New paradigms for the design, manufacturing and operation of food processing and packaging equipment 2nd Presentation of Final Workshop PARADIGM 1 DEMONSTRATOR ELEMENTS Aimed at the rationalization of components and cost, increase of yield and of hygienic design 3D printing and bulk ceramic components for improved cleanability and longer maintenance interval Project web site: http://www.npfp.it/en

1. Rotary manifold used in filling machines: 3D printing
and bulk ceramic components for improved
cleanability and longer maintenance interval
Ing. Filippo Dazzi
Sidel

2. NPFP 2
Targets
MANDATORY CONDITION
Targets to be achieved stating the constraint of
- food compliance (since the component is along product circuit)
- Machine functional specifications
- CIP cleaning aggressive conditions (contact with chemicals at high T)
 Driver1: switch from «make to stock» to «make to order» production strategy;
evaluate the application of 3D printing technology to obtain parts not
manufacturable by machining technology – necessary to review the design of the
parts to fully benefit of the potentiality of A.M.
 Driver2: eliminate contact sealing parts from rotary manifold; evaluate the
possility to use ceramic materials with ultra-high wear resistance, machined to
achieve (Parmalapping contribute) the required degree of precisione in the
coupling;
 Driver3: in case Driver 2 is not achieved, increase of sealing feature by optimizing
both gaskets material and coating/bulk material of rotary manifold parts;

3. NPFP 3
TECHINCAL SPECIFICATIONS
 Operating pressures up to 7bar
 AISI 316L
 External dimensions not higher than current
 Rotation speed max 25 rpm
 Duration held at least 12000h
 Absence of lubrication
 Presence of humidity
 Maximum temperature during sanitization 90 ° C
 Chemically aggressive agents
Product rotary manifold
Red part = rotating
Gaskets

4. NPFP 4
Product rotary manifold

5. NPFP 5
Sidel targeted a part of one type of
rotary manifold that would benefit the
free-form realization through additive
manufacturing (AM).
By today the distribution channels
require deep holes and 90° crossed
hole, that result in difficult cleanability;
Product rotary manifold

6. NPFP 6
DRIVER1: VERIFICATION OF THE POTENTIAL OF AM
FOR THE DESIGN AND CONSTRUCTION OF A MANIFOLD
Parti fisse e rotanti del collettore interamente
in additive di Ti-6Al-4V (alimentare) senza
variare l’attuale strategie di tenuta, diminuendo
no. parti e peso (ovvero volume e costi)
togliendo materiale ove non necessario
Costo elevato; difficoltà
nel mantenere le tolleranze
Media
Realizzazione in additive solo dei componenti più piccoli e
geometricamente più complessi.
Parti fisse e rotanti del collettore interamente
in additive di Ti-6Al-4V (alimentare) senza
variare l’attuale strategie di tenuta, diminuendo
no. parti e peso (ovvero volume e costi)
togliendo materiale ove non necessario
Mantenimento delle
rugosità richieste per i
vincoli igienici Ra<0,8
Elevato Elevato
Realizzazione di campioni (eventualmente in scala) e
verificà della rugosità ottenibile
Parte fissa del collettore interamente in
additive di Ti-6Al-4V (alimentare) senza
variare l’attuale strategie di tenuta diminuendo
il peso (ovvero volume e costi) togliendo
materiale ove non necessario e facendo canali
interni fluidodinamicamente migliorati
Costo elevato; difficoltà
nel mantenere le tolleranze
Basso Elevato
Realizzazione di una parte fissa collettore più corta (ad es.
corrispondente ad un solo canale di distribuzione anziché i
tre visibili in Fig. 3)
CONCEPTUAL SOLUTIONS AND RISK ANALYSIS FOR THE USE OF ADDITIVE
MANUFACTURING IN THE MANIFOLD CONSTRUCTION
The research was carried out in two parallel ways: (i) design and printing of a
simplified channel; (ii) redesign, according to the criteria of the Design for Additive
manufacturing, of a manifold optimized for production technology

7. NPFP 7
CONTROL OF ROUGHNESS REQUIRED FOR HYGIENIC
CONSTRAINTS
3D printed
channel
simulating
manifold
channels
 Prototype of one channel of manifold central body was studied for by 3D printing
 Material: AISI 316L – EN 1.404

8. NPFP 8
 A prototype replicating the 90° channel was 3D printed (AISI 316L – EN 1.404)
 Material: Ra, Sa, Sz [µm] mean internal roughness measured on printed channel
prototype;
CONTROL OF ROUGHNESS REQUIRED FOR HYGIENIC
CONSTRAINTS
N
S E
O
1 2
3

9. NPFP 9
REDESIGN OF ROTARY MANIFOLD PARTS WITH
DESIGN FOR ADDITIVE MANUFACTURING APPROACH
 Optimization of geometry to benefit the A.M. technology removing not hygienic shapes
 Study of the most efficient deposition sequence to bear the weight of non self-supporting
material zones
Solution 1 for material supportation
Solution 2 for material supportation
Alternative shapes design

10. NPFP 10
OUTPUT AND NEXT STEPS
 Need to improve surface finishing; on-going evaluation of:
 Abrasive slurry circulation vs. electropolishing for internal surfaces
 Grinding for extternal surfaces
 Comparative cleanability studies to be done:
 Surface as is
 After abrasive slurry (internal)
 After grinding (external)
 Surface finishing achived at the present time is not compliant with food contact and can’t be
applied as is; also the costs of the technology are still high;
 The developlment of the technology in the forthcoming years has to achieveat least the target
of surface finishing ;

11. NPFP 11
DRIVER 2: DESIGN OF A GASKET-FREE MANIFOLD
 Target to eliminate sliding gaskets from manifold in order to reduce sensibly the maintenance
operations on rotary manifold;
 As «Light» alternative the use of integral ceramic instead of caoating rings was considered to at
least increase gaskets operational life;
 Risk analysis was done to analyze all possible alternatives applicable and needed actions;

12. NPFP 12
ACC. TEST BENCH
STRUCTURAL
PARTS (ROTATING)
GREEN PARTS
ACC. TEST BENCH
GASKETS PARTS
(FIXED)
RED PARTS
ACC. TEST
BENCH
COATING
PARTS
WHITE PARTS
SILIPPERS
SOLUTION 1:
SEAL-FREE CONTACT USING CERAMIC RINGS ELASTICALLY
MOUNTED (1A) OR BRAZED (1B) ON STAINLESS STEEL
 Basic concept is to replace coatings done on manifold parts on which elastomer gaskets slide;
 Two alternatives evaluated (1A - 1B) for integral ceramic rings elastic-coupled to replace coatings;
 Target for the demonstrator has been considered the application on Sidel gaskets test bench (Sidel
reliability Lab) – test bench scale, not real manifold scale.

13. NPFP 13
SOLUTION 1A
SEAL-FREE CONTACT USING CERAMIC RINGS ELASTICALLY MOUNTED
ON STAINLESS STEEL
MASSIVE THERMAZYL
BUSHINGS
10 mm GAP
 This solution aims to realize the sealing with direct interface of ceramic-ceramic cylindrical
surfaces, setting correct clearance; this to eliminate sliding gaskets whose wear represents the
most limitating factor in rotary manifold duration.
 Rotating part (internal) is
composed by a AISI 316 ring (1)
and a ring in Alumina-zirconia
stabilized (2, Thermazyl),
assembled coaxial to a fixed
external ring in AISI 316 (4).
Instead of sliding gaskets a
ceramic ring (3) is mounted on
the fixed external ring.
 Validation to be done adapting
gaskets accelerated test bench
(Sidel reliability Lab)
 Solutions 1 A and 1B present the issue that they need to have additional static seals;
these would be unlikely for aseptic application and also for maintenance (compression
set of o-rings)

14. NPFP 14
Thermo-structural FE model CFD model
Ok for different load cases Not ok for Co2 -> 43mg/s
CIP hot water ->18mg/s
SOLUTION 1A
SEAL-FREE CONTACT USING CERAMIC RINGS ELASTICALLY MOUNTED
ON STAINLESS STEEL: SIMULATION OF STRESS AND LEAKAGE
 Thermo-structural FE simulation done to calculate thermal dilatation and stresses in service
conditions
 CFD simulation done to quantify the leakages that could be reached with the system
 According to CFD results the solution could be applied on pneumatic circuit and CIP
return if only water is leaking – not acceptable if chemical leakage can occur)
 Not applicable in CO2 circuit (CO2 diffusion in environment)
 Not applicable in Vacuum circuit (risk of contamination from external)

15. NPFP 15
 Solution 1B – BASIC CONCEPT
 New design of the module based on
ceramic raw materials actually available
SOLUTION 1B
SEAL-FREE CONTACT USING CERAMIC RINGS BRAZED ON STAINLESS STEEL

16. NPFP 16
SOLUTION 1B
DEVELOPMENT OF BRAZING CYCLE ON SMALL SAMPLES
 Alloys compliant for braze-welding process
 Base know-how of ECOR
 Bibliographic research
 Solutions identified:
 Layer Mo-Mn + Nichel plating + brazing
alloy
 PVD deposition of a Ti layer (activator
element) on Allumina layer and
interposition of brazing alloy
identified:
 Variable parameters:
 Type of materials on the interface
 Layers thickness
 Clearance between surfaces
 Option 1B was selected in order to avoid static seals for elastic mounting

17. NPFP 17
Braze-welding execution on
samples metela-ceramic - DONE
Design of surfaces for braze-welding
on real test bench scale - DONE
Thermal shock tests and
corrosion tests to be done on
braze-welded
Surface and interface analysis to be
done on samples after tests (on SEM)
SOLUTION 1B
DEVELOPMENT OF BRAZING CYCLE ON 1:1 SCALE PIECES

18. NPFP 18
SOLUTION 1B
DEVELOPMENT OF 1:1 SCALE MANUFACTURING CYCLE

19. NPFP 19
DRIVER 3: Contingency plan in caso di difficoltà
realizzative
 Scouting is on-going to find treatment for increasing steel hardness to >50 HRC
 Most promizing alternative is DLC on Ti (better corrosion resistance and no issues of origination of
bubbles on the coating)
 Alternative solutions have been evaluated as backup contingency plan in case of issues highlighted
during samples manufacturing or test;

20. NPFP 20
Block-on-ring friction and wear testThermazyl rod (purchased by Sidel)
ELASTOMER/BULK CERAMIC SEALING USING CERAMIC
RINGS ELASTICALLY MOUNED ON STAINLESS STEEL
 Passing from a sliding surface coated on bulk material to a sliding surface for gaskets that is
manufactured separately and assembled on rotating part;
 Validation done on bench scale by tribological tests (UNIPR test bench) + gaskets accelerated test
bench (Sidel reliability Lab)

21. NPFP 21
 Tribological test PTFE gasket on LC4 coating vs. Thermazyl
 Thermazyl generates a much lower wear rate of the gasket respect to LC4
ELASTOMER/BULK CERAMIC SEALING USING CERAMIC
RINGS ELASTICALLY MOUNED ON STAINLESS STEEL

22. NPFP 22
 Tribological test PTFE gasket on LC4
coating vs. Thermazyl
 Thermazyl gives lower friction
coefficient with PTFE than LC4;
 Resisting torques generate are
correspondingly much lower;
 Zirconia and Expanite ceramic
produce similar friction coefficient.
ELASTOMER/BULK CERAMIC SEALING USING CERAMIC
RINGS ELASTICALLY MOUNED ON STAINLESS STEEL

23. NPFP 23
Participants to this activity
• Alessandro Pirondi, Federica Bondioli
Paolo Casoli
• Elena Bassoli
• Domenico Stocchi, Ivan Moretti
• Roberto Germiniasi, Filippo Dazzi
• Roberto Antolotti
Thanks you for your attention!
www.npfp.it