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 technology to convey various emulsions into a spray tower, the place they’re dried into powder. But the feed and booster pump that was getting used proved to be an uncertainty factor as a end result of the diaphragm required for the pumping process tended to tear when the pump was started up. Generally, such production interruptions may be corrected by way of immediate upkeep and restore work.
However, it is very expensive to exchange a diaphragm or a complete system. DSM was seeking an alternate and at last made a find after they talked to the pump specialists at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex course of diaphragm pump for the spray tower utility. The drive unit features a safe start-up mode that retains the diaphragm located within the neutral place, and continuous regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it’s easy to satisfy the food industry’s stringent hygienic provisions.
“Pump know-how plays a central function in drying oil-in-water emulsions for the meals and pharmaceutical industries. These emulsions contain substances such as nutritional vitamins, carotenoids, or polyunsaturated fatty acids as active components,” explains Natalie Ibald, plant manager 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 chance of unforeseen interruptions to this course of couldn’t be ruled out. As a result, the totally different emulsions couldn’t be processed further. In other words, it was not potential to dry them into powder. The pump diaphragm was the explanation: it was usually too delicate to face up to the stress positioned on it when starting up the pump and would rupture. Replacing the diaphragm decreased the system’s service life and sometimes meant that trouble-free operation couldn’t be guaranteed.
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In the course of searching for a dependable various, DSM got in touch with the Swiss subsidiary of pump producer Lewa.
“We have been already conversant in Lewa Nikkiso Switzerland as a provider of strong methods with long service lives in the SFP sector. To guarantee trouble-free spray drying, we thought it would be sensible to affix forces with the experts from Lewa and give you a design to resolve the technical issues,” says Ibald.
DSM is committed to repeatedly improving its processes and investing in expertise. This commitment, together with prior expertise with the short service lives of the earlier pumps, led DSM to position particular concentrate on dependable function and a sturdy design through the venture planning phase. The listing of necessities additionally included a substantial number of stringent hygienic provisions that needed to be fulfilled.
“Certain meals have provisions regarding microbiological purity which are many instances extra stringent than these for producing different meals products,” explains Ibald. “This meant that the new feed and booster pump needed to meet these more challenging conditions and every type of contamination needed to be dominated out to supply the widest potential number of products on the system.”
Royal DSM is a global science-oriented firm that is especially active within the areas of vitamin, health, and sustainable residing. DSM’s mission is to enhance the lives of all. Products and solutions from DSM handle a number of the world’s greatest challenges while concurrently creating financial, environmental, and societal worth for all its stakeholders—including customers, staff, shareholders, and society at massive.
DSM delivers revolutionary solutions for the vitamin, animal nutrition, private care and aromatics, medical merchandise, environmentally friendly merchandise and purposes, in addition to new mobility and interconnectivity.
DSM and its affiliated companies employ more than 23,000 individuals and generate an annual net turnover of approximately 10 billion euros. The company was based in 1902 and is listed on the Euronext Amsterdam inventory trade.
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After a visit at the firm premises to think about the spatial and technical parameters, Lewa Nikkiso Switzerland really helpful a type G3F triplex process diaphragm pump for the spray tower software. This pump contains a fully safe start-up operation, since a spring continuously holds the integrated sandwich diaphragm situated in a impartial position.
This protects the diaphragm against incorrect positioning and prevents it from being broken whereas the pump is beginning up, growing system availability substantially. And the Lewa triplex is managed utilizing a stress relief valve that’s put in within the hydraulic half and may be configured for the precise situation. Therefore, the pump can be tailored to different operational conditions in order to prevent any overloads which will arise. This ensures that the unit has an extended service life and easy common operation for the whole system.
In addition to the pressure aid valve and the spring control, the design of the diaphragm also plays an important function in making certain reliable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms which are extremely long-lasting. They are linked to one another via positive interlocking through the discharge stroke and mechanical force-fitting through the suction stroke.
This makes the pump hermetically tight and effectively prevents external contamination. As an additional safety feature, the DPS monitoring system from Lewa repeatedly screens the situation of the diaphragm. The monitoring unit promptly displays any injury to the device that leads to elevated strain within the diaphragm space.
This makes it potential to hold out preventive upkeep and repair work earlier than the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it’s often unnecessary to modify the pump off immediately, which signifies that neither the pumping process nor spray drying are negatively impacted to a significant extent. If damage to a diaphragm is detected, manufacturing can continue with none issues up to a deliberate maintenance cease. 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 extra than just ensure reliable continuous operation. It can additionally be a central element for fulfilling the stringent hygiene provisions that the spray tower software is subject to. The Lewa triplex maintains a hermetically tight area without dynamic seals, guaranteeing utterly clear and aseptic manufacturing circumstances. 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 different alkaline and acidic brokers and without prior dismantling, it’s potential to fulfill the special necessities for baby meals as nicely. The provisions for child meals are 1,000 occasions extra stringent than these for other products 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 standard.
The first quote was received in June of 2018 and in September of the same year, DSM Nutritional Products AG placed an order for the triplex course of diaphragm pump. In operation since April 2019, the pump has become an indispensable a half of manufacturing at the plant in Sisseln.
“In each part of the challenge, Lewa Nikkiso Switzerland demonstrated fast response occasions and well-founded expertise, which made a key contribution to implementing the venture successfully,” says Ibald. “Our specs with regard to quality, robustness, and hygiene had been followed to the letter in this project. As a result, our production has become noticeably extra environment friendly and dependable.”
Lewa develops technologies and offers solutions for the vast array of purposes amongst its customers. Its products are used primarily within the oil and fuel industry, in fuel odorization, in refineries and petrochemicals, in addition to within the manufacturing of plastics, detergents, and cleaners. Additional software areas embrace the chemical business, cosmetics business, prescription drugs and biotechnology, food and beverage trade, and energy utilities. For more data, visit

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