Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

The Swiss subsidiary of Dutch firm DSM Nutritional Products AG uses the spray drying methodology when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The process makes use of pump know-how to convey varied emulsions into a spray tower, the place 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 manufacturing interruptions can be corrected via immediate maintenance and repair work.
However, it is very expensive to exchange a diaphragm or a complete system. DSM was in search of another and eventually made a discover once they talked to the pump experts at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower utility. The drive unit includes a secure start-up mode that keeps the diaphragm situated within the neutral place, and continuous regulation utilizing an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s simple to meet the meals industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump technology performs a central role in drying oil-in-water emulsions for the food and pharmaceutical industries. เกจ์ออกซิเจนsumo contain substances corresponding to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as energetic components,” 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 earlier system, the danger of unexpected interruptions to this course of couldn’t be ruled out. As a result, the completely different emulsions couldn’t be processed additional. In other phrases, it was not potential to dry them into powder. The pump diaphragm was the explanation: it was typically too sensitive to withstand the stress positioned on it when beginning up the pump and would rupture. Replacing the diaphragm lowered the system’s service life and typically meant that trouble-free operation couldn’t be assured.
FINDING THE RIGHT PARTNER
In the course of trying to find a reliable various, DSM got in contact with the Swiss subsidiary of pump producer Lewa.
“We were already conversant in Lewa Nikkiso Switzerland as a provider of robust systems with lengthy service lives in the SFP sector. To ensure trouble-free spray drying, we thought it might be sensible to join forces with the consultants from Lewa and provide you with a design to unravel the technical issues,” says Ibald.
DSM is committed to repeatedly enhancing its processes and investing in know-how. This dedication, together with prior experience with the short service lives of the previous pumps, led DSM to place particular focus on reliable perform and a sturdy design through the project planning phase. The listing of requirements also included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain foods have provisions regarding microbiological purity that are many instances more stringent than these for producing different food merchandise,” explains Ibald. “This meant that the new feed and booster pump needed to meet these more challenging circumstances and each type of contamination had to be ruled out to produce the widest possible variety of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented firm that is particularly lively within the areas of vitamin, well being, and sustainable living. DSM’s mission is to enhance the lives of all. Products and options from DSM handle a number of the world’s greatest challenges whereas concurrently creating economic, environmental, and societal worth for all its stakeholders—including customers, staff, shareholders, and society at massive.
DSM delivers progressive options for the nutrition, animal nutrition, personal care and aromatics, medical merchandise, environmentally pleasant merchandise and functions, in addition to new mobility and interconnectivity.
DSM and its affiliated companies employ more than 23,000 people and generate an annual web turnover of roughly 10 billion euros. The company was based in 1902 and is listed on the Euronext Amsterdam stock trade.
For extra data, go to www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit on the firm premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland recommended a sort G3F triplex process diaphragm pump for the spray tower software. This pump contains a completely safe start-up operation, since a spring repeatedly holds the built-in sandwich diaphragm positioned in a impartial place.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged while the pump is starting up, growing system availability considerably. And the Lewa triplex is controlled using a pressure reduction valve that’s installed in the hydraulic half and could be configured for the precise situation. Therefore, the pump could be adapted to completely different operational conditions to be able to prevent any overloads that may come up. This ensures that the unit has a long service life and easy common operation for the complete system.
THE POWER OF DESIGN
In addition to the stress aid valve and the spring control, the design of the diaphragm also plays an important function in ensuring reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extremely long-lasting. They are linked to each other through optimistic interlocking during the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and successfully prevents exterior contamination. As a further security feature, the DPS monitoring system from Lewa constantly monitors the situation of the diaphragm. The monitoring unit promptly displays any damage to the system that leads to elevated stress within the diaphragm area.
This makes it potential to carry out preventive maintenance and repair work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s usually unnecessary to change the pump off instantly, which means that neither the pumping course of nor spray drying are negatively impacted to a significant extent. If harm to a diaphragm is detected, manufacturing can continue with none problems up to a planned upkeep stop. The parts can then be replaced quickly and easily by releasing the cassette for the assembly.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the method diaphragm pump does more than simply guarantee reliable continuous operation. It can also be a central part for fulfilling the stringent hygiene provisions that the spray tower software is subject 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 additionally electropolished, which makes it possible to make sure FDA-compliant pump operation.
Because the pump could be cleaned in place (CIP) utilizing different alkaline and acidic brokers and with out prior dismantling, it is potential to meet the special requirements for baby food as nicely. The provisions for baby food are 1,000 times more stringent than those for other products in the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we were in a position to 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 received in June of 2018 and in September of the identical 12 months, 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 part of manufacturing at the plant in Sisseln.
“In each part of the challenge, Lewa Nikkiso Switzerland demonstrated quick response instances and well-founded experience, which made a key contribution to implementing the project efficiently,” says Ibald. “Our specs with regard to quality, robustness, and hygiene have been followed to the letter on this challenge. As a outcome, our production has turn into noticeably more environment friendly and reliable.”
FOR MORE INFORMATION
Lewa develops technologies and offers options for the vast array of applications among its clients. Its products are used mainly in the oil and gas business, in gasoline odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional software areas embrace the chemical business, cosmetics trade, prescription drugs and biotechnology, meals and beverage trade, and power utilities. For more info, go to www.lewa.com.
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