HYGIENIC MACHINE INSTALLATION Jens Moellmann, Murrelektronik
Figures & Facts MURRELEKTRONIK Jens Moellmann Sales Manager Americas Additional Focus on Food & Beverage & Packaging Industry Phone: +49 173 744 1787 Mail: jens.moellmann@murrelektronik.com SN Machine Building Jan Kronenberg Head of Electrical Design www.sn-maschinenbau.com
Figures & Facts MURRELEKTRONIK ABOUT US Headquartered in Oppenweiler in Southern Germany Founded in 1975 by Franz Hafner Family-owned company Over 2,200 employees worldwide Represented in over 50 countries 5 production plants Over 1 million products in stock MURRELEKTRONIK Is Your Partner
MURRELEKTRONIK ABOUT US WHO WE ARE Specialists for decentralized automation WHAT WE DO We develop and produce high-quality products for electrical and electronic machine and plant installations WHY WE'RE UNIQUE Innovative products Excellent customer service & market experience Culture of teamwork Top quality
STAGES OF IMPLEMENTATION THE CORE OF OUR INNOVATIVE STRENGTH Point-to-Point Decentralized ZERO CABINET PLC + I/O Control Cabinet PLC + I/O Control Cabinet Our mission: zero cabinet strategy
THE INNOVATIONS CUSTOMER ORIENTED
CHALLENGES IN THE DESIGN OF PLANT AND MACHINERY Reduction of downtimes in the event of faults Energy efficiency and management Modern installation concepts Reduction of cleaning time Total cost of ownership Durable and standardcompliant materials Safety for operators & machines Use of forward-looking technologies Hygienic design Easy commissioning
LEGAL FRAMEWORK CONDITIONS IMPORTANT STANDARDS AND APPROVALS DIN EN ISO 1672-2 General design principles and hygiene requirements for food machinery DIN EN ISO 14159 Safety of machines Hygiene requirements for the design of machines As your partner......we understand the demands placed on you...we offer installation concepts and products for optimum design of the corresponding zones Categorization of plant and machinery into hygiene zones: The product must not be contaminated by surfaces and materials Surfaces and materials must not absorb the product
LEGAL FRAMEWORK CONDITIONS IMPORTANT STANDARDS AND APPROVALS EC Machinery Directive 2006/42 Appendix I, 2.1: Food machinery for cosmetic or pharmaceutical products. Surfaces in contact with products (Zone 1 + 2) must: be smooth and must not have any protrusions or recesses on/in which organic substances can accumulate reduce edges and recesses on components to a minimum be easy to clean and disinfect, and also corrosion-resistant must have fillets with a sufficient radius to enable easy cleaning The recommended cleaning and disinfection agents and procedures must be stated in the operating instructions. As your partner......we ensure that the design is easy to clean, e.g. due to large distances between distribution boxes and modules...we use permanent laser labeling instead of sign plates to avoid unnecessary recesses...we use smooth, electropolished surfaces... we use stainless steel and qualified plastics adapted to your cleaning methods.
LEGAL FRAMEWORK CONDITIONS IMPORTANT STANDARDS AND APPROVALS Regulation (EC) No. 1935/2004 General regulations for materials and objects which are intended for contact with foods (Zone 1 + packaging material) Regulation (EC) No. 10/2011 Special regulations for materials and objects which are intended for contact with foods (Zone 1 + packaging material) positive list FDA Regulation 21 CFR 100-199 (USA) 21 CRF 170 et seq. Plastics in the Food Industry Special regulation for plastics which are intended for contact with foods (Zone 1 + packaging material) negative list As your partner......we comply with international legal regulations in the selection of our plastics... offer you products whose areas which contact products are exclusively made of compliant materials. Our products do not require approval.... we are glad to assist you in the selection of the right components for your specific application.
LEGAL FRAMEWORK CONDITIONS INTERNATIONAL INSTITUTES European Hygienic Engineering and Design Group (EHEDG) Safe and hygienic production of food Hygienic Design criteria for cleanability of components Certification of plant and components Guidelines for the hygienic installation of plant and machinery (e.g. sufficient cleaning gaps) The main guideline is Document 8 3-A Sanitary Standard and Accepted Practices Equivalent to the EHEDG in the USA FDA (Food and Drug Administration) Government body for health and consumer protection within the US Department of Health. As your partner......we know the relevant guidelines and consult these for the design of our components. Our products do not require certification....we not only offer you individual components for hygienic installation, but also solutions which revolutionize the hygienic standard of your automated systems.... we are glad to assist you in the selection of the right components for your specific application.
HYGIENIC DESIGN WHAT IS IT? Hygienic Design includes design principles to avoid structural weak points which lead to hygiene-related hazards. For this, the cleaning capability of the materials, surfaces and structural elements are key to Hygienic Design. Dirt of any kind must not adhere or accumulate, or it must be easy to remove. All materials which are used must not only be resistant to cleaning agents, but must also have the appropriate conformity for use in the food industry. Hygienic Design comprises Legal specifications and standards for the design of components and machines up to entire production areas and factories. Legal specifications and standards for selecting materials. Recommendations by relevant institutions which greatly exceed statutory requirements. Approval/durability of materials for the corresponding cleaning processes and cleaning agents. Installation approaches and products for optimum design of the corresponding zones.
HYGIENIC DESIGN GENERAL DESIGN GUIDELINES Our field bus modules and passive distribution boxes are fully welded. Entry of dirt is therefore impossible. Our M12 PP Line Connectors are round, with appropriate radii to enable perfect cleaning. min. Radius =3 mm ideal 6 mm Use of e.g. passive distribution boxes avoids complex parallel wiring of sensors. Instead of parallel wiring, a homerun cable made from compliant material is used. Hygienic installation of terminal boxes is timeconsuming and expensive. By decentralization with stainless steel field bus modules, the "dirty area" is drastically reduced. Sensor/ actuator cable
CLEANING PROCESS HOW IS CLEANING PERFORMED? Cleaning process parameters: 1. Cleaning and the accompanying downtime of the plant is a large cost driver in the food sector. As well as dirt, two other parameters influence the duration and extent of the process: 2. By using hygienic components from Murrelektronik and above all by selecting the correct installation system, you can reduce the necessary cleaning time. 3. Our components withstand extreme conditions. Our stainless steel and resistant plastic products with protection classes up to IP69K withstand all cleaning processes.
INSTALLATION CONCEPTS CORRECT INSTALLATION Hygienic Design does not stop at components and devices. For good cleanability in the processing area, the electrical installation must also be correctly run. Parallel installation of cables on stainless steel grids Leave gaps so that the spaces between the cables can be cleaned with pressure washers Fasten the cables with cable ties, usually made of detectable plastics Use the advantages of decentralized installation to save time and cost! Sensor/ actuator cable Examples of use
PRODUCTS FOR THE FOOD INDUSTRY CONNECTORS: M12 PP-LINE PRODUCTS FOR THE FOOD INDUSTRY CONNECTORS Optimal connection in all zones! Dry Zone up to Food Zone Aseptic areas (H 2 O 2 ) IP69K for high pressure cleaning Extensive use of cleaning agents Standard-compliant plastics (FDA, EG 1935, EC 10/2011) The blue plastic enables visual detection. M12 Steel connectors with a stainless steel sheath are unbreakable. This connector functions well where other connectors reach their limits in the cleaning process. Special sealing systems:
PRODUCTS FOR THE FOOD INDUSTRY PASSIVE DISTRIBUTION BOX MVP12 STEEL PRODUCTS FOR THE FOOD INDUSTRY PASSIVE DISTRIBUTION BOX MVP12 STEEL Stainless steel distribution box in IP69K IP69K - permanent protection Sealed stainless steel housing and threaded sleeves in V4A (1.4404) FDA and EC 1935, 10/2011 compliant cables Cleaning-resistant plastics LED status display directly at the slot Large spacing for optimum cleaning Encapsulated housing, resistant to shocks and vibration Sensor/ actuator cable
PRODUCTS FOR THE FOOD INDUSTRY CUBE67 HYGIENIC DESIGN PRODUCTS FOR THE FOOD INDUSTRY CUBE67 HYGIENIC DESIGN Active in the food zone IP69K - permanent protection Sealed stainless steel housing and threaded sleeves in V4A (1.4404) LED status display directly at the slot Entire familiar Cube67 functionality Large spacing for optimum cleaning Encapsulated housing, resistant to shocks and vibration Also ideal in combination with standard modules Matching Cube67 F&B cables The perfect supplement to Hygienic Design valve terminals Stainless steel drives
INSTALLATION CONCEPTS FOR THE FOOD INDUSTRY Installation concept: POINT TO POINT Number of sensors/actuators 48 Wires installed in mesh (m) 960 m Number of cable ties (every 30 cm): 2880 Mesh length: 60 m 30 m 20 m 10 m 10 m Sensor/ actuator cable
INSTALLATION CONCEPTS FOR THE FOOD INDUSTRY Installation concept: PASSIVE Number of sensors/actuators 48 Wires installed in mesh (m) 120 m Number of cable ties (every 30 cm): 360 Mesh length: 60 m 30 m 20 m 10 m 10 m Sensor/ actuator cable
INSTALLATION CONCEPTS FOR THE FOOD INDUSTRY Installation concept: MODULAR Number of sensors/actuators 48 Wires installed in mesh (m) 60 m Number of cable ties (every 30 cm): 180 Mesh length: 60 m 30 m 20 m 10 m 10 m Sensor/ actuator cable
Hygienic Design 22
Hygienic Design Requirements to a new mechanical design As less horizontal surfaces as possible Avoidance of hollow profile No elongated holes Reduction of parts Easy cleanability 23
Hygienic Design Requirements to a new electrical design Reduction of cables Avoidance of junction boxes Uncritical materials Decrease assembly costs due to decentralization Maintenance-friendly One concept for Rockwell and Siemens PLCs 24
Hygienic Design Supply concept Supply from the top Separate mediums in grid-tubes Machine built in segments Segments plugable 25
Hygienic Design Valve terminals Valve terminals of Typ Festo MPAC-VI in hygienic design Connection by IO-Link with standard connection cable M12 and Murrelektronik Cube 67+ 26
Hygienic Design Decentralised I/Os Active modules of the type Murrelektronik Cube 67+ in stainless steel IO-Link Master Cube 67+ in stainless steel Passive distribution boxes of the type Murr MVP Steel All connectors are with stainless steel screw Modules mounted with enough space for cleaning 27
Hygienic Design Analog signals Converted to IO-Link at sensor or actor by converter Connection to a IO-Link master No special shielded cables or modules needed 28
Hygienic Design Sensor cable All sensor cables with stainless steel screw Thread in upper area deburred Hexagon fastening instead of corrugated surface Cable fixer throughout decetable, not just the loop 29
Hygienic Design Cable glands Sealing material FDA compliant No exposed threads Stainless steel or plastic EHEDG certified 30
Hygienic Design Connectors Plastic connectors in hygienic design EHEDG certified Easy to clean Sealing material FDA compliant 31
Hygienic Design Construction in general Supporting beams rotated through 45 Cable and tubes in grid-tubes 32 All hollow bodies completly welded Assembly on hollow bodies just by welding threads
Hygienic Design Manufacturing specification Weld joints fine rippled welded Joints welded / brushed radius minimum 6mm Clearance minimum 6mm Surface roughnes average 3,2 (brushed) 33
Hygienic Design Construction foils production No table tops drives, motors below foil track if possible, no components above the foil track 34
Hygienic Design Construction foils production Full automation sealing adjustment by servo drives and recipe handling system Sealing drive through cleaningfriendly polygon shaft Last junction box box for supply of the sealing 35
Hygienic Design Filling area Table tops as small as possible Components as hygienic as possible due to construction Well visible construction to see pollution easily Complete machine with lighting 36
Hygienic Design Filling area Base body almost halved in volume Dosing can be brought close to filling position Loading flaps easily accessible Shop floor easy to see and clean 37
Hygienic Design Covering Good visibility Good accessibility Covering can completely be opened for cleaning All hinges external 38
Hygienic Design Panel Stainless steel panel Stainless steel support arm Support arm heightadjustable User-friendly 17 Panel 39
Hygienic Design Machine maintenance All machine parts visible and lighted In machine segments with an error, the lighting changes to red Format parts pluggable All three-phase motors pluggable Error message with first fault Murrelektronik Diagnostic Gateway 40
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