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 meals industries. The procedure uses pump technology to convey various emulsions into a twig tower, the place they’re dried into powder. But the feed and booster pump that was getting used proved to be an uncertainty issue as a outcome of the diaphragm required for the pumping process tended to tear when the pump was started up. Generally, such production interruptions can be corrected by way of instant maintenance and restore work.
However, it is rather expensive to switch a diaphragm or an entire system. DSM was looking for another and at last made a discover when they talked to the pump experts at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower software. The drive unit includes a secure start-up mode that keeps the diaphragm located within the impartial position, and continuous regulation utilizing an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is straightforward to satisfy the food industry’s stringent hygienic provisions.
100 PERCENT INTEGRATION
“Pump know-how plays a central position in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions comprise substances similar to vitamins, carotenoids, or polyunsaturated fatty acids as energetic ingredients,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As 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 the previous system, the risk of unforeseen interruptions to this process couldn’t be dominated out. As a end result, the completely different emulsions couldn’t be processed additional. In different words, it was not attainable to dry them into powder. The pump diaphragm was the explanation: it was often too sensitive 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 could not be assured.
FINDING THE RIGHT PARTNER
In the course of searching for a reliable alternative, DSM obtained in touch with the Swiss subsidiary of pump producer Lewa.
“We had been already familiar with Lewa Nikkiso Switzerland as a provider of robust systems with lengthy service lives within the SFP sector. To guarantee trouble-free spray drying, we thought it might be smart to join forces with the experts from Lewa and provide you with a design to solve the technical issues,” says Ibald.
DSM is committed to continually enhancing its processes and investing in technology. This commitment, along with prior expertise with the quick service lives of the earlier pumps, led DSM to position particular focus on reliable operate and a sturdy design during the project planning part. The record of necessities also included a substantial number of stringent hygienic provisions that needed to be fulfilled.
“Certain foods have provisions regarding microbiological purity which might be many occasions more stringent than those for producing different food products,” explains Ibald. “This meant that the new feed and booster pump had to meet these more challenging circumstances and every type of contamination had to be dominated out to produce the widest potential variety of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented firm that’s particularly energetic in the areas of vitamin, 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 greatest challenges whereas simultaneously creating financial, environmental, and societal worth for all its stakeholders—including prospects, workers, shareholders, and society at massive.
DSM delivers progressive solutions for the nutrition, animal nutrition, private care and aromatics, medical merchandise, environmentally friendly merchandise and purposes, as well as new mobility and interconnectivity.
DSM and its affiliated firms employ more than 23,000 people and generate an annual web turnover of roughly 10 billion euros. The company was founded in 1902 and is listed on the Euronext Amsterdam inventory change.
For extra data, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to at the firm premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a kind G3F triplex process diaphragm pump for the spray tower utility. This pump includes a utterly secure start-up operation, since a spring constantly holds the integrated sandwich diaphragm situated in a neutral position.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being damaged whereas the pump is beginning up, rising system availability considerably. And the Lewa triplex is controlled using a pressure reduction valve that’s put in within the hydraulic half and could be configured for the particular situation. Therefore, compound gauge ราคา may be adapted to completely different operational situations to have the ability to forestall any overloads that may come up. This ensures that the unit has a long service life and smooth regular operation for the complete system.
THE POWER OF DESIGN
In addition to the pressure reduction valve and the spring control, the design of the diaphragm also performs an essential function in ensuring reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extremely long-lasting. They are connected to each other via optimistic 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 external contamination. As an additional security function, the DPS monitoring system from Lewa continuously screens the condition of the diaphragm. The monitoring unit promptly shows any harm to the device that results in increased stress within the diaphragm area.
This makes it potential to hold out preventive maintenance and restore work before the diaphragm even begins to rupture and probably contaminates the pumped fluid. Thus, it’s usually pointless to modify the pump off right away, which implies that neither the pumping process nor spray drying are negatively impacted to a major extent. If injury to a diaphragm is detected, production can proceed without any issues as a lot as a deliberate upkeep stop. The parts can then get replaced shortly and simply by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the method diaphragm pump does more than just guarantee reliable steady operation. It is also a central part for fulfilling the stringent hygiene provisions that the spray tower utility is subject to. The Lewa triplex maintains a hermetically tight area with out dynamic seals, guaranteeing completely clean and aseptic production conditions. 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 can be cleaned in place (CIP) using totally different alkaline and acidic agents and with out prior dismantling, it’s possible to meet the particular requirements for child meals as properly. The provisions for child food are 1,000 instances more stringent than these for different products 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 commonplace.
QUICK RESPONSE TIMES AND WELL-FOUNDED EXPERTISE
The first quote was obtained 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 half of production at the plant in Sisseln.
“In each phase of the venture, Lewa Nikkiso Switzerland demonstrated quick response instances 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 have been adopted to the letter in this project. As a outcome, our production has become noticeably extra efficient and dependable.”
FOR MORE INFORMATION
Lewa develops technologies and offers solutions for the huge array of applications among its customers. Its products are used primarily in the oil and fuel business, in gas odorization, in refineries and petrochemicals, in addition to within the production of plastics, detergents, and cleaners. Additional software areas embrace the chemical trade, cosmetics industry, prescribed drugs and biotechnology, food and beverage trade, and energy utilities. For more information, go to www.lewa.com.
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