Suitable for integration into open machine architecture, resistant to chemicals and corrosion, residue-free cleaning, microbiologically safe and economical to purchase, operate and maintain – hygienic planetary gearboxes, servo actuators and small servo drive systems built by WITTENSTEIN unite all of these attributes. Germs no longer stand a chance and reliable protection from contamination is assured – with benefits for machine manufacturers and operators as well as end users.
The new, integrated axenia value motor-gearbox unit in hygienic design is no exception. The servo actuators in this series and indeed all other solutions in WITTENSTEIN’s Hygienic Design portfolio – the low-backlash planetary gearboxes in the HDP+ and HDV product families – comply with all relevant recommendations and guidelines of the European Hygienic Engineering & Design Group (EHEDG). In particular, this means
When developed with open architecture, production and packaging machines for foodstuffs can be completely built and accepted with a hygienic design using such components, which can be integrated without further protective measures in a process and maintenance-friendly way.
Hygienic drive technology: No alternative in many cases
Hygienic production and packaging is a key safety factor when it comes to food and beverages as well as pharmaceuticals and sterile medical sterile devices – because hygiene means avoiding germs and hence contamination. Consequently, no product risks must be posed by machine components. However, hygienic design cannot simply be imposed on a machine – on the contrary, enclosed or encapsulated gearboxes and servo actuators, for example, which have been standard practice for years, are today increasingly being given the thumbs down by food producers. Aside from actuator failure risks as a result of heat build-up, rust formation or leakage, this is mainly due to the fact that dust, water vapor or deposits can be a cause of dirt pockets in enclosures. Since these are difficult to reach, removing them simultaneously entails considerable time and effort for cleaning and disinfection. Hygienic drive technology, on the other hand, is readily accessible and therefore fundamental for product safety. In other words, it “kills two birds with one stone”: by definition, it minimizes the risk of contamination and at the same time it supports efficient machine cleaning and disinfection. It is no wonder that automation components in hygienic design in general and hygienic servo actuator technology in particular are enjoying increased demand.
Reliable hygiene, reliable performance: The axenia value servo actuator
The development of WITTENSTEIN alpha’s new axenia value servo actuator was simply the next logical step. The series stands for precision actuators designed to strictly hygienic principles. These servo actuators consist of a compact, high-performance synchronous motor and a precision planetary gearbox with a gear ratios from i=10 to i=25 that is mounted directly. They are available in three sizes and transmit acceleration of 32 Nm, 80 Nm or 200 Nm. A holding brake and digital motor encoders systems such as EnDat 2.2, HIPERFACE DSL or DRIVE-CLiQ can be supplied as options. All components of the system toolkit have perfectly matched electrical characteristics. As a result, axenia value – unlike motor and gearbox combinations from two different manufacturers – offers the security of tested performance data and hence robust information on how the servo actuator performs in practice. Furthermore, owing to the system design, this performance data is scalable – for instance to ensure that the servo actuator does not exceed the maximum permitted surface temperature. Apart from protecting against burn injuries if the surface is touched, this also prevents substances from baking or coagulating on the housing – a significant hygienic aspect.
HDV and HDP+: Hygienic gearboxes for safe, direct integration in the process
WITTENSTEIN alpha’s portfolio of Hygienic Design and EHEDG-compliant drive technology also includes the low-backlash planetary gearboxes in the HDV and HDP+ series with, respectively, an output shaft or an output flange – both in a compact, elegant and hygiene-optimized stainless steel design, with a triple sealing concept and food-grade lubrication.The technology impresses with very high positioning accuracy and power density. For example, the HDP+ gearbox with its torsional backlash of less than 1 arcmin and maximum acceleration torque of 795 Nm is perfect for highly dynamic and compact applications such as in delta robotics.
Hygienic and sterile: The small servo motors in the cyber® dynamic line
The small servo motors in the cyber® dynamic line product family from WITTENSTEIN cyber motor likewise facilitate hygienic drive automation for production and packaging machines. The individual housing connections are welded into a single unit while the integrated sealing concept and the cable gland with IP69X protection ensure the highest levels of safety against the ingress of moisture. This makes them suitable for CIP and SIP and they can be foamed, blasted at high pressure and cleaned without hesitation. The biggest advantage when these compact servo motors, which have an outer diameter of 40 mm, are integrated is that they no longer have to be provided with complex encapsulation or concealed in the plinth of the machine; instead, they can be used close to the process directly in the axes of a pick-and-place robot, for example, or a bottling valve. Hygienic Design solutions are designed for output ratings up to 335 W and have a high dynamic factor: they achieve excellent acceleration, cycle rates and machine throughput.
Machine manufacturers, operators, consumers – hygienic drive solutions have benefits for everyone
Servo actuators in hygienic design have long ceased to be a niche market – have become established today as a successful alternative for food processing, beverage bottling or the manufacture of pharmaceutical products. This is largely due to the fact that have benefits for everyone involved.
Machine manufacturers require no additional certification to integrate solutions like the axenia value servo actuator, the HDV and HDP+ planetary gearboxes or the small servo motors in the cyber® dynamic line into their hygienically designed systems – a distinct asset compared to enclosure or encapsulation. They fulfill fundamental requirements of the Machinery Directive 2006/42/EC regarding the need for, and form of, machine and automation components with a hygienic design quasi automatically. They are moreover on the safe side when it comes to conformity with standards such as DIN EN ISO 14159:2008-07 for machines where general hygiene risks can occur, DIN EN 1672-2:2021-05 specifically for food processing machinery and hygiene regulations such as 1935/2004/EC on materials and articles intended to come into contact with food. At the same time, by resorting to actuators in hygienic design, they are employing a leading-edge technology that reduces mechanical complexity. This adds to the innovative nature their machines, helping to establish a competitive advantage – especially since a growing number of operators are demanding open, hygienic and easy-to-clean machine architecture. After all, it should not be forgotten that fabricating and installing enclosures or encapsulations entails costs that can potentially be economized – in other words, that impact on cost efficiency and value for money.
Key performance indicators such as TCO (total cost of ownership) or OEE (overall equipment effectiveness) are usually decisive for operators. When broken down to the level of the machine, this means a long service life, high productivity, minimized downtime and a reduced risk of lost production with faster, more efficient and more resource-friendly cleaning and disinfection processes. Actuators in hygienic design mean more availability, because significant failure and contamination risks due to enclosures or encapsulations are quite simply non-existent. Less maintenance is required – and should a service technician ever need to replace a component, it is much easier and quicker to access in the open machine architecture. The drastically reduced time and effort for cleaning – which is unproductive and expensive – are a crucial factor in daily operation. According to experts, this amounts to about 25 percent of total production time in the food industry – so that every percentage point less translates into hard cash. At the same time, easier cleaning also means safer cleaning. In the US, for example, it is estimated that food contamination causes 30 billion dollars in damage every year – a quarter of which can be attributed to cleaning problems. In addition to direct costs, publicity-generating food scares and recall campaigns also involve indirect costs and inflict damage on the company’s image. What food manufacturers and machine operators want is exactly the opposite, namely to save costs, use resources sustainably and offer lower prices to end customers – in short, to secure a competitive edge.
That puts the emphasis on the benefits for consumers. Changing consumer habits and demographic trends are leading to more highly customized demand, for example in the form of different pack sizes for single and family households, an increasing range of convenience and organic products and the steadily growing availability of portion-packed foods far exceeding cold cuts and cheese. Demand for products of higher quality and with a longer service life is likewise increasing. Production, processing and packaging machines designed in accordance with hygienic guidelines are a good way to positively influence a product’s minimum shelf life by ensuring a high level of process security and product safety. This applies not only to processing and packaging of meat, fish and sausages but also to dairy products or when filling liquid or pasty foods and beverages. And the more different products or batches are produced or packed on one machine, the more process-related time and money savings, for example in cleaning, can reduce the cost per packing unit – and thus the retail selling price.
Everyone benefits from hygienic design as an indispensable feature of modern food and packaging equipment – and WITTENSTEIN-built Hygienic Design drive technology is already making a contribution today.
https://www.wittenstein.de/en-en/hygienic-design/
The axenia value series stands for precision servo actuators designed according to strictly hygienic principles.
The small servo motors in the cyber dynamic line are suitable for CIP and SIP and they can be foamed, blasted at high pressure blasted and cleaned without hesitation.
The small servo actuators in the cyber dynamic line in hygienic design also open up applications in wet areas, for example in manufacturing, packing, filling and bottling plants for food and beverage products.
The HDV planetary gearbox is designed for the food contact and sterile areas of production and packaging plants for food processing, beverage bottling or pharmaceutical manufacturing.
WITTENSTEIN alpha’s HDP+ Hygienic Design gearbox meets the requirements for hygienic production and packaging machines in every respect.
The smooth rolled housing surface of the HDP+ and HDV with no dead spaces minimizes the risk of product adhesion and allows cleaning materials and disinfectants to be rinsed or drained off without leaving any residue.
