Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

The Swiss subsidiary of Dutch firm DSM Nutritional Products AG uses the spray drying method when producing vitamin and carotenoid powders for the pharmaceutical and food industries. The process uses pump technology to convey various emulsions into a twig tower, where they’re 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 manufacturing interruptions may be corrected through immediate maintenance and restore work.
However, it is extremely costly to exchange a diaphragm or a whole system. DSM was looking for an alternate and finally made a find once they talked to the pump consultants at Lewa Nikkiso Switzerland, who recommended 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 situated in the neutral position, and continuous regulation utilizing an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is simple to fulfill the meals industry’s stringent hygienic provisions.
100 PERCENT INTEGRATION

“Pump technology performs a central position in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions contain substances similar to vitamins, carotenoids, or polyunsaturated fatty acids as active elements,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As a half of the method chain, each pump is 100% integrated 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 dominated out. As a outcome, the different emulsions could not be processed further. In other words, it was not possible to dry them into powder. The pump diaphragm was the reason: it was typically too delicate to withstand the stress placed on it when beginning up the pump and would rupture. Replacing the diaphragm decreased the system’s service life and typically meant that trouble-free operation could not be assured.
FINDING THE RIGHT PARTNER

In the course of searching for a reliable alternative, DSM received in touch with the Swiss subsidiary of pump producer Lewa.
“We have been already familiar with Lewa Nikkiso Switzerland as a provider of strong methods with lengthy service lives in the SFP sector. To ensure trouble-free spray drying, we thought it would be smart to affix forces with the specialists from Lewa and give you a design to solve the technical issues,” says Ibald.
DSM is committed to continually improving its processes and investing in technology. This dedication, together with prior experience with the short service lives of the previous pumps, led DSM to put particular concentrate on dependable perform and a sturdy design through the challenge planning part. The listing of requirements also included a substantial variety of stringent hygienic provisions that needed to be fulfilled.
“Certain meals have provisions concerning microbiological purity that are many times extra stringent than these for producing other food merchandise,” explains Ibald. “This meant that the new feed and booster pump needed to meet these tougher situations and every type of contamination needed to be ruled out to supply the widest attainable number of products on the system.”

ROYAL DSM: PARTNER PROFILE

Royal DSM is a world science-oriented company that’s especially energetic within the areas of vitamin, 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 biggest challenges whereas simultaneously creating economic, environmental, and societal worth for all its stakeholders—including customers, staff, shareholders, and society at large.
DSM delivers progressive solutions for the vitamin, animal nutrition, personal care and aromatics, medical products, environmentally friendly merchandise and applications, as well as new mobility and interconnectivity.
DSM and its affiliated companies employ greater than 23,000 individuals and generate an annual internet turnover of approximately 10 billion euros. The company was founded in 1902 and is listed on the Euronext Amsterdam inventory exchange.
For more data, go to www.dsm.com.
GUARANTEED SAFE START-UP OPERATION

After a visit on the firm premises to consider the spatial and technical parameters, Lewa Nikkiso Switzerland recommended a type G3F triplex course of diaphragm pump for the spray tower software. This pump features a utterly secure start-up operation, since a spring constantly holds the integrated sandwich diaphragm positioned in a neutral position.
This protects the diaphragm towards incorrect positioning and prevents it from being damaged while the pump is starting up, growing system availability considerably. And the Lewa triplex is managed utilizing a stress reduction valve that is installed within the hydraulic part and may be configured for the specific situation. Therefore, the pump could be adapted to totally different operational conditions so as to forestall any overloads which will come up. This ensures that the unit has an extended service life and easy common operation for the entire system.
THE POWER OF DESIGN

In addition to the stress relief valve and the spring control, the design of the diaphragm additionally plays an necessary function in making certain reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extremely long-lasting. They are related to every other through constructive interlocking during the discharge stroke and mechanical force-fitting in the course of the suction stroke.
This makes the pump hermetically tight and effectively prevents exterior contamination. As a further safety function, the DPS monitoring system from Lewa constantly screens the situation of the diaphragm. The monitoring unit promptly shows any harm to the device that results in increased strain in the diaphragm house.
This makes it possible to hold out preventive maintenance and restore work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s often unnecessary to switch the pump off instantly, which implies that neither the pumping process nor spray drying are negatively impacted to a major extent. If harm to a diaphragm is detected, manufacturing can continue without any problems up to a deliberate upkeep stop. The components can then get 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 guarantee reliable continuous operation. It can additionally be a central element for fulfilling the stringent hygiene provisions that the spray tower utility is topic to. The Lewa triplex maintains a hermetically tight area without dynamic seals, guaranteeing fully clean and aseptic manufacturing conditions. 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 completely different alkaline and acidic brokers and without prior dismantling, it is potential to satisfy the particular requirements for child meals as well. The provisions for baby meals are 1,000 times extra stringent than these for different merchandise within the meals sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we had been able to rule out any contamination of the pumped medium and clearly meet the required hygiene normal.
QUICK RESPONSE TIMES AND WELL-FOUNDED EXPERTISE

The first quote was acquired in June of 2018 and in September of the same 12 months, 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 half of production on the plant in Sisseln.
“In every part of the venture, Lewa Nikkiso Switzerland demonstrated quick response times and well-founded experience, which made a key contribution to implementing the project successfully,” says Ibald. “Our specifications with regard to high quality, robustness, and hygiene have been adopted to the letter in this challenge. As ไดอะแฟรม , our manufacturing has turn out to be noticeably extra environment friendly and reliable.”

FOR MORE INFORMATION

Lewa develops applied sciences and supplies solutions for the huge array of purposes amongst its clients. Its merchandise are used primarily within the oil and gasoline trade, in fuel odorization, in refineries and petrochemicals, as well as in the production of plastics, detergents, and cleaners. Additional application areas embody the chemical business, cosmetics industry, prescribed drugs and biotechnology, food and beverage business, and energy utilities. For extra information, visit www.lewa.com.
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