LAPP SOLUTIONS FOR F&B INDUSTRY

Transcription

1 ISAB/F&B Symp/ /Slide No. 1 National Symposium on Automation & Digital Transformation of Food & Beverage Industry 26 th & 27 th February 2016 LAPP SOLUTIONS FOR F&B INDUSTRY Standards Certification Education & Training Publishing Conferences & Exhibits S Prasad Narasimha DGM Product Engineering Lapp Group prasad@lappindia.com

2 ISAB /F&B Symp / /Slide No. 2 S Prasad Narasimha Academic -B. E. (Electrical Engineering), Bangalore University Worked in: - DELTON CABLES LIMITED, for 4 years as technical support for South India. - SIMPLEX BUILDING AUTOMATION for 3 years in charge of projects implementation. Currently working with: - LAPP INDIA PVT. LTD., - Handled various functions like production, planning, purchase, stores, maintenance, process quality. - Presently handling Product Engineering.

3 ISAB /F&B Symp / /Slide No. 3 Agenda Introduction to Lapp Global Scenario in F&B Industry Safety & Standards Application Areas/Zones for Cabling Key Challenges F&B Industry Lapp Product Offerings Q&A

4 ISAB /F&B Symp / /Slide No. 4 LAPP GROUP FOOD & BEVERAGE

5 ISAB /F&B Symp / /Slide No. 5 LAPP GROUP Founded in 1959, headquartered in Stuttgart, Germany 8 Brands 40,000+ products 3200 employees 820 M Euros 18 production sites 40 sales companies 100 national partners worldwide

6 ISAB /F&B Symp / /Slide No. 6 LAPP INDIA 300 Employees 2 Manufacturing plants at Bangalore and Bhopal 4 regional offices in metro cities and 25 sales offices across the country 5 Warehouses - near Delhi, Bangalore, Bhopal, Delhi & Mumbai and extensive dealer network to ensure product availability PAN India 4 Service points Bangalore, Coimbatore, Pune and Dharuhera (Delhi) Full fledged technology and innovation centre

7 ISAB /F&B Symp / /Slide No. 7 LAPP INDIA 146 dealer network across India customers across 25 business verticals Bangalore Plant Bhopal Plant Lapp India started operations in 1996 in Jigani, Bangalore More than 120,000 kms of cables produced per year In 2012, Lapp India opened the 2 nd state of the art manufacturing plant at Pilukedi, Bhopal Bhopal plant produces more than 220,000 kms of Single Core Cables per annum

8 ISAB /F&B Symp / /Slide No. 8 Brand Quality 8 strong brands, which are international industry standards From standard to custom-made products ÖLFLEX HITRONIC ETHERLINE SKINTOP UNITRONIC More than 40,000 standard products for various industry requirement SILVYN Tailored solutions for customer-specific applications FLEXIMARK CUSTOMIZED PRODUCTS EPIC

9 ISAB /F&B Symp / /Slide No. 9 GLOBAL SCENARIO billion 6.49 billion 11 billion GROWTH OF POPULATION AND WHAT IT LEADS TO Increasing demand for food, especially in developing countries as a result of growth of population and salary increase (more money for food). Change in quality of consumption food quality gets better in developing and developed countries. Increasing competition between land for food industry and workable land for required raw materials is leading to raised costs for food (and) transport. A chain (or connection) is only Limited resources like workable as strong land require as is weakest more sophisticated link! equipment (GPS supported tractor) this leads to more specialized and demanding machinery. Source: Source: FAO, DBV-Berechnungen, UN

10 ISAB /F&B Symp / /Slide No. 10 GLOBAL FOOD PROCESSING MACHINERY INDUSTRY LAPP GROUP CUSTOMERS BY F&B INDUSTRY Demand for food processing machinery will grow by 7.6 % annually to $73 billion in Main drivers are industrializing nations, where strong consumer demand for processed foods is emerging. The present world food processing machinery industry turnover is $50.5 billion. Source: Food-Processing-Machinery.html gleich.asp?pkaktienr=2020 % of the present LAPP GROUP F&B customers are active in the Following F&B industries. Sugar Meet Bakery Tobacco Diary Beverages Oil & Fat Packaging

11 ISAB /F&B Symp / /Slide No. 11 FOOD PROCESSING MACHINERY INDUSTRY ASIA/PACIFIC REGION TO BE FASTEST GROWING MARKET Source: Freedoniagroup.com Asia/Pacific is predicted to outperform its demand and growth from 2011 to 2016, averaging 9.5 percent per year.

12 ISAB /F&B Symp / /Slide No. 12 APAC F&B INDUSTRY TURNOVERS IN BILLION / MILLIARD URO Further reasons for demand for food processing machinery and equipment are in some cases that government programs aim at strengthen local meat, poultry, fish, milk, and dairy production - such as in Indonesia. Increasing incomes will lead to increased demand for processed foods and a dietary shift toward more costly, non-staple items, while advancing industrialization in these nations will make it more efficient to process basic foods such as grains, fruits, vegetables, and nuts by machine rather than manually. According Freedoniagroup (2015) the sales of food processing machinery in other developing areas will, generally speaking, climb at Source: Freedoniagroup.com a healthy pace.

13 ISAB /F&B Symp / /Slide No. 13 SAFETY & STANDARDS SAFETY IN 3 DIMENSIONS SAFETY AT WORK HEALTH OF THE END-CONSUMER No injuries (e.g. short circuit) Reduction of hygienic related risks (i.e. aggressive media or environment) Cleanliness and hygiene in the overall production Avoid or reduce microbes and bacteria Prevent contamination of food and resulting poisoning (e.g. broken glass, plastic in food) Avoid delayed secondary damage (e.g. chemical related by contaminated ready to eat fresh cut salad) PROCESS SAFETY Avoid down time of machinery Long service intervals (e.g. machinery cleaning, workplace preparation) Optimization of operative cost (e.g. by usage of long lasting, suitable products)

14 ISAB /F&B Symp / /Slide No. 14 BASIC DESIGN CONCEPTS AND RELEVANT STANDARDS FOR FOOD MACHINERY Risk-Analysis - Hazard Analysis and Critical Control Points / Management system for food safety Expert groups for hygienic conform production, machine design and case studies Basic design concepts Int. material parameters and practical assessment DIN ISO Given design concepts and recommended materials can be transferred to further machinery and equipment as well as on components of the food and beverage industry. Accordingly the hygiene-grade and safety during and after the food production can be increased. Further features such as detectability of products, resistance against aggressive cleaning and disinfection agents according to provide an additional benefit.

15 ISAB /F&B Symp / /Slide No. 15 BASIC DESIGN CONCEPTS AND RELEVANT STANDARDS FOR FOOD MACHINERY Hygienic design examples related to radius, edge and angle Quelle:

16 ISAB /F&B Symp / /Slide No. 16 INCREMENTA L EVOLUTION WITHIN PRODUCT DESIGN PRODUCT PERFORMANCE (Chemical resistance, cleanability, etc.) EVOLUTIONARY STEPS WITH REGARDS TO PRODUCT PERFORMANCE TIME

17 ISAB /F&B Symp / /Slide No. 17 APPLICATION AREA F&B MACHINERY EXAMPLE INCLUDING ZONE CLASSIFICATION

18 ISAB /F&B Symp / /Slide No. 18 LOCATION AND ZONE CLASSIFICATION ACCORDING TO SAFE FOOD FACTORY Locations (common wording) Food Zone Direct contact Indirect contact Splash zone Non-Food zone Zone Classifications (further used terms by branch pro`s) Zone B(asic) - basic hygiene: only with packed food products Zone M(edium) - temporarily open food products: cables (and components) have to be easily accessible and cleanable Zone H(igh) - highest hygienic requirements (also air quality): special attention for cables and components

19 ISAB /F&B Symp / /Slide No. 19 IDEAL CABLING SOULTIONS FOR F&B

20 ISAB /F&B Symp / /Slide No. 20 Food and Beverage Industry Challenges and Solutions Environmental- Chemical s & Oil Ability of the cable jacket to resist the effect of oil / chemicals resulting in longer lasting cables Flame / Fire Sample Image Cables must comply with varying degrees of flame resistance requirements. They need to be flame retardant, flame retardant low smoke and low halogen, Halogen Free Flame Retardant ( HFFR) Electrical EMI (Electro Sample Magnetic image Interference) & EMC Electromagnetic Interference impacts the performance of the system Cable should be properly shielded with aluminium foil / copper screen for EMI & EMC protection to reduce unwanted noise 7

21 ISAB /F&B Symp / /Slide No. 21 Food & Beverage Industry Challenges and Solutions Electrical Loss less transmission Loss less transmission High conductivity High insulation resistance For data / signal low capacitance Low line attenuation Sample image Sample image Mechanical Temperature Cable to operate within the temperature range. In general application temperature ranges from -5 0 C to C Higher temperature range for industrial applications is required Flexible, high bending radius Tensile, elongates, high insulation resistance Cables can be exposed to mechanical forces

22 ISAB /F&B Symp / /Slide No. 22 LAPP PRODUCT OFFERINGS Wires & Cables ÖLFLEX UNITRONIC ETHERLINE HITRONIC POWER LV & OLFLEX INSTRUM AS PER IS/BS FIELD BUS CABLE Cable Protection SILVYN Cable Glands SKINTOP Marking System FLEXIMARK Industrial Connectors EPIC

23 ISAB /F&B Symp / /Slide No. 23 ÖLFLEX & UNITRONIC SERIES Food & Beverage Machinery and Equipment For global usage in F&B machinery and equipment HIGHLIGHT ECOLAB Certified Oil resistant Chemical resistance Flexibility Further processing Number of approvals PUR e.g. ÖLFLEX CLASSIC 400 CP etc. Examples for Selection Criteria for Wires & Cables Halogen free (e.g. BeNeLux) Way of installation (TC / ER) Wash-Down Approvals EMI protection Thermal resistance Mechanical resistance Chemical resistance (future: clean room conformity)

24 ISAB /F&B Symp / /Slide No. 24 UNITRONIC BUS FF-844 UNITRONIC BUS FF incorporates a complete cabling solution for the implementation of field automation and field control. Fieldbus is a Digital, Serial, Multidrop, data bus for communication with low level industrial control and instrumentation devices such as transducers, actuators, and local controllers. Product Features :- Conforming to FF 844, BS EN IEC , IEC XLPE insulated TM-53 Jacket Electrical Parameters Parameter Max. Cond. Resistance 25 C (18 AWG) Characteristic Impedance at KHz Attenuation at 39 KHz Capacitance Unbalance (Wire to Shield) Propagation Delay ( KHz) Value 24 Ω/Km 100 Ω +/-20% 3 db/km Max. 4 pf/mtr Max. 1.7 μ Sec/Km Benefits & Advantages :- Operating Temperature -30 deg C to +90 deg C. Product Variant:- Unarmoured / Armoured / Steel Wire Braid Indoor / Outdoor applications No.of pairs - 1 to 25 STP Max Bus Length( Including Spurs) Shielding Coverage Temperature Range 1900 m Minimum 100% coverage. Metalized Polyester Tape. -30 C to +90 C

25 ISAB /F&B Symp / /Slide No. 25 ÖLFLEX SERIES AN ABSTRACT ÖLFLEX ROBUST FD High flexible power chain cable, resistant against various chemicals, oil, fats, hot water ÖLFLEX CLASSIC 110 PVC control cable, VDE-registered, oil res and flexible for various applications ÖLFLEX CONTROL TM PVC control cable, 0,6/1 kv, UL TC-ER/ WTTC/ AWM 20886/ WET/ OIL RES, CSA AWM ÖLFLEX CLASSIC 400 CP Screened control cable for multi use, oil-, cut- and abrasion resistant polyurethane sheath Approvals / Laboratory tests (depending on product) ECOLAB Certified UL / CSA VDE Chemical resistance Oil res Cold flexible High flexible Wash-Down resistant EMC protection

26 ISAB /F&B Symp / /Slide No. 26 UNITRONIC & ETHERLINE SERIES AN ABSTRACT UNITRONIC BUS PB ROBUST PROFIBUS DP cable, resistant against various chemicals, oil, fats, hot water ETHERLINE ROBUST PN PROFINET cable, resistant against various chemicals, oil, fats, hot water, Cat.5 und Cat.7 rated ETHERLINE PN Cat.6A Y FLEX Flexible Cat.6A cable with PVC sheath and (UL) CMG approval, also suitable for PROFINET applications S/A-Kabel: Hygienic Design for Food & Beverage 4-pol. M12 connector with open end, hygienic design, with stainless steel knurl Approvals / Laboratory tests (depending on product) ECOLAB Certified UL / CSA VDE Chemical resistance Oil res Cold flexible High flexible Wash-Down resistant EMC protection

27 ISAB /F&B Symp / /Slide No. 27 SKINTOP COLD Cable glands for extreme negative temperatures HIGHLIGHT VDE-approval for - 70 C Low-high temperature range Application Advantage Approvals Cold Storage of food Food freezing equipment Air con (e.g. in trucks) Flash freezing - Contact freezing (-40 C n. 1 Min.) - Cold air freezing Large, variable clamping range Extreme cold resistant Food safe seal For negative temperature down to -70 C VDE IP bar (-50 C n. 1 Min.) - Cryogen freezing (-78 C w/ carbon dioxide)

28 ISAB /F&B Symp / /Slide No. 28 SKINTOP INOX SKINTOP INOX SC Stainless steel cable gland with optimized F&B design. Also available as EMI type. HIGHLIGHT Basic series EMI version Application Advantage Approvals Splash zone and non product zone in food machinery EMI critical areas Cold storage Food freezing equipment Stainless steel - V4A ( / 316L) Food safe silicone seal Optimized F&B design Compact geometry Corrosion resistant SC type with high conductive copperberyllium EMI- Acc. to DIN EN Food machinery concepts Acc. to DIN EN ISO Food machine design and safety IP 69 / IP 68 ECOLAB Certified

29 ISAB /F&B Symp / /Slide No. 29 SKINTOP HYGIENIC Hygiene design version HIGHLIGHT EHEDG Certified Product zone Application Advantage Approvals For use in all zones within food production Hygienic critical areas Packaging machinery Breweries Easy to use One complete part in comparison to competitors Large, variable clamping range Stainless steel - V4A ( / 316L) EHEDG Certified (functional and design test) ECOLAB Certified FDA components NSF components IP 69 / IP 68 Bakeries Chemical resistance ( Pharma industry ) Wash-Down No microbes or bacteria remain on plain surface

30 ISAB /F&B Symp / /Slide No. 30 SILVYN FG NM (Food Grade Non- Metallic) Hygienic design conduit HIGHLIGHT Flexible and stable Application For use in all zones within food production Hygienic critical areas Packaging machinery Breweries Bakeries ( Pharma industry ) Disinfection equipment Butchery Suitable conduit gland e.g. SILVYN HYGIENIC Advantages Liquid tight Easy to clean Smooth inner and outer surface Heat resistance Flame retardant Approvals NSF material FDA material UL pending ECOLAB Certified

31 ISAB /F&B Symp / /Slide No. 31 EPIC ULTRA Special coated zinc die-cast connector with stainless steel components HIGHLIGHT EMI-version Corrosion resistant Application Advantages Approvals For use in non product zone or splash zone according to customers assessment Packaging industry Diary shop Ice machines Butcheries Cutting machines Robust Long lasting Mechanical strength 360 EMI screen contact Corrosion resistant Covered seal IP 68 / IP 65 (depending on size of housing) Corrosion test, salt spray test DIN EN DIN EN ISO 9227 NSS 480h Sulfur resistance acc. DIN EN ISO 6988: DIN 50018: Corrosion test, mixed sprayed gas acc. to DIN EN : Test KE, method 4

32 ISAB /F&B Symp / /Slide No. 32 FLEXIMARK MARKING SYSTEMS HIGHLIGHT Wipe resistant Chemical resistance Application Advantage Approvals Marking of components in F&B applications For use in all zones acc. to customers risk assessment Pharma Industry Stainless steel series Stainless steel - AISI 316 Acid resistance Temperature range -80 C to +500 C PUR type / LCK wrapping series Wipe resistance Chemical resistance Oil resistance Stainless steel series PUR type Material aging and chemical resistance acc. to SP 2171 ECOLAB Certified MIL Standard UL 94 V0

33 ISAB /F&B Symp / /Slide No. 33 APPLICATION EXAMPLE CHEESE PRODUCTION AT COMPANY ALPMA WITH A CHEESE ROBOT BY COMPANY RHEM, GERMANY

34 ISAB /F&B Symp / /Slide No. 34 APPLICATION EXAMPLE CHEESE PRODUCTION AT COMPANY ALPMA WITH A CHEESE ROBOT BY COMPANY RHEM, GERMANY

35 ISAB /F&B Symp / /Slide No. 35 APPLICATION EXAMPLE HEINEKEN BREWERY

36 ISAB /F&B Symp / /Slide No. 36 REFERENCES Industrial Machinery Food & Beverage Manufacturers

37 ISAB /F&B Symp / /Slide No. 37 Question & Answers

38 ISAB /F&B Symp / /Slide No. 38 THANK YOU