The Swiss subsidiary of Dutch firm 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 makes use of pump expertise to convey various emulsions into a spray tower, the place 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 process tended to tear when the pump was began up. Generally, such production interruptions could be corrected via quick maintenance and repair work.
However, it is extremely costly to exchange a diaphragm or an entire system. DSM was looking for another and at last made a find once they talked to the pump consultants at Lewa Nikkiso Switzerland, who beneficial a Lewa triplex process diaphragm pump for the spray tower utility. The drive unit includes a protected 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 is easy to satisfy the food industry’s stringent hygienic provisions.
100 PERCENT INTEGRATION
“Pump expertise plays a central function in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions comprise substances corresponding to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as active components,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As a part of the process chain, each 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 risk of unforeseen interruptions to this process couldn’t be dominated out. As a outcome, the different emulsions could not be processed additional. In different words, it was not attainable to dry them into powder. เกจวัดแรงดันpsi was the explanation: it was often too sensitive to withstand the stress positioned on it when starting up the pump and would rupture. Replacing the diaphragm decreased the system’s service life and typically meant that trouble-free operation couldn’t be guaranteed.
FINDING THE RIGHT PARTNER
In the course of trying to find a reliable various, DSM obtained in contact with the Swiss subsidiary of pump manufacturer Lewa.
“We had been already familiar with Lewa Nikkiso Switzerland as a provider of robust methods with long service lives within the SFP sector. To ensure trouble-free spray drying, we thought it might be good to affix forces with the specialists from Lewa and provide you with a design to resolve the technical problems,” says Ibald.
DSM is dedicated to repeatedly enhancing its processes and investing in expertise. This dedication, together with prior expertise with the quick service lives of the earlier pumps, led DSM to place special focus on dependable operate and a sturdy design during the project planning phase. The record of necessities also included a substantial variety of stringent hygienic provisions that needed to be fulfilled.
“Certain meals have provisions relating to microbiological purity which are many instances extra stringent than those for producing different meals merchandise,” explains Ibald. “This meant that the model new feed and booster pump needed to meet these more challenging circumstances and each kind of contamination had to be ruled out to produce the widest attainable number of products on the system.”
ROYAL DSM: PARTNER PROFILE
Royal DSM is a world science-oriented firm that is particularly active within the areas of nutrition, health, and sustainable dwelling. DSM’s mission is to enhance the lives of all. Products and solutions from DSM tackle some of the world’s greatest challenges whereas simultaneously creating economic, environmental, and societal worth for all its stakeholders—including prospects, workers, shareholders, and society at massive.
DSM delivers revolutionary solutions for the diet, animal nutrition, personal care and aromatics, medical merchandise, environmentally friendly merchandise and applications, as properly as new mobility and interconnectivity.
DSM and its affiliated companies employ more than 23,000 people 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 more information, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION
After a go to at the firm premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a kind G3F triplex course of diaphragm pump for the spray tower utility. This pump features a completely safe start-up operation, since a spring repeatedly holds the built-in sandwich diaphragm situated in a impartial place.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being damaged while the pump is beginning up, rising system availability considerably. And the Lewa triplex is managed using a strain relief valve that’s put in within the hydraulic half and may be configured for the specific state of affairs. Therefore, the pump could be adapted to totally different operational situations to be able to stop any overloads that will arise. This ensures that the unit has a protracted service life and smooth common operation for the entire system.
THE POWER OF DESIGN
In addition to the strain reduction valve and the spring management, the design of the diaphragm additionally plays an necessary role in guaranteeing dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extraordinarily long-lasting. They are connected to each other via positive interlocking in the course of the discharge stroke and mechanical force-fitting during the suction stroke.
This makes the pump hermetically tight and effectively prevents exterior contamination. As a further security feature, the DPS monitoring system from Lewa constantly displays the situation of the diaphragm. The monitoring unit promptly shows any damage to the device that results in elevated strain within the diaphragm house.
This makes it potential to carry out preventive upkeep and restore work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s often unnecessary to change the pump off right away, which implies that neither the pumping process nor spray drying are negatively impacted to a significant extent. If injury to a diaphragm is detected, manufacturing can continue with none problems as much as a deliberate upkeep cease. The components can then get replaced shortly and easily by releasing the cassette for the meeting.
ASEPTIC, FDA-COMPLIANT OPERATION
The hermetically tight design of the method diaphragm pump does more than simply guarantee reliable steady operation. It can additionally be a central element 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 completely clear and aseptic production circumstances. All pump heads that come into contact with the product are also electropolished, which makes it attainable 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 is attainable to meet the special requirements for baby food as well. The provisions for baby food are 1,000 instances extra stringent than those for different merchandise within the food 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 acquired in June of 2018 and in September of the identical year, DSM Nutritional Products AG positioned an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has turn into an indispensable a half of manufacturing on the plant in Sisseln.
“In every part 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 were adopted to the letter in this venture. As a end result, our manufacturing has turn into noticeably more efficient and reliable.”
FOR MORE INFORMATION
Lewa develops applied sciences and supplies solutions for the vast array of applications amongst its prospects. Its merchandise are used mainly in the oil and gas industry, in gasoline odorization, in refineries and petrochemicals, as well as in the production of plastics, detergents, and cleaners. Additional utility areas embody the chemical business, cosmetics business, prescription drugs and biotechnology, food and beverage business, and power utilities. For more information, go to www.lewa.com.