The Swiss subsidiary of Dutch company DSM Nutritional Products AG uses the spray drying technique when producing vitamin and carotenoid powders for the pharmaceutical and meals industries. The process uses pump expertise to convey numerous emulsions into a twig 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 outcome of the diaphragm required for the pumping course of tended to tear when the pump was began up. Generally, such production interruptions could be corrected by way of instant upkeep and repair work.
However, it is extremely costly to exchange a diaphragm or a complete system. DSM was looking for another and at last made a discover once they talked to the pump consultants at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower software. The drive unit contains a protected start-up mode that retains the diaphragm located in the neutral place, and continuous regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is simple to satisfy the meals industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump expertise performs a central position in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions contain substances similar to vitamins, carotenoids, or polyunsaturated fatty acids as lively elements,” 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 earlier system, the danger of unforeseen interruptions to this process couldn’t be dominated out. As a outcome, the completely different emulsions could not be processed additional. In other words, it was not potential to dry them into powder. The pump diaphragm was the explanation: it was typically too delicate to withstand 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 guaranteed.
FINDING THE RIGHT PARTNER
In the course of looking for a reliable alternative, DSM obtained in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We have been already acquainted with Lewa Nikkiso Switzerland as a provider of strong techniques with lengthy service lives within the SFP sector. To ensure trouble-free spray drying, we thought it might be smart to join forces with the experts from Lewa and give you a design to unravel the technical problems,” says Ibald.
DSM is committed to continually bettering its processes and investing in know-how. This dedication, along with prior expertise with the quick service lives of the previous pumps, led DSM to place special give attention to dependable function and a sturdy design during the challenge planning section. The listing of requirements additionally included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions relating to microbiological purity that are many times more stringent than those for producing different meals merchandise,” explains Ibald. “This meant that the new feed and booster pump had to meet these more difficult conditions and every kind of contamination needed to be dominated out to provide the widest potential variety of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented company that is particularly energetic in the areas of diet, health, and sustainable living. DSM’s mission is to improve the lives of all. Products and solutions from DSM address a number of the world’s largest challenges while simultaneously creating financial, environmental, and societal value for all its stakeholders—including prospects, employees, shareholders, and society at giant.
DSM delivers progressive options for the nutrition, animal vitamin, personal care and aromatics, medical merchandise, environmentally pleasant products and functions, in addition to new mobility and interconnectivity.
DSM and its affiliated firms 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 trade.
For more data, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to on the firm 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 features a completely safe start-up operation, since a spring continuously holds the built-in sandwich diaphragm located in a impartial place.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged whereas the pump is starting up, rising system availability substantially. And the Lewa triplex is managed utilizing a pressure relief valve that is installed in the hydraulic part and can be configured for the precise state of affairs. Therefore, the pump could be tailored to totally different operational conditions in order to prevent any overloads that will come up. This ensures that the unit has a protracted service life and smooth common operation for the entire system.
THE POWER OF DESIGN
In addition to the stress relief valve and the spring management, the design of the diaphragm additionally plays an important role in guaranteeing dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extraordinarily long-lasting. They are linked to one another via constructive interlocking through the discharge stroke and mechanical force-fitting during the suction stroke.
This makes the pump hermetically tight and successfully prevents external contamination. As a further security characteristic, the DPS monitoring system from Lewa repeatedly screens the situation of the diaphragm. The monitoring unit promptly displays any harm to the device that leads to elevated strain in the diaphragm space.
This makes it potential to hold out preventive upkeep and repair work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s usually pointless 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 with none problems as a lot as a deliberate upkeep stop. The elements can then get replaced shortly and simply by releasing the cassette for the assembly.
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The hermetically tight design of the method diaphragm pump does extra than just ensure reliable steady operation. It is also a central part for fulfilling the stringent hygiene provisions that the spray tower application is topic to. The Lewa triplex maintains a hermetically tight area with out dynamic seals, guaranteeing completely clear and aseptic production conditions. All pump heads that come into contact with the product are also electropolished, which makes it potential to make sure FDA-compliant pump operation.
Because the pump can be cleaned in place (CIP) using totally different alkaline and acidic agents and with out prior dismantling, it’s potential to satisfy the particular necessities for child meals as properly. The provisions for baby meals are 1,000 times extra stringent than those for different merchandise within the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we had 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 received in June of 2018 and in September of the identical 12 months, DSM Nutritional Products AG placed an order for the triplex process diaphragm pump. In operation since April 2019, the pump has become an indispensable a part of manufacturing at the plant in Sisseln.
“In every section of the challenge, Lewa Nikkiso Switzerland demonstrated fast response instances and well-founded expertise, which made a key contribution to implementing the challenge 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 manufacturing has turn into noticeably extra efficient and reliable.”
FOR MORE INFORMATION
Lewa develops technologies and provides options for the huge array of applications amongst its clients. Its merchandise are used mainly in the oil and gas industry, in gasoline odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional software areas embody the chemical business, cosmetics business, prescription drugs and biotechnology, meals and beverage business, and energy utilities. For extra data, visit www.lewa.com.
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