In large-scale production plants, this is typically done using a large programmable logic controller (PLC) that controls all the pumps in the system. While smaller PLCs are available, these systems are still expensive and require custom design and programming. A simple setup can easily cost twice as much as one of our pumps.
Our new VFD controllers have a small built-in PLC to control the pump. This lets the pump be turned on or off, have its speed adjusted, or be paused and started again when needed. To set up the pump, you provide a target (pressure, flow, level, or temperature), install a sensor downstream, and the VFD automatically adjusts the pump speed to maintain that setpoint. It works like an operator watching a gauge, but faster, more precise, and able to pause and restart with the filler as needed.
These controllers work with pressure sensors (for pressurized fillers), tank level sensors, flow meters (for blending or pasteurizing), and temperature sensors (for heating or cooling via a heat exchanger). They’re also used in large buildings to supply water to upper floors.
The only additional costs are the sensor and a small amount of programming time.