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เกจวัดแรงดันpressuregauge of Dutch company DSM Nutritional Products AG uses the spray drying methodology when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The process uses pump expertise to convey numerous 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 end result of the diaphragm required for the pumping process tended to tear when the pump was started up. Generally, such production interruptions may be corrected through quick maintenance and repair work.
However, it is very expensive to exchange a diaphragm or an entire system. DSM was in search of an alternate and at last made a find when they talked to the pump consultants at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex course of diaphragm pump for the spray tower software. The drive unit features a safe start-up mode that retains the diaphragm located within the neutral place, and steady regulation utilizing an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is easy to satisfy the food industry’s stringent hygienic provisions.
100 PERCENT INTEGRATION
“Pump know-how plays a central function in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions comprise substances such as nutritional vitamins, carotenoids, or polyunsaturated fatty acids as energetic ingredients,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As a half of the method chain, every pump is 100% built-in into the closed plant system. The pumps 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 ruled out. As a result, the totally different emulsions could not be processed further. In other phrases, it was not possible to dry them into powder. The pump diaphragm was the reason: it was usually too delicate to face up to the stress placed on it when starting up the pump and would rupture. Replacing the diaphragm decreased the system’s service life and typically meant that trouble-free operation couldn’t be assured.
FINDING THE RIGHT PARTNER
In the course of trying to find a dependable alternative, DSM got in touch with the Swiss subsidiary of pump producer Lewa.
“We have been already conversant in Lewa Nikkiso Switzerland as a provider of strong systems with lengthy service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it might be smart to hitch forces with the consultants from Lewa and give you a design to solve the technical problems,” says Ibald.
DSM is committed to continually bettering its processes and investing in know-how. This commitment, together with prior experience with the quick service lives of the previous pumps, led DSM to place special give attention to reliable operate and a strong design through the venture planning phase. The listing of necessities also included a considerable number of stringent hygienic provisions that needed to be fulfilled.
“Certain foods have provisions relating to microbiological purity which might be many occasions more stringent than those for producing other food products,” explains Ibald. “This meant that the model new feed and booster pump had to meet these more difficult conditions and each type of contamination had to be ruled out to provide the widest attainable variety of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented company that’s particularly energetic in the areas of nutrition, well being, 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 biggest challenges while simultaneously creating financial, environmental, and societal value for all its stakeholders—including clients, staff, shareholders, and society at massive.
DSM delivers revolutionary options for the diet, animal vitamin, private care and aromatics, medical products, environmentally friendly products and functions, in addition to new mobility and interconnectivity.
DSM and its affiliated firms make use of greater than 23,000 individuals and generate an annual web turnover of approximately 10 billion euros. The firm was based in 1902 and is listed on the Euronext Amsterdam stock change.
For more data, 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 beneficial a type G3F triplex process diaphragm pump for the spray tower application. This pump contains a utterly secure start-up operation, since a spring constantly holds the integrated sandwich diaphragm positioned in a neutral place.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged whereas the pump is beginning up, increasing system availability substantially. And the Lewa triplex is managed using a strain aid valve that is put in within the hydraulic part and may be configured for the particular situation. Therefore, the pump can be adapted to completely different operational conditions to find a way to stop any overloads which will come up. This ensures that the unit has an extended service life and smooth common operation for the whole system.
THE POWER OF DESIGN
In addition to the strain reduction valve and the spring control, the design of the diaphragm also plays an important role in guaranteeing reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extremely long-lasting. They are linked to each other through positive interlocking during the discharge stroke and mechanical force-fitting during the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As an extra safety characteristic, the DPS monitoring system from Lewa repeatedly monitors the situation of the diaphragm. The monitoring unit promptly displays any harm to the device that leads to elevated stress within the diaphragm house.
This makes it possible to carry out preventive maintenance and repair work earlier than the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it’s usually unnecessary to change the pump off instantly, which means that neither the pumping process nor spray drying are negatively impacted to a big extent. If damage to a diaphragm is detected, manufacturing can continue without any problems as much as a deliberate upkeep cease. The components can then get replaced quickly and easily by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the method diaphragm pump does more than just guarantee reliable steady operation. It can also be a central part for fulfilling the stringent hygiene provisions that the spray tower application is topic to. The Lewa triplex maintains a hermetically tight space 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 potential to ensure FDA-compliant pump operation.
Because the pump could be cleaned in place (CIP) utilizing completely different alkaline and acidic agents and without prior dismantling, it is potential to fulfill the particular requirements for child food as well. The provisions for child meals are 1,000 instances extra stringent than these for other products within the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we were 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 acquired 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 into an indispensable part of production at the plant in Sisseln.
“In every 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 followed to the letter on this project. As a result, our production has become noticeably extra 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 primarily in the oil and fuel trade, in gas odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional application areas include the chemical trade, cosmetics trade, pharmaceuticals and biotechnology, meals and beverage trade, and vitality utilities. For extra information, visit www.lewa.com.
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