Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

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 food industries. The process uses pump know-how to convey various emulsions into a sprig tower, the place they are dried into powder. But Soaring and booster pump that was getting used proved to be an uncertainty issue as a outcome of the diaphragm required for the pumping course of tended to tear when the pump was began up. Generally, such manufacturing interruptions can be corrected by way of instant upkeep and restore work.
However, it is extremely costly to replace a diaphragm or an entire system. DSM was seeking another and eventually made a discover once they talked to the pump consultants at Lewa Nikkiso Switzerland, who beneficial a Lewa triplex process diaphragm pump for the spray tower application. The drive unit contains a secure start-up mode that keeps the diaphragm situated in the impartial place, and steady regulation utilizing an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s simple to fulfill the food industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump technology plays a central position in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions include substances corresponding to vitamins, carotenoids, or polyunsaturated fatty acids as energetic components,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As part of the method chain, each pump is one hundred pc built-in 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 outcome, the completely different emulsions could not be processed additional. In other phrases, it was not potential to dry them into powder. The pump diaphragm was the explanation: it was usually too delicate to resist the stress placed on it when starting up the pump and would rupture. Replacing the diaphragm lowered the system’s service life and sometimes meant that trouble-free operation couldn’t be guaranteed.
FINDING THE RIGHT PARTNER
In the course of searching for a reliable different, DSM got in touch with the Swiss subsidiary of pump producer Lewa.
“We were already conversant in Lewa Nikkiso Switzerland as a supplier of strong systems with lengthy service lives in the SFP sector. To ensure trouble-free spray drying, we thought it will 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 know-how. This commitment, along with prior expertise with the brief service lives of the previous pumps, led DSM to place special give consideration to reliable function and a strong design during the venture planning part. The listing of requirements also included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions concerning microbiological purity which are many times extra stringent than these for producing other food merchandise,” explains Ibald. “This meant that the new feed and booster pump had to meet these more challenging situations and each kind of contamination needed to be dominated out to produce the widest attainable variety of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented company that is particularly active in the areas of vitamin, health, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and options from DSM address some of the world’s largest challenges whereas simultaneously creating economic, environmental, and societal worth for all its stakeholders—including prospects, workers, shareholders, and society at massive.
DSM delivers innovative solutions for the diet, animal nutrition, private care and aromatics, medical merchandise, environmentally friendly merchandise and functions, in addition to new mobility and interconnectivity.
DSM and its affiliated corporations make use of greater than 23,000 folks and generate an annual internet turnover of roughly 10 billion euros. The firm was based in 1902 and is listed on the Euronext Amsterdam stock trade.
For more info, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to at the company premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a sort G3F triplex course of 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 situated in a impartial place.
This protects the diaphragm against incorrect positioning and prevents it from being broken whereas the pump is beginning up, growing system availability substantially. And the Lewa triplex is managed utilizing a strain reduction valve that is installed within the hydraulic part and can be configured for the precise situation. Therefore, the pump could be tailored to totally different operational situations in order to prevent any overloads which will arise. This ensures that the unit has a protracted service life and clean regular operation for the entire system.
THE POWER OF DESIGN
In addition to the pressure reduction valve and the spring management, the design of the diaphragm also performs an important function in making certain 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 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 exterior contamination. As an additional safety function, the DPS monitoring system from Lewa continuously screens the condition of the diaphragm. The monitoring unit promptly shows any harm to the system that leads to increased stress in the diaphragm area.
This makes it possible to hold out preventive maintenance and repair work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s normally unnecessary to modify the pump off instantly, which means that neither the pumping course of nor spray drying are negatively impacted to a significant extent. If injury to a diaphragm is detected, manufacturing can proceed without any issues up to a deliberate upkeep stop. The components can then be replaced quickly and easily by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does extra than simply ensure reliable continuous operation. It is also a central element for fulfilling the stringent hygiene provisions that the spray tower software is topic to. The Lewa triplex maintains a hermetically tight house with out dynamic seals, guaranteeing fully clean and aseptic production situations. 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) utilizing completely different alkaline and acidic brokers and without prior dismantling, it is possible to meet the special requirements for child food as nicely. The provisions for baby food are 1,000 times extra stringent than those for other merchandise within the food 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 received in June of 2018 and in September of the identical year, 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 times and well-founded expertise, which made a key contribution to implementing the challenge successfully,” says Ibald. “Our specifications with regard to quality, robustness, and hygiene had been followed to the letter in this project. As a outcome, our production has become noticeably extra environment friendly and dependable.”
FOR MORE INFORMATION
Lewa develops technologies and provides solutions for the huge array of functions amongst its prospects. Its merchandise are used mainly in the oil and gasoline industry, in gasoline odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional application areas include the chemical business, cosmetics industry, prescription drugs and biotechnology, meals and beverage business, and energy utilities. For extra data, go to www.lewa.com.
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