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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 meals industries. The process makes use of pump expertise to convey numerous 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 factor as a outcome 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 immediate upkeep and restore work.
However, it is extremely costly to switch a diaphragm or a complete system. DSM was looking for an alternative and finally made a find once they talked to the pump consultants at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex course of diaphragm pump for the spray tower utility. The drive unit includes a secure start-up mode that retains the diaphragm situated in the neutral place, and steady regulation using an built-in 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 expertise performs a central role in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions contain substances corresponding to vitamins, carotenoids, or polyunsaturated fatty acids as energetic ingredients,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As a part of the process 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 earlier system, the danger of unforeseen interruptions to this course of couldn’t be dominated out. As a end result, the completely different emulsions couldn’t be processed further. In เพรสเชอร์เกจลม , it was not attainable to dry them into powder. The pump diaphragm was the rationale: it was usually too delicate to face up to the stress placed on it when beginning up the pump and would rupture. Replacing the diaphragm decreased the system’s service life and typically meant that trouble-free operation could not be assured.
FINDING THE RIGHT PARTNER
In the course of trying to find a dependable alternative, DSM received in touch with the Swiss subsidiary of pump producer Lewa.
“We had been already conversant in Lewa Nikkiso Switzerland as a provider of strong methods with long service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it would be good to hitch forces with the specialists from Lewa and provide you with a design to solve the technical problems,” says Ibald.
DSM is dedicated to continually bettering its processes and investing in expertise. This commitment, along with prior expertise with the quick service lives of the earlier pumps, led DSM to position particular focus on dependable perform and a sturdy design through the venture planning part. The list of necessities also included a substantial variety of stringent hygienic provisions that had to be fulfilled.
“Certain meals have provisions relating to microbiological purity which would possibly be many times extra stringent than these for producing other meals products,” explains Ibald. “This meant that the brand new feed and booster pump needed to meet these more difficult conditions and every type of contamination needed to be ruled out to provide the widest possible variety of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented firm that’s especially energetic in the areas of nutrition, well being, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and options from DSM handle a few of the world’s biggest challenges whereas simultaneously creating financial, environmental, and societal worth for all its stakeholders—including prospects, employees, shareholders, and society at massive.
DSM delivers revolutionary solutions for the nutrition, animal nutrition, personal care and aromatics, medical products, environmentally friendly merchandise and applications, in addition to new mobility and interconnectivity.
DSM and its affiliated companies employ greater than 23,000 folks and generate an annual net turnover of roughly 10 billion euros. The firm was based in 1902 and is listed on the Euronext Amsterdam inventory exchange.
For more information, 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 type G3F triplex course of diaphragm pump for the spray tower utility. This pump contains a fully safe start-up operation, since a spring constantly holds the built-in sandwich diaphragm located in a neutral place.
This protects the diaphragm towards incorrect positioning and prevents it from being broken while the pump is beginning up, rising system availability considerably. And the Lewa triplex is managed using a pressure aid valve that is installed in the hydraulic half and can be configured for the specific situation. Therefore, the pump can be tailored to completely different operational situations to be able to stop any overloads that will arise. This ensures that the unit has an extended service life and clean common operation for the entire system.
THE POWER OF DESIGN
In addition to the strain reduction valve and the spring management, the design of the diaphragm also performs an essential position in making certain dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which may be extremely long-lasting. They are related to one another via optimistic interlocking through the discharge stroke and mechanical force-fitting in the course of the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As an additional safety feature, the DPS monitoring system from Lewa constantly monitors the situation of the diaphragm. The monitoring unit promptly shows any harm to the gadget that leads to increased strain in the diaphragm area.
This makes it potential to hold out preventive upkeep and restore work before the diaphragm even begins to rupture and probably contaminates the pumped fluid. Thus, it is normally pointless to change the pump off right away, which means that neither the pumping course of nor spray drying are negatively impacted to a major extent. If harm to a diaphragm is detected, manufacturing can proceed with none problems as a lot as a deliberate maintenance stop. The components can then get replaced rapidly and easily by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the method diaphragm pump does extra than simply ensure dependable steady operation. It can be a central component for fulfilling the stringent hygiene provisions that the spray tower software is subject to. The Lewa triplex maintains a hermetically tight house without dynamic seals, guaranteeing completely 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 different alkaline and acidic agents and with out prior dismantling, it is attainable to satisfy the special requirements for baby meals as properly. The provisions for baby meals are 1,000 times extra stringent than those for different products within the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we have been able to 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 same 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 venture, Lewa Nikkiso Switzerland demonstrated quick response times and well-founded expertise, which made a key contribution to implementing the challenge efficiently,” says Ibald. “Our specs with regard to quality, robustness, and hygiene have been adopted to the letter on this project. As a end result, our manufacturing has turn into noticeably extra efficient and dependable.”
FOR MORE INFORMATION
Lewa develops applied sciences and provides solutions for the huge array of purposes among its clients. Its products are used mainly within the oil and fuel industry, in gasoline odorization, in refineries and petrochemicals, as properly as in the production of plastics, detergents, and cleaners. Additional application areas embrace the chemical trade, cosmetics trade, prescription drugs and biotechnology, food and beverage trade, and vitality utilities. For more information, visit www.lewa.com.
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