Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
National Symposium on
Automation & Digital Transformation of
Food & Beverage Industry26th & 27th February 2016
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S Prasad NarasimhaDGM – Product Engineering
Lapp Group
LAPP SOLUTIONS FOR F&B INDUSTRY
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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.
S Prasad Narasimha
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• 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
Agenda
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LAPP GROUP
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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
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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
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LAPP INDIA
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 2nd state of the art
manufacturing plant at
Pilukedi, Bhopal
• Bhopal plant produces more
than 220,000 kms of Single
Core Cables per annum
•146 dealer
network across
India
• 3000+ customers
across 25
business verticals
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8 strong brands,
which are international
industry standards
Brand Quality
From standard
to custom-made
products
More than 40,000
standard products for
various industry
requirement
SILVYN®
EPIC®
Tailored solutions
for customer-specific
applications
ÖLFLEX ® HITRONIC®
ETHERLINE® UNITRONIC®
CUSTOMIZED PRODUCTS
SKINTOP®
FLEXIMARK®
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A chain (or connection) is only
as strong as is weakest link!
1970 2005 2050
3.687 billion6.49 billion
11 billionGLOBAL
SCENARIO
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.
Limited resources like workable land require more sophisticated
equipment (GPS supported tractor)
…this leads to more specialized and demanding machinery.
Source: http://www.worldometers.info/
Source: FAO, DBV-Berechnungen, UN
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GLOBAL
FOOD
PROCESSING
MACHINERY
INDUSTRY
LAPP GROUP
CUSTOMERS
BY F&B
INDUSTRY
…% 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
Demand for food processing machinery will grow by 7.6 %
annually to $73 billion in 2019.
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:
http://www.freedoniagroup.com/World-
Food-Processing-Machinery.html
http://www.finanzen.net/aktien/aktien_ver
gleich.asp?pkAktieNr=2020
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FOOD PROCESSING
MACHINERY
INDUSTRY
ASIA/PACIFIC
REGION TO
BE FASTEST
GROWING
MARKET
• Asia/Pacific is predicted to outperform its demand and growth from
2011 to 2016, averaging 9.5 percent per year.
Source: Freedoniagroup.com
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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
a healthy pace.Source: Freedoniagroup.com
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SAFETY &
STANDARDS
SAFETY IN
3 DIMENSIONS
• No injuries (e.g. short circuit)
• Reduction of hygienic related risks (i.e. aggressive media or environment)
SAFETY AT WORK
• 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)
HEALTH OF THE END-CONSUMER
• 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)
PROCESS SAFETY
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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
DIN ISO 14159
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.
Int. material
parameters and
practical
assessment
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BASIC
DESIGN
CONCEPTS
AND
RELEVANT
STANDARDS
FOR FOOD
MACHINERY
Hygienic design examples related to radius, edge and angleQuelle: http://www.foodsafetymagazine.com/fsm/assets/Image/2303CoverStory2Fig1-4.jpg
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INCREMENTA
L EVOLUTION
WITHIN
PRODUCT
DESIGN
EVOLUTIONARY
STEPS WITH
REGARDS TO
PRODUCT
PERFORMANCE
TIME
PRODUCT PERFORMANCE
(Chemical resistance, cleanability, etc.)
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APPLICATION
AREA
F&B MACHINERY
EXAMPLE
INCLUDING
ZONE
CLASSIFICATION
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LOCATION AND
ZONE
CLASSIFICATION
ACCORDING TO
SAFE FOOD
FACTORY
Food Zone
Direct contact
Indirect contact
Splash zone
Non-Food zone
Locations (common wording)
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
Zone Classifications (further used terms by branch pro`s)
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IDEAL CABLING SOULTIONS FOR F&B
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Food and
Beverage
Industry
Challenges
and Solutions
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)
Sample image Environmental-Chemical s & Oil
Ability of the cable
jacket to resist the
effect of oil /
chemicals resulting in
longer lasting cables
Electrical – EMI
(Electro Magnetic
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
signals
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Food & Beverage
Industry
Challenges
and Solutions
Sample image Sample image Mechanical
Flexible, high
bending radius
Tensile, elongates,
high insulation
resistance
Cables can be
exposed to
mechanical forces
Electrical – Loss less
transmission
Loss less
transmission
High conductivity
High insulation
resistance
For data / signal –
low capacitance
Low line attenuation
Temperature
Cable to operate
within the
temperature range. In
general application
temperature ranges
from -50C to +900C
Higher temperature
range for industrial
applications is
required
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Wires & Cables
ÖLFLEX®
UNITRONIC®
ETHERLINE®
HITRONIC®
Cable Glands
SKINTOP®
Industrial Connectors
EPIC®
MarkingSystem
FLEXIMARK®
Cable Protection
SILVYN®
POWER LV &
OLFLEX
INSTRUM AS
PER IS/BS
FIELD BUS
CABLE
LAPP PRODUCT OFFERINGS
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ÖLFLEX® &
UNITRONIC®
SERIES
For global usage in
F&B machinery and
equipment
HIGHLIGHT
ECOLAB® Certified
Oil resistant
Chemical resistance
Flexibility
Further processing
Number of approvals
Food & Beverage Machinery and Equipment
PURe.g.
ÖLFLEX® CLASSIC 400 CP
etc.
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)
Examples for Selection Criteria for Wires & Cables
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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 50288-7
IEC 60332-3-24, IEC 61158-3
XLPE insulated
TM-53 Jacket
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
Electrical Parameters
Parameter Value
Max. Cond. Resistance DC @ 25 C
(18 AWG)24 Ω/Km
Characteristic Impedance at 31.25
KHz100 Ω +/-20%
Attenuation at 39 KHz 3 dB/Km
Capacitance Unbalance (Wire to
Shield)Max. 4 pF/mtr
Propagation Delay ( 7.9 …. 39 KHz)Max. 1.7 μ
Sec/Km
Max Bus Length( Including Spurs) 1900 m
Shielding Coverage
Minimum 100%
coverage.
Metalized
Polyester Tape.
Temperature Range -30°C to +90°C
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ÖLFLEX® SERIES –
AN ABSTRACTÖLFLEX® 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
ECOLAB
®
Certified
UL / CSA
VDE
Approvals / Laboratory tests (depending on product)
Chemical
resistance
Oil res
Cold flexible
High flexible
Wash-Down
resistant
EMC
protection
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UNITRONIC® &
ETHERLINE®
SERIES –
AN ABSTRACT
26
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
ECOLAB
®
Certified
UL / CSA
VDE
Chemical
resistance
Oil res
Cold flexible
High flexible
Wash-Down
resistant
EMC
protection
Approvals / Laboratory tests (depending on product)
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SKINTOP® COLD
Cable glands for
extreme negative
temperatures
HIGHLIGHT
VDE-approval for -
70°C
Low-high
temperature range
VDE
IP 68 – 10 bar
27
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
(-50°C n. 1 Min.)
- Cryogen freezing
(-78°C w/ carbon dioxide)
Application
Large, variable
clamping range
Extreme cold
resistant
Food safe seal
For negative
temperature down
to -70°C
Advantage Approvals
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SKINTOP® INOX
SKINTOP® INOX SC
Stainless steel cable
gland with optimized
F&B design. Also
available as EMI type.
HIGHLIGHT
Basic series
EMI version
Splash zone and
non product zone
in food machinery
EMI critical areas
Cold storage
Food freezing
equipment
Stainless steel -
V4A (1.4044 / 316L)
Food safe silicone
seal
Optimized F&B
design
Compact geometry
Corrosion resistant
SC type with high
conductive copper-
beryllium EMI-
contact spring
Acc. to DIN EN 1672-
2 Food machinery
concepts
Acc. to DIN EN ISO
14159 Food machine
design and safety
IP 69 / IP 68
ECOLAB® Certified
Application Advantage Approvals
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SKINTOP®
HYGIENIC
Hygiene design
version
HIGHLIGHT
EHEDG Certified
Product zone
EHEDG Certified
(functional and
design test)
ECOLAB® Certified
FDA components
NSF components
IP 69 / IP 68
For use in all
zones within food
production
Hygienic critical
areas
Packaging
machinery
Breweries
Bakeries
( Pharma industry )
Easy to use
One complete part
in comparison to
competitors
Large, variable
clamping range
Stainless steel -
V4A (1.4044 / 316L)
Chemical resistance
Wash-Down
No microbes or
bacteria remain on
plain surface
Application Advantage Approvals
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SILVYN® FG NM(Food Grade Non-
Metallic)
Hygienic design
conduit
HIGHLIGHT
Flexible and stable
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
Application
Liquid tight
Easy to clean
Smooth inner and
outer surface
Heat resistance
Flame retardant
Advantages
NSF material
FDA material
UL pending
ECOLAB®
Certified
Approvals
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EPIC® ULTRA
Special coated zinc
die-cast connector
with stainless steel
components
HIGHLIGHT
EMI-version
Corrosion resistant
For use in non
product zone or
splash zone
according to
customers
assessment
Packaging industry
Diary shop
Ice machines
Butcheries
Cutting machines
Application
Corrosion test, salt spray test
DIN EN 60068-2-52
DIN EN ISO 9227 NSS 480h
Sulfur resistance acc.
DIN EN ISO 6988: 1997-03
DIN 50018: 1997-06
Corrosion test, mixed sprayed gas acc. to DIN EN 60068-2-60: 1996-09 Test KE, method 4
Advantages Approvals
Robust
Long lasting
Mechanical strength
360° EMI screen contact
Corrosion resistant
Covered seal
IP 68 / IP 65 (depending on size of housing)
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Stainless steel series
Material aging and chemical
resistance acc. to SP 2171
ECOLAB® Certified
PUR type
MIL Standard 81531
UL 94 V0
FLEXIMARK®
MARKING
SYSTEMS
HIGHLIGHT
Wipe resistant
Chemical resistance
Marking of
components in
F&B
applications
For use in all
zones acc. to
customers risk
assessment
Pharma Industry
Application
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
Advantage Approvals
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APPLICATION
EXAMPLE
CHEESE
PRODUCTION AT
COMPANY ALPMA
WITH A CHEESE
ROBOT BY COMPANY
RHEM, GERMANY
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APPLICATION
EXAMPLE
CHEESE
PRODUCTION AT
COMPANY ALPMA
WITH A CHEESE
ROBOT BY COMPANY
RHEM, GERMANY
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APPLICATION
EXAMPLE
HEINEKEN BREWERY
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REFERENCESIndustrial Machinery
Food & Beverage
Manufacturers
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Question & Answers
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THANK YOU
