Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

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 procedure makes use of pump know-how to convey various 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 issue as a outcome of the diaphragm required for the pumping course of tended to tear when the pump was started up. Generally, such manufacturing interruptions could be corrected through quick upkeep and repair work.
However, it is very expensive to exchange a diaphragm or a complete system. DSM was looking for another and finally made a find after they talked to the pump specialists at Lewa Nikkiso Switzerland, who recommended a Lewa triplex process diaphragm pump for the spray tower software. The drive unit includes a secure start-up mode that retains the diaphragm positioned within the neutral position, and continuous regulation using an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is straightforward to satisfy the food industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump know-how plays a central function in drying oil-in-water emulsions for the meals and pharmaceutical industries. These emulsions contain substances such as vitamins, carotenoids, or polyunsaturated fatty acids as energetic elements,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As a part of the process chain, each pump is 100% built-in into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With the previous system, the chance of unforeseen interruptions to this process couldn’t be ruled out. As a result, the different emulsions could not be processed additional. In other phrases, it was not potential to dry them into powder. The pump diaphragm was the rationale: it was often too sensitive to withstand the stress positioned on it when starting up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and typically meant that trouble-free operation couldn’t be assured.
FINDING THE RIGHT PARTNER
In the course of looking for a reliable different, DSM got in contact with the Swiss subsidiary of pump producer Lewa.
“We have been already familiar with Lewa Nikkiso Switzerland as a supplier of strong systems with lengthy service lives within the SFP sector. To guarantee trouble-free spray drying, we thought it might be sensible to hitch forces with the consultants from Lewa and give you a design to resolve the technical issues,” says Ibald.
DSM is committed to continually improving its processes and investing in know-how. This commitment, together with prior expertise with the short service lives of the previous pumps, led DSM to position particular concentrate on reliable perform and a robust design in the course of the project planning section. The list of requirements additionally included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions concerning microbiological purity which might be many occasions more stringent than these for producing different food products,” explains Ibald. “This meant that the brand new feed and booster pump had to meet these tougher conditions and each type of contamination needed to be ruled out to produce the widest possible number of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a global science-oriented firm that’s particularly lively in the areas of nutrition, well being, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and solutions from DSM tackle a few of the world’s largest challenges whereas simultaneously creating financial, environmental, and societal value for all its stakeholders—including prospects, workers, shareholders, and society at massive.
DSM delivers revolutionary options for the vitamin, animal diet, personal care and aromatics, medical merchandise, environmentally friendly products and purposes, in addition to new mobility and interconnectivity.
DSM and its affiliated firms employ greater than 23,000 folks and generate an annual web turnover of roughly 10 billion euros. The firm was based in 1902 and is listed on the Euronext Amsterdam stock change.
For more info, 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 beneficial a kind G3F triplex process diaphragm pump for the spray tower application. This pump contains a utterly safe start-up operation, since a spring repeatedly holds the built-in sandwich diaphragm situated in a neutral place.
This protects the diaphragm towards incorrect positioning and prevents it from being broken whereas the pump is starting up, rising system availability considerably. And the Lewa triplex is controlled utilizing a strain aid valve that’s put in in the hydraulic half and can be configured for the precise state of affairs. Therefore, the pump could be tailored to completely different operational situations so as to prevent any overloads which will arise. This ensures that the unit has a protracted service life and easy common operation for the entire system.
THE POWER OF DESIGN
In addition to the pressure relief valve and the spring management, 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 may be extraordinarily long-lasting. They are related to each other 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 effectively prevents exterior contamination. As a further security feature, the DPS monitoring system from Lewa continuously screens the condition of the diaphragm. The monitoring unit promptly shows any injury to the device that results in elevated pressure in the diaphragm house.
This makes it possible to carry out preventive maintenance and repair work before the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it’s often pointless to modify the pump off immediately, which signifies that neither the pumping course of nor spray drying are negatively impacted to a big extent. If harm to a diaphragm is detected, production can continue with none problems up to a planned maintenance stop. The parts can then be 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 simply ensure dependable 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 fully clear and aseptic manufacturing circumstances. All pump heads that come into contact with the product are also electropolished, which makes it possible to make sure FDA-compliant pump operation.
Because the pump can be cleaned in place (CIP) using totally different alkaline and acidic brokers and without prior dismantling, it’s possible to meet the particular necessities for baby meals as nicely. The provisions for child food are 1,000 times extra stringent than those for different products in the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we had been capable of rule out any contamination of the pumped medium and clearly meet the required hygiene commonplace.
Building blocks TIMES AND WELL-FOUNDED EXPERTISE
The first quote was received in June of 2018 and in September of the same 12 months, DSM Nutritional Products AG positioned an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has turn out to be an indispensable a part of manufacturing at the plant in Sisseln.
“In each phase of the venture, Lewa Nikkiso Switzerland demonstrated fast response occasions and well-founded experience, which made a key contribution to implementing the venture efficiently,” says Ibald. “Our specifications with regard to quality, robustness, and hygiene had been adopted to the letter on this project. As a outcome, our production has turn into noticeably more efficient and reliable.”
FOR MORE INFORMATION
Lewa develops technologies and provides solutions for the vast array of applications amongst its clients. Its merchandise are used mainly within the oil and fuel industry, in gas odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional software areas embody the chemical trade, cosmetics industry, prescription drugs and biotechnology, food and beverage industry, and vitality utilities. For Plain , visit www.lewa.com.
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