The Swiss subsidiary of Dutch company DSM Nutritional Products AG uses the spray drying technique when producing vitamin and carotenoid powders for the pharmaceutical and meals industries. The process uses pump know-how to convey varied emulsions into a twig tower, the place they are dried into powder. But the feed and booster pump that was getting used proved to be an uncertainty issue as a end result of the diaphragm required for the pumping process tended to tear when the pump was started up. Generally, such manufacturing interruptions can be corrected through quick maintenance and restore work.
However, it is very expensive to replace a diaphragm or a complete system. DSM was looking for an alternative and eventually made a find once they talked to the pump consultants at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower application. The drive unit includes a safe start-up mode that retains the diaphragm situated within the neutral place, and steady regulation utilizing 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.
100 PERCENT INTEGRATION
“Pump technology performs a central role in drying oil-in-water emulsions for the meals and pharmaceutical industries. These emulsions include substances corresponding to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as energetic elements,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As a half of the process chain, every pump is 100 percent built-in into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With the earlier system, the chance of unforeseen interruptions to this process couldn’t be dominated out. As a end result, the completely different emulsions couldn’t be processed further. In other phrases, it was not potential to dry them into powder. The pump diaphragm was the rationale: it was typically too sensitive to face up to the stress placed on it when beginning up the pump and would rupture. Replacing the diaphragm lowered the system’s service life and generally meant that trouble-free operation couldn’t be assured.
FINDING THE RIGHT PARTNER
In the course of trying to find a reliable alternative, DSM received in contact with the Swiss subsidiary of pump producer Lewa.
“We have been already familiar with Lewa Nikkiso Switzerland as a supplier of strong methods with lengthy service lives within the SFP sector. To guarantee trouble-free spray drying, we thought it would be sensible to hitch forces with the specialists from Lewa and provide you with a design to solve the technical problems,” says Ibald.
DSM is dedicated to repeatedly enhancing its processes and investing in expertise. This dedication, together with prior experience with the quick service lives of the previous pumps, led DSM to put particular focus on reliable function and a robust design during the project planning section. The listing of requirements additionally included a considerable variety of stringent hygienic provisions that had to be fulfilled.
“Certain meals have provisions concerning microbiological purity which may be many times extra stringent than these for producing different meals merchandise,” explains Ibald. “This meant that the new feed and booster pump needed to meet these tougher situations and each kind of contamination had to be dominated out to provide the widest attainable number of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a worldwide science-oriented company that is particularly lively in the areas of diet, well being, and sustainable residing. DSM’s mission is to improve the lives of all. Products and solutions from DSM handle a few of the world’s biggest challenges while concurrently creating financial, environmental, and societal worth for all its stakeholders—including clients, staff, shareholders, and society at giant.
DSM delivers progressive options for the nutrition, animal vitamin, private care and aromatics, medical products, environmentally friendly merchandise and purposes, as nicely as new mobility and interconnectivity.
DSM and its affiliated firms make use of greater than 23,000 folks and generate an annual internet turnover of approximately 10 billion euros. The firm was founded in 1902 and is listed on the Euronext Amsterdam inventory trade.
For extra info, go to www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit at the firm premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a type G3F triplex process diaphragm pump for the spray tower application. This pump contains a completely safe start-up operation, since a spring continuously holds the integrated sandwich diaphragm located in a neutral place.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being broken while the pump is starting up, rising system availability substantially. And the Lewa triplex is managed using a strain relief valve that’s installed in the hydraulic part and can be configured for the specific situation. Therefore, the pump may be tailored to totally different operational situations so as to prevent any overloads which will arise. This ensures that the unit has a long service life and clean common operation for the whole system.
THE POWER OF DESIGN
In addition to the stress aid valve and the spring management, the design of the diaphragm also performs an important function in guaranteeing dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extraordinarily long-lasting. They are linked to one another by way of constructive interlocking in the course of the discharge stroke and mechanical force-fitting during the suction stroke.
This makes the pump hermetically tight and successfully prevents exterior contamination. As an additional security function, the DPS monitoring system from Lewa constantly monitors the condition of the diaphragm. The monitoring unit promptly displays any damage to the system that leads to increased strain within the diaphragm house.
This makes it possible to carry out preventive upkeep and repair work earlier than the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it’s often pointless to change the pump off instantly, which implies that neither the pumping course of nor spray drying are negatively impacted to a major extent. If เกจวัดแรงดัน4นิ้วราคา to a diaphragm is detected, manufacturing can continue without any issues up to a planned upkeep stop. The parts can then get replaced shortly 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 just guarantee dependable continuous operation. It can also be a central element for fulfilling the stringent hygiene provisions that the spray tower application is topic to. The Lewa triplex maintains a hermetically tight house without dynamic seals, guaranteeing fully clear and aseptic production situations. 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 could be cleaned in place (CIP) using different alkaline and acidic brokers and with out prior dismantling, it is attainable to satisfy the special requirements for baby meals as properly. The provisions for baby food are 1,000 instances extra stringent than these for different products within the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we were 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 obtained 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 become an indispensable a part of manufacturing on the plant in Sisseln.
“In each section of the project, Lewa Nikkiso Switzerland demonstrated fast response occasions and well-founded experience, which made a key contribution to implementing the venture efficiently,” says Ibald. “Our specs with regard to quality, robustness, and hygiene have been followed to the letter in this challenge. As a result, our manufacturing has turn out to be noticeably extra environment friendly and reliable.”
FOR MORE INFORMATION
Lewa develops technologies and supplies solutions for the huge array of applications amongst its clients. Its merchandise are used mainly in the oil and gas industry, in gasoline odorization, in refineries and petrochemicals, in addition to in the production of plastics, detergents, and cleaners. Additional utility areas embrace the chemical business, cosmetics industry, prescribed drugs and biotechnology, meals and beverage industry, and vitality utilities. For more data, go to www.lewa.com.
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