Masterflex Peristaltic Pumps: Complete Beginner's Guide

Peristaltic pumps represent one of the most versatile and reliable fluid handling technologies in laboratory and industrial applications. Masterflex, manufactured by Cole-Parmer, has been the industry leader in peristaltic pump technology for over 50 years. This comprehensive beginner's guide explains how these pumps work, their key advantages, and how to select the right system for your application.

What Are Peristaltic Pumps?

A peristaltic pump is a positive displacement pump that moves fluids by compressing flexible tubing with rotating rollers or shoes. The name comes from peristalsis, the biological process used by the human digestive system to move food through the intestines. This biomimetic design creates a gentle, pulsation-free fluid transfer mechanism ideal for sensitive applications.

How Masterflex Peristaltic Pumps Work

Basic Operating Principle

Compression Phase: Rotating rollers compress flexible tubing against a curved pump head surface
Fluid Displacement: As rollers rotate, they create a moving seal that pushes fluid forward
Expansion Phase: Behind the roller, tubing expands, creating suction that draws in more fluid
Continuous Flow: Multiple rollers ensure continuous flow with minimal pulsation

Key Components

Drive Motor: Provides rotational power

PMDC (Permanent Magnet DC) motors in most L/S series
Brushless motors in advanced models (07523-70)
Power ratings from 1/10 HP to 1/5 HP depending on model

Pump Head: Houses the tubing and compression mechanism

Easy-Load II design (77200-62, 77200-60, 77200-50)
Multi-channel heads for parallel processing (07519-10, 07536-04)
Quick-Load designs for fast tubing changes (07021-20)

Flexible Tubing: The only component in contact with fluid

Various materials: PharMed BPT, Tygon, Norprene, C-Flex
Sizes range from L/S 13 (smallest) to L/S 36 (largest)
Different wall thicknesses for pressure applications

Control System: Regulates pump speed and operation

Fixed-speed drives (07540-01): Simple, cost-effective
Variable analog drives (07559-00): Manual speed control
Digital drives (07522-20): Precise, programmable control
Process drives (77411-00): Industrial automation compatible

Safety Precautions

⚠️ IMPORTANT SAFETY INFORMATION

Always wear appropriate personal protective equipment (PPE) when working with chemicals or biological materials. Ensure proper chemical compatibility between tubing material and process fluids. Never operate pumps with damaged or worn tubing. Follow all applicable safety standards including OSHA guidelines for laboratory equipment operation. Disconnect power before performing maintenance or tubing changes.

Masterflex Product Lines

L/S Series (Laboratory/Small Volume)

Flow Range: 0.00001 to 3400 mL/min Applications: Precise dispensing, analytical chemistry, cell culture

Popular Models:

MK-77712-36: Precision digital console, 0.36-3400 mL/min
07522-20: Digital drive, 600 RPM maximum
7791620: Variable speed analog console
07540-01: Fixed-speed drive for simple applications

I/P Series (Industrial/Process)

Flow Range: 0.0006 to 26 LPM (0.08 to 4.5 GPM) Applications: Chemical processing, industrial dosing, large volume transfer

Popular Models:

07592-20: Digital modular drive, 20-650 RPM
77411-00: Brushless process drive
7796100: Console pump system
07549-64: Variable speed console drive

Tubing Selection Guide

Material Characteristics

PharMed BPT (Biocompatible Pump Tubing)

Biocompatibility: USP Class VI compliant
Applications: Pharmaceutical, biotechnology, medical
Features: Long service life, excellent for viscous fluids
Temperature Range: -75°F to 275°F (-60°C to 135°C)

Tygon A-60-F (Food Grade)

Certifications: FDA, 3A, NSF-51
Applications: Food, beverage, laboratory
Features: Excellent chemical resistance, autoclavable
Pressure Rating: 19 PSI (1.37 bar)

Tygon A-60-G (Chemical Dispensing)

Applications: Industrial cleaning, chemical dispensing
Features: Superior acid/base resistance, heat/UV/ozone resistant
Pressure Rating: 19 PSI (1.3 bar)
Color: Black for chemical identification

Norprene

Performance: Longest life in pressure applications
Features: Firm material, quick recovery from compression
Benefits: 20-30% longer life with high-performance variants
Applications: General pumping, high-pressure systems

C-Flex

Material: Thermoplastic elastomer
Characteristics: High tensile strength, low gas permeability
Features: Smooth surface, reduced contamination risk
Biocompatibility: USP Class VI (ADCF formulation)

Size Selection

L/S Tubing Sizes and Flow Rates (at 6-600 RPM):

L/S 13: 0.36 to 36 mL/min
L/S 14: 1.3 to 130 mL/min
L/S 16: 4.8 to 480 mL/min
L/S 25: 10 to 1000 mL/min
L/S 17: 17 to 1700 mL/min
L/S 18: 23 to 2300 mL/min

I/P Tubing Sizes: Larger bore for higher flow rates

I/P 73: Medium flow applications
I/P 82: High flow, 1/2 inch ID
I/P 88: Maximum flow capacity

Basic Operation

Setup Procedure

System Preparation
- Place pump on stable, vibration-free surface
- Ensure adequate ventilation around motor
- Connect to appropriate power supply (115V or 230V)
Tubing Installation (Easy-Load II)
- Open pump head by releasing latch
- Route tubing through head, ensuring proper alignment
- Close head firmly - spring-loaded mechanism secures tubing
- Leave slack in tubing runs to accommodate head movement
Priming
- Start pump at low speed (10-50 RPM)
- Allow system to prime until steady flow observed
- Increase to operating speed once primed
Operation
- Set desired flow rate or RPM
- Monitor for proper operation
- Adjust as needed for application requirements

Flow Rate Calculation

Flow rate depends on several factors:

Drive RPM: Higher RPM = higher flow
Tubing size: Larger tubing = higher flow
Tubing material: Affects compression efficiency
System pressure: Back pressure reduces flow
Fluid viscosity: Viscous fluids flow slower

Example Calculation: L/S 16 tubing at 100 RPM = approximately 80 mL/min (Based on 4.8 mL/min at 6 RPM, scaled linearly)

Key Advantages of Masterflex Pumps

Contamination-Free Operation

Fluid only contacts tubing interior
No valves, seals, or wetted parts to contaminate fluid
Easy to clean and sterilize
Ideal for sterile or high-purity applications

Self-Priming Capability

No manual priming required in most applications
Can lift fluids up to 8 feet (varies by model)
Handles air bubbles without losing prime
Excellent for intermittent operation

Reversible Flow

Most models support bidirectional operation
Useful for priming, purging, or process reversal
No check valves or flow restrictions
Simple direction control via motor reversing

Low Maintenance

Only tubing requires regular replacement
No internal seals or valves to service
Simple bearing lubrication (quarterly)
Typical tubing life: 100-6000+ hours depending on application

Precise Flow Control

Speed control accuracy to ±0.25% (digital models)
Excellent repeatability
Linear relationship between RPM and flow
Easy calibration and adjustment

Common Applications

Laboratory Applications

Analytical Chemistry: Reagent addition, sample preparation
Cell Culture: Media delivery, pH control, waste removal
Chromatography: Mobile phase delivery, fraction collection
Clinical Diagnostics: Sample processing, reagent dispensing

Industrial Applications

Chemical Processing: Additive injection, pH adjustment
Water Treatment: Chemical dosing, filtration
Food & Beverage: Ingredient addition, CIP systems
Pharmaceutical: API transfer, sterile processing

Frequently Asked Questions

1. How do I select the right pump model?

Answer: Consider your flow rate requirements, fluid compatibility, precision needs, and control requirements. L/S series for laboratory applications (0.001-3400 mL/min), I/P series for industrial use (0.08-4.5 GPM).

2. How often should I replace tubing?

Answer: Tubing life varies from 100-6000+ hours depending on application. Monitor for visible wear, reduced performance, or pinhole leaks. Advance tubing 8-12 inches periodically to distribute wear.

3. Can I pump viscous fluids?

Answer: Yes, peristaltic pumps excel with viscous fluids. Use firmer tubing materials (Norprene, PharMed BPT) for better performance. Reduce speed for very viscous fluids to prevent tubing damage.

4. What's the maximum pressure capability?

Answer: Pressure depends on tubing material and size. Tygon A-60 series: 19 PSI, high-pressure variants available. I/P series can handle up to 2.7 bar with appropriate tubing.

5. How accurate are the flow rates?

Answer: Digital drives offer ±0.25% speed control accuracy. Actual flow accuracy depends on tubing consistency, system pressure, and calibration. Recalibrate after tubing changes.

6. Can I use the pump for abrasive fluids?

Answer: Yes, but tubing life will be reduced. Consider using thicker-wall tubing or more abrasion-resistant materials. Monitor tubing condition closely.

7. What power supply do I need?

Answer: Most models offer universal voltage (90-260 VAC, 50/60 Hz). Check specific model requirements. Some fixed-speed drives are voltage-specific (115V or 230V only).

8. How do I prime the pump?

Answer: Start at low speed (10-50 RPM) until steady flow observed. Most pumps self-prime within 30-60 seconds. For difficult applications, manually fill tubing first.

9. Can I run the pump dry?

Answer: Brief dry running won't damage the pump, but extended operation without fluid will accelerate tubing wear. Always maintain fluid supply during operation.

10. What maintenance is required?

Answer: Minimal maintenance required. Regular tubing inspection/replacement, quarterly bearing lubrication, annual calibration verification. See maintenance guide for detailed procedures.

11. How do I clean the system?

Answer: Flush with appropriate cleaning solution, then rinse with distilled water. For biological applications, consider sanitizing solutions. Tubing is the only wetted component.

12. Can I automate pump operation?

Answer: Yes, many models offer external control inputs (4-20 mA, 0-10 V, start/stop signals). Digital models can interface with PLCs and automation systems.

13. What's the difference between precision and high-performance tubing?

Answer: High-performance tubing offers 20-30% longer life and higher flow rates. Precision tubing provides tighter flow tolerances. Both are available in multiple materials.

14. How do I calculate tubing costs?

Answer: Factor tubing price, expected life, and replacement labor. Higher-quality tubing costs more initially but often provides better value through longer service life.

15. Can I repair tubing leaks?

Answer: No, replace damaged tubing immediately. Temporary repairs may fail and cause contamination or safety hazards. Keep spare tubing in inventory.

Getting Started Recommendations

For New Users

Start with L/S series for laboratory applications
Choose digital drives for best control and features
Select tubing based on chemical compatibility first
Begin with higher-quality tubing for longer life
Establish maintenance routine from day one

System Sizing

Calculate required flow rate with 20% safety margin
Consider pressure requirements and tubing limitations
Plan for future expansion needs
Factor in duty cycle and application intensity

External Resources

Cole-Parmer Pump Selection Guide - Interactive selection tools and specifications
OSHA Laboratory Safety Guidelines - Safety requirements for laboratory equipment
Masterflex Technical Support - Application assistance and troubleshooting

⚠️ Legal Disclaimer: This guide provides general information about Masterflex peristaltic pump operation and selection. Always consult official manufacturer documentation for specific model requirements and procedures. Equipment operation should only be performed by qualified personnel following proper safety procedures and regulatory requirements.