The Swiss subsidiary of Dutch firm DSM Nutritional Products AG uses the spray drying technique when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The process uses pump expertise to convey varied emulsions into a spray 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 result of the diaphragm required for the pumping course of tended to tear when the pump was started up. Generally, digital pressure gauge can be corrected through quick maintenance and repair work.
However, it is rather costly to switch a diaphragm or a whole system. DSM was seeking another and finally made a discover once they talked to the pump consultants at Lewa Nikkiso Switzerland, who recommended a Lewa triplex course of diaphragm pump for the spray tower software. The drive unit includes a protected start-up mode that keeps the diaphragm positioned in 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 fulfill the meals industry’s stringent hygienic provisions.
100 PERCENT INTEGRATION

“Pump know-how plays a central role 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 lively elements,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As a part of the method chain, every 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 earlier system, the danger of unforeseen interruptions to this course of couldn’t be ruled out. As a result, the completely different emulsions could not be processed additional. In different phrases, it was not potential to dry them into powder. The pump diaphragm was the reason: 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 typically meant that trouble-free operation couldn’t be assured.
FINDING THE RIGHT PARTNER

In the course of looking for a dependable different, DSM got in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We had been already conversant in Lewa Nikkiso Switzerland as a provider of robust techniques with lengthy service lives within the SFP sector. To ensure trouble-free spray drying, we thought it might be smart to hitch forces with the consultants from Lewa and come up with a design to resolve the technical issues,” says Ibald.
DSM is dedicated to repeatedly enhancing its processes and investing in know-how. This dedication, together with prior expertise with the brief service lives of the earlier pumps, led DSM to place particular concentrate on reliable operate and a sturdy design through the challenge planning section. The record of requirements additionally included a considerable variety of stringent hygienic provisions that needed to be fulfilled.
“Certain foods have provisions concerning microbiological purity that are many occasions more stringent than these for producing other food merchandise,” explains Ibald. “This meant that the new feed and booster pump needed to meet these tougher conditions and each kind of contamination had to be ruled out to supply the widest attainable number of merchandise on the system.”

ROYAL DSM: PARTNER PROFILE

Royal DSM is a global science-oriented firm that’s particularly energetic within the areas of vitamin, health, and sustainable residing. DSM’s mission is to improve the lives of all. Products and options from DSM tackle some of the world’s largest challenges whereas concurrently creating financial, environmental, and societal worth for all its stakeholders—including customers, employees, shareholders, and society at large.
DSM delivers revolutionary options for the diet, animal vitamin, personal care and aromatics, medical products, environmentally pleasant products and applications, as well as new mobility and interconnectivity.
DSM and its affiliated firms make use of greater than 23,000 people and generate an annual internet turnover of approximately 10 billion euros. The firm was based in 1902 and is listed on the Euronext Amsterdam stock trade.
For extra information, visit www.dsm.com.
GUARANTEED SAFE START-UP OPERATION

After a go to on the company premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a sort G3F triplex course of diaphragm pump for the spray tower software. This pump features a completely safe start-up operation, since a spring constantly holds the integrated sandwich diaphragm situated in a impartial position.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged whereas the pump is beginning up, increasing system availability considerably. And the Lewa triplex is managed using a strain reduction valve that is put in within the hydraulic half and can be configured for the precise situation. Therefore, the pump can be tailored to different operational situations to find a way to forestall any overloads that may arise. This ensures that the unit has an extended service life and smooth common operation for the whole system.
THE POWER OF DESIGN

In addition to the pressure relief valve and the spring management, the design of the diaphragm additionally performs an essential position in guaranteeing dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extremely long-lasting. They are linked to one another by way of optimistic interlocking during the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and successfully prevents external contamination. As a further safety function, the DPS monitoring system from Lewa continuously monitors the condition of the diaphragm. The monitoring unit promptly displays any damage to the gadget that leads to increased stress in the diaphragm space.
This makes it potential to hold out preventive maintenance and repair work earlier than the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it’s normally pointless to change the pump off instantly, which means that neither the pumping course of nor spray drying are negatively impacted to a big extent. If damage to a diaphragm is detected, production can proceed without any problems up to a planned upkeep cease. 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 method diaphragm pump does more than just ensure dependable steady operation. It can 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 house without dynamic seals, guaranteeing fully clear and aseptic production situations. All pump heads that come into contact with the product are additionally electropolished, which makes it potential to make sure FDA-compliant pump operation.
Because the pump could be cleaned in place (CIP) using completely different alkaline and acidic agents and without prior dismantling, it’s attainable to fulfill the particular necessities for child meals as properly. The provisions for baby food are 1,000 occasions extra stringent than these for other products within the meals 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 standard.
QUICK RESPONSE TIMES AND WELL-FOUNDED EXPERTISE

The first quote was acquired in June of 2018 and in September of the identical 12 months, DSM Nutritional Products AG positioned an order for the triplex process diaphragm pump. In operation since April 2019, the pump has turn out to be an indispensable part of manufacturing on the plant in Sisseln.
“In every part of the challenge, Lewa Nikkiso Switzerland demonstrated fast response times and well-founded expertise, which made a key contribution to implementing the challenge efficiently,” says Ibald. “Our specifications with regard to high quality, robustness, and hygiene had been adopted to the letter in this venture. As a result, our manufacturing has become noticeably more efficient and dependable.”

FOR MORE INFORMATION

Lewa develops applied sciences and supplies solutions for the vast array of functions among its customers. pressure gauge are used mainly within the oil and fuel business, in gasoline odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional application areas embrace the chemical trade, cosmetics industry, prescription drugs and biotechnology, meals and beverage business, and power utilities. For more info, go to www.lewa.com.
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