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 meals industries. The procedure uses pump know-how to convey varied 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 issue as a result of the diaphragm required for the pumping process tended to tear when the pump was began up. Generally, such manufacturing interruptions may be corrected by way of quick maintenance and repair work.
However, it is rather expensive to exchange a diaphragm or an entire system. DSM was looking for an alternate and at last made a discover when they talked to the pump consultants at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower software. The drive unit includes a safe start-up mode that retains the diaphragm positioned within the impartial position, and steady regulation utilizing an built-in monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is easy to meet the meals 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 such as vitamins, carotenoids, or polyunsaturated fatty acids as active components,” explains Natalie Ibald, plant supervisor of formulations at DSM Nutritional Products AG. “As part of the process chain, every 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 previous system, the risk of unexpected interruptions to this process couldn’t be dominated out. As a end result, the completely different emulsions could not be processed further. In different phrases, it was not attainable to dry them into powder. The pump diaphragm was the reason: it was usually 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 could not be guaranteed.
In the course of trying to find a reliable different, DSM received in touch with the Swiss subsidiary of pump manufacturer Lewa.
“We have been already acquainted with Lewa Nikkiso Switzerland as a supplier of sturdy techniques with lengthy service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it would be good to hitch forces with the experts from Lewa and provide you with a design to unravel the technical problems,” says Ibald.
DSM is committed to repeatedly enhancing its processes and investing in expertise. This commitment, together with prior experience with the brief service lives of the earlier pumps, led DSM to put particular concentrate on dependable operate and a strong design during the challenge planning phase. The record of requirements also included a considerable number of stringent hygienic provisions that had to be fulfilled.
“Certain meals have provisions relating to microbiological purity that are many occasions extra stringent than those for producing different food merchandise,” explains Ibald. “This meant that the new feed and booster pump needed to meet these tougher situations and each type of contamination had to be ruled out to provide the widest possible variety of merchandise on the system.”
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Royal DSM is a global science-oriented firm that’s especially lively in the areas of vitamin, well being, and sustainable living. DSM’s mission is to enhance the lives of all. Products and solutions from DSM handle a variety of the world’s biggest challenges whereas concurrently creating financial, environmental, and societal value for all its stakeholders—including customers, workers, shareholders, and society at massive.
DSM delivers innovative solutions for the nutrition, animal diet, personal care and aromatics, medical merchandise, environmentally pleasant merchandise and functions, as nicely as new mobility and interconnectivity.
DSM and its affiliated companies make use of more than 23,000 folks and generate an annual internet turnover of approximately 10 billion euros. The firm was based in 1902 and is listed on the Euronext Amsterdam inventory change.
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After a visit on the firm premises to suppose about the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a sort G3F triplex course of diaphragm pump for the spray tower software. This pump contains a completely secure start-up operation, since a spring continuously holds the built-in sandwich diaphragm situated in a neutral position.
This protects the diaphragm in opposition to incorrect positioning and prevents it from being broken while the pump is starting up, rising system availability considerably. And the Lewa triplex is controlled using a pressure relief valve that is installed within the hydraulic part and can be configured for the specific scenario. Therefore, the pump can be tailored to totally different operational situations so as to forestall any overloads that will arise. This ensures that the unit has a long service life and smooth common operation for the entire system.
In addition to the pressure aid valve and the spring management, the design of the diaphragm additionally performs an necessary role in making certain dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which may be extraordinarily long-lasting. They are related to each other via constructive interlocking in the course of the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As a further security function, the DPS monitoring system from Lewa constantly displays the situation of the diaphragm. The monitoring unit promptly displays any damage to the system that leads to elevated strain in the diaphragm area.
This makes it attainable to hold out preventive upkeep and restore work earlier than the diaphragm even begins to rupture and doubtlessly contaminates the pumped fluid. Thus, it’s often pointless to switch the pump off right away, which means that neither the pumping process nor spray drying are negatively impacted to a big extent. If damage to a diaphragm is detected, production can proceed with none problems up to a planned maintenance stop. The parts can then be replaced rapidly and simply by releasing the cassette for the assembly.
The hermetically tight design of the method diaphragm pump does more than simply guarantee reliable steady operation. It can 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 utterly clear and aseptic manufacturing conditions. 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 could be cleaned in place (CIP) utilizing totally different alkaline and acidic agents and without prior dismantling, it’s potential to satisfy the special necessities for child meals as well. The provisions for child food are 1,000 instances extra stringent than those for other products in the food sector. Thanks to the hermetically tight design, electropolishing, and CIP cleaning, we have been in a position to rule out any contamination of the pumped medium and clearly meet the required hygiene standard.
The first quote was obtained in June of 2018 and in September of the same year, DSM Nutritional Products AG placed 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 phase of the venture, Lewa Nikkiso Switzerland demonstrated fast response times and well-founded experience, which made a key contribution to implementing the venture successfully,” says Ibald. “Our specs with regard to quality, robustness, and hygiene had been adopted to the letter in this challenge. As a result, our manufacturing has become noticeably extra efficient and dependable.”
Lewa develops technologies and provides options for the huge array of applications among its customers. Its products are used primarily in the oil and gas industry, in gas odorization, in refineries and petrochemicals, in addition to in the manufacturing of plastics, detergents, and cleaners. Additional software areas embody the chemical trade, cosmetics trade, prescribed drugs and biotechnology, meals and beverage trade, and power utilities. For extra data, go to

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