Reliable, Durable Aseptic Process Pump Makes Key Contribution to Success

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 procedure uses pump expertise to convey various emulsions into a twig tower, where they are dried into powder. But the feed and booster pump that was getting used proved to be an uncertainty issue as a outcome of the diaphragm required for the pumping course of tended to tear when the pump was began up. Generally, such production interruptions could be corrected via quick upkeep and restore work.
However, it is extremely costly to replace a diaphragm or a whole system. DSM was in search of an alternate and eventually made a find once they talked to the pump experts at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower application. The drive unit features a safe start-up mode that keeps the diaphragm positioned within the neutral place, and continuous regulation using an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s simple to fulfill the food industry’s stringent hygienic provisions.
“Pump know-how performs a central function in drying oil-in-water emulsions for the food and pharmaceutical industries. These emulsions comprise substances similar to nutritional vitamins, carotenoids, or polyunsaturated fatty acids as lively elements,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As part of the process chain, each pump is one hundred pc integrated 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 process couldn’t be dominated out. As a outcome, the different emulsions could not be processed further. In other words, it was not potential to dry them into powder. The pump diaphragm was the reason: it was typically too sensitive to withstand the stress positioned on it when starting up the pump and would rupture. Replacing the diaphragm lowered the system’s service life and sometimes meant that trouble-free operation couldn’t be assured.
In the course of trying to find a reliable different, DSM obtained in touch with the Swiss subsidiary of pump producer Lewa.
“We were already familiar with Lewa Nikkiso Switzerland as a provider of robust methods with lengthy service lives within the SFP sector. To guarantee trouble-free spray drying, we thought it might be sensible to hitch forces with the consultants from Lewa and give you a design to solve the technical problems,” says Ibald.
DSM is dedicated to repeatedly improving its processes and investing in know-how. This dedication, along with prior experience with the brief service lives of the previous pumps, led DSM to put special focus on reliable function and a strong design in the course of the challenge planning phase. pressure gauge 4 นิ้ว of requirements also included a substantial variety of stringent hygienic provisions that needed to be fulfilled.
“Certain meals have provisions relating to microbiological purity that are many times extra stringent than these for producing different food merchandise,” explains Ibald. “This meant that the brand new feed and booster pump had to meet these more difficult situations and every type of contamination had to be dominated out to supply the widest potential number of merchandise on the system.”
Royal DSM is a worldwide science-oriented firm that’s especially active within the areas of nutrition, well being, and sustainable living. DSM’s mission is to improve the lives of all. Products and options from DSM tackle a few of the world’s largest challenges while simultaneously creating financial, environmental, and societal worth for all its stakeholders—including prospects, workers, shareholders, and society at large.
DSM delivers progressive options for the nutrition, animal nutrition, private care and aromatics, medical merchandise, environmentally pleasant merchandise and applications, in addition to new mobility and interconnectivity.
DSM and its affiliated corporations employ more than 23,000 folks and generate an annual net turnover of roughly 10 billion euros. The company was based in 1902 and is listed on the Euronext Amsterdam inventory exchange.
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After a go to at the firm premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a sort G3F triplex course of diaphragm pump for the spray tower utility. This pump features a utterly secure start-up operation, since a spring repeatedly holds the integrated sandwich diaphragm located in a impartial position.
This protects the diaphragm against incorrect positioning and prevents it from being broken whereas the pump is starting up, rising system availability considerably. And the Lewa triplex is controlled using a stress relief valve that’s put in in the hydraulic part and may be configured for the precise situation. Therefore, the pump can be adapted to totally different operational situations so as to prevent any overloads that will come up. This ensures that the unit has a long service life and easy common operation for the whole system.
In addition to the pressure reduction valve and the spring control, the design of the diaphragm additionally performs an necessary position in making certain reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which would possibly be extremely long-lasting. They are linked to one another via optimistic interlocking during the discharge stroke and mechanical force-fitting during the suction stroke.
This makes the pump hermetically tight and effectively prevents exterior contamination. As an extra security feature, the DPS monitoring system from Lewa constantly displays the condition of the diaphragm. The monitoring unit promptly displays any injury to the device that results in elevated pressure within the diaphragm area.
This makes it possible to carry out preventive maintenance and repair work before the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it is usually unnecessary to modify the pump off instantly, which signifies that neither the pumping process nor spray drying are negatively impacted to a big extent. If harm to a diaphragm is detected, manufacturing can continue without any issues as much as a deliberate maintenance cease. The parts can then be replaced shortly and easily by releasing the cassette for the assembly.
The hermetically tight design of the process diaphragm pump does extra than simply ensure dependable continuous operation. It is also a central part for fulfilling the stringent hygiene provisions that the spray tower application is subject to. The Lewa triplex maintains a hermetically tight space with out dynamic seals, guaranteeing completely clear and aseptic production conditions. All pump heads that come into contact with the product are also electropolished, which makes it potential to ensure FDA-compliant pump operation.
Because the pump may be cleaned in place (CIP) utilizing completely different alkaline and acidic agents and without prior dismantling, it’s attainable to fulfill the special necessities for baby meals as properly. The provisions for baby meals are 1,000 occasions extra stringent than these for different products within the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we have been capable of rule out any contamination of the pumped medium and clearly meet the required hygiene normal.
The first quote was obtained in June of 2018 and in September of the identical yr, DSM Nutritional Products AG placed an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has turn into an indispensable part of production at the plant in Sisseln.
“In each section of the challenge, Lewa Nikkiso Switzerland demonstrated fast response times and well-founded expertise, which made a key contribution to implementing the challenge successfully,” says Ibald. “Our specifications with regard to high quality, robustness, and hygiene had been adopted to the letter on this project. As a result, our production has become noticeably more environment friendly and dependable.”
Lewa develops applied sciences and provides options for the vast array of purposes among its customers. Its products are used primarily in the oil and fuel industry, in gasoline odorization, in refineries and petrochemicals, as properly as within the manufacturing of plastics, detergents, and cleaners. Additional utility areas embrace the chemical trade, cosmetics trade, prescribed drugs and biotechnology, food and beverage business, and energy utilities. For more info, visit

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