath clean. However, the open tanks release corrosive acid fumes into the workshop. At the same time, the acid contains a large amount of iron oxide sludge, creating both chemical corrosion and particle wear inside the pump.

The Problems

Before working with Meibao, AAL had tried several pump brands, but none could provide stable operation under these conditions.

The main problems included:
● Acid fumes attacked the motor and bearings.
● Iron oxide particles caused wear on the impeller and pump casing.
● The average pump service life was only about 12 months.
● Pump failures caused repeated repairs and replacements.
● Production downtime reached around 15 days per year.
● Acid leakage occurred 2–4 times per year, creating safety and EHS concerns.

The customer needed more than a pump with better corrosion resistance. The solution also had to address acid-fume exposure, leakage, and changing tank levels.

Root Cause

Why were the previous pumps failing?
1. Acid-fume exposureOpen pickling tanks continuously released HCl + Hβ‚‚SOβ‚„ fumes. Horizontal pumps left the motor and bearing area exposed to the corrosive environment.
2. Corrosion + particle wearThe 20% mixed acid attacked wetted components, while iron oxide sludge accelerated mechanical wear.
3. Shaft-seal leakageThe shaft seal became a weak point under corrosive conditions, leading to repeated acid leakage.
4. Tank-level changesChanges in liquid level could make the horizontal pump more likely to lose stable suction conditions, increasing the risk of cavitation.

Before Meibao

Metric Before Meibao Impact
Pump Lifespan About 1 year Frequent replacement
Annual Downtime 15 days/year About 2 weeks of production lost
Leakage Incidents 2–4 times/year EHS and operator safety concerns
Annual Pump Cost $500/set Purchase + labor + downtime
Acid Concentration 20% HCl + Hβ‚‚SOβ‚„ mixed acid
Operating Temperature 60Β°C Increased corrosion and seal wear



A Vertical Pump with PPH Wetted Parts

After reviewing AAL's actual operating conditions, Meibao identified three key requirements::

Keep the motor away from acid fumes. Prevent shaft-seal leakage. Maintain stable operation when the tank level changes.
A conventional horizontal pump could not fully address these issues.Meibao therefore recommended the MIT-40VK-55NF vertical pump.Its vertical design places the motor above the liquid level, while the seal-less structure removes the traditional shaft-seal leakage point. PPH wetted parts were selected for the customer's mixed-acid application and 60Β°C operating temperature.

Why MIT-40VK-55NF?

Selection Requirement MIT-40VK-55NF Advantage
Acid-fume exposure Motor is positioned above the liquid level and away from the main fume area
Corrosive liquid PPH wetted parts are designed for corrosive chemical service
Leakage prevention Seal-less design removes the mechanical shaft-seal leakage point
Changing liquid levels Vertical submerged pump design helps maintain stable liquid intake
Circulation flow Up to 450 L/min for filter-machine circulation


Key Advantages

Vertical Design Β· Seal-Less Structure Β· Stable Operation
● Motor away from acid fumes: The vertical design keeps the motor above the liquid level, reducing exposure to corrosive fumes.
● No shaft-seal leakage: The seal-less design removes a common leakage point found in conventional shaft-seal pumps.
● Better handling of changing liquid levels: The submerged pump section stays in the liquid, helping maintain stable suction as the tank level changes.
● PPH wetted parts: The wetted components are made from PPH for corrosion resistance in the customer's mixed-acid application.


Selected Pump Specifications

Specification MIT-40VK-55NF Key Benefit
Wetted Material    PPH Corrosion-resistant wetted parts
Drive Type Vertical direct drive Seal-less pump design
Max. Flow 450 L/min Stable circulation to filter machines
Max. Head 21 m Handles system back pressure
Motor Power 3.75 kW Suitable for the application
Units Installed 6 Covers the customer's pickling system
Sealing Seal-less No mechanical shaft seal
Certification None required Standard industrial application



Project Timeline

Stage Timeline What Happened
Application Review Week 1–2 Reviewed the pickling process, liquid-level changes, and piping layout    
Production & Testing Week 3–5 Six MIT-40VK-55NF pumps were customized to match the customer's connections and fully inspected before shipment
Installation & Commissioning Week 6–7 Pumps were installed, connected, tested, and commissioned under load
Stable Operation Month 7+ Pumps have continued running without failure and are still being monitored


03  The Result


Zero Leakage and Stable Operation for 7+ Months

Since installation and commissioning were completed in November 2025, all six MIT-40VK-55NF vertical pumps have operated continuously for more than 7 months in AAL's pickling workshop.

During this period:
● 0 leakage incidents
● 0 days of production downtime caused by the pumps
● Stable circulation of up to 450 L/min
● No pump failures requiring replacement
● Significantly less maintenance compared with the previous pumps
The vertical design also keeps the motor above the liquid level, reducing its exposure to the acid-fume environment.
At the same time, the seal-less design removes the shaft-seal leakage point, helping keep the working area cleaner and reducing EHS concerns related to acid leakage.

Customer Feedback

β€œMeibao pumps provide stable corrosion resistance and rarely leak during continuous operation. Compared with other brands, they need much less maintenance and have significantly reduced production downtime.”

β€” Patel, Director, AAL

Before vs. After

Area Before: Horizontal Pumps After: MIT-40VK-55NF Result
Corrosion Wetted parts required replacement after about 12 months PPH wetted parts have operated for 7+ months with no reported corrosion-related failure Longer expected service life
Acid Leakage 2–4 incidents/year 0 incidents Leakage eliminated during the reported period
Production Downtime 15 days/year 0 days caused by pump failure during the reported period Production interruptions reduced
EHS Risk Repeated acid leakage created safety and environmental concerns No reported leakage since installation Lower leakage-related risk
Annual Pump Cost About $500/set About $200/set equivalent based on reported annual saving About $300/year saving

Note: The reported 7+ month operating period confirms the current performance of the installed pumps. Longer-term service-life improvements will be evaluated as operation continues.



Products Deployed in This Project

IT-40VK-55NF Vertical Pump

Specification

Details

Flow

450 L/min

Head

21 m

Wetted Material

PPH

Motor Power

3.75 kW

Drive

Vertical direct drive

Temperature Rating

80Β°C

Quantity

6 Units

Configuration: Standard configuration. No additional spare parts package was supplied.

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