Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

The Swiss subsidiary of Dutch company 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 varied emulsions into a spray tower, where they are dried into powder. But the feed and booster pump that was getting used proved to be an uncertainty factor as a result of the diaphragm required for the pumping course of tended to tear when the pump was began up. Generally, such manufacturing interruptions can be corrected by way of immediate upkeep and repair work.
However, it is rather costly to switch a diaphragm or a complete system. DSM was seeking an alternative and eventually made a find once they talked to the pump specialists at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower application. The drive unit contains a secure start-up mode that keeps the diaphragm located within the impartial place, and steady regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is straightforward to fulfill the food industry’s stringent hygienic provisions.
“Pump know-how performs a central function in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions contain substances similar to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as lively ingredients,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As part of the process chain, each pump is 100% integrated into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With the previous system, the danger of unforeseen interruptions to this process couldn’t be ruled out. As a end result, the completely different emulsions could not be processed additional. In different words, it was not possible to dry them into powder. The pump diaphragm was the explanation: it was usually too sensitive to resist the stress positioned on it when beginning up the pump and would rupture. Replacing the diaphragm lowered the system’s service life and typically meant that trouble-free operation couldn’t be guaranteed.
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In the course of looking for a reliable alternative, DSM obtained in contact with the Swiss subsidiary of pump producer Lewa.
“We have been already acquainted with Lewa Nikkiso Switzerland as a provider of sturdy systems with long service lives within the SFP sector. To guarantee trouble-free spray drying, we thought it will be sensible to affix forces with the consultants from Lewa and provide you with a design to resolve the technical problems,” says Ibald.
DSM is dedicated to repeatedly bettering its processes and investing in technology. This dedication, together with prior experience with the brief service lives of the previous pumps, led DSM to place special concentrate on dependable operate and a sturdy design in the course of the project planning section. The listing of requirements additionally included a considerable variety of stringent hygienic provisions that had to be fulfilled.
“Certain meals have provisions concerning microbiological purity that are many occasions extra stringent than those for producing other food products,” explains Ibald. “This meant that the new feed and booster pump had to meet these tougher circumstances and every sort of contamination needed to be dominated out to supply the widest potential variety of merchandise on the system.”
Royal DSM is a worldwide science-oriented firm that’s particularly active in the areas of vitamin, well being, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and options from DSM address a number of the world’s greatest challenges whereas simultaneously creating financial, environmental, and societal value for all its stakeholders—including clients, employees, shareholders, and society at giant.
DSM delivers innovative solutions for the vitamin, animal vitamin, private care and aromatics, medical merchandise, environmentally pleasant products and applications, in addition to new mobility and interconnectivity.
DSM and its affiliated firms employ more than 23,000 people and generate an annual net turnover of approximately 10 billion euros. The firm was founded in 1902 and is listed on the Euronext Amsterdam inventory trade.
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After a go to on the firm premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a kind G3F triplex process diaphragm pump for the spray tower software. This pump features a completely secure start-up operation, since a spring repeatedly holds the integrated sandwich diaphragm positioned in a neutral place.
This protects the diaphragm against incorrect positioning and prevents it from being damaged while the pump is starting up, rising system availability substantially. And the Lewa triplex is controlled utilizing a stress reduction valve that is installed within the hydraulic half and could be configured for the particular scenario. Therefore, the pump could be tailored to different operational situations to have the ability to stop any overloads which will come up. This ensures that the unit has a long service life and clean common operation for the whole system.
In addition to the stress relief valve and the spring management, the design of the diaphragm also performs an essential role in making certain reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extraordinarily long-lasting. They are connected to every other through constructive interlocking in the course of the discharge stroke and mechanical force-fitting during the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As a further security characteristic, the DPS monitoring system from Lewa constantly monitors the situation of the diaphragm. The monitoring unit promptly shows any damage to the system that results in elevated stress in the diaphragm area.
This makes it possible to hold out preventive maintenance and repair work before the diaphragm even begins to rupture and probably contaminates the pumped fluid. Thus, it is usually unnecessary to change the pump off immediately, which implies that neither the pumping course of nor spray drying are negatively impacted to a major extent. If harm to a diaphragm is detected, production can continue without any problems up to a deliberate maintenance stop. The components can then be replaced quickly and simply by releasing the cassette for the meeting.
The hermetically tight design of the process diaphragm pump does extra than simply ensure reliable continuous operation. It is also a central element for fulfilling the stringent hygiene provisions that the spray tower software is subject to. The Lewa triplex maintains a hermetically tight area without dynamic seals, guaranteeing fully clean and aseptic production circumstances. All pump heads that come into contact with the product are additionally electropolished, which makes it attainable to make sure FDA-compliant pump operation.
Because the pump could be cleaned in place (CIP) using completely different alkaline and acidic brokers and with out prior dismantling, it is potential to meet the special necessities for baby food as nicely. The provisions for child food are 1,000 times more stringent than these for other products within the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we had been in a place to rule out any contamination of the pumped medium and clearly meet the required hygiene commonplace.
The first quote was received in June of 2018 and in September of the identical yr, DSM Nutritional Products AG placed an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has turn out to be an indispensable a part of production on the plant in Sisseln.
“In every phase of the project, Lewa Nikkiso Switzerland demonstrated quick response instances and well-founded experience, which made a key contribution to implementing the venture successfully,” says Ibald. “Our specifications with regard to quality, robustness, and hygiene had been adopted to the letter in this venture. As a outcome, our production has turn out to be noticeably more efficient and reliable.”
Lewa develops technologies and offers options for the huge array of functions amongst its customers. Its merchandise are used mainly within the oil and fuel industry, in fuel odorization, in refineries and petrochemicals, as properly as within the manufacturing of plastics, detergents, and cleaners. Additional utility areas include the chemical trade, cosmetics trade, prescription drugs and biotechnology, meals and beverage business, and power utilities. For more info, go to

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