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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 process uses pump know-how to convey numerous emulsions into a spray 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 result of the diaphragm required for the pumping course of tended to tear when the pump was began up. Generally, such manufacturing interruptions could be corrected by way of instant upkeep and repair work.
However, it is rather costly to replace a diaphragm or a complete system. DSM was looking for an alternative and finally made a find when they talked to the pump experts at Lewa Nikkiso Switzerland, who recommended a Lewa triplex course of diaphragm pump for the spray tower utility. The drive unit features a secure start-up mode that keeps the diaphragm positioned in 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 meals industry’s stringent hygienic provisions.
a hundred PERCENT INTEGRATION
“Pump technology plays a central role in drying oil-in-water emulsions for the meals and pharmaceutical industries. These emulsions contain substances similar to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as lively components,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As part of the method 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 earlier system, the danger of unforeseen interruptions to this course of couldn’t be dominated out. As a outcome, the different emulsions couldn’t be processed additional. In different phrases, it was not potential to dry them into powder. The pump diaphragm was the rationale: it was typically too delicate to resist the stress placed on it when starting up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and generally meant that trouble-free operation couldn’t be assured.
FINDING THE RIGHT PARTNER
In the course of trying to find a dependable various, DSM got in contact with the Swiss subsidiary of pump producer Lewa.
“We have been already acquainted with Lewa Nikkiso Switzerland as a provider of sturdy methods with lengthy service lives within the SFP sector. To guarantee trouble-free spray drying, we thought it would be smart to affix forces with the specialists from Lewa and provide you with a design to solve the technical issues,” says Ibald.
DSM is committed to continually enhancing its processes and investing in know-how. This commitment, together with prior expertise with the brief service lives of the previous pumps, led DSM to put particular concentrate on dependable function and a robust design during the venture planning part. The listing of requirements additionally included a substantial variety of stringent hygienic provisions that had to be fulfilled.
“Certain meals have provisions concerning microbiological purity that are many instances more stringent than these for producing other meals products,” explains Ibald. “This meant that the brand new feed and booster pump had to meet these more challenging circumstances and each type of contamination had to be ruled out to produce the widest possible number of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a world science-oriented firm that’s especially active in the areas of diet, health, and sustainable dwelling. DSM’s mission is to enhance the lives of all. Products and solutions from DSM handle a variety of the world’s greatest challenges while concurrently creating economic, environmental, and societal worth for all its stakeholders—including prospects, employees, shareholders, and society at giant.
DSM delivers revolutionary solutions for the vitamin, animal vitamin, personal care and aromatics, medical merchandise, environmentally friendly products and applications, in addition to new mobility and interconnectivity.
DSM and its affiliated companies employ more than 23,000 folks and generate an annual internet turnover of roughly 10 billion euros. The company was founded in 1902 and is listed on the Euronext Amsterdam inventory trade.
For extra information, go to www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit at the company premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland recommended a kind G3F triplex process diaphragm pump for the spray tower software. This pump contains a utterly safe start-up operation, since a spring continuously holds the built-in sandwich diaphragm situated in a neutral position.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being broken whereas the pump is starting up, increasing system availability substantially. And the Lewa triplex is controlled utilizing a pressure reduction valve that’s put in in the hydraulic part and may be configured for the precise state of affairs. Therefore, the pump can be tailored to totally different operational conditions in order to prevent any overloads that may come up. This ensures that the unit has a long service life and easy regular operation for the complete system.
THE POWER OF DESIGN
In addition to the strain aid valve and the spring management, the design of the diaphragm also plays an essential role in making certain dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extremely long-lasting. They are related to each 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 function, the DPS monitoring system from Lewa constantly screens the situation of the diaphragm. The monitoring unit promptly displays any damage to the gadget that leads to elevated pressure within the diaphragm space.
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 is often unnecessary to change the pump off immediately, which signifies that neither the pumping process nor spray drying are negatively impacted to a big extent. If harm to a diaphragm is detected, manufacturing can proceed without any issues as a lot as a planned upkeep stop. The parts can then be replaced rapidly and easily by releasing the cassette for the assembly.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does more than just ensure dependable continuous operation. It can be a central element for fulfilling the stringent hygiene provisions that the spray tower application is topic to. The Lewa triplex maintains a hermetically tight space without dynamic seals, guaranteeing fully clear and aseptic manufacturing situations. 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 possible to meet the special necessities for baby meals as nicely. The provisions for baby meals are 1,000 occasions more stringent than those for other products within the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we had been capable of rule out any contamination of the pumped medium and clearly meet the required hygiene standard.
QUICK RESPONSE TIMES AND WELL-FOUNDED EXPERTISE
The first quote was received in June of 2018 and in September of the identical year, 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 on the plant in Sisseln.
“In เกจ์วัดแรงดันน้ำ of the venture, 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 have been followed to the letter in this venture. As a end result, our production has turn into noticeably more environment friendly and reliable.”
FOR MORE INFORMATION
Lewa develops applied sciences and offers solutions for the vast array of purposes amongst 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 utility areas embody the chemical trade, cosmetics business, prescription drugs and biotechnology, meals and beverage business, and energy utilities. For extra info, visit www.lewa.com.
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