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 meals industries. The procedure uses pump know-how to convey varied emulsions into a spray tower, the place they’re dried into powder. But the feed and booster pump that was being used proved to be an uncertainty factor as a end result of the diaphragm required for the pumping process tended to tear when the pump was began up. Generally, such production interruptions may be corrected by way of immediate maintenance and repair work.
However, it is rather costly to exchange a diaphragm or an entire system. DSM was in search of another and finally made a discover when they talked to the pump experts at Lewa Nikkiso Switzerland, who beneficial a Lewa triplex course of diaphragm pump for the spray tower software. The drive unit features a secure start-up mode that keeps the diaphragm situated within the neutral position, and continuous regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is easy to meet the food industry’s stringent hygienic provisions.
“Pump expertise performs a central role in drying oil-in-water emulsions for the food 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 100 percent integrated into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With the previous system, the danger of unforeseen interruptions to this process couldn’t be ruled out. As a end result, the completely different emulsions could not be processed further. In different phrases, it was not possible to dry them into powder. The pump diaphragm was the explanation: it was usually too delicate to withstand the stress positioned on it when beginning up the pump and would rupture. Replacing the diaphragm decreased the system’s service life and generally meant that trouble-free operation could not be guaranteed.
In the course of trying to find a dependable different, DSM got in touch with the Swiss subsidiary of pump producer Lewa.
“We had been already conversant in Lewa Nikkiso Switzerland as a supplier of robust techniques with long service lives within the SFP sector. To ensure trouble-free spray drying, we thought it will be sensible to hitch forces with the consultants from Lewa and give you a design to resolve the technical problems,” says Ibald.
DSM is committed to continually improving its processes and investing in expertise. This commitment, along with prior expertise with the short service lives of the earlier pumps, led DSM to put particular give attention to dependable function and a sturdy design during the project planning part. The record of requirements additionally included a substantial number of stringent hygienic provisions that had to be fulfilled.
“Certain meals have provisions concerning microbiological purity which might be many instances extra stringent than those for producing other meals merchandise,” explains Ibald. “This meant that the model new feed and booster pump needed to meet these more challenging conditions and each type of contamination needed to be dominated out to produce the widest possible variety of products on the system.”
Royal DSM is a world science-oriented company that’s particularly lively within the areas of nutrition, well being, and sustainable residing. DSM’s mission is to enhance the lives of all. Products and options from DSM address a number of the world’s greatest challenges while concurrently creating economic, environmental, and societal value for all its stakeholders—including clients, staff, shareholders, and society at massive.
DSM delivers revolutionary solutions for the nutrition, animal diet, private care and aromatics, medical merchandise, environmentally friendly products and functions, as properly as new mobility and interconnectivity.
DSM and its affiliated companies employ more than 23,000 individuals 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 trade.
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After a visit at the firm premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a kind G3F triplex course of diaphragm pump for the spray tower utility. This pump features a completely secure start-up operation, since a spring repeatedly holds the integrated sandwich diaphragm positioned in a neutral position.
This protects the diaphragm against incorrect positioning and prevents it from being broken while the pump is beginning up, rising system availability considerably. And the Lewa triplex is controlled utilizing a pressure relief valve that is installed in the hydraulic half and could be configured for the specific scenario. Therefore, the pump may be tailored to totally different operational situations to find a way to prevent any overloads which will come up. This ensures that the unit has a long service life and easy regular operation for the entire system.
In addition to the stress aid valve and the spring control, the design of the diaphragm additionally plays an necessary role in guaranteeing reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which might be extraordinarily long-lasting. They are related to each other by way of constructive interlocking during the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As เพรสเชอร์เกจnuovafima , the DPS monitoring system from Lewa constantly screens the situation of the diaphragm. The monitoring unit promptly shows any injury to the device that results in increased strain in the diaphragm house.
This makes it potential to carry 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 instantly, which means that neither the pumping process nor spray drying are negatively impacted to a big extent. If damage to a diaphragm is detected, manufacturing can continue without any problems as a lot as a deliberate upkeep cease. The parts can then be replaced shortly and easily by releasing the cassette for the assembly.
The hermetically tight design of the process diaphragm pump does extra than simply guarantee reliable continuous operation. It can be a central component for fulfilling the stringent hygiene provisions that the spray tower application is subject to. The Lewa triplex maintains a hermetically tight area with out dynamic seals, guaranteeing completely clean and aseptic manufacturing conditions. All pump heads that come into contact with the product are also electropolished, which makes it attainable to ensure FDA-compliant pump operation.
Because the pump can be cleaned in place (CIP) using completely different alkaline and acidic agents and without prior dismantling, it’s potential to fulfill the special requirements for child food as well. The provisions for baby meals are 1,000 times extra stringent than those for different products within the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we were in a place to rule out any contamination of the pumped medium and clearly meet the required hygiene normal.
The first quote was received in June of 2018 and in September of the same yr, DSM Nutritional Products AG positioned an order for the triplex process diaphragm pump. In operation since April 2019, the pump has become an indispensable a half of production at the plant in Sisseln.
“In every section of the project, Lewa Nikkiso Switzerland demonstrated quick response instances and well-founded expertise, which made a key contribution to implementing the venture successfully,” says Ibald. “Our specs with regard to high quality, robustness, and hygiene have been adopted to the letter on this project. As a outcome, our production has turn into noticeably more environment friendly and dependable.”
Lewa develops applied sciences and supplies options for the vast array of functions amongst its customers. Its products are used mainly within the oil and gas business, in gas odorization, in refineries and petrochemicals, as well as within the manufacturing of plastics, detergents, and cleaners. Additional software areas include the chemical business, cosmetics industry, prescription drugs and biotechnology, meals and beverage industry, and power utilities. For more info, go to