Vertical Pumps for Electroplating Pickling & Surface Finishing
Zero-Leakage Vertical Pumps for Mixed-Acid Pickling: 5,800 L/h Circulation, 7+ Months Uninterrupted
Meibao pumps deliver stable corrosion resistance and rarely leak during continuous operation. The vertical structure keeps the motor above the liquid surface, helping protect it from acid fumes. Unlike horizontal pumps, they are less likely to draw in air when the liquid level changes. The after-sales service is also very good.
Case Study: Vertical Pumps for Electroplating Pickling & Surface Finishing
How an Indian electroplating facility reduced downtime, acid-fume corrosion, and leakage across pickling, anodising, and zinc-nickel plating lines by switching to FRPP vertical pump
Multiple Process Lines, Multiple Chemicals, and Heavy Acid Fumes
The customer is an electroplating company in India with several surface-treatment processes, including pickling, anodising, and zinc-nickel plating.
Different process lines use hydrochloric acid, mixed hydrochloric/sulfuric acid, and other plating solutions. Operating temperatures can reach 60–65°C. At the same time, the open pickling tanks continuously release corrosive acid fumes, creating a highly corrosive environment throughout the workshop.
The production system had 11 tank positions that required continuous liquid circulation to filter machines. The pumps therefore had to operate reliably under demanding chemical, temperature, and installation conditions.
The Main Problems
Before switching to Meibao, the customer had tried several pump brands, but the pumps could not provide stable long-term operation in this environment.
1. Acid-Fume Corrosion
The workshop contained high levels of corrosive HCl + H₂SO₄ fumes. On conventional horizontal pumps, the motor and bearing areas were exposed to the fumes for long periods, leading to frequent electrical and mechanical problems.
2. Chemical Corrosion and Particle Wear
Iron oxide sludge in the acid solution, together with the chemicals used in the plating processes, attacked the wetted parts and increased wear.
3. Repeated Leakage
The shaft seal was a weak point in the previous horizontal-pump setup. Exposure to corrosive fumes and liquid could damage the seal, resulting in 2–4 acid leakage incidents per year.
4. Changing Liquid Levels
Changes in tank level could cause horizontal pumps to draw in air, increasing the risk of unstable operation and cavitation.
As a result, the average pump service life was only about 12 months. Pump failures required maintenance or replacement and caused around 15 days of production downtime per year.
Root Cause
Why were the previous pumps failing?
1. Multiple corrosive media
The production lines handled pickling acids, anodising solutions, and zinc-nickel plating solutions. The pumps needed to handle several demanding chemical environments.
2. Acid-fume exposure
Open tanks continuously released HCl + H₂SO₄ fumes, exposing horizontal-pump motors and bearings to a corrosive environment.
3. Shaft-seal problems
The shaft seal was a major potential leakage point under corrosive operating conditions.
4. Solid particles in the liquid
Iron oxide sludge increased wear and could further affect sealing components.
Before Meibao
Metric | Before Meibao | Impact |
Pump Lifespan | About 1 year | Replacement required across 11 stations |
Annual Downtime | 15 days/year | Significant production time lost |
Leakage Incidents | 2–4 times/year | EHS and operator safety concerns |
Annual Equipment Cost | $500/set | Purchase + labor + downtime |
Medium Concentration | 20% | Mixed HCl + H₂SO₄ |
Operating Temperature | 60–65°C | Increased corrosion and seal wear |
Process Lines | Pickling / Anodising / Zn-Ni Plating | Multiple corrosive media |
One Vertical Pump Solution for 11 Process Stations
After reviewing the customer's operating conditions, Meibao found that the problem was not simply about replacing one pump with another.
The customer needed a solution that could support pickling, anodising, and zinc-nickel plating, handle different corrosive liquids, reduce exposure to acid fumes, and address the leakage problems associated with shaft seals.
For this reason, Meibao recommended the MFL Series vertical pump and replaced the existing pumps at all 11 tank positions.
Why the MFL-206-MNX-F-1?
- Vertical design: Keeps the motor above the liquid level and away from the main acid-fume area.
- FRPP wetted parts: Fiber-reinforced polypropylene provides corrosion resistance for the customer's chemical applications.
- Seal-less design: Removes the mechanical shaft seal as a common leakage point.
- One pump model across the lines: Simplifies operation and spare-parts management.
Product Selection
Selection Requirement | MFL-206-MNX-F-1 Advantage |
Vertical installation | Motor is positioned above the liquid level and away from the main fume area |
FRPP wetted parts | Fiber-reinforced polypropylene for the customer's pickling, anodising, and zinc-nickel applications |
Seal-less design | Removes the mechanical shaft-seal leakage point |
Changing liquid levels | Submerged pump design helps maintain stable liquid intake |
Stable circulation | 5,800 L/h circulation for the filter machines |
One standard model | 11 identical pumps simplify operation and spare-parts management |
Key Technical Advantages
Vertical Design · Seal-Less Structure · One Solution Across the Lines
· Motor away from acid fumes: The vertical design keeps the motor above the liquid level, reducing exposure to corrosive fumes.
· No mechanical shaft seal: The seal-less design removes a common leakage point.
· Stable operation with changing liquid levels: The submerged pump section remains in the liquid, helping maintain stable liquid intake.
· FRPP wetted parts: Fiber-reinforced polypropylene combines corrosion resistance with good mechanical strength for demanding chemical service.
· One model for all 11 stations: Using the same pump model across the process lines makes operation and maintenance simpler.
Selected Pump Specifications
Specification | MFL-206-MNX-F-1 | Key Benefit |
Wetted Material | FRPP (Fiber-Reinforced Polypropylene) | Corrosion-resistant for mixed acid, anodising, and zinc-nickel solutions |
Drive Type | Vertical direct drive | Seal-less pump design |
Max. Flow | 5,800 L/h | Stable circulation to filter machines |
Max. Head | 14 m | Handles system back pressure |
Motor Rating | 1 HP (750 W) | Suitable power for the application |
Units Installed | 11 units | Covers all process lines |
Sealing | Seal-less, vertical submerged design | Removes the mechanical shaft seal |
Certification | None required | Standard industrial application |
Project Timeline
Stage | Timeline | Details |
Application Review | Week 1–2 | Reviewed the three process lines, operating conditions, and piping layout |
Production & Testing | Week 3–5 | 11 MFL-206-MNX-F-1 pumps customized to the customer's connections and inspected before shipment |
Installation & Commissioning | Week 6–7 | Installed all 11 pumps, connected the piping, and completed commissioning and load testing |
Stable Operation | Month 7+ | Continuous operation without reported pump failure; performance continues to be monitored |
Zero Leakage, Zero Pump-Related Downtime, and $1,000 in Annual Savings
Since the pumps were commissioned in April 2026, all 11 MFL-206-MNX-F-1 vertical pumps have operated across the customer's three surface-treatment process lines.
During the reported operating period, the pump system has achieved:
- 7+ months of continuous operation
- 0 reported leakage incidents
- 0 pump-related production downtime
- Stable circulation of up to 5,800 L/h
- Lower maintenance requirements compared with the previous pumps
- Approximately $1,000 in annual equipment-related savings
The vertical design keeps the motor above the liquid surface, helping reduce exposure to acid fumes. The seal-less design also removes the mechanical shaft seal as a common leakage point.
Ambarish, the Managing Director, also highlighted Meibao's after-sales service as an important part of the overall experience.
Customer Feedback
“Meibao pumps deliver stable corrosion resistance and rarely leak during continuous operation. The vertical structure keeps the motor above the liquid surface, helping protect it from acid fumes. Unlike horizontal pumps, they are less likely to draw in air when the liquid level changes. The after-sales service is also very good.”
— Ambarish, Managing Director
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