Abrasive materials contain solid particles that can quickly wear down standard pumping equipment. These include silicone sealants with mineral fillers, construction mastics with aggregates, adhesives containing ceramic or metal particles, and heavy greases reinforced with solid lubricants. These fluids need specialized handling to avoid premature pump damage and maintain reliable performance.
Pumps not designed for abrasive materials wear out quickly. Plungers and cylinders degrade faster, flow becomes inconsistent, seals fail more often, and leaks increase. These issues lead to unplanned downtime, higher maintenance costs, and wasted material — all of which hurt your bottom line.
1. Choose equipment designed for abrasive duty
Not all pumps are built to handle abrasive materials, so it’s important to choose equipment specifically designed for this type of service. Look for abrasive duty pumps with hardened or ceramic coated internal components that resist wear and protect high friction surfaces. ARO piston pumps use ceramic coated plunger rods and cylinder tubes. These reinforced components help maintain sealing integrity, reduce internal friction, and extend service intervals under abrasive conditions.
2. Match pump pressure, flow, and technology to the material
Correctly matching pump pressure and flow rate to the material is critical. Oversized pumps can increase internal velocity and wear. Undersized pumps may struggle to maintain steady flow, leading to pressure spikes and quality issues.
Material viscosity plays a key role in pump selection. Low- to medium-viscosity abrasive fluids, such as coatings or thinner adhesives with fillers, benefit from piston pump designs that deliver smooth, uniform flow with minimal shear. Higher-viscosity materials, including construction sealants, mastics, and heavy greases, require pumps capable of maintaining prime and generating sufficient pressure without disrupting material consistency.
3. Maintain smooth, consistent flow
Flow instability increases internal stress and accelerates wear when handling abrasive materials. Pressure fluctuations and pulsation can also affect application quality, especially in extrusion and dispensing processes. Pump designs with controlled displacement help maintain steady flow, protecting components while improving repeatability at the application point.
4. Implement proper system design
Beyond pump selection, your complete system design affects performance with abrasive materials.
5. Establish regular maintenance schedules
Even the most durable equipment requires maintenance when handling abrasive materials:
Our piston pumps are designed with serviceability in mind—accessible plungers and standardized service kits minimize downtime during routine maintenance.
Catching equipment wear early prevents costly failures and unplanned downtime. Watch for these indicators that your pump may be experiencing abrasive-related issues:
If you notice any of these signs, inspect your equipment promptly. Early intervention with maintenance or component replacement prevents minor wear from becoming major failures.
Choose pumping equipment based on:
ARO piston pumps are engineered to support manufacturers working with sealants, adhesives, and other abrasive, high-viscosity materials. Technologies such as 2-Ball and Chop-Check piston pumps address different viscosity ranges and application needs. Both pump types are available as complete, ready-to-install packages, helping reduce setup time and ensure system compatibility from day one.
2-Ball piston pumps are designed for uniform, consistent fluid delivery. They handle a variety of applications, from simple transfer of fluids to the extrusion of low- to medium-viscosity materials.
Chop-Check pumps are designed to move medium-to-high viscosity fluids in difficult applications.
When evaluating pumping equipment for abrasive materials, consider the complete cost picture beyond the initial purchase price. A standard pump might cost less upfront, but frequent seal replacements, worn plunger rods, and unplanned downtime quickly add up. Equipment designed for abrasive service typically requires replacement parts half as often.
Factor in your labor costs for maintenance, the value of lost production during repairs, and material waste from inconsistent flow. Many operations find that abrasive-rated equipment pays for the price difference within the first year through reduced downtime alone. The longer service intervals and extended component life continue delivering savings throughout the equipment's lifetime.
Every operation has unique requirements based on materials, production volumes, and application methods. Working with experienced fluid handling specialists ensures you select equipment matched to your specific needs.
Our technical team brings decades of experience supporting operations that work with challenging, high‑viscosity and abrasive materials. We review your complete application requirements—from material properties to production goals—and provide tailored recommendations that maximize reliability and minimize total cost of ownership.
Whether you're handling thick construction sealants, adhesives and sealants, or heavy industrial lubricants, the right pumping solution keeps your operation running smoothly.
Contact us to discuss your abrasive material handling challenges, request a quote for your specific application, or find a local dealer for hands-on support.
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Raw materials are your largest production cost—but how much might you be losing to waste? Many sealant and adhesive manufacturers experience hidden material losses from inefficient pumping systems, costly changeovers, and unexpected downtime. This guide explores practical strategies that could help minimize waste in material transfer, reduce cleaning time during batch changes, and prevent equipment failures. Optimizing your material handling equipment may lower disposal costs, improve product quality, and increase production capacity.
Your formulation hasn't changed. Your process parameters look identical. Yet one batch passes quality control with flying colors while the next gets rejected for inconsistent viscosity or trapped air bubbles. The real issue? Unstable flow during transfer and dispensing.
Air-operated piston pump technology uses compressed air to move a piston back and forth in a cylinder. During the intake stroke, air goes to one side of the piston. This creates pressure that makes the piston pull back.
ARO offers hydraulic piston pumps and pneumatic piston pumps for a variety of applications. Find the right piston pump solution for a range of viscous fluids.
Chop-Check pumps are designed to move medium-to-high viscosity fluids in difficult applications.
2-Ball piston pumps are designed for uniform, consistent fluid delivery. They handle a variety of applications, from simple transfer of fluids to the extrusion of low- to medium-viscosity materials.
Reach out to us