The Swiss subsidiary of Dutch company DSM Nutritional Products AG makes use of the spray drying technique when producing vitamin and carotenoid powders for the pharmaceutical and meals industries. The procedure uses pump expertise to convey various emulsions into a spray tower, where they’re 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 process tended to tear when the pump was started up. Generally, such production interruptions may be corrected via instant maintenance and repair work.
However, it is very costly to replace a diaphragm or an entire system. DSM was in search of an alternative and finally made a discover after they talked to the pump specialists at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower software. The drive unit contains a safe start-up mode that retains the diaphragm situated in the neutral position, and steady regulation using an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s simple to satisfy the food industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump expertise performs a central position in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions comprise substances similar to vitamins, carotenoids, or polyunsaturated fatty acids as energetic elements,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As part of the process 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 unexpected interruptions to this course of couldn’t be dominated out. As a end result, the totally different emulsions couldn’t be processed further. In different words, it was not attainable to dry them into powder. The pump diaphragm was the rationale: it was typically too sensitive to withstand 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 could not be guaranteed.
FINDING THE RIGHT PARTNER
In the course of trying to find a reliable alternative, DSM got in contact with the Swiss subsidiary of pump producer Lewa.
“We were already familiar with Lewa Nikkiso Switzerland as a provider of sturdy techniques with lengthy service lives in the SFP sector. To ensure trouble-free spray drying, we thought it will be good to join forces with the consultants from Lewa and give you a design to solve the technical issues,” says Ibald.
DSM is committed to repeatedly improving its processes and investing in technology. This dedication, along with prior expertise with the short service lives of the previous pumps, led DSM to place particular concentrate on reliable perform and a robust design during the challenge planning phase. The list of necessities additionally included a substantial number of stringent hygienic provisions that needed to be fulfilled.
“Certain foods have provisions regarding microbiological purity which are many times extra stringent than these for producing other meals merchandise,” explains Ibald. “This meant that the new feed and booster pump needed to meet these more difficult situations and every kind of contamination needed to be dominated out to produce the widest attainable variety of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a world science-oriented firm that is particularly active in the areas of diet, health, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and solutions from DSM address a variety of the world’s largest challenges while concurrently creating financial, environmental, and societal worth for all its stakeholders—including prospects, employees, shareholders, and society at large.
DSM delivers progressive options for the nutrition, animal vitamin, private care and aromatics, medical products, environmentally pleasant merchandise and functions, in addition to new mobility and interconnectivity.
DSM and its affiliated companies employ greater than 23,000 people and generate an annual net turnover of approximately 10 billion euros. The company was founded in 1902 and is listed on the Euronext Amsterdam inventory exchange.
For extra data, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit at the company premises to think about the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a sort G3F triplex process diaphragm pump for the spray tower application. This pump contains a completely secure start-up operation, since a spring continuously holds the integrated sandwich diaphragm positioned in a neutral place.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being damaged while the pump is beginning up, increasing system availability substantially. And the Lewa triplex is managed utilizing a pressure aid valve that is installed within the hydraulic part and may be configured for the specific state of affairs. Therefore, the pump can be tailored to completely different operational conditions so as to stop any overloads that may arise. This ensures that the unit has a long service life and smooth common operation for the whole system.
THE POWER OF DESIGN
In addition to the stress aid valve and the spring control, the design of the diaphragm also performs an essential position in ensuring dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extremely long-lasting. They are related to each other through optimistic interlocking through the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As an additional security characteristic, the DPS monitoring system from Lewa continuously displays the condition of the diaphragm. The monitoring unit promptly displays any injury to the device that results in increased strain within the diaphragm space.
This makes it attainable to carry out preventive upkeep and repair work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it is often unnecessary to modify the pump off right away, which means that neither the pumping process nor spray drying are negatively impacted to a significant extent. If injury to a diaphragm is detected, production can proceed with none issues up to a deliberate upkeep stop. The components can then get replaced rapidly and simply by releasing the cassette for the assembly.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does more than just ensure reliable continuous operation. It can 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 space without dynamic seals, guaranteeing utterly clean and aseptic production conditions. 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 different alkaline and acidic brokers and without prior dismantling, it’s possible to fulfill the special necessities for baby food as well. The provisions for child food are 1,000 times more stringent than these for different merchandise in the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we have been capable of 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 obtained in June of 2018 and in September of the same yr, 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 production on the plant in Sisseln.
“In digital pressure gauge ราคา of the venture, Lewa Nikkiso Switzerland demonstrated quick response times and well-founded experience, which made a key contribution to implementing the venture successfully,” says Ibald. “Our specs with regard to high quality, robustness, and hygiene had been followed to the letter on this project. As a result, our production has turn into noticeably more environment friendly and reliable.”
FOR MORE INFORMATION
Lewa develops applied sciences and supplies options for the vast array of functions amongst its customers. Its products are used mainly in the oil and gasoline trade, in gas odorization, in refineries and petrochemicals, in addition to in the manufacturing of plastics, detergents, and cleaners. Additional utility areas include the chemical trade, cosmetics business, prescribed drugs and biotechnology, food and beverage trade, and energy utilities. For extra data, go to www.lewa.com.
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