Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

The Swiss subsidiary of Dutch firm DSM Nutritional Products AG uses the spray drying methodology when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The process makes use of pump technology to convey various emulsions into a spray tower, the place they’re dried into powder. But the feed and booster pump that was being used proved to be an uncertainty factor as a end result of the diaphragm required for the pumping course of tended to tear when the pump was began up. Generally, such production interruptions can be corrected through quick maintenance and repair work.
However, it is very costly to switch a diaphragm or a whole system. DSM was seeking an alternate and eventually made a discover after they talked to the pump experts at Lewa Nikkiso Switzerland, who recommended a Lewa triplex course of diaphragm pump for the spray tower application. The drive unit features a protected start-up mode that retains the diaphragm situated in the impartial place, and continuous regulation using an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is straightforward to fulfill the meals industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump expertise plays a central role in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions comprise substances similar to vitamins, carotenoids, or polyunsaturated fatty acids as active ingredients,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As part of the method chain, every pump is 100 percent integrated into the closed plant system. เกจวัดแรงดันลม10bar are used for conveying the mixtures into the spray tower.”
With the previous system, the chance of unexpected interruptions to this course of couldn’t be dominated out. As a result, the completely different emulsions could not be processed further. In different words, it was not attainable to dry them into powder. The pump diaphragm was the reason: it was usually too delicate to resist the stress positioned on it when beginning up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and typically meant that trouble-free operation couldn’t be guaranteed.
FINDING THE RIGHT PARTNER
In the course of trying to find a dependable different, DSM received in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We had been already acquainted with Lewa Nikkiso Switzerland as a supplier of strong methods with lengthy service lives within the SFP sector. To ensure trouble-free spray drying, we thought it will be good to join forces with the specialists from Lewa and provide you with a design to resolve the technical problems,” says Ibald.
DSM is committed to repeatedly bettering its processes and investing in know-how. This dedication, along with prior experience with the quick service lives of the previous pumps, led DSM to position special give attention to reliable function and a strong design during the challenge planning phase. The list of requirements additionally included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions concerning microbiological purity that are many instances extra stringent than these for producing other meals products,” explains Ibald. “This meant that the new feed and booster pump had to meet these more difficult situations and each type of contamination had to be ruled out to supply the widest attainable number of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a world science-oriented company that is particularly active within the areas of vitamin, health, and sustainable living. DSM’s mission is to enhance the lives of all. Products and solutions from DSM handle a few of the world’s greatest challenges while concurrently creating economic, environmental, and societal worth for all its stakeholders—including clients, employees, shareholders, and society at large.
DSM delivers innovative options for the vitamin, animal vitamin, private care and aromatics, medical products, environmentally friendly merchandise and purposes, as well as new mobility and interconnectivity.
DSM and its affiliated companies employ more than 23,000 folks and generate an annual net turnover of approximately 10 billion euros. The company was founded in 1902 and is listed on the Euronext Amsterdam stock trade.
For more info, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to at the firm premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a type G3F triplex process diaphragm pump for the spray tower software. This pump contains a completely safe start-up operation, since a spring constantly holds the integrated sandwich diaphragm located in a neutral place.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged whereas the pump is beginning up, rising system availability considerably. And the Lewa triplex is controlled utilizing a pressure reduction valve that’s put in within the hydraulic half and may be configured for the precise situation. Therefore, the pump can be adapted to different operational conditions in order to stop any overloads which will come up. This ensures that the unit has a protracted service life and clean regular operation for the complete system.
THE POWER OF DESIGN
In addition to the pressure relief valve and the spring control, the design of the diaphragm additionally performs an essential position in guaranteeing reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which might be extraordinarily long-lasting. They are related to one another via positive interlocking in the course of the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and successfully prevents external contamination. As an extra security characteristic, the DPS monitoring system from Lewa continuously displays the situation of the diaphragm. The monitoring unit promptly shows any injury to the gadget that results in increased stress within the diaphragm house.
This makes it potential to carry out preventive maintenance and repair work before the diaphragm even begins to rupture and probably contaminates the pumped fluid. Thus, it’s normally unnecessary to change the pump off right away, which means that neither the pumping process nor spray drying are negatively impacted to a big extent. If harm to a diaphragm is detected, production can proceed with none issues up to a deliberate maintenance cease. The parts can then be replaced rapidly and simply by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does more than simply guarantee dependable continuous operation. It is also a central component for fulfilling the stringent hygiene provisions that the spray tower application is topic to. The Lewa triplex maintains a hermetically tight house with out dynamic seals, guaranteeing completely clear and aseptic production conditions. 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 different alkaline and acidic agents and with out prior dismantling, it’s potential to satisfy the special necessities for baby food as well. The provisions for baby meals are 1,000 times extra stringent than these for other products within the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we were in a position 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 yr, DSM Nutritional Products AG positioned an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has become an indispensable part of manufacturing on the plant in Sisseln.
“In every phase of the venture, Lewa Nikkiso Switzerland demonstrated quick response times 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 challenge. As a result, our manufacturing has become noticeably more efficient and reliable.”
FOR MORE INFORMATION
Lewa develops applied sciences and provides options for the vast array of applications among its customers. Its products are used mainly in the oil and fuel trade, in fuel odorization, in refineries and petrochemicals, in addition to within the production of plastics, detergents, and cleaners. Additional application areas embody the chemical trade, cosmetics trade, prescribed drugs and biotechnology, food and beverage trade, and vitality utilities. For more data, visit www.lewa.com.
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