Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

The Swiss subsidiary 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 procedure uses pump know-how 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 because the diaphragm required for the pumping process tended to tear when the pump was began up. Generally, such manufacturing interruptions could be corrected via quick upkeep and repair work.
However, it is rather expensive 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 specialists at Lewa Nikkiso Switzerland, who beneficial a Lewa triplex course of diaphragm pump for the spray tower software. The drive unit features a protected start-up mode that keeps the diaphragm situated within the impartial place, and continuous regulation using an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is simple to meet the food 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 comprise substances such as nutritional vitamins, carotenoids, or polyunsaturated fatty acids as lively 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 unforeseen interruptions to this course of couldn’t be dominated out. As a end result, the totally different emulsions could not be processed additional. In other phrases, it was not potential to dry them into powder. The pump diaphragm was the reason: it was usually too delicate to face up to the stress positioned 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 guaranteed.
FINDING THE RIGHT PARTNER
In the course of trying to find a dependable various, DSM obtained in contact with the Swiss subsidiary of pump producer Lewa.
“We were already familiar with Lewa Nikkiso Switzerland as a provider of strong systems with long service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it would be good to affix forces with the consultants from Lewa and provide you with a design to resolve the technical problems,” says Ibald.
DSM is committed to continually enhancing its processes and investing in know-how. This dedication, along with prior expertise with the short service lives of the previous pumps, led DSM to put particular give attention to reliable operate and a robust design during the project planning part. The listing of necessities also included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions regarding microbiological purity which would possibly be many occasions extra stringent than those for producing other food merchandise,” explains Ibald. “This meant that the new feed and booster pump needed to meet these more difficult conditions and each sort of contamination needed to be dominated out to supply the widest possible variety of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented company that is especially active within the areas of nutrition, health, and sustainable residing. DSM’s mission is to enhance the lives of all. Products and options from DSM address some of the world’s largest challenges while simultaneously creating economic, environmental, and societal worth for all its stakeholders—including clients, workers, shareholders, and society at large.
DSM delivers revolutionary options for the diet, animal diet, personal care and aromatics, medical merchandise, environmentally pleasant merchandise and purposes, in addition to new mobility and interconnectivity.
DSM and its affiliated firms make use of greater than 23,000 folks and generate an annual internet turnover of roughly 10 billion euros. The company was based in 1902 and is listed on the Euronext Amsterdam stock trade.
For more data, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit on the company premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a sort G3F triplex process diaphragm pump for the spray tower utility. This pump contains a utterly secure start-up operation, since a spring repeatedly holds the integrated sandwich diaphragm positioned in a impartial position.
This protects the diaphragm towards incorrect positioning and prevents it from being broken while the pump is beginning up, rising system availability substantially. And the Lewa triplex is controlled using a strain aid valve that’s put in within the hydraulic part and can be configured for the precise scenario. Therefore, the pump may be adapted to different operational situations to find a way to stop any overloads which will come up. This ensures that the unit has a protracted service life and smooth regular 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 additionally plays an necessary position in ensuring dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extraordinarily long-lasting. They are connected to each other through constructive interlocking in the course of the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and effectively prevents exterior contamination. As a further safety function, the DPS monitoring system from Lewa constantly displays the situation of the diaphragm. The monitoring unit promptly displays any harm to the gadget that leads to increased strain in the diaphragm space.
This makes it attainable to carry out preventive maintenance and restore work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it is usually pointless to modify the pump off immediately, which means that neither the pumping process nor spray drying are negatively impacted to a big extent. If injury to a diaphragm is detected, manufacturing can proceed with none issues up to a planned maintenance cease. The parts can then get replaced quickly and simply by releasing the cassette for the assembly.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the method diaphragm pump does more than simply ensure dependable steady operation. It can be a central component 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 utterly clear and aseptic manufacturing circumstances. All pump heads that come into contact with the product are additionally electropolished, which makes it possible 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’s attainable to meet the particular requirements for child food as nicely. เกจวัดแรงดันแก๊สlpg for baby meals are 1,000 occasions extra stringent than those for different merchandise in the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we were 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 identical 12 months, DSM Nutritional Products AG placed an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has become an indispensable a half of production at the plant in Sisseln.
“In each section of the challenge, Lewa Nikkiso Switzerland demonstrated fast response occasions and well-founded experience, which made a key contribution to implementing the project efficiently,” says Ibald. “Our specifications with regard to quality, robustness, and hygiene were adopted to the letter on this project. As a result, our manufacturing has become noticeably extra environment friendly and reliable.”
FOR MORE INFORMATION
Lewa develops technologies and provides options for the huge array of functions amongst its clients. Its products are used mainly in the oil and gasoline business, in gasoline odorization, in refineries and petrochemicals, as nicely as in the manufacturing of plastics, detergents, and cleaners. Additional utility areas embody the chemical trade, cosmetics industry, prescribed drugs and biotechnology, food and beverage trade, and vitality utilities. For more info, go to www.lewa.com.
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