The Swiss subsidiary of Dutch firm DSM Nutritional Products AG makes use of the spray drying method when producing vitamin and carotenoid powders for the pharmaceutical and meals industries. The process uses pump technology to convey various emulsions into a sprig tower, the place they’re dried into powder. But the feed and booster pump that was getting used proved to be an uncertainty issue 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 via instant maintenance and repair work.
However, it is extremely costly to exchange a diaphragm or an entire system. DSM was in search of an alternative and eventually made a discover once they talked to the pump specialists at Lewa Nikkiso Switzerland, who recommended a Lewa triplex course of diaphragm pump for the spray tower software. The drive unit includes a safe start-up mode that keeps the diaphragm positioned in the neutral place, and steady regulation utilizing an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s straightforward to fulfill the meals industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump know-how plays a central role in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions contain substances similar to vitamins, carotenoids, or polyunsaturated fatty acids as energetic components,” explains Natalie Ibald, plant manager 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 previous system, the risk of unexpected interruptions to this process couldn’t be ruled out. As a outcome, the different emulsions couldn’t be processed further. In other phrases, it was not potential to dry them into powder. The pump diaphragm was the rationale: it was usually too sensitive to face up to the stress placed on it when starting up the pump and would rupture. Replacing the diaphragm lowered the system’s service life and sometimes meant that trouble-free operation could not be guaranteed.
FINDING THE RIGHT PARTNER
In the course of trying to find a dependable various, DSM received in contact with the Swiss subsidiary of pump manufacturer Lewa.
“We had been already acquainted with Lewa Nikkiso Switzerland as a provider of robust systems with lengthy service lives within the SFP sector. To guarantee trouble-free spray drying, we thought it might be smart to affix forces with the consultants from Lewa and come up with a design to solve the technical issues,” says Ibald.
DSM is dedicated to repeatedly enhancing its processes and investing in technology. This dedication, together with prior experience with the short service lives of the earlier pumps, led DSM to put special concentrate on dependable operate and a sturdy design through the project planning phase. The listing of requirements also included a considerable variety of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions concerning microbiological purity which might be many instances extra stringent than these for producing other meals products,” explains Ibald. “This meant that the new feed and booster pump needed to meet these tougher situations and every type of contamination had to be ruled out to produce the widest potential variety of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented firm that is particularly lively within the areas of vitamin, well being, and sustainable dwelling. DSM’s mission is to enhance the lives of all. Products and solutions from DSM tackle a few of the world’s greatest challenges whereas simultaneously creating financial, environmental, and societal worth for all its stakeholders—including clients, staff, shareholders, and society at large.
DSM delivers revolutionary solutions for the nutrition, animal nutrition, private care and aromatics, medical products, environmentally pleasant products and purposes, as nicely as new mobility and interconnectivity.
DSM and its affiliated corporations make use of more than 23,000 folks and generate an annual internet turnover of approximately 10 billion euros. The company was founded in 1902 and is listed on the Euronext Amsterdam inventory exchange.
For extra info, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit at the company 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 includes a completely safe start-up operation, since a spring constantly holds the integrated sandwich diaphragm situated in a neutral position.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged whereas the pump is starting up, rising system availability substantially. And the Lewa triplex is managed utilizing a pressure aid valve that’s put in within the hydraulic half and could be configured for the specific state of affairs. Therefore, the pump can be tailored to different operational conditions so as to stop any overloads that may arise. This ensures that the unit has an extended service life and smooth regular 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 may be extremely long-lasting. They are connected to one another 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 an additional safety function, the DPS monitoring system from Lewa continuously monitors the condition of the diaphragm. The monitoring unit promptly shows any damage to the device that leads to increased strain in the diaphragm house.
This makes it possible to hold out preventive maintenance and restore work earlier than the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it’s usually pointless to switch the pump off instantly, which implies that neither the pumping process nor spray drying are negatively impacted to a significant extent. If harm to a diaphragm is detected, production can continue with none problems as much as a planned maintenance cease. The parts can then get 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 can be a central part for fulfilling the stringent hygiene provisions that the spray tower software is topic to. The Lewa triplex maintains a hermetically tight space without dynamic seals, guaranteeing completely clear and aseptic manufacturing conditions. All pump heads that come into contact with the product are also electropolished, which makes it possible to make sure FDA-compliant pump operation.
Because the pump may be cleaned in place (CIP) using different alkaline and acidic agents and with out prior dismantling, it is possible to satisfy the particular necessities for child food as nicely. The provisions for baby food are 1,000 instances more stringent than those for other products within the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we have been able to rule out any contamination of the pumped medium and clearly meet the required hygiene commonplace.
QUICK RESPONSE TIMES AND WELL-FOUNDED EXPERTISE
The first quote was acquired in June of 2018 and in September of the identical 12 months, DSM Nutritional Products AG placed an order for the triplex process diaphragm pump. In operation since April 2019, the pump has turn into an indispensable a part of manufacturing at the plant in Sisseln.
“In each phase of the challenge, Lewa Nikkiso Switzerland demonstrated fast response times and well-founded experience, which made a key contribution to implementing the project successfully,” says Ibald. “Our specifications with regard to high quality, robustness, and hygiene have been adopted to the letter in this challenge. As a result, our production has turn into noticeably extra environment friendly and dependable.”
FOR MORE INFORMATION
Lewa develops applied sciences and offers options for the vast array of functions amongst its customers. Its products are used primarily in the oil and gasoline business, in gasoline odorization, in refineries and petrochemicals, in addition to in the production of plastics, detergents, and cleaners. Additional software areas embrace the chemical trade, cosmetics business, pharmaceuticals and biotechnology, food and beverage trade, and vitality utilities. For more info, visit www.lewa.com.
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