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8. Food Industry Specific Requirements/Recommendations

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8.1 Terms and definitions
but where there is no risk of its returning into the food process. The requirements for both materials and design are similar to those in the food contact areas, but somewhat less stringent. Non-edible lubricants may be used if it means no adverse influence on the food. Non-food area All areas that are neither food or splash areas. The general requirements are valid. Exposed surfaces should be made of corrosion-proof or corrosion-protected material. The surfaces should be cleanable and wherever possible self-draining. In order to be able to give the right recommendations, Rexroth Mecman differ between dry and wet areas. The following definitions have been used. Wet area Area in which liquid, moist or sticky food flows around machine parts. For pneumatic components this means that the components are only temporarily exposed to known conditions of pressure and time. Dry area Areas in which no water can come into contact with machine parts and where the relative humidity is equal to that of the normal area (up to 70%) Lubricants The lubricants used in the food industry can be divided into different categories. Both 3A and USDA have a classification for lubricants. For example USDA use the following classes. 1 Industrial lubricants 2 Special lubricants USDA H2 3 Food lubricants USDA H1 The USA is currently the only country that classifies different types of lubricants and authorises their use. Permitted lubricants Permitted lubricants are classified as follows. 1 The USDA H1 category of lubricants for use when contact with food is technically unavoidable. 2 The USDA H2 category of lubricants for use when contact with food can be avoided. Each category has a maximum number of germs permitted in the lubricant. The following table shows the proportion of lubricants permitted in food production. Table 8.1.1 Maximum permitted lubricant in food Production areas In the European standard EN 1672-2, (Food Processing machinery part 2, Not Hygiene Requirements) three different zones with different demands are defined. Food area This area includes all surfaces that come into or could come into contact with food and where there is a risk of food splash returning into the food process. In addition to the general requirements, the materials used should be corrosion resistant, non-toxic and nonabsorbent. The design must permit good and complete cleaning with a surface finish which will prevent particles from remaining. Use of screws, bolts, etc. should be avoided. The surfaces should be self-draining without dead spaces. Food grade lubricants should be used. These requirements are also valid for the other areas if there is a risk of cross-contamination. Splash area This includes the surfaces where the food may splash or flow along, Mineral oil Synthetic oil 10 ppm (0,01 g/kg) 10 ppm (0,01 g/kg)

The following definitions and recommendations for terms used are selected from EN 1672-2, as they can be applied to pneumatic components. Material General recommendations are that the material shall be suitable for its intended use, that the surfaces are easy to clean and resistant to external influences. The following definitions are used: Corrosion-resistant material Material that can withstand normal chemical or electro-chemical demands. This term encompasses processing as well as cleaning and disinfecting processes. Non-absorbent materials Materials that do not absorb other materials when they come into contact with them, as long as these are used properly. Resistance Ability of a surface to withstand the intended conditions of use, e.g. to resist damage from detergents. Non-toxic materials Materials that are non-toxic, or do not release toxic substances which could damage health. (89/109/EEC) Hygienic design Crevices Detrimental effect on cleaning due to defects in the surface, e.g. scratches, cracks. Dead space A position where various materials can become stuck or cannot be removed completely by cleaning. Self-draining A surface designed so that its shape and materials will prevent liquids from accumulating. Smooth Surface shape appropriate to the operational and hygiene requirements. Seal Filling in an area to prevent unwanted materials from penetrating or permeating.

Selecting lubricants Before selecting a lubricant, an analysis is made using the HACCP system to establish whether there is any risk of food contamination. If there is no risk USDA H2 lubricants are recommended. If, however, a risk cannot be excluded, then USDA H1 lubricants must be used. USDA H1-approved lubricants are Food Grade Lubricants and are legally acceptable, are not damaging to health, have a neutral taste and are internationally recognised. As long as there are no clear regulations regarding lubricants within the EU, the internationally recognised regulations of the USA are observed.

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cleaning process and for obtaining optimum hygiene. Today it usually works the other way around: The cleaning process cannot be optimal because of the fact that the material is not resistant enough. For more information about specific applications, please contact Henkel-Ecolab directly. When selecting the right material you have to consider several points. Exposure Material/media

Non-lubricated air The food industry is changing ever increasingly to non-lubricated air. This means that the components have got an initial lubrication. Only appropriate permitted lubricants may be used in this initial lubrication process. In addition to the type of lubricant, e.g. USDA H1, the amount if lubrication coming into contact with food is also of significance, as is each microbiological reaction. The addition of bactericides to the lubricant is not permitted. Thorough cleaning and disinfecting are also of equal importance. Cleaning Cleaning an object in the food industry is a basic requirement of hygiene. Detergents and methods of cleaning influence the choice of materials used in the food machinery and equipment. The other way round, with a good hygienic design the cleaning can be done in a shorter time, at lower temperatures and with less aggressive detergents. Plastic and rubber The approval of plastics regarding their chemical composition can only be given by the manufacturers. In Europe there is a special directive for materials in general for the Food Industry, 89/109/EEC. Added to this there are special directives, for example plastics approved for the food industry (90/128/EEC). As the choice of plastic is far too extensive, no general statements can be made. Suitability is divided into categories depending on food condition and the detergents and disinfectants used. Corrosion-resistant steel Corrosion-resistant steel can also suffer surface corrosion and various forms of local corrosion. DIN 11483, Part 1, provides a list of different levels of resistance for comparison. Detergents When cleaning food machinery and equipment, manufacturers instructions must be observed. Detergents must also be used as directed by the manufacturer. It is important for the relevant materials, cleaning procedures and detergents to be compatible. Selection of material We have included the following table to help you find suitable materials. The table incorporates the materials of our components alongside their resistance to detergents and chemicals. The contents of the table are to be regarded only as a guide. Various combinations of different detergents or chemicals and various food stuffs can cause new aggressive media. A definitive understanding of the resistance of materials can only be determined through your own series of tests. Material/Media To decide whether a material is suitable for a specific application or not, is an important but complicated issue. In most of the applications where pneumatics are used, low-grade material is enough. However, in this chapter we are only concerned with the tough applications where the products are frequently washed and put under a strong environmental stress. In this issue we will try to help you by giving you some information about the compatibility of some of the most commonly used materials for pneumatics and their durability against e.g. typical detergents. Henkel-Ecolab has supported us with this part. Henkel-Ecolab is one of the worlds leading suppliers of detergents and systems for cleaning in the food industry. They have extensive experience and consider that material standards should be raised within the food industry. This means that the recommendations do not really reflect the reality. They are instead based on the most suitable material for the optimum

Choice of product
Function Influencing factors

Fig. 8.1.1 There are many factors that interplay and have an effect on the material. Function The type of effect that the environment might have on the function must be determined i.e. whether it is potentially dangerous or whether the effect is purely aesthetic. That is to say, to establish in what way environmental stress affects performance. Influencing factors Depending in the temperature, the concentration of active substances, the combination of materials that can function as voltaic elements and the mechanical stress, the effects can vary considerably. Exposure Depending on whether exposure is constant or sporadic the effect will be different. A constant exposure is the most difficult to handle.Periodic standstill can result in the media drying up and having an adverse effect on the example sealings. Material From a general point of view, the material can be well suited or not so well suited to the environment. In Table 8.1.3 we present the material durability against some of Henkel-Ecolabs commonly used detergent when cleaned in a normal cleaning cycle, 15-60 minutes per day. Expected life-length is more than two years. To be able to use the tables in the right way, it must be stressed that they only give one part of the story. Each case must be considered separately in accordance with the model above. The tables take into consideration the effect of the detergents on the material, but not the way the components are used or any adverse effect caused by the foodstuff. Another aspect is that it considers only the environmental effect on the material and not its suitability for use with food stuff.

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Table 8.1.3 C 19 P3-topax 19 A strong alkaline product with complexing agents, sodium hydroxide and nonionic surfactants. D 66 P3-topax 66 An alkaline product based on sodium hydroxide, hypochlorite and nonionic surfactants. E 68 P3-topax 68 An alkaline product based on sodium hydroxide, hypochlorite, silicates and nonionic surfactants. F 56 P3-topax 56 An acid detergent based on phosphoric acid, nonionic surfactants and corrosion inhibitors. A 99 P3-topax 99 A mild alkaline to neutral disinfectant based on fatty ammonium acetates.

In the tables, the following scale has been used: Table 8.1.2 Scale 1 2 3 Meaning Well suited Good Usable Definition Not affected at all, mechanically or visually. Not affected mechanically. Might be some visual effect. Acceptable resistance. Risk of minor mechanical effect. Observe frequency and exposure.

Limited use/ Risk of mechanical effect. Varied outcomes. not suited Only sporadic cleaning recommended. Each case must be judged individually.

Commonly used Henkel Ecolab detergent A 12 P3-topax 12 A mild alkaline product based on phosphates and anionic surfactants. B 17 P3-topax 17 An alkaline product with complexing agents, nonionic surfactants, sodium hydroxide and silicates.

Part

Material

End-covers, barrels, piston rods, mounting screws, mounting Piston rods Mountings, screws, nuts Screws, valves Mountings Connection threads Fittings FRL bodies End-covers shuttle cylinder End-covers, valve bodies Cylinder barrels, end-covers Cylinder barrels, end-covers End-covers, valve bodies Cylinder barrels, valve bodies Cables for sensors Scrapers FRL bowls Sealings Sealings, bushings Suction cups

Steel AISI 316, 303, 304 Steel AISI 420, 430 F Zink-plated steel Nickel-plated steel Bronze Brass Nickel-plated brass Zinc Painted zinc Aluminium, painted aluminium Anodised aluminium Chemically nickel-plated aluminium Acetal Plastic (POM) Polyamide plastic (P PVC Polyurethane (PU) Polycarbonate Fluoroplastic (PTFE) Nitrile rubber (NBR) Silicone rubber (Q)

1 2 2 2 2 1 2 1 1 1 1 1 1 1 1 1 0 1 2 1

1 2 2 2 2 2 2 0 3 3 3 1 0 3 1 2 0 1 2 1

1 2 3 2 3 3 2 0 0 0 0 1 0 3 1 2 0 1 2 1

1 2 3 2 3 3 2 0 0 3 3 1 0 3 1 0 0 1 2 1

1 2 2 2 2 2 2 0 0 2 2 1 0 3 1 0 0 1 2 1

1 2 3 2 3 3 2 0 3 2 2 1 0 3 1 2 0 1 2 1

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A 99 Mild disinfectant 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1

C 19 Strong alkaline

A 12 Light alkaline

B 17 Alkaline

D 66 Alkaline

E 68 Alkaline

F 56 Acid

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Table 8.1.4 When we combine Henkel-Ecolab results above with the commonly used detergents in specific branches and add some practical experience, we recommend the following for different branches (once again based on the hardest condition).

Part

Material/branch

End-covers, barrels, piston rods, mounting screws, mounting Piston rods Mountings, screws, nuts Screws, valves Mountings Connection threads Fittings FRL bodies End-covers shuttle cylinder End-covers, valve bodies Cylinder barrels, end-covers Cylinder barrels, end-covers End-covers, valve bodies Cylinder barrels, valve bodies Cables for sensors Scrapers FRL bowls Sealings Sealings, bushings Suction cups

Steel AISI 316, 303, 304 Hard chromium-plated steel AISI 420, 430 F Zink-plated steel Nickel-plated steel Bronze Brass Nickel-plated brass Zinc Painted zinc Aluminium, painted aluminium Anodised aluminium Chemically nickel-plated aluminium Acetal plastic (POM) Polyamide plastic (P PVC Polyurethane (PU) Polycarbonate Fluoroplastic (PTFE) Nitrile rubber (NBR) Silicone rubber (Q)

1 3 0 3 3 3 3 0 0 2 2 0 0 3 1 0 0 1 2 1

1 3 0 3 3 3 3 0 0 0 0 0 0 3 1 2 0 1 2 1

1 3 0 3 3 3 3 0 0 0 3 0 0 3 1 0 0 1 2 1

1 3 0 3 3 3 2 0 0 3 3 3 0 3 1 2 0 1 2 1

In general, surface treatment is good as long as the coating is intact, When material is chosen with a grade worse than two, each case has to be judged individually. Corrosion always means a hygiene risk. From a hygienic point of view only grades one and two are acceptable in sensitive environments. The most important exceptions according to our experience in the food industry over the years, are as follows: Note! If POM is not dried off enough after cleaning with acid, there is a risk of formaldehyde being produced. In general the characteristics of plastics differ from case to case and from quality to quality. The risk of absorption by the plastics must also be considered. In general our experience of plastic in the food industry is better than the tables indicate. There are considerable differences in the quality of different suppliers of e.g. Polyamide. Carbon steel is durable against alkaline cleaning. The difference between stainless and carbon steels is shown in a strong acid environment. Phosphoric acid, however, is commonly used in detergents and low-grade steels such as AISI 420 can withstand this for short periods. The detergents usually have inhibitors that protect the material. One of the biggest risks lies in the galvanic corrosion when combining for example stainless steel with aluminium in wet environments. Aluminium cannot withstand either strong alkaline or strong acid environments. The durability may increase when it is painted or anodised, but it depends on the quality of the surface treatment. Hard chromium plating on low grade stainless steel risks substrate corrosion, in which case the platins will peel off in flakes.

but can in many cases increase the speed of the corrosion process if damaged. Please note that the evaluation is based on the worst case. In most situations where pneumatics is used in the food industry, standard components will suffice.

Fruit & vegetable 1 2 0 3 3 1 2 0 0 3 3 3 0 3 1 0 0 1 2 1

Bakery

Dairy

Meat

Fish

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components.

8.2 Product recommendation for specific requirements

Table 8.2.1 Corrosion durability classes Class 1 This chapter will discuss our recommendations for using pneumatic components in food processing machines. We have classified our products in order to assist you in selecting the appropriate products. Cleanability Components used in the food production process must be easy to maintain in order for precautions to be taken against microbiological pollution. This means the components have to be easy to clean and must be protected against pollution. For pneumatics this signifies several specific requirements that have to be met by the products. In general it is unusual for pneumatic components to come into contact with food. If this, however, is the case then the surface has to be resistant to the foodstuff. A further important aspect for consideration is that the surface has to be easily accessible for both visual control and manual cleaning. For this reason valves should not be mounted in other areas than the non-food area. When the valves are mounted outside a cabinet, they have to be cleanable and must therefore be corrosion resistant and have a high electrical protection class. For valves mounted inside a cabinet, Rexroth Mecman have developed Mec Proof, a special method of cost-efficient and clean mounting. Material Material coming into contact with food has to be mechanically stable, have smooth surfaces and be easy to clean. Some types of surface coating may degrade. These should be avoided in food areas. In this context not only the design and material are important. For example, in open factories the environmental influences regarding the hygienic requirements play an important role. Exhaust air The exhaust air of pneumatic components can have adverse effects, for example if: -the compressor gives off oil and water into the air -the pneumatic part of the machinery has not been maintained -there is no piped exhaust air -the compressed air is lubricated for specific reasons -the filtration is not carried out properly. In general lubricated air should be avoided. When there is a need for lubrication, the exhaust air should be piped. Pneumatic components are initially greased and do not need any added lubricants. New components are developed to be leakage free, which are of great importance, when aiming for a hygienic pneumatic system. The recommendations in this chapter are a generalisation and the aim is merely to give an outline of this topic. Therefore, each application has to be considered separately, taking into consideration the specific circumstances. Definitions for product classifications There are different demands on products for different applications. In order to be able to classify our components according to their ability to withstand corrosion, their suitability from a hygiene point of view and their electrical protection class, we have defined the following classes for corrosion durability, hygiene and electrical protection. This classification will be used later on when classifying of our components recommended for the food industry. The classification is to some extent based on the tables from HenkelEcolab, see tables 8.1.3 and 8.1.4, is more based on practical experience. The materials mentioned are the ones that are part of our 2 Materials - Acid-proof and stainless steel - Plastic such as PVC, polythene, PTFE, silicon rubber - Hard chromium-plated steel - Steel such as AISI 420, 430F - Nickel-plated steel and brass - Chemically nickel-plated and anodised aluminium - Plastics such as Polyamide 6.6, POM Rubbers PU, nitrile rubber, NBR, Perbunan - Zinc-plated steel - Bronze, brass, zinc - Plastics such as polycarbonate - Plain aluminium

Table 8.2.2 Hygiene classes Class Design 1 hygiene design - smooth surface (no dangerous grooves or pores) - rounded corners and edges - no dead spaces - self-draining 2 clean design - might be some dead spaces - self-draining 3 standard design - dead spaces not completely avoided - moderately cleanable Table 8.2.3 Electrical protection classes Class Protection against touch, foreign bodies and water 1 High protection class IP 67 (4) Protection against dust, water and detergents. Water must not enter when the operating material is immersed in water when under conditions of pressure and time. 2 Medium protection class IP 65 (4) Protection against dust and splash water. A jet of water spraying from all directions onto the operating material must have no detremental effect. The requirements for pneumatics in food industry are divided into following categories by Rexroth Mecman, regarding the categories of hygienic design and with the consideration of possible corrosion. Irrespective of product risk the choice of pneumatic components is influenced by the method of cleaning. There are, therefore, some preculiarities that need to be considered, but these can only be resolved on an individual basis. Hygiene class 1 Selectograph for pneumatics Corrosion durability Requirements for pneumatic components Electrical protection class 1 2 3 3

Product risk highly sensitive (e.g. meat, milk, fresh eggs) moderately sensitive (depends on processing stage) less sensitive (e.g. cereals, coffee)

Environment (cleaning) wet wet dry wet dry

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Table 8.2.4 Definitions for product classification, cylinders Series 2702 Standard Series Shape (mm dia.) 20, 32 and profile 40 Corrosion resistance class 1/2 Hygiene Options class 2/3 single acting Wet area Non food area Dry area Splash area

2700

12100

profile

2/3

single acting, with guide, through piston rod single acting

The cylinder Splash is not suited area for this application area. Splash area Splash area

132 / 133

ISO

832

virtuall round

522

ISO

1025

virtuall round

2/3

single acting, adjustable cushioning

The cylinder Splash is not suited area for this application area. The cylinder Splash is not suited area for this application area. Splash area Splash area

168

ISO VDMA CNOMO

25100

profile

2/3

high temperature

168 Clean

ISO VDMA CNOMO

25100

profile

2/3

high temperature

Euromec Compact

25100

profile

2/3

high temperature

The cylinder Splash is not suited area for this application area. Non food area No food area

167; Acid-prood

ISO

32320

tie-rod

high temperature

VDMAcylinder. Yellow

ISO VDMA CNOMO

32125

profile

2/3

1/2

high Non food temperature, area for proximity switch position sensor for proximity Food area switch position sensor

Food area

Rextreme

ISO

3280

round

Food area

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Table 8.2.5 Definitions for product classification, valves Series 590 Size ISO 1, ISO 01 Function 2 x 3/2 5/2 5/3 Actuation electrical Piped exhaust yes Electrical Corrosion Wet area protection protected class IP 67 IP 65 1/2 Non food area Dry area Non food area

840

ND 3

4/2

pneumatic or no electrical

Ip 65

Valves should be mounted in cabinets. Valves should be mounted in cabinets. Non food area

Non food area

740: no lubricant

ND 7

5/2

pneumatic or no electrical

IP 65

Non food area

343; acid proof

ND 4

3/2

manual or mechanical

yes

Non food area

563

ND 7

3/2

manual

no

Non food area

Non food area

579

3/2

electrical

yes

IP 65

Valves should be mounted in cabinets. Valves should be mounted in cabinets. Valves should be mounted in cabinets. Valves should be mounted in cabinets. Non food area

Non food area

Compact 10

ND 3,5

5/2 5/3 vacuumejector 5/2 5/3

Non food area

Compact 15

electrical

yes

IP 65

Non food area

Compact 18

ND 5

5/2 5/3 vacuumejector

pneumatic or electrical

yes

IP 65 IP 67

Non food area

344, 345 and 346; acid-proof

non-return throttle, throttle, non-return valve fitting

Non food area

corrosion fittnings

ND 4 12

Splash area

Splash area

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