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 makes use of pump know-how to convey varied 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 as a result of the diaphragm required for the pumping process tended to tear when the pump was started up. Generally, such production interruptions can be corrected through quick upkeep and repair work.
However, it is rather costly to replace a diaphragm or a whole system. DSM was seeking an alternate and finally made a discover after they talked to the pump experts at Lewa Nikkiso Switzerland, who really helpful a Lewa triplex process diaphragm pump for the spray tower utility. The drive unit includes a safe start-up mode that retains the diaphragm located in the neutral position, and continuous regulation using an integrated monitoring system. Since the hermetically tight pumps are electropolished and CIP-approved, it is easy to fulfill the meals industry’s stringent hygienic provisions.

“Pump expertise 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 ingredients,” explains Natalie Ibald, plant manager of formulations at DSM Nutritional Products AG. “As a half of the process chain, every pump is 100 percent integrated into the closed plant system. The pumps are used for conveying the mixtures into the spray tower.”

With the earlier system, the risk of unforeseen interruptions to this course of couldn’t be ruled out. As a end result, the different emulsions couldn’t be processed further. In other words, it was not attainable to dry them into powder. The pump diaphragm was the explanation: it was usually too sensitive to face up to the stress positioned on it when beginning 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 guaranteed.

In the course of searching for a reliable alternative, DSM got in contact with the Swiss subsidiary of pump producer Lewa.
“We were 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 might be good to hitch forces with the experts from Lewa and come up with a design to unravel the technical issues,” says Ibald.
DSM is dedicated to continually enhancing its processes and investing in technology. This commitment, along with prior expertise with the quick service lives of the earlier pumps, led DSM to put particular give consideration to reliable function and a robust design through the challenge planning section. The listing of requirements additionally included a substantial variety of stringent hygienic provisions that had to be fulfilled.
“Certain meals have provisions concerning microbiological purity that are many times extra stringent than those for producing other meals products,” explains Ibald. “This meant that the new feed and booster pump had to meet these more challenging situations and each kind of contamination had to be dominated out to produce the widest possible variety of products on the system.”


Royal DSM is a world science-oriented firm that is particularly active within the areas of nutrition, health, and sustainable residing. DSM’s mission is to improve the lives of all. Products and options from DSM address a few of the world’s greatest challenges while concurrently creating financial, environmental, and societal value for all its stakeholders—including prospects, staff, shareholders, and society at giant.
DSM delivers innovative solutions for the nutrition, animal diet, private care and aromatics, medical products, environmentally friendly products and functions, as properly as new mobility and interconnectivity.
DSM and its affiliated corporations employ greater than 23,000 people and generate an annual net turnover of approximately 10 billion euros. The firm was founded in 1902 and is listed on the Euronext Amsterdam inventory exchange.
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After a visit on the company premises to contemplate the spatial and technical parameters, Lewa Nikkiso Switzerland beneficial a kind G3F triplex process diaphragm pump for the spray tower software. This pump includes a fully safe start-up operation, since a spring continuously holds the integrated sandwich diaphragm positioned in a neutral place.
This protects the diaphragm towards incorrect positioning and prevents it from being broken while the pump is beginning up, increasing system availability substantially. And the Lewa triplex is controlled using a stress aid valve that’s put in in the hydraulic half and could be configured for the specific situation. Therefore, the pump may be tailored to totally different operational conditions to be able to forestall any overloads that may arise. This ensures that the unit has a long service life and smooth common operation for the entire system.

In addition to the stress reduction valve and the spring management, the design of the diaphragm additionally performs an necessary position in guaranteeing dependable pump operation. The patented sandwich diaphragm consists of two separate PTFE diaphragms that are extraordinarily long-lasting. They are related to one another through positive 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 an extra security characteristic, the DPS monitoring system from Lewa constantly displays the situation of the diaphragm. The monitoring unit promptly shows any injury to the device that leads to increased strain within the diaphragm area.
This makes it attainable to hold out preventive upkeep and restore work earlier than the diaphragm even begins to rupture and potentially contaminates the pumped fluid. Thus, it’s usually pointless to switch the pump off instantly, which signifies that neither the pumping process nor spray drying are negatively impacted to a major extent. If injury to a diaphragm is detected, manufacturing can proceed with none issues as a lot as a deliberate maintenance stop. The parts can then be replaced shortly and simply by releasing the cassette for the assembly.

The hermetically tight design of the process diaphragm pump does more than just guarantee reliable continuous operation. It is also a central component for fulfilling the stringent hygiene provisions that the spray tower application is topic to. The Lewa triplex maintains a hermetically tight house without dynamic seals, guaranteeing fully clean and aseptic manufacturing conditions. All pump heads that come into contact with the product are additionally electropolished, which makes it attainable to make sure FDA-compliant pump operation.
Because the pump may be cleaned in place (CIP) utilizing different alkaline and acidic brokers and without prior dismantling, it’s attainable to satisfy the special requirements for baby meals as nicely. The provisions for child food are 1,000 times extra stringent than those 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 standard.

The first quote was acquired in June of 2018 and in September of the identical year, 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 a half of production at the plant in Sisseln.
“In every phase of the project, Lewa Nikkiso Switzerland demonstrated fast response times and well-founded expertise, which made a key contribution to implementing the venture efficiently,” says Ibald. “Our specifications with regard to quality, robustness, and hygiene had been adopted to the letter on this challenge. As a outcome, our production has become noticeably extra efficient and dependable.”

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