The Swiss subsidiary of Dutch company DSM Nutritional Products AG uses the spray drying methodology when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The procedure uses pump technology to convey various emulsions into a twig tower, the place they are dried into powder. But the feed and booster pump that was being used proved to be an uncertainty issue because the diaphragm required for the pumping process tended to tear when the pump was began up. Generally, such production interruptions may be corrected through instant maintenance and repair work.
However, it is very costly to exchange a diaphragm or a complete system. DSM was in search of an alternate and eventually made a find when they talked to the pump consultants at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex course of diaphragm pump for the spray tower utility. The drive unit contains a secure start-up mode that keeps the diaphragm positioned in the impartial place, and continuous regulation using an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is easy to meet the meals industry’s stringent hygienic provisions.
a hundred 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 part of the process chain, every pump is 100% built-in 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 outcome, the different emulsions couldn’t be processed additional. In other phrases, it was not attainable to dry them into powder. The pump diaphragm was the reason: it was typically too delicate to resist the stress placed on it when beginning up the pump and would rupture. Replacing the diaphragm reduced the system’s service life and sometimes meant that trouble-free operation could not be assured.
FINDING THE RIGHT PARTNER
In the course of looking for a dependable various, DSM received in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We have been already acquainted with Lewa Nikkiso Switzerland as a supplier of strong techniques with long service lives in the SFP sector. To ensure trouble-free spray drying, we thought it might be smart to affix forces with the experts from Lewa and give you a design to unravel the technical problems,” says Ibald.
DSM is dedicated to repeatedly enhancing its processes and investing in technology. This commitment, together with prior experience with the brief service lives of the earlier pumps, led DSM to position particular concentrate on reliable perform and a strong design through the challenge planning section. The record of necessities additionally included a considerable number of stringent hygienic provisions that needed to be fulfilled.
“Certain foods have provisions relating to microbiological purity which are many instances extra stringent than those for producing other food merchandise,” explains Ibald. “This meant that the brand new feed and booster pump had to meet these more challenging circumstances and each sort 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 global science-oriented firm that is particularly active within the areas of vitamin, well being, and sustainable dwelling. DSM’s mission is to improve the lives of all. Products and options from DSM handle a few of the world’s greatest challenges whereas concurrently creating economic, environmental, and societal worth for all its stakeholders—including customers, workers, shareholders, and society at large.
DSM delivers progressive solutions for the diet, animal diet, personal care and aromatics, medical merchandise, environmentally pleasant merchandise and purposes, in addition to new mobility and interconnectivity.
DSM and its affiliated corporations employ greater than 23,000 people and generate an annual web turnover of approximately 10 billion euros. The company was based in 1902 and is listed on the Euronext Amsterdam stock trade.
For more info, go to www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a visit at the firm premises to assume about the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a kind G3F triplex course of diaphragm pump for the spray tower utility. This pump contains a fully safe start-up operation, since a spring repeatedly 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, growing system availability considerably. And the Lewa triplex is managed utilizing a strain aid valve that is put in within the hydraulic half and could be configured for the specific scenario. Therefore, the pump can be tailored to completely different operational conditions so as to prevent any overloads that may arise. This ensures that the unit has a long service life and easy common operation for the entire system.
THE POWER OF DESIGN
In addition to the stress aid valve and the spring management, the design of the diaphragm additionally plays an necessary position in ensuring reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extraordinarily long-lasting. They are connected to every other by way of constructive interlocking in the course of the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As an extra safety function, the DPS monitoring system from Lewa repeatedly monitors the condition of the diaphragm. The monitoring unit promptly shows any injury to the system that results in increased 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 potentially contaminates the pumped fluid. Thus, it’s often pointless to switch the pump off instantly, which implies that neither the pumping process nor spray drying are negatively impacted to a significant extent. If harm to a diaphragm is detected, production can continue without any problems up to a planned upkeep stop. The components can then get replaced quickly and easily by releasing the cassette for the assembly.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the process diaphragm pump does more than simply ensure dependable continuous operation. It can also 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 completely clear and aseptic production conditions. 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 could be cleaned in place (CIP) utilizing totally different alkaline and acidic brokers and without prior dismantling, it is potential to meet the particular requirements for child meals as properly. The provisions for baby food are 1,000 times extra stringent than these for other merchandise within the food 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 standard.
เพรสเชอร์เกจ4นิ้ว TIMES AND WELL-FOUNDED EXPERTISE
The first quote was received in June of 2018 and in September of the identical year, DSM Nutritional Products AG placed an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has become an indispensable part of manufacturing on the plant in Sisseln.
“In each part of the venture, Lewa Nikkiso Switzerland demonstrated fast response times and well-founded experience, which made a key contribution to implementing the venture successfully,” says Ibald. “Our specs with regard to quality, robustness, and hygiene have been adopted to the letter in this venture. As a outcome, our production has become noticeably extra environment friendly and reliable.”
FOR MORE INFORMATION
Lewa develops technologies and supplies solutions for the huge array of functions among its prospects. Its products are used primarily in the oil and gasoline trade, in gasoline odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional utility areas embrace the chemical industry, cosmetics trade, prescription drugs and biotechnology, meals and beverage industry, and vitality utilities. For extra information, go to www.lewa.com.