The Swiss subsidiary of Dutch firm DSM Nutritional Products AG uses the spray drying method when producing vitamin and carotenoid powders for the pharmaceutical and meals industries. The process uses pump technology to convey varied emulsions into a twig tower, where they’re dried into powder. But the feed and booster pump that was being used proved to be an uncertainty issue as a result 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 restore work.
However, it is rather expensive to switch a diaphragm or an entire system. DSM was in search of an alternate and finally made a discover once they talked to the pump consultants at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex course of diaphragm pump for the spray tower software. The drive unit contains a protected start-up mode that keeps the diaphragm positioned in the neutral place, and continuous regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s easy to meet the food industry’s stringent hygienic provisions.
one hundred PERCENT INTEGRATION
“Pump know-how plays a central position in drying oil-in-water emulsions for the meals and pharmaceutical industries. These emulsions contain substances corresponding to vitamins, carotenoids, or polyunsaturated fatty acids as active ingredients,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As part of the process chain, every pump is 100% integrated into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With the earlier system, the risk of unforeseen interruptions to this course of couldn’t be dominated out. As a end result, the totally different emulsions could not be processed further. In other words, it was not attainable to dry them into powder. The pump diaphragm was the explanation: it was usually too delicate to face up to the stress positioned on it when starting up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and generally meant that trouble-free operation couldn’t be guaranteed.
FINDING THE RIGHT PARTNER
In the course of looking for a reliable various, DSM received in touch with the Swiss subsidiary of pump producer Lewa.
“We were already conversant in Lewa Nikkiso Switzerland as a supplier of strong techniques with long service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it will be smart to affix forces with the experts from Lewa and come up with a design to resolve the technical issues,” says Ibald.
DSM is dedicated to continually bettering its processes and investing in expertise. This commitment, together with prior experience with the brief service lives of the previous pumps, led DSM to put special concentrate on reliable perform and a strong design during the project planning part. The listing of necessities additionally included a substantial variety of stringent hygienic provisions that needed to be fulfilled.
“Certain meals have provisions relating to microbiological purity that are many instances more stringent than those for producing different food products,” explains Ibald. “This meant that the brand new feed and booster pump needed to meet these tougher conditions and each sort of contamination needed to be dominated out to produce the widest attainable number of merchandise on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a global science-oriented firm that is especially energetic within the areas of diet, health, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and solutions from DSM handle a few of the world’s greatest challenges while concurrently creating financial, environmental, and societal value for all its stakeholders—including clients, employees, shareholders, and society at large.
DSM delivers revolutionary options for the vitamin, animal nutrition, private care and aromatics, medical products, environmentally friendly merchandise and purposes, as properly as new mobility and interconnectivity.
DSM and its affiliated firms make use of greater than 23,000 individuals and generate an annual internet turnover of roughly 10 billion euros. The firm was founded in 1902 and is listed on the Euronext Amsterdam stock change.
For more data, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to at the company premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a kind G3F triplex course of diaphragm pump for the spray tower application. This pump features a completely secure start-up operation, since a spring constantly holds the integrated sandwich diaphragm situated in a neutral place.
This protects the diaphragm against incorrect positioning and prevents it from being damaged whereas the pump is starting up, growing system availability substantially. And the Lewa triplex is controlled utilizing a stress aid valve that’s put in in the hydraulic part and could be configured for the precise scenario. Therefore, the pump can be tailored to different operational situations to be able to stop any overloads that 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 reduction valve and the spring control, the design of the diaphragm also performs an necessary function in guaranteeing reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extraordinarily long-lasting. They are related to every other via constructive 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 a further safety feature, the DPS monitoring system from Lewa constantly monitors the situation of the diaphragm. The monitoring unit promptly displays any harm to the device that results in elevated stress within the diaphragm space.
This makes it attainable to hold out preventive upkeep and restore work before the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it is often unnecessary to switch the pump off immediately, which means that neither the pumping course of nor spray drying are negatively impacted to a big extent. If injury to a diaphragm is detected, production can proceed without any problems up to a deliberate upkeep stop. The elements can then be replaced rapidly and easily by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does more than simply ensure dependable continuous operation. It can be a central part for fulfilling the stringent hygiene provisions that the spray tower utility is topic to. The Lewa triplex maintains a hermetically tight area without dynamic seals, guaranteeing fully clear and aseptic manufacturing 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 may be cleaned in place (CIP) utilizing totally different alkaline and acidic agents and with out prior dismantling, it’s potential to satisfy the particular necessities for baby meals as well. The provisions for baby meals are 1,000 occasions more stringent than these for other merchandise in the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we have been in a place 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 same year, 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 part of production on the plant in Sisseln.
“In each part of the challenge, Lewa Nikkiso Switzerland demonstrated fast response instances and well-founded experience, which made a key contribution to implementing the challenge successfully,” says Ibald. “Our specifications with regard to high quality, robustness, and hygiene had been followed to the letter on this project. As เกจวัดแรงดันไฟฟ้า , our production has turn out to be noticeably more efficient and reliable.”
FOR MORE INFORMATION
Lewa develops applied sciences and offers options for the huge array of applications amongst its customers. Its products are used mainly within the oil and fuel business, in fuel odorization, in refineries and petrochemicals, in addition to in the manufacturing of plastics, detergents, and cleaners. Additional application areas embrace the chemical industry, cosmetics business, prescription drugs and biotechnology, food and beverage trade, and vitality utilities. For more info, visit www.lewa.com.