energy efficiency through hygienic design

Sando Selchow Market Development Manager Food & Beverage June 2011 1

Innovation in Energy Efficiency

National Centre for Food Manufacturing

Innovation in Energy Efficiency

National Centre for Food Manufacturing


Innovations in Energy Efficiency

Energy Efficiency by Design

Only those who use energy will be successful in the long run.

Whether in energy distribution, automation, building services or IT infrastructure – there is savings potential waiting to be uncovered in every corner of a company.

But it will likely go unnoticed without close scrutiny of the overarching processes and correlations.



Rittal offers integrated solutions with tangible savings potential, from analysis and planning through to

implementation. All from a single source – that is what we mean by

RITTAL – THE SYSTEM



Products + Engineering + Realisation

- energy –saving products and systems

- monitor overall performance with comprehensivesoftware tools

- take care of the whole “energy efficiency chain” throughanalysis + planning + implementation


Innovations in Energy EfficiencyEnergy Efficiency by Design

Systematic and Planning software Commissioning time-based EPLAN Energy reviewCFD analyses Therm 6.01 System moni-Thermography RICAD 3D toring

Software toolsRiZone &RiRFID

Comprehensive analysis + efficiency planning

+ integrated implementation



Planning software EPLAN

The world's leading electrical engineering software -proven to save you time and money!

Some 70 to 80% of the material, productionand operating costs are already defined at theengineering stage.Optimisation of the influencing factors permits a significantreduction of these costs. The following threeexamples show how costs can be tackled at theirsource.Example: RiCAD 3D● All 3D design data are made available immediatelyand can be used directly for planning in your ownCAD system.● Drawing data from RiCAD 3D form the basis for efficientenclosure configuration in EPLAN Cabinet.



Out of our 7 SBU’s strategic business units, we show the following product innovations that all help the energy efficiency in the F&B processing plants.

-SBU1 Industrial Enclosure Systems

HD hygienic design enclosure system

-SBU3 Climate control systems

Fans, heaters, cooling units, free cooling

Hygienic Design compact enclosures

Modular enclosure systemsProduct overview – Special requirements

Hygienic Design terminal boxes

Hygienic Design accessories

Hygienic Design highlights

Facts and features:The blue slot-free silicone seal as a frame can be clearly distinguished from food and is resistant to cleaning agents.If the seal is damaged nonetheless, it can be replaced on-site quickly and securely.

Internal hinges allow the door to be completely sealed externally without any gapsNo germs, no cross-contamination, no time-consuming or costly cleaning

30° roof tilt in the HD compact enclosureThe roof can be easily inspected at a short distance, prevents objects from being deposited on it and allows fluids to drain off unimpeded.

Hygienic Design lock systems prevent unauthorised access to systemsEffective cleaning thanks to external contours with hygiene-compliant minimum radii. Yet, it can only be opened with a special key.

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Modular enclosure systemsHygienic Design compact enclosures

Saves time and costs by means of... • Longer maintenance cycles with shorter maintenance

times when replacing seals• Fast and simple cleaning

Facts and features:+ Protection category IP 66 applies to exterior sealing edge+ Assembly plate dimensions similar to comparable AE

housings AE10xx.600 -> HD13xx.600+ Seal is protected by overhang edge and a sufficient gap

for cleaning.

HD wall spacer bracketsThe housing should not be mounted directly to the wall in order to allow for thorough cleaning.

Saves time by means of... • Facilitating cleaning work

- because of the sloped enclosure sides all-round

- Slot-free silicone seal all-round• Simple assembly

- Hygiene-compliant quick-release fasteners

$ Saves cost by means of... • Facilitating the on-site replacement of gaskets

Facts and features:+ Can be mounted horizontally or

vertically – all-round 3° housing tilt+ Designed to suit the open processes in

food and consumables industry+ Assembly plates and support rails can be used across

the entire KL range+ IP 69K

Modular enclosure systemsHD terminal boxes

The HD cable gland completes the system of hygienic machine control.

Flush termination between the cap nut and the enclosure The critical threaded points are hidden.

Optimised shape:Smooth, solid exterior surfaces prevent the deposit of harmful micro-organisms. Significant reduction in cleaning workload for traditional cable glands.

Seal directly at the cable entry

Resistant to high-pressure cleaners in accordance with protection category IP 69K

Stainless steel versions M12-M25/EMC M16-M25

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Modular enclosure systemsHD cable gland

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Prevent contamination

Modular enclosure systemsHygienic Design

Modular enclosure systemsProfitability of Hygienic Design solutions

1 day = 24 hrs = 1,440 min (three-shift operations)

40%* cleaning time per day = 576 min

In the case of 240 working days/year = 1,382 min

* Experience gathered from the meat processing industry

1,382 min ≈ 1 daymore production time during the year!

Activity: 1% of cleaning time is saved thanks to Rittal Hygienic Design

Save cleaning time to gain in productivity!

Modular enclosure systemsHygienic Design solutions

Advantages of Hygienic Design solutions for:

Innovative in the face of the competitionEasily fulfilsspecifications

Mechanical engineers in the food sector

Food producers Planning offices

More security with regardto certifications (IFS, BRC)Innovation is guaranteed thanks to long-lastingproducts

Minimise liability riskProximity to the standard –state-of-the-art technologyin building planning(e.g. gate controls)Improved quality ofconsultation and therefore a more valuable contact partner for food producers

BXM 434 LOIN with BFE1K

Enclosures are often covered by a machine hood in the mechanical engineering food sector, so no HD is required

Instead of the complete housing, Maja used Rittal Hygienic Design seals, cams and hinges in all removable machine panels. For example, in camera housings for optical meat inspections.

• An expert in meat processing machines and flake ice generators

• worldwide < 30,000 MAJA machines often in operation around the clock

Hygienic Design expansion of existing machine parts

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Modular enclosure systemsReference – Housing solutions

Access to 'Standard' sale of products thanks to a modular customer-specific solution

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• Leading brand in the beverage industry• Sells over 230 beverage brands in

approx. 200 countries in the world• Employs 92,800 people worldwide

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Rittal supplied 175 modified operating housings based on HD compact enclosures for TFT and PC integration, including pedestal, 19" stainless steel keyboard and keyboard support to the Coca-Cola Company in England.

Use in areas of dry and moist production athuman-machine interfaces, e.g., bottling system, bottle lifter

Coca-Cola switched to Rittal because the Rittal operating housing guarantees system availability and hygiene in the various production areas.

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http://upload.wikimedia.org/wikipedia/de/9/9c/The_Coca-Cola_Company.svg

Hygienic Design applications in the food and beverage industry


• Annual production of 80 million snacks and meals

• 35,000 metric tons of deep-frozen products

• 15,500 employees

+ HD housings in accordance with the European Hygienic Engineering & Design Group (EHEDG) guideline designed for open and closed processes

+ Small HD housings protect touch screens in the high-risk area on the Tray line. The housings used on the Tray line apply the 'open door principle'. A mirror on the inside of the enclosure door allows several systems to be used simultaneously.

+ Large HD compact enclosures are used to control the plate froster as well as for the conveyor and packaging belts, mobile pumping stations, among other applications.

+ Power supply and control are protected by retrofitted, hygiene-compliant TS8 enclosures (stainless steel TS8 with sloped roof stops and supporting structures).

Tray linePlate frosters Final packaging Voltage supply


Innovations in Energy Efficiency

A high percentage of energy is used to cool components and equipment in process applications.

Innovative and energy efficient products help to harness the use of energy. Together with the tools necessary to identify heat loads and respective cooling solution and the engineering capability to design in such products

achieve energy efficiency.

Here are examples of cooling solutions:


Best practice, identify and design a solution

Thermal non reversible labels– Use to convince customers of heat

load issues within their panels– Temperature range selected to cover

critical temperatures for Drives

Customer visits to conduct Thermal Check

Provide optimisation for more efficient runningconditions using Rittal Innovations

Use Efficiency calculators to provide ROI

Use FREE “Therm” software for calculations & product selection

Contact us on 07866 411191 or [email protected] to help

Component lifetimes are critically reduced if enclosure temperatures exceed manufacturers guidelines

Is your equipment getting too hot?

6561575349454137


Use of USP‘s to push Cool Efficiency units


Use of USP‘s for more TopTherm fan and filter units


USP‘s for air/water heat exchangers & free cooling


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Use of Unique Selling Points of heating units


Success stories – Food and Beverage industry

Frito Lay – PepsiCo

Replaced a number of manufacturers models:

different Ice Qube different ISC/Thermal Edge different Mclean/Hoffman

Product requirements

Stainless SteelIP 65Low maintenanceEnergy efficientLow environmental impact

Logistic and special requirements

Solve procurement problemsDrastically reduce backup inventory from multiple vendor cooling devices.


Success stories – Food and Beverage industry

SABmiller brewery

Product requirements:

Possibility to use cooling solution for acid resistanceDump proofHigh temperature Easy to keep a units clean

Results:

Heat exchangers water/air roof mounted ( V4a)Heat exchangers water/air wall mounted ( V4a)Mini chiller V4A 3334.609

Concept extend space in cabinets

Customer extended front of the cabinetsand built construction for mounting chiller on the top


Any Questions?

Sando SelchowMarket Development Manager

Food & Beverage Sector07974205376

[email protected]

mailto:[email protected]

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