The share of Pumps in the Energy used in Industries is 30%.

We have gathered with Masdaf Business Development Manager Ahmet Yılmaz to speak about the energy efficiency provided with pump selection. He has given information on the advantages provided by accurate pump selection and applications.

 Incorporated in 1977 with the principle to use water and energy in en efficient manner and therefore protecting the vital resources, Masdaf produces environmentally-friendly and innovative “liquid technologies” which provide energy efficiency.

We spoke with Masdaf Business Development Manager Ahmet Yılmaz about the energy efficiency provided by accurate pump selection and applications. Yılmaz says that “In order to provide energy efficiency in industrial facilities, the pump must be tailor-made and must be operated in the accurate spot. Otherwise, the pump will not provide the targeted energy efficiency in the industrial facility.” 

 Can you give us information on the establishment of Masdaf brand and where it is right now?

 Masdaf is a pump company established in 1977 with 100% domestic capital. It is a leading company which makes important investments in engineering, in other words, R&D and technology. We are exporting our pump technologies to more than 70 countries. With the pump production technologies in our factory build in 2006 on 40.000 m2 area including 22.000 m2 covered area in Düzce, we are minimising the risk of errors in production. Additionally, with our “Pump Test Station” to be commissioned by March 2020, we are conducting witness tests for the performances of our pumps. With this test station which is unexampled in Turkey, we plan to provide services to other pump producers in the future.

 There are two important advantages of making 100% domestic production in Turkey. Therefore, you are able to provide direct solutions to all kinds of needs and also give faster service. Actually, I want to ask you about the tailor-made solutions provided for industrial facilities. Can you give us information on your tailor-made service approach?

 Since the day it was established, Masdaf carries out its activities with a “customer oriented service approach”. Therefore, it has adopted the “tailor-made” production approach which meets the needs of customers.  Especially, in order to provide energy efficiency in industrial facilities, the pump must be tailor-made and must be operated in the accurate spot. Otherwise, the pump will not provide the targeted energy efficiency in the industrial facility.

 Although pumps have a basic operating mechanism, they have different characteristics. They consume energy in the event they transmit the specified amount of water to the targeted point or take the water higher with a certain pressure. If pumps are not operated at the point in which energy efficiency is maximised, a loss of energy occurs.

 Energy efficiency, in a sense, means that the factory is producing its own energy. What do pumps do at this point? How does the balance in accurate project and product selection maintained? What should be taken into consideration while making a selection?

 You made a very accurate statement. Benefiting from the renewable energy resources or using the wind power is very important. However, before realising this investment, the production lines of the industrial facilities must be positioned correctly. As you walk in the factory, you can see the water dripping from the taps, leaks in the compressed air line, lighting systems that are forgotten to be turned off and pumps operating unnecessarily. Even though you invest in solar energy without bringing your production facility to ideal conditions, you will not make a profit with your energy investment.

We provide economical products to our business partners since pumps have an important 30% share in the energy used in industries. Accurate pump selection is as important as making the production, however, pump selection needs a serious amount of engineering work. In the selection of an economic system, the yield of “pump, engine and inverter” is very important. System characteristic curve affects the pump selection materially. The less the losses in the system, less energy consumption is made. Especially the suitability of the diameter of the impeller running dynamically in the centrifugal pumps for the project is very important in terms of efficiency.  Therefore, a full diameter impeller should not be used where it is not necessary. At this point, our production approach which we call tailor-made steps in and only products suitable for the needs of that project are produced.

 Can you give us information on your production site and your products? What is your production capacity?

In our factory located in Düzce 1st OIZ, built on 40.000 m2 area; we have initiated our studies to render the information processing infrastructure compliant to Industry 4.0. Our investments in smart production technologies are ongoing. We have started experiencing the benefits of the investments we made. Our efficiency in production has increased by 18% since last year.

With our high-tech production facilities in Düzce, we produce end-suction pumps, inline pumps, axial detachable pumps, hydrophores, expansion tanks, fire pumps, staged pumps, process pumps, submersible pumps, column pumps, self-priming pumps and gear-type pumps. In our Headquarters located in Tuzla, we carry out the production of more specific products.

 What are the criteria you take into consideration during production?

As Masdaf, our primary target is to provide “100% customer satisfaction” under all circumstances. Therefore, I can say that our most important criteria are “quality” and “efficiency”. We prioritise quality in production, because a number of parameters are moving in parallel with quality. For example, one of the biggest expense items in the pump industry in Turkey is casting, because most of the pumps are made with casting material. Each year, the amount of casting imported by the pump manufacturers in Turkey is around 14 -15 thousand tons. I would like to highlight the word quality I just said. Because, if you are making quality production, you don’t forgive even the slightest mistake in the casting. The raw parts received from casting are returned. Working with the correct supplier in order to meet the quality standard is also very important. We produce the pump technologies we have developed with both high quality and we optimise the costs.

 You are one of the companies who put a lot of effort in terms of R&D. You are also very active in terms of exports. Are these going in parallel? Can you give us information on the developments in R&D?

 We have led innovation and technology in fluid systems for nearly half a century. We consider export as a driving force. In order to be able to compete in global markets, we continue our R&D works for the improvement of energy performances of our pump technologies at full speed.

We strive to respond all requests from abroad with our R&D team. For example, we are using different simulations in order to make our pump more efficient. We receive some requests we are not accustomed to in Turkey from abroad.  For example, there is no sugar cane production in Turkey, but there are different requests from countries producing in this field abroad. We respond to these requests by preparing special pump designs.

 Can you give us information on your export activities?

 We are taking important steps in terms of globalisation. We are completing important projects by establishing the sales and service network we established in the domestic market in the countries where we export with our world-class production approach. Currently, we are exporting to more than 70 countries. The share of exports to turnover has reached 50% level. We include new ones among the countries we export to every year and we make strong distributorship agreements in these countries.