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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 uses pump technology to convey varied emulsions into a spray 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 production interruptions could be corrected via immediate maintenance and repair work.
However, it is very expensive to exchange a diaphragm or a whole system. DSM was seeking an alternative and finally made a find after they talked to the pump experts at Lewa Nikkiso Switzerland, who beneficial a Lewa triplex course of diaphragm pump for the spray tower utility. The drive unit includes a protected start-up mode that retains the diaphragm located in the neutral place, 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.
100 PERCENT INTEGRATION
“Pump technology plays a central function in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions contain substances similar to vitamins, carotenoids, or polyunsaturated fatty acids as energetic elements,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As part of the method chain, every 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 danger of unexpected interruptions to this course of couldn’t be dominated out. As a outcome, the totally different emulsions could not be processed further. In different words, it was not attainable to dry them into powder. The pump diaphragm was the reason: it was typically too delicate to withstand the stress positioned on it when beginning up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and generally meant that trouble-free operation could not be assured.
FINDING THE RIGHT PARTNER
In the course of searching for a reliable different, DSM obtained in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We have been already acquainted with Lewa Nikkiso Switzerland as a provider of sturdy techniques with lengthy service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it will be good to join forces with the consultants from Lewa and provide you with a design to solve the technical problems,” says Ibald.
เกจวัดแรงลม is dedicated to continually enhancing its processes and investing in expertise. This commitment, together with prior expertise with the short service lives of the previous pumps, led DSM to place particular give consideration to dependable function and a sturdy design through the challenge planning phase. The record of requirements also included a considerable number of stringent hygienic provisions that needed to be fulfilled.
“Certain foods have provisions regarding microbiological purity that are many times more stringent than those for producing different meals products,” explains Ibald. “This meant that the new feed and booster pump had to meet these more challenging circumstances and every sort of contamination had to be ruled out to provide the widest possible number of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a world science-oriented firm that is especially lively in the areas of vitamin, health, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and options from DSM tackle a few of the world’s biggest challenges whereas concurrently creating financial, environmental, and societal worth for all its stakeholders—including clients, staff, shareholders, and society at massive.
DSM delivers revolutionary solutions for the nutrition, animal nutrition, private care and aromatics, medical products, environmentally friendly products 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 company was based in 1902 and is listed on the Euronext Amsterdam stock trade.
For extra information, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to at the firm premises to assume about the spatial and technical parameters, Lewa Nikkiso Switzerland recommended a kind G3F triplex process diaphragm pump for the spray tower application. This pump contains a fully secure start-up operation, since a spring continuously holds the integrated sandwich diaphragm positioned in a neutral place.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged whereas the pump is beginning up, increasing system availability considerably. And the Lewa triplex is controlled using a stress aid valve that’s installed within the hydraulic half and may be configured for the precise scenario. Therefore, the pump can be tailored to different operational conditions to be able to prevent any overloads that will come up. This ensures that the unit has a protracted service life and clean common operation for the complete system.
THE POWER OF DESIGN
In addition to the pressure aid valve and the spring management, the design of the diaphragm also plays an essential role in ensuring reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extremely long-lasting. They are linked to one another through constructive interlocking during the discharge stroke and mechanical force-fitting in the course of the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As an extra safety feature, the DPS monitoring system from Lewa constantly monitors the situation of the diaphragm. The monitoring unit promptly shows any injury to the system that leads to elevated strain 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 probably contaminates the pumped fluid. Thus, it’s usually unnecessary to modify the pump off immediately, which implies that neither the pumping process nor spray drying are negatively impacted to a major extent. If harm to a diaphragm is detected, manufacturing can proceed with none issues as a lot as a planned maintenance cease. The parts can then get replaced rapidly and simply by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does extra than just guarantee reliable continuous operation. It is also a central component for fulfilling the stringent hygiene provisions that the spray tower utility is subject to. The Lewa triplex maintains a hermetically tight space with out dynamic seals, guaranteeing utterly clean and aseptic production circumstances. All pump heads that come into contact with the product are additionally electropolished, which makes it attainable to make sure FDA-compliant pump operation.
Because the pump can be cleaned in place (CIP) utilizing totally different alkaline and acidic agents and without prior dismantling, it’s attainable to meet the particular requirements for baby meals as well. The provisions for baby food are 1,000 times more stringent than those for other merchandise in the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we had been 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 received in June of 2018 and in September of the identical 12 months, DSM Nutritional Products AG positioned an order for the triplex process 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 every section of the venture, Lewa Nikkiso Switzerland demonstrated quick response occasions and well-founded experience, which made a key contribution to implementing the challenge efficiently,” says Ibald. “Our specs with regard to high quality, robustness, and hygiene were followed to the letter on this challenge. As a outcome, our manufacturing has turn into noticeably extra environment friendly and reliable.”
FOR MORE INFORMATION
Lewa develops applied sciences and supplies options for the huge array of applications amongst its prospects. Its products are used primarily within the oil and gasoline business, in gas odorization, in refineries and petrochemicals, as nicely as in the production of plastics, detergents, and cleaners. Additional software areas embrace the chemical business, cosmetics business, prescribed drugs and biotechnology, meals and beverage business, and vitality utilities. For more information, visit www.lewa.com.
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