Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

The Swiss subsidiary of Dutch company DSM Nutritional Products AG makes use of the spray drying technique when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The procedure makes use of pump expertise 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 factor because the diaphragm required for the pumping course of tended to tear when the pump was started up. Generally, such production interruptions can be corrected via quick upkeep and repair work.
However, it is rather expensive to exchange a diaphragm or an entire system. DSM was looking for another and finally made a find when they talked to the pump consultants at Lewa Nikkiso Switzerland, who beneficial a Lewa triplex process diaphragm pump for the spray tower application. The drive unit contains a secure start-up mode that retains the diaphragm situated in the impartial place, and steady regulation utilizing an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is simple to satisfy the meals industry’s stringent hygienic provisions.
“Pump technology plays a central position in drying oil-in-water emulsions for the meals and pharmaceutical industries. These emulsions comprise substances similar to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as lively ingredients,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As part of the method chain, each pump is 100% built-in into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”
With the previous system, the danger of unforeseen interruptions to this process couldn’t be ruled out. As a result, the totally different emulsions could not be processed additional. In different words, it was not possible to dry them into powder. The pump diaphragm was the reason: it was usually too delicate 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.
In the course of searching for a dependable various, DSM obtained in contact with the Swiss subsidiary of pump producer Lewa.
“We have been already familiar with Lewa Nikkiso Switzerland as a supplier of strong systems with lengthy service lives in the SFP sector. To ensure trouble-free spray drying, we thought it will be good to hitch forces with the consultants from Lewa and give you a design to resolve the technical problems,” says Ibald.
DSM is dedicated to continually enhancing its processes and investing in know-how. This dedication, along with prior experience with the short service lives of the earlier pumps, led DSM to place special concentrate on reliable perform and a strong design in the course of the challenge planning section. The list of requirements additionally included a substantial number of stringent hygienic provisions that needed to be fulfilled.
“Certain meals have provisions relating to microbiological purity which might be many times more stringent than these for producing different meals products,” explains Ibald. “This meant that the new feed and booster pump had to meet these more challenging situations and every sort of contamination needed to be dominated out to provide the widest attainable number of products on the system.”
Royal DSM is a world science-oriented company that’s particularly energetic in the areas of vitamin, well being, and sustainable residing. DSM’s mission is to enhance the lives of all. Products and solutions from DSM tackle some of the world’s greatest challenges whereas concurrently creating economic, environmental, and societal value for all its stakeholders—including clients, staff, shareholders, and society at large.
DSM delivers progressive options for the diet, animal vitamin, personal care and aromatics, medical merchandise, environmentally friendly products and functions, in addition to new mobility and interconnectivity.
DSM and its affiliated companies make use of more than 23,000 individuals and generate an annual internet turnover of roughly 10 billion euros. The company was based in 1902 and is listed on the Euronext Amsterdam inventory change.
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After a go to at the company premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland recommended a kind 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 positioned in a impartial place.
This protects the diaphragm towards incorrect positioning and prevents it from being broken while the pump is starting up, rising system availability substantially. And the Lewa triplex is controlled utilizing a stress reduction valve that’s installed in the hydraulic half and may be configured for the specific state of affairs. Therefore, the pump can be adapted to totally different operational situations in order to stop any overloads that may come up. This ensures that the unit has a long service life and clean regular operation for the whole system.
In addition to the stress relief valve and the spring management, the design of the diaphragm also plays an essential position 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 through optimistic interlocking during the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and effectively prevents exterior contamination. As a further safety characteristic, the DPS monitoring system from Lewa repeatedly displays the situation of the diaphragm. The monitoring unit promptly displays any harm to the system that results in increased stress within the diaphragm house.
This makes it attainable to carry out preventive upkeep and repair work earlier than the diaphragm even begins to rupture and probably contaminates the pumped fluid. Thus, it’s normally unnecessary to modify the pump off instantly, which implies that neither the pumping process nor spray drying are negatively impacted to a significant extent. If damage to a diaphragm is detected, production can continue with none issues as a lot as a planned maintenance cease. The parts can then be replaced quickly and simply by releasing the cassette for the assembly.
The hermetically tight design of the method diaphragm pump does extra than just guarantee reliable steady operation. It can be a central element for fulfilling the stringent hygiene provisions that the spray tower application is subject to. The Lewa triplex maintains a hermetically tight area with out dynamic seals, guaranteeing utterly clear and aseptic manufacturing situations. All pump heads that come into contact with the product are also electropolished, which makes it attainable to ensure FDA-compliant pump operation.
Because the pump may be cleaned in place (CIP) using completely different alkaline and acidic agents and without prior dismantling, it’s possible to fulfill the particular necessities for child meals as well. The provisions for baby meals are 1,000 times extra stringent than these for different products in the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleansing, we have been able to rule out any contamination of the pumped medium and clearly meet the required hygiene commonplace.
The first quote was received in June of 2018 and in September of the same 12 months, DSM Nutritional Products AG placed an order for the triplex process diaphragm pump. In operation since April 2019, the pump has turn into an indispensable part of production on the plant in Sisseln.
“In each section of the challenge, Lewa Nikkiso Switzerland demonstrated fast response instances and well-founded expertise, which made a key contribution to implementing the project successfully,” says Ibald. “ เกจวัดแรงดันแก๊สlpg with regard to high quality, robustness, and hygiene had been adopted to the letter in this project. As a outcome, our production has turn into noticeably extra efficient and dependable.”
Lewa develops technologies and provides solutions for the huge array of applications amongst its customers. Its merchandise are used primarily within the oil and gas trade, in fuel odorization, in refineries and petrochemicals, in addition to in the production of plastics, detergents, and cleaners. Additional application areas embrace the chemical trade, cosmetics trade, pharmaceuticals and biotechnology, meals and beverage business, and power utilities. For more data, go to

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