Energy Efficiency through Hygienic Design

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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.Energy Efficiency by Design
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

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Energy Efficiency through Hygienic Design

  1. 1. Innovation in Energy EfficiencyNational Centre for Food Manufacturing Sando Selchow Market Development Manager Food & Beverage June 2011 1
  2. 2. Innovations in Energy Efficiency Energy Efficiency by DesignOnly those who use energy will be successful in the long run. Whether in energy distribution, automation, buildingservices 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. Sando Selchow Market Development Manager Food & Beverage June 2011 2
  3. 3. Energy Efficiency by DesignRittal 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 Sando Selchow Market Development Manager Food & Beverage June 2011 3
  4. 4. Energy Efficiency by DesignProducts + Engineering + Realisation- energy –saving products and systems- monitor overall performance with comprehensive software tools- take care of the whole “energy efficiency chain” through analysis + planning + implementation Sando Selchow Market Development Manager Food & Beverage June 2011 4
  5. 5. Innovations in Energy Efficiency Energy Efficiency by DesignComprehensive analysis + efficiency planning + integrated implementationSystematic and Planning software Commissioningtime-based EPLAN Energy reviewCFD analyses Therm 6.01 System moni-Thermography RICAD 3D toring Software tools RiZone &RiRFID Sando Selchow Market Development Manager Food & Beverage June 2011 5
  6. 6. Innovations in Energy Efficiency Energy Efficiency by DesignPlanning software EPLANThe worlds leading electrical engineering software -proven to save you time and money! Some 70 to 80% of the material, production and operating costs are already defined at the engineering stage. Optimisation of the influencing factors permits a significant reduction of these costs. The following three examples show how costs can be tackled at their source. Example: RiCAD 3D ● All 3D design data are made available immediately and can be used directly for planning in your own CAD system. ● Drawing data from RiCAD 3D form the basis for efficient enclosure configuration in EPLAN Cabinet. Sando Selchow Market Development Manager Food & Beverage June 2011 6
  7. 7. Innovations in Energy Efficiency Energy Efficiency by DesignOut of our 7 SBU’s strategic business units, we show thefollowing product innovations that all help the energyefficiency 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 Sando Selchow Market Development Manager Food & Beverage June 2011 7
  8. 8. Modular enclosure systemsProduct overview – Special requirements Hygienic Design compact enclosures Hygienic Design terminal boxes Hygienic Design accessories
  9. 9. 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 gaps No germs, no cross-contamination, no time-consuming or costly cleaning+ 30° roof tilt in the HD compact enclosure The 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 systems Effective cleaning thanks to external contours with hygiene-compliant minimum radii. Yet, it can only be opened with a special key.
  10. 10. Modular enclosure systemsHygienic Design compact enclosures 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. Saves time and costs by means of... • Longer maintenance cycles with shorter maintenance times when replacing seals • Fast and simple cleaning HD wall spacer brackets The housing should not be mounted directly to the wall in order to allow for thorough cleaning.
  11. 11. Modular enclosure systemsHD terminal boxesFacts 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 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
  12. 12. Modular enclosure systemsHD cable glandThe 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
  13. 13. Modular enclosure systemsHygienic DesignPrevent contamination
  14. 14. Modular enclosure systemsProfitability of Hygienic Design solutions1 day = 24 hrs = 1,440 min (three-shift operations)40%* cleaning time per day = 576 min Activity: 1% of cleaning time is saved thanks to Rittal Hygienic DesignIn the case of 240 working days/year = 1,382 min1,382 min ≈ 1 day Save cleaning timemore production time during the year! to gain in productivity! * Experience gathered from the meat processing industry
  15. 15. Modular enclosure systems Hygienic Design solutionsAdvantages of Hygienic Design solutions for: Mechanical engineers in Food producers Planning offices the food sector Innovative in the face More security with regard Minimise liability risk of the competition to certifications (IFS, BRC) Proximity to the standard – Easily fulfils Innovation is guaranteed state-of-the-art technology specifications thanks to long-lasting in building planning products (e.g. gate controls) Improved quality of consultation and therefore a more valuable contact partner for food producers
  16. 16. Modular enclosure systems Reference – Housing solutions Hygienic Design expansion of existing machine parts • An expert in meat processing machines and flake ice generators • worldwide < 30,000 MAJA machines often in operation around the clock 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.
  17. 17. Modular enclosure systems Reference – Housing solutions Access to Standard sale of products thanks to a modular customer-specific solution • Leading brand in the beverage industry • Sells over 230 beverage brands in approx. 200 countries in the world • Employs 92,800 people worldwide+ 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 at human-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.
  18. 18. Modular enclosure systemsReference – Housing solutionsHygienic Design applications in the food and beverage industry • Annual production of 80 million snacks and meals • 35,000 metric tons of deep-frozen products Plate frosters • 15,500 employees Tray line Final packaging Voltage supply+ 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).
  19. 19. Innovations in Energy EfficiencyA 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: Sando Selchow Market Development Manager Food & Beverage June 2011 19
  20. 20. Best practice, identify and design a solution Is your equipment getting too hot?Thermal non reversible labels 65 Component lifetimes – Use to convince customers of heat 61 are critically reduced load issues within their panels 57 if enclosure 53 – Temperature range selected to cover 49 temperatures exceed critical temperatures for Drives 45 manufacturers 41 guidelines 37Customer visits to conduct Thermal Check Contact us on 07866 411191 or cooling@rittal.co.uk to helpProvide optimisation for more efficient runningconditions using Rittal InnovationsUse Efficiency calculators to provide ROIUse FREE “Therm” software for calculations & product selection Sando Selchow Market Development Manager Food & Beverage June 2011 20
  21. 21. Use of USP‘s to push Cool Efficiency units Sando Selchow Market Development Manager Food & Beverage June 2011 21
  22. 22. Use of USP‘s for more TopTherm fan and filter units Sando Selchow Market Development Manager Food & Beverage June 2011 22
  23. 23. USP‘s for air/water heat exchangers & free cooling Sando Selchow Market Development Manager Food & Beverage June 2011 23
  24. 24. Use of Unique Selling Points of heating units Sando Selchow Market Development Manager Food & Beverage June 2011 24 1
  25. 25. Success stories – Food and Beverage industry Frito Lay – PepsiCoProduct requirements Stainless Steel IP 65 Low maintenance Energy efficient Low environmental impactLogistic and special requirements Solve procurement problems Drastically reduce backup inventory from multiple vendor cooling devices.Replaced a number of manufacturersmodels: different Ice Qube different ISC/Thermal Edge different Mclean/Hoffman Sando Selchow Market Development Manager Food & Beverage June 2011 25
  26. 26. Success stories – Food and Beverage industry SABmiller breweryProduct requirements: Possibility to use cooling solution for acid resistance Dump proof High temperature Easy to keep a units cleanResults: Heat exchangers water/air roof mounted ( V4a) Heat exchangers water/air wall mounted ( V4a) Mini chiller V4A 3334.609Concept extend space in cabinets Customer extended front of the cabinets and built construction for mounting chiller on the top Sando Selchow Market Development Manager Food & Beverage June 2011 26
  27. 27. Any Questions? Sando SelchowMarket Development Manager Food & Beverage Sector 07974205376 sselchow@rittal.co.uk Sando Selchow Market Development Manager Food & Beverage June 2011 27

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