The Swiss subsidiary of Dutch firm DSM Nutritional Products AG makes use of the spray drying methodology when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The procedure uses pump technology to convey numerous emulsions into a twig tower, where they’re dried into powder. But the feed and booster pump that was getting used proved to be an uncertainty factor as a outcome of the diaphragm required for the pumping process tended to tear when the pump was began up. Generally, such manufacturing interruptions could be corrected through immediate maintenance and restore work.
However, it is extremely expensive to replace a diaphragm or a whole system. DSM was seeking an alternate and at last made a find after they talked to the pump experts at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower software. The drive unit includes a protected start-up mode that retains the diaphragm positioned in the impartial position, and continuous regulation utilizing an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is easy to meet the food industry’s stringent hygienic provisions.
100 PERCENT INTEGRATION
“Pump know-how plays a central position in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions comprise substances such as vitamins, carotenoids, or polyunsaturated fatty acids as lively components,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As a half of the process chain, each pump is 100 percent integrated into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With the earlier system, the danger of unexpected interruptions to this process couldn’t be ruled out. As a outcome, the totally different emulsions could not be processed additional. In different phrases, it was not attainable to dry them into powder. The pump diaphragm was the explanation: it was usually too delicate to withstand the stress placed on it when starting up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and typically meant that trouble-free operation could not be guaranteed.
FINDING THE RIGHT PARTNER
In the course of trying to find a dependable various, DSM got in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We were already familiar with Lewa Nikkiso Switzerland as a supplier of sturdy methods with long service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it will be smart to join forces with the consultants from Lewa and give you a design to resolve the technical problems,” says Ibald.
DSM is dedicated to continually enhancing its processes and investing in technology. This commitment, along with prior experience with the quick service lives of the previous pumps, led DSM to put special give consideration to reliable perform and a robust design through the challenge planning part. The record of necessities also included a considerable variety of stringent hygienic provisions that needed to be fulfilled.
“Certain meals have provisions concerning microbiological purity which may be many occasions extra stringent than those for producing other food merchandise,” explains Ibald. “This meant that the model new feed and booster pump had to meet these tougher situations and each type of contamination needed to be dominated out to supply the widest potential variety of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a world science-oriented firm that’s particularly lively in the areas of diet, health, and sustainable residing. DSM’s mission is to improve the lives of all. Products and options from DSM address a few of the world’s largest challenges whereas concurrently creating economic, environmental, and societal worth for all its stakeholders—including clients, staff, shareholders, and society at massive.
DSM delivers revolutionary options for the nutrition, animal nutrition, personal care and aromatics, medical merchandise, environmentally pleasant products and applications, as nicely as new mobility and interconnectivity.
DSM and its affiliated corporations employ greater than 23,000 folks and generate an annual net turnover of approximately 10 billion euros. The company was based in 1902 and is listed on the Euronext Amsterdam stock change.
For more data, go to www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to on the company premises to suppose about the spatial and technical parameters, Lewa Nikkiso Switzerland recommended a kind G3F triplex course of diaphragm pump for the spray tower utility. This pump features a fully secure start-up operation, since a spring constantly holds the integrated sandwich diaphragm situated in a neutral position.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being broken while the pump is starting up, growing system availability substantially. And the Lewa triplex is controlled utilizing a stress aid valve that’s installed within the hydraulic part and could be configured for the particular situation. Therefore, the pump may be adapted to completely different operational situations so as to prevent any overloads which will come up. This ensures that the unit has a long service life and smooth common operation for the whole system.
THE POWER OF DESIGN
In addition to the pressure aid valve and the spring management, the design of the diaphragm additionally performs an important function in ensuring reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extraordinarily long-lasting. They are linked to one another by way of positive interlocking in the course of the discharge stroke and mechanical force-fitting during the suction stroke.
This makes the pump hermetically tight and successfully prevents external contamination. As an additional security feature, the DPS monitoring system from Lewa repeatedly screens the condition of the diaphragm. The monitoring unit promptly shows any harm to the device that leads to elevated pressure in the diaphragm area.
This makes it potential to hold out preventive maintenance and restore work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s often pointless to modify the pump off right away, which implies that neither the pumping process nor spray drying are negatively impacted to a significant extent. If damage to a diaphragm is detected, manufacturing can proceed without any issues up to a deliberate upkeep cease. The elements can then be replaced shortly and simply by releasing the cassette for the assembly.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the method diaphragm pump does more than simply guarantee reliable continuous operation. It is also a central part for fulfilling the stringent hygiene provisions that the spray tower utility is subject to. The Lewa triplex maintains a hermetically tight space without dynamic seals, guaranteeing utterly clear and aseptic manufacturing conditions. All pump heads that come into contact with the product are also electropolished, which makes it attainable to make sure FDA-compliant pump operation.
Because the pump may be cleaned in place (CIP) utilizing totally different alkaline and acidic brokers and with out prior dismantling, it’s attainable to meet the particular necessities for baby food as well. The provisions for baby food are 1,000 occasions extra stringent than those for different merchandise within the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we were able to rule out any contamination of the pumped medium and clearly meet the required hygiene normal.
QUICK RESPONSE TIMES AND WELL-FOUNDED EXPERTISE
The first quote was received in June of 2018 and in September of the same year, DSM Nutritional Products AG placed an order for the triplex course of diaphragm pump. In weksler ea14 since April 2019, the pump has become an indispensable a part of manufacturing on the plant in Sisseln.
“In every part of the challenge, Lewa Nikkiso Switzerland demonstrated fast response occasions and well-founded experience, which made a key contribution to implementing the challenge successfully,” says Ibald. “Our specifications with regard to high quality, robustness, and hygiene have been followed to the letter on this venture. As a outcome, our production has turn into noticeably more efficient and dependable.”
FOR MORE INFORMATION
Lewa develops applied sciences and offers solutions for the vast array of purposes amongst its clients. Its merchandise are used mainly within the oil and gasoline business, in fuel odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional utility areas embody the chemical industry, cosmetics industry, prescribed drugs and biotechnology, meals and beverage business, and energy utilities. For extra information, go to www.lewa.com.
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