The Swiss subsidiary of Dutch firm DSM Nutritional Products AG uses the spray drying method when producing vitamin and carotenoid powders for the pharmaceutical and meals industries. The procedure uses pump expertise to convey varied emulsions into a spray tower, where they are dried into powder. But the feed and booster pump that was being 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 may be corrected by way of quick maintenance and restore work.
However, it is very costly to replace a diaphragm or an entire system. DSM was in search of an alternative and eventually made a find once they talked to the pump consultants at Lewa Nikkiso Switzerland, who recommended a Lewa triplex process diaphragm pump for the spray tower application. The drive unit contains a protected start-up mode that keeps the diaphragm positioned in the impartial position, and steady regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is simple to meet the food industry’s stringent hygienic provisions.
a hundred PERCENT INTEGRATION
“Pump technology performs a central function in drying oil-in-water emulsions for the meals and pharmaceutical industries. These emulsions contain substances corresponding to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as lively elements,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As a part of the process chain, each pump is one hundred pc integrated into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With pressure gauge น้ำ , the chance of unexpected interruptions to this course of couldn’t be dominated out. As a result, the totally different emulsions couldn’t be processed further. 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 placed on it when starting up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and generally meant that trouble-free operation could not be assured.
FINDING THE RIGHT PARTNER
In the course of searching for a reliable alternative, DSM got in contact with the Swiss subsidiary of pump manufacturer Lewa.
“We had been already familiar with Lewa Nikkiso Switzerland as a supplier of strong systems 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 give you a design to unravel the technical problems,” says Ibald.
DSM is dedicated to continually bettering its processes and investing in expertise. This dedication, along with prior expertise with the brief service lives of the earlier pumps, led DSM to place special give consideration to reliable perform and a robust design in the course of the challenge planning part. The list of requirements also included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions relating to microbiological purity which would possibly be many times extra stringent than those for producing other meals products,” explains Ibald. “This meant that the new feed and booster pump needed to meet these tougher situations and every kind of contamination had to be ruled out to produce the widest attainable number of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a world science-oriented firm that is especially active in the areas of diet, well being, and sustainable living. DSM’s mission is to enhance the lives of all. Products and solutions from DSM handle a number of the world’s largest challenges while simultaneously creating financial, environmental, and societal value for all its stakeholders—including customers, workers, shareholders, and society at massive.
DSM delivers innovative solutions for the diet, animal vitamin, private care and aromatics, medical products, environmentally pleasant products and functions, in addition to new mobility and interconnectivity.
DSM and its affiliated corporations make use of more than 23,000 people and generate an annual net turnover of approximately 10 billion euros. The company was founded in 1902 and is listed on the Euronext Amsterdam inventory trade.
For more information, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit at the company premises to think about the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a kind G3F triplex course of diaphragm pump for the spray tower software. This pump includes a completely safe start-up operation, since a spring continuously holds the integrated sandwich diaphragm positioned in a impartial place.
This protects the diaphragm against incorrect positioning and prevents it from being damaged whereas the pump is starting up, rising system availability considerably. And the Lewa triplex is controlled using a pressure aid valve that is installed in the hydraulic half and could be configured for the precise situation. Therefore, the pump may be adapted to different operational situations so as to prevent any overloads that may come up. This ensures that the unit has an extended service life and clean regular operation for the whole system.
THE POWER OF DESIGN
In addition to the stress reduction valve and the spring control, the design of the diaphragm also plays an essential position in ensuring dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extremely long-lasting. They are linked to one another by way of optimistic interlocking in the course of the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and successfully prevents exterior contamination. As an extra security function, the DPS monitoring system from Lewa continuously screens the condition of the diaphragm. The monitoring unit promptly shows any damage to the gadget that results in elevated pressure in the diaphragm space.
This makes it attainable to hold out preventive upkeep and restore work before the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s often unnecessary 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 injury to a diaphragm is detected, production can continue with none issues as much as a planned upkeep stop. The parts can then get replaced rapidly and easily by releasing the cassette for the assembly.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does extra than just ensure dependable continuous operation. It can also 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 area with out dynamic seals, guaranteeing utterly clean and aseptic manufacturing circumstances. All pump heads that come into contact with the product are also electropolished, which makes it potential to ensure FDA-compliant pump operation.
Because the pump may be cleaned in place (CIP) using completely different alkaline and acidic agents and without prior dismantling, it is potential to meet the particular necessities for child food as well. The provisions for child food are 1,000 instances extra stringent than those for other products within the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we were capable of 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 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 out to be an indispensable part of manufacturing at the plant in Sisseln.
“In each section of the project, Lewa Nikkiso Switzerland demonstrated quick response occasions and well-founded experience, which made a key contribution to implementing the project successfully,” says Ibald. “Our specs with regard to quality, robustness, and hygiene were adopted to the letter in this project. As a result, our production has turn out to be noticeably extra efficient and reliable.”
FOR MORE INFORMATION
Lewa develops applied sciences and provides options for the huge array of applications amongst its prospects. Its merchandise are used mainly in the oil and fuel industry, in gas odorization, in refineries and petrochemicals, as well as in the production of plastics, detergents, and cleaners. Additional application areas embody the chemical business, cosmetics business, prescribed drugs and biotechnology, meals and beverage business, and energy utilities. For more data, go to www.lewa.com.
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