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    Archive for category: Food and Beverage Success Stories

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    FrieslandCampina: Hygienic Design allows process-oriented automation

    In dairy enterprises, pneumatic valves ensure that networked systems consisting of pipes, heaters and stainless steel tanks work precisely. Up to now, pneumatic actuators have been controlled by valve islands installed for reasons of technical cleanliness, and which were kept in standardised stainless steel enclosures located at a safe distance from the actual application. The new AirLINE Quick valve islands from fluid control system provider Bürkert, which are installed in Rittal Hygienic Design enclosures, now offer a number of benefits.

    “Pneumatic enclosures so close to the process took some getting used to at first. However, we noticed a long time ago that these necessary cleaning procedures are really not a problem!”
    Tim Borgstaedt, dairy master at FrieslandCampina

    Ready for automation in the midst of the hygienic environment

    With the valve island, the need was for fast installation and the highest operational reliability. The new automation system was technically optimised for hygiene through the clever combination with stainless steel enclosures from Rittal’s Hygienic Design series. These HD enclosures, tailored to the high hygienic standards of the food industry, can be easily cleaned. Through the symbiosis of the AirLINE Quick with the HD modular system a complete solution is now available that can actually be used within a hygienic environment in a dairy or brewery.

    Advantages of the “on-site” system

    This solution offers users short distances to actuators and sensors, far shorter times and reduced costs for installing pneumatic hoses and control cables, the quick detection of any possible hose leaks, better monitoring and maintenance of the overall system, low air consumption, as well as substantial improvements in the hygiene of the entire system.

    The innovation also shows its strengths in terms of costbenefit ratio: In many cases, the extra costs of the new “local” system can be offset by the savings of hundreds of metres of hose and cable.

    Use at FrieslandCampina

    Installing the system at a new dessert and yoghurt line at FrieslandCampina in Gutersloh represents a reference project. The process valve nodes that control which medium is currently being moved and in which dosage, are regulated by 42 HD enclosures, each with two 24-fold AirLINE Quick valve islands, including digital feedback inputs.

    The bulk of the pneumatic enclosures are lined – in rank and file – next to the valve nodes, so they installed right in the middle of the hygiene-sensitive process field.

    Where once 20, 30 or even 50 metres would have been necessary, now just five metres are sometimes enough to get from the enclosure to the actuator or sensor in this improved installation option.

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    Celler Land Geflügel: Hygienic protection of the control electronics

    Every day, more than 500,000 packages of fresh chicken leave the two slaughterhouses and cutting plants at Landgeflügel. The highest standards of hygiene have to be adhered to when preparing fresh poultry. Hygienic Design enclosures from Rittal offer protection for the sensitive control electronics during the daily cleaning and disinfection of the system components.

    “Our experience has been so positive that we chose HD enclosures across the board when fitting out the new site at Wietze.”
    Fabian Thölke, Head of Maintenance at Celler Land Frischgeflügel

    Hygienic Design enclosures at the centre of the process field

    Hygienic Design enclosures (HD) from Rittal, specially designed to meet the hygiene requirements of the foodstuff sector, offer Landgeflügel added product and process safety in the production process: Made of stainless steel and with a sloping roof, they can be cleaned without leaving behind any residues. The hallmark of the HD is its blue, external silicone gasket. It seals without leaving any gaps, so protecting the electronic components installed in the enclosure from penetrating water.

    Enclosures stand up to being cleaned every day

    The Hygienic Design enclosures made their debut in some parts of the production system at Emsland Frischgeflügel. At the headquarters of Landgeflügel, which was opened in 2003, individual enclosures were first tested in running operation. What really mattered was that the test enclosures withstood being cleaned every day. Porous gaskets and leaks that had occurred over and over again in earlier enclosure solutions, and which caused damage to the sensitive control electronics, no longer occurred with the HD range.

    Use in the conveyor belt and packaging fields

    The main application field of the HD enclosures at the Wietze site are the conveyor belts, several kilometres long, which ensure the precisely timed transport or the exact outward transfer of the various chicken products following the complex cutting processes.
    The enclosures also represent a key constant in the packaging area, which consists of eight different lines.

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    Karl Schnell: Robust enclosures for the meat processing industry

    Cleanliness is vital in the meat processing industry. However, the clearly defined cleaning and disinfection intervals make huge demands on the machinery. For plant constructor Karl Schnell, Rittal’s stainless steel Hygienic Design enclosures are the first choice when it comes to food safety; they can be cleaned until free of any residues and always withstand the burdens of everyday operations.

    “We took a good look at what the market had to offer, but found there was no system that came close to the HD series.”
    Volker Walch, Head of Electrical Design at Karl Schnell

    Rittal’s Hygienic Design enclosures are home to the heart of the system

    One of the key elements of product safety is the hygienic design of the machinery and equipment from Karl Schnell, used mainly by large food production companies. Each component must be designed so that product residue, dirt and microorganisms are unable to build up. The components must also be easy to clean. Today, the controls – the heart of every system – are housed in Hygienic Design enclosures from Rittal.

    Enclosures made to meet EHEDG recommendations

    With the HD series, Rittal is actively facing up to the challenges of the EHEDG’s tough requirements and providing stainless steel enclosures that have optimum surface properties and can be cleaned quickly and safely.

    Features include wall-mounted housings and command panels, designed without gaps or outer hinges where bacteria and other microorganisms can take a hold and start to multiply. Details like the levelling feet have been designed so that all the threaded parts are concealed inside the housing after installation.

    Moreover, every HD enclosure is fitted with a roof that slopes forward at an angle of 30 degrees to ensure optimum visibility.

    Easily replaceable silicone gaskets

    One special feature of the machine concept is the gasket: Silicone is used instead of polyurethane, as it is more resistant to every kind of detergent and disinfectant. Unlike seals that are sold by the metre, the easily replaceable, external silicone gasket ensures gap-free sealing.

    Hygienic Design enclosure systems now form an integral part of Karl Schnell’s system concept.

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    OSI Food Solutions: Hygiene for the burger industry

    Hygienic Enclosure solutions for the food industry

    Pure hygiene – that is the claim made by OSI Food Solutions Germany, and it is backed up with the very latest technology. The OSI plant in Günzburg uses the world’s most advanced hamburger production line to manufacture 5.5 million patties a day, primarily for the huge network of McDonald’s restaurants in Germany. OSI is always searching for innovative solutions that will help it optimise the hygiene of its production operations.

    “To meet our duty of care in all areas, we work intensively to ensure all the machinery and plants in our production systems are designed and built to the highest hygiene standards.”
    Wolfgang von Vegesack, Engineering Support Officer Europe, OSI

    Hygienic Design (HD) enclosures from Rittal have been an essential requirement at OSI Food Solutions Germany for years. Throughout the entire production system, the reliable compact enclosures and terminal boxes from Rittal’s HD range protect sensitive control technology from water and cleaning agents – and provide effective protection against micro-organisms and dangerous cross-contamination.

    Products specially for the food industry

    For years, OSI has been safeguarding the hygienic design of its production operations by using protective enclosures from the Hygienic Design (HD) range that Rittal launched in 2007, and which has been designed from A to Z to meet the needs of the food industry. The hygiene-centric HD enclosures score particularly highly in relation to open processes, i.e. applications where sensitive foodstuffs such as fresh meat, fish and dairy products are processed in an unpacked and unsealed state.

    Everything optimised for hygiene

    The trademark of the HD is its blue external silicone seal, which delivers gap-free sealing that protects the electronics installed in the enclosure against humidity and creeping moisture. The seal is a single piece and can be replaced in a matter of moments. The HD modular system is rounded off with special accessories that have been optimised for hygienic applications. These range from a locking system with rounded surfaces to special levelling feet and cable glands with all threads being deliberately located on the inside.

    Hygienic Design written into specifications

    “Even the first HD compact enclosures that we saw at Hannover Messe 2007 got us curious – and inspired us to start some practical tests,” recalls OSI technology boss, Thomas Schnitzler. HD enclosures were installed right in the heart of the process field, where they demonstrated impressive leak-tightness and excellent cleaning properties – with the result that they were quickly written into OSI specifications. “Whenever we’re planning new machines and plants, we automatically specify that compact enclosures and/or terminal boxes from the Hygienic Design system must be used,” adds Schnitzler.

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    Westfalenland Fleischwaren: Process scales optimised for hygiene

    Optimum hygiene is vital when it comes to portioning and filling systems for highly sensitive foodstuffs. While developing its “CWP Neptune” wet area checkweigher (process scales), manufacturer Bizerba closely based its design on Rittal’s modular “Hygienic Design” (HD) range. Systematically proven components were taken over from the Rittal HD range for the Neptune series system concept. Launch customer and partner for the prototype development was the fresh meat specialist “Westfalenland”.

    “Never before have we had process scales that could be cleaned as easily and with such high availability. A clean solution to the problem – that’s how I weigh it up!”
    Michael Huster, Technical Director at Westfalenland

    EHEDG specifications as a guideline

    The checkweigher has been designed so that all hygienically sensitive areas remain unobstructed and are easily accessible (in line with EHEDG specifications). The use of curves and diagonals ensures that detergents and water flow off on their own without remaining or even accumulating.

    The front cover and conveyor belt can be removed in a few simple steps, so that the unit can be easily cleaned. The electronic components are packaged to protect them safely from water. One feature in particular: The load cell, the real heart of the system, is hermetically sealed and so fully guarded against penetrating and condensing water.

    HD enclosures for control technology

    The number of individual components in the new checkweigher has been reduced. It only needs a single conveyor belt and just one motor. Cleaning cycles are kept short thanks to the way the entire system has been built.

    The entire control system for the conveyor belt and the load cell are housed in a Rittal HD enclosure. Instead of conventional closure systems, a special HD-lock is used and the outer, resistant silicone seals prevent product being deposited. Patented cable entries as per protection class IP 69K allow the system to be washed down with high-pressure cleaning equipment.

    Tried at tested at Westfalenland Fleischwaren

    As launch customer and partner for the prototype development, Westfalenland was already able to introduce its practical experience and requirements into the pre-production series. Immediately after leaving the IFFA 2010 trade fair, the prototype was sent to Westfalenland in Münster, where it was put directly into service on one of the portioning and packing lines for freshly ground meat, running in two-shift operation.

    The company was so impressed by the new checkweigher that it has now integrated a further five Neptuneseries devices in its production facilities.

    Every 24 hours, the complete minced meat lines – including the Bizerba checkweigher – are thoroughly cleaned with foam and at low pressure before being disinfected.

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    Bürger: Reliable protection of the electronic control functions during wet cleaning

    “Maultaschen” (ravioli-like filled pasta cases) are a Swabian speciality and every day, nearly 1.5 million of them leave Bürger, a local, family-run business. Bürger attaches great importance to the latest production and process technology, and to uppermost hygienic standards. To protect the electronic control functions installed in the middle of the process field from leaks and failures due to water penetrating every day while the entire system is wet cleaned, the Swabians have consistently focused on the Hygienic Design enclosure system from Rittal – from small terminal boxes to large compact enclosures.

    “Our practical experience with Hygienic Design solutions from Rittal was so convincing that we itemised them in our specifications.”
    Bernd Müller, head of Bürger’s maintenance team

    Residue-free cleaning

    For several years, Bürger has been using enclosure technology from Rittal’s modular Hygienic Design (HD) range, designed to meet the high hygiene requirements of the food industries down to the smallest detail. These stainless steel HD enclosures, which can be distinguished at first glance from ‘regular’ enclosures by their sloping roofs, can be cleaned without leaving any residue. They have been designed to EHEDG guidelines, and above all they succeed in open processes – in other words, where products such as fresh Maultaschen are processed while still unsealed.

    Tightly sealed – without dead spaces

    The hallmark of Rittal’s HD product line is the blue, external silicone gasket. It seals without leaving any gaps, protecting the electronics installed in the enclosure from moisture and creeping wetness during the daily prescribed wet cleaning process performed with water, foam and disinfectants.

    The gasket is made in one piece and can be replaced very quickly. Unlike gaskets sold by the metre, they do not suffer from the sealing strip being pulled out during assembly, which would then lead to gaps at the ends. Gaps, external hinges or inaccessible dead spaces that can serve as breeding grounds for microorganisms are purposely eliminated – so preventing any potential cross-contamination.

    In use at the sharp end

    Hygienic Design enclosures of various sizes are used in production at the plant. One of the smallest of these “lone wolves” is a mini-HD enclosure on the automatic machine for Schupfnudel (finger-sized Swabian potato noodles). This compact enclosure offers safe protection for the motor drive, so ensuring that these special potato delicacies are made in a flash.

    As many as five larger compact enclosures from the modular HD range can be found in the modern packaging plant, which is housed within a special cleanroom zone.

    The pasta manufacturer is also increasingly turning to Rittal’s hygiene-optimised protective enclosures at the periphery of its production area. Thus, HD enclosures have already been used at Crailsheim to house telephone and time recording systems for a while.

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    Rittal Hygienic Design (HD) enclosures contribute to quality at Zweifel Pomy-Chips

    Zweifel Chips, a well-known Swiss brand of crisps and snacks, was established in 1962. More than half a century later, quality is still the company’s number-one priority. Moreover, food manufacturing is subject to stringent national and international regulations. Rittal’s stainless steel enclosures help Zweifel Chips to meet both its internal quality standards and applicable ISO and IFS requirements. Rittal’s solutions are specifically designed for the food industry, with IP69k rated ingress protection and gap-free gaskets.

    “Rittal’s HD products are outstanding, and highly regarded throughout the world.
    Their competitors simply cannot match them for quality.”

    Marco Lo Giudice, electrical designer, Zweifel Pomy-Chips

    Rittal’s HD enclosures stand for quality – worldwide

    Rittal regards itself is not merely as a supplier, but as a partner and advisor. Zweifel’s initial inquiry was followed up with a face-to-face meeting to determine its specific requirements. For example, how many enclosures did the customer require in what environments? How much space for computer hardware and cooling units was needed in a specific enclosure? Was Zweifel looking for a temporary or a long-term solution? Rittal Switzerland subsequently developed a number of options, outlining the feasibility, advantages and drawbacks, and costs of each. This gave the customer a clear basis for decision-making.

    Rittal TS 8 stainless steel enclosures now in use

    Zweifel’s senior executives chose a solution based on the TS 8 product range. Rittal configured the enclosures in line with the customer’s exact specifications, delivered the products, and made all preparations for installation. Zweifel then fitted the enclosures with the components required.

    Exceptional businesses choose exceptional partners

    Zweifel Pomy-Chips was impressed by Rittal’s flexibility and its expert advice. “They propose solutions tailored precisely to our business needs. Anything is possible, the choice is ours – including the scope of services provided by Rittal. That’s my idea of a true partnership,” says Marco lo Guidice.

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