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The Swiss subsidiary of Dutch firm DSM Nutritional Products AG makes use of the spray drying technique when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The process uses pump expertise to convey varied emulsions into a sprig tower, where they are dried into powder. But the feed and booster pump that was being used proved to be an uncertainty issue as a outcome of the diaphragm required for the pumping course of tended to tear when the pump was began up. Generally, such production interruptions may be corrected by way of immediate maintenance and repair work.
However, ไดอะแฟรม is rather costly to replace a diaphragm or an entire system. DSM was seeking an alternative and at last made a discover after they talked to the pump specialists at Lewa Nikkiso Switzerland, who recommended a Lewa triplex course of diaphragm pump for the spray tower application. The drive unit features a secure start-up mode that retains the diaphragm located within the impartial position, and continuous regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s simple to meet 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 nutritional vitamins, carotenoids, or polyunsaturated fatty acids as active 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 previous system, the risk of unexpected interruptions to this process couldn’t be dominated out. As a outcome, the completely different emulsions couldn’t be processed additional. In different phrases, it was not attainable to dry them into powder. The pump diaphragm was the rationale: it was usually too delicate to withstand the stress placed on it when beginning up the pump and would rupture. Replacing the diaphragm lowered the system’s service life and generally meant that trouble-free operation couldn’t be guaranteed.
FINDING THE RIGHT PARTNER

In the course of looking for a dependable various, DSM obtained in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We were already conversant in Lewa Nikkiso Switzerland as a supplier of robust methods with long service lives within the SFP sector. To ensure pressure gauge -free spray drying, we thought it would be sensible to affix forces with the consultants from Lewa and give you a design to resolve the technical issues,” says Ibald.
DSM is dedicated to continually improving its processes and investing in technology. This dedication, along with prior experience with the brief service lives of the earlier pumps, led DSM to put special focus on reliable function and a robust design in the course of the venture planning phase. The record of necessities also included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions regarding microbiological purity which are many times more stringent than those for producing other meals products,” explains Ibald. “This meant that the new feed and booster pump needed to meet these tougher circumstances and each kind of contamination needed to be ruled out to provide the widest attainable number of products on the system.”

ROYAL DSM: PARTNER PROFILE

Royal DSM is a global science-oriented firm that is especially active in the areas of nutrition, well being, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and solutions from DSM tackle some of the world’s greatest challenges whereas simultaneously creating economic, environmental, and societal worth for all its stakeholders—including clients, staff, shareholders, and society at large.
DSM delivers revolutionary solutions for the nutrition, animal vitamin, personal care and aromatics, medical products, environmentally friendly products and applications, in addition to new mobility and interconnectivity.
DSM and its affiliated companies make use of more than 23,000 people and generate an annual web turnover of approximately 10 billion euros. The company 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 visit at the company premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a sort G3F triplex course of 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 located in a neutral place.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being broken while the pump is starting up, rising system availability substantially. And the Lewa triplex is managed utilizing a pressure reduction valve that is put in within the hydraulic half and could be configured for the precise scenario. Therefore, the pump may be adapted to different operational conditions so as to stop any overloads which will come up. This ensures that the unit has a long service life and clean common operation for the entire system.
THE POWER OF DESIGN

In addition to the stress reduction valve and the spring management, the design of the diaphragm also plays an necessary position in guaranteeing dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extraordinarily long-lasting. They are connected to each other via optimistic 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 exterior contamination. As a further safety feature, the DPS monitoring system from Lewa constantly screens the situation of the diaphragm. The monitoring unit promptly shows any damage to the system that leads to elevated stress in the diaphragm area.
This makes it potential to hold out preventive upkeep and repair work before the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it is normally unnecessary to modify the pump off instantly, which implies that neither the pumping course of nor spray drying are negatively impacted to a big extent. If harm to a diaphragm is detected, manufacturing can proceed without any problems as much as a deliberate maintenance stop. The parts can then get replaced quickly 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 steady operation. It can 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 house without dynamic seals, guaranteeing fully clean and aseptic production conditions. All pump heads that come into contact with the product are additionally electropolished, which makes it possible to make sure FDA-compliant pump operation.
Because the pump could be cleaned in place (CIP) using totally different alkaline and acidic agents and with out prior dismantling, it is potential to fulfill the special necessities for child food as nicely. The provisions for child food are 1,000 times extra stringent than these for different merchandise within the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we were able 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 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 manufacturing at the plant in Sisseln.
“In each part of the challenge, Lewa Nikkiso Switzerland demonstrated quick response occasions and well-founded experience, which made a key contribution to implementing the venture efficiently,” says Ibald. “Our specifications with regard to quality, robustness, and hygiene had been adopted to the letter in this project. As a end result, our manufacturing has turn into noticeably extra environment friendly and reliable.”

FOR MORE INFORMATION

Lewa develops applied sciences and supplies options for the vast array of purposes amongst its customers. Its products are used primarily in the oil and fuel industry, in gas odorization, in refineries and petrochemicals, as nicely as within the production of plastics, detergents, and cleaners. Additional utility areas include the chemical industry, cosmetics trade, prescribed drugs and biotechnology, meals and beverage business, and power utilities. For more info, visit www.lewa.com.
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