KNOWLEDGE TUTORIAL KBT-02 - Flexible Conduit Systems used for Hygienic Applications - AFC Cable Systems
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KNOWLEDGE TUTORIAL KBT-02
Flexible Conduit Systems
used for Hygienic Applications
Allied Tube Flexicon
& Conduit
Cable Protection Solutions for Food &
Beverage Applications
Learning Objectives
To understand Hygiene Design Standards and identify
Which products are suitable for Hygienic
relevant International approvals in relation to Cable
applications?
Protection.
What are the relevant hazards for different applications Which products are suitable for Food & Beverage
within the Hygienic Industry? applications?
Introduction
There are numerous applications where hygiene considerations are critical. Perhaps the most obvious
is in the Food and Beverage industry but there are many others such as Hospitals, Clean rooms and
Pharmaceutical production facilities. This tutorial primarily focuses on Food & Beverage applications
and discusses some of the challenges and solutions for protecting critical power and data cabling
within the Food Manufacturing Industry.
Food & Beverage is the EU’s largest Manufacturing Sector. Equipment manufacturers are continuously
developing equipment and systems to deliver food and drink safely, whilst maximising efficiency,
incorporating sustainability and delivering profitability.
It is critical to avoid downtime and maintain quality standards from Farm to Fork within the Food &
Beverage industry. It takes years to build brand reputations and trust, but this can be quickly eroded,
damaging Companies Sales Revenues and Profitability.
Food & Drink processors are rapidly investing in automation solutions and processes to deliver these
objectives, resulting in an increasing reliance on the continuity of power and data cabling to deliver
results. Manufacturers face continuous challenges of efficiencies, reliability, available floor space,
modularity of design and operational safety throughout the supply chain.
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Hygienic Approvals
Manufacturers commitment to the delivery of food
safety needs to consider and minimise all risks
associated with operating processes. Stringent food
safety protocols and risk assessments are required to
maintain quality output and ensure that the business
is protected from hygiene incidents as well as
providing operator safety.
Within the Food and Beverage Industry there are
numerous challenges presented by operating
environments and processes used, and these can
vary dramatically depending on the type of Category.
Product Categories can include Meat, Fish,
Fruit–vegetable, Oil, Dairy, Cereals, Bakery, Sugar,
Confectionery, Beverages, Spirits, and other food
products.
The Food Industry is highly regulated due to the potential risks and hazards to consumers, and
manufacturers together with the supply chain all have key responsibilities in delivering food safety.
Plant Managers, Quality Managers, Food Safety Managers, Maintenance Managers, Production
Supervisors, Process Engineers all have an important role to play.
Regulatory Authorities and Industry associations include;
EHEDG – European Hygienic Engineering & Design Group
FDA - Food & Drug Administration
NSF - National Sanitation Federation
GMP – Good Manufacturing Practices
HACCP - Hazard Analysis Critical Control Point
BRC – British Retail Consortium
3A Sanitary Standards – USA
Food standards and Hygienic design requirements protect the integrity of the processes and product
but more importantly the health of the consumer.
Allied Tube EN 61373 Cat2 EN ISO 14159
BS EN ISO9001 2015
Approved
&BSConduit
EN IEC 61386 EU Regulation 10/2011 EN 1672-2
Ingredients
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Potential Hazards
Food Safety is important to consumers and critically important to
those engaged in the food industry. Product recalls are expensive
resulting in fines, litigation and damage to brand reputation.
Equipment operating within the Food & Beverage industry not only
has to perform its designed function safely, it also must achieve this
hygienically.
There are 3 types of Significant hazards which can be reduced using hygienically designed products
and systems;
1) Biological causes - such as pathogens, spoilage micro organisms, toxins or vermin
2) Chemical causes - from cleaning, disinfecting agents or lubricant substances
3) Foreign bodies - from raw materials, machinery or other sources
Numerous technical challenges such as cleanability,
wide temperature ranges, chemicals, ingress, vibration
resistance and strength and integrity are all factors due
consideration. Material selection should be carefully
considered after a thorough analysis of the processing
environment and the hazards faced.
Overlooking one element of the process or machinery /
equipment could potentially create an environment for
incubation and spread of harmful bacteria.
Hygienic Design needs to consider the materials & potential
hazards. All materials should be durable and not harbour micro-organisms.
All plastics used in food contact applications must meet EU regulations (10/2011). FDA regulations
consider elastomers and plastics as indirect food additives and this is covered by CFR 21 - Title 21. The
requirements for Plastic materials used in food processing machinery depends on the zones and
likelihood of the component or material having food contact. Equipment that is designed to not come
into direct contact with food will have less stringent demands although any products used should
consider hygienic design to minimise the potential risk of bacteria and aid cleaning regimes. Typically
zones are defined as follows - Food Zone, Splash Zone, Non-food Zone and Unexposed Non-Food
Zone.
The following additional hazards should be carefully considered;
Corrosion;
Materials can fail due to corrosion, which can often lead to component and system failure. Stainless
Steel is widely used within the food industry due to its high level of corrosion resistance. The level
of resistance is typically reduced if exposed to chlorides which can be present in Supply Waters,
Detergents, brines and food products (many foods contain Sodium chloride). The performance
also depends on the grade of Stainless Steel used. Corrosion can take many forms including pitting
corrosion, crevice corrosion or deposit attack.
Elastomeric materials are commonly used for seals and gaskets and the performance properties can
vary depending on the compound mix. Performance can be compromised by physical or chemical
changes if exposed to certain chemicals, i.e. cleaning agents, food ingredients or processing fluids.
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Temperature
High Temperatures can age materials leading to an increased rate of degradation of mechanical
performance, and reduction in the service lifetime of components. Low Temperatures can make
materials brittle and even lead to brittle cracking. Expansion or contraction can occur, especially with
elastomeric materials, with changes in temperature and this must be carefully considered if used in
conjunction with metallic materials.
Impact
This can lead to the piercing of protective coatings, loss of ingress protection, deformation of
profile, crushing of cables and must be assessed carefully. Food processing plants often involve the
movement of materials which can require lifting equipment, manual handling or moving machinery.
What would happen if cables were subjected to impact and would they be adequately protected?
Wear and Abrasion
If equipment is moving or has moving components, abrasion resistance is important to reduce the
potential risks of damage to protective coatings or loss of ingress protection. Surfaces can be worn
away which can reduce the thickness of any protective coatings.
Surface Finish
The rougher the surface, generally the more difficult it is to clean with the increased likelihood that
matter could stick to it. The method of processing to achieve a surface finish contributes to the rate at
which contamination can build up, i.e. turning, milling, mechanical polishing, casting etc.
Fatigue
Materials can suffer fatigue if constantly moving therefore material construction should be carefully
considered. Potential risks to product include cracking and brittleness.
Chemical Compatibility
Data is typically published by manufacturers showing a materials relative performance to attack. For
example, Polyurethane (PU) jacket materials are not suitable for cleaning with chemicals containing
chlorine. Chemical data charts are based on performance of exposure to one chemical, therefore
if a combination of chemicals, higher concentrations or elevated temperatures are present it is
recommended you contact the manufacturer for further guidance.
Colour
For plastic materials, Blue is typically used within food applications as it offers increased visibility of any
contaminants in the food product.
White materials are typically used within pharmaceutical environments, so it does not cause any
colour contamination
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& Conduit
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Soil
Soil can be defined as any material that is out of place. There are various
methods used for cleaning and a selection are discussed below;
Methods of Cleaning;
▲ Manual
▲ Circulation (CIP, spray cleaning)
▲ Soak
▲ Spray washing
▲ Long contact vertical surface clearing using foams / gels
▲ Steam cleaning (High temperature)
Chemical Resistance Properties
Cleaning agents, chemicals and lubricants can often come into contact with conduit systems within
the Food Industry. It is important that any system can offer protection and resistance against these
chemicals to prolong life and ensure continuous performance with no compromise on safety.
Manufacturers will provide a Chemical Resistance chart highlighting the level of resistance against
different Chemicals (extract below from Flexicon Product & Selection Guide - PG12).
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Standards differ depending on the region or territory but all
standards are there to protect consumers. Given the increasing
globalisation of the Food & Beverage Industry, mistakes can lead
to worldwide product recalls affecting multiple markets and
consumers anywhere in the world.
In Europe, standard EN 1672 -2 prescribe the requirements for Food
Processing Machinery. Basic concepts. Hygiene requirements.
Regulation EU 10/2011 applies rules for plastic materials and articles
intended to come into contact with food.
In the USA the following standards apply under FSMA Food Standards
Modernisation Act, ISO 14159 and NSF 169 with NSF 51 relevant for food grade materials. CFR 21 is the
Code of Federal Regulations - Title 21 is reserved for rules of the Food and Drug Administration.
NSF / ANSI 51 - Relates to the Food Equipment Materials used. NSF / ANSI 169 - Extends to Design
criteria.
The use of Flexible Conduit is a well-established and proven method
to protect critical cabling across multiple industries including Rail,
Construction, Automation, and with careful consideration, can be
applied within Hygienic Applications.
As manufacturing and processing equipment becomes more
sophisticated, with an increasing reliance on automation, protecting
power and data cabling is more critical now than ever before.
What would happen if your production line failed?
Traditionally, wiring would consist of specialist cables, terminated using specialist hygienic cable
glands to maintain system integrity and prevent ingress.
This can often lead to over specification due to the need for specialist
cables (perhaps requiring mechanical protection and / or screening)
and specialist cable glands. This can result in the requirement for larger
enclosure sizes (due to more glanding entry points, i.e. one per cable).
The more glanding or termination points there are, the higher the risk
from build up of bacteria or failure of seals or components to ingress.
This also results in an increase in cost due to more components and the
time required to terminate each individual component.
Using Hygienic Flexible Conduit can offer the following benefits;
Space Saving Reduced Maintenance
Group multiple cables in Circuits can be added / replaced with ease
one system and cables are mechanically protected
Speed of Installation
One entry point per conduit
Fixing & Routing
termination, versus on entry point per Easy to clean - one surface vs multiple
cable with cable glands surfaces. Avoid bundling of exposed cables.
Simplicity Allied Tube
One system to fix rather than individual
cables
Reliable ingress protection and no need
for specialist cable
& Conduit
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Using Hygienic Flexible Conduit can offer the following benefits;
Flexible Conduit provides an inherent mechanical barrier for cabling, but it can offer many more
benefits allowing users and specifers to challenge traditional installation practices whilst offering
unrivalled product performance.
Simplicity
Using a Hygienic Flexible Conduit system means
you can avoid the need for specialist hygienic or
non standard cables.
Single core or standard cables can be grouped together
in one protected system meaning reduced leadtimes
and potential stock holdings. Manufacturers can simplify
their supply chain to support maintenance, with fewer
components required, offering more flexibility.
Space
Space is considered a premium within
manufacturing facilities therefore if machinery
size can be reduced it can help with capacity and
operations planning.
Hygienic Flexible Conduit systems enable installers and
specifiers to group cables within one system whilst
mechanically protecting the cables as standard. This can
provide significant space saving benefits and reduce the
area required for termination.
This picture illustrates how one Hygienic conduit has replaced 3 equivalent specialist cables each with
individual hygienic cable gland terminations. Cost savings can be achieved using smaller enclosures
and machinery design can be optimised to reduce the overall footprint.
Speed of Installation
Fewer terminations mean a reduction in installation
time. This includes, less holes to drill, less fittings
to terminate and less enclosure entry points to
maintain.
By grouping cables into one Hygienic Flexible Conduit
system means that there is only one system to fix as
opposed to individual and multiple cables requiring
separate fixings. This also provides easier access for
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Reduced Maintenance
Existing circuits can be replaced or added with
ease using a Hygienic Flexible conduit system,
throughout the life of the installation.
Future proofing equipment is an essential consideration
when specifying. Flexibility to adapt and cope with
changing demands or technologies is critical and can offer
competitive advantage. Hygienic Flexible Conduit systems
help achieve this as wiring can be upgraded or changed
with minimal effort and disruption.
If more circuits need to be added in the future, this could be achieved using the existing hygienic
conduit system (space permitting) rather than having to drill out new entry points in the enclosure,
purchase new Hygienic Cable Glands and create new fixing and routing for any new cabling.
Fixing and Routing
By using a Hygienic Flexible Conduit system, it
is easier to route and mount on machines than
numerous cables routed individually or bundled
together.
This reduces the hygiene risk as the conduit offers one
smooth outer cover, offering easy access with the ability to
wipe clean.
The bundling of exposed cables must typically be avoided,
with cables having sufficient space from one another to allow for cleaning. With multiple cables this
creates multiple surfaces to clean compared to the simplicity of one Hygienic Conduit system .
Flexicon have developed a new Hygienic Connection box which has been designed for use with
Hygienic Cable Glands and / or Hygienic Flexible conduit systems. This product offers design flexibility
and allows circuits to be added or extended without the need for expensive or large enclosures.
Constructed from Stainless Steel 316L, using design principles from EN 1672-2 and EN ISO 14159, this
product offers high ingress protection of IP66, IP67, IP68 and IP69 and is ideal for use on machines or
equipment as a termination box.
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Manufacturers are continuously looking for solutions to increase output and efficiencies.
& Conduit
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Hygienic Flexible conduit systems must be designed and manufactured to prevent the build-up of
any contaminants or bacteria, ensure that materials used in manufacture do not release any toxic
chemicals and must allow for easy and thorough cleaning.
This leads to the following requirements;
▲ All outside surfaces must be very smooth and without any crevices where bacteria
could develop.
▲ No sharp corners.
▲ No visible or accessible threads.
▲ No roll marking of the fitting as this would disturb the outer smoothness of the fitting.
▲ All face and conduit seals must be flush with the fitting body
Many of these requirements are detailed within two food equipment design standards; EN 1672-2:
Food Processing Machinery, basic concepts and hygiene requirements and EN ISO 14159: Hygiene
Requirements for the Design of Food Machinery.
Flexicon’s Hygienic conduits and
fittings have been designed and
manufactured in accordance with
these requirements for repeat contact
at the conduits full temperature range
(with the exception of fatty foods). Of
course, it would be most unlikely that
a food machine was designed in a way
that the flexible conduit was intended
to be in contact with food but splashes
and accidental contact should be
considered.
Flexicon can offer 10 different types of
Flexible conduit systems specifically for
Hygienic applications.
The application of these products
is determined by the typical operating environments or any specific hazards the cabling may be
subjected to, but these ranges can be classified as either non-metallic or metallic systems.
What should you look for in a Hygienic Flexible Conduit System?
All Hygienic conduits are terminated using a Hygienically designed fitting to ensure the ends are
sealed thus providing high levels of ingress protection. This fitting is typically manufactured from
Stainless Steel (316L) offering high corrosion and chemical resistance together with smooth surface
which is easy to clean.
All of the Hygienic range of conduits offer a smooth outer covering which can be easily cleaned and
does not provide any areas for build up of soil. The conduits and coating materials should have been
independently tested for suitability for food contact use.
flexiconsales@atkore.com www.atkore.com/flexiconShould I use a non-metallic or metallic Hygienic Flexible Conduit System?
Non-metallic conduits offer the benefit of inherent corrosion resistance and light weight
performance. They are easy to cut and highly flexible.
Non-metallic Hygienic Conduits
LPC-FG is a smooth flexible PVC conduit with rigid uPVC reinforcement spiral
for strength and manufactured in different colours. All the flexible PVC used is
food grade and has been independently tested to European food regulation
10/2011. It is suitable for repeat contact at the conduits full temperature range
(with the exception of fatty foods).
The conduit and fitting interface must be able to withstand tensile stress
caused by the weight of the cabling or dynamic load through movement or
vibration. The tensile strength performance of LPC-FG when used with a Flexicon Hygienic conduit
fitting is 70kg.
Flexicon can also offer a non-metallic hygienic solution that is UL listed from the AFC range of
Conduits. This product is LFNC-B for splash zones and is compliant with NSF 169 component for
“splash zones” in food production areas.
Metallic Hygienic Conduits
Metallic conduits offer the benefit of increased compression strength together
with an increased operating temperature range.
LTP-FG systems consist of a steel inner core and a variety of smooth coating
materials and colours to suit different applications. The PVC coating used is food
grade and has been independently tested to European food regulation 10/2011.
It is suitable for repeat contact at the conduits full temperature range (with the
exception of fatty foods).
The conduit and fitting interface offers higher tensile strength performance than a non metallic
system. The LTP-FG metallic conduit, with a Flexicon Hygienic conduit fitting is 130kg thus providing a
strong and reliable connection.
High levels of compression strength can also be achieved (400kg / 100mm) for 20mm Liquid Tight
from Flexicon (LTP-FG) in comparison to 120kg / 100mm for 20 mm LPC equivalent.
LTBRDP-FG has a steel core, with a layer of galvanised steel braid with a smooth
outer coating to maintain high levels of Ingress Protection. This system offers
enhanced EMC screening.
LTP-FG is also available in versions with a stainless steel (grade 316L) inner core LTPSS-FG, and there
is a version with UL listing and NSF 169 compliance for “splash zones” in food production areas from
AFC range of Conduits - LFMC-UL. (pictured right)
Allied Tube
& Conduit
flexiconsales@atkore.com www.atkore.com/flexiconThe conduit fitting and conduit interface is key to the integrity and sealing performance of the
system. This is achieved using an insert which typically screws into the conduit bore, providing the
link between the conduit and the fitting. It offers protection to the cable from any sharp edges and
enhances pull off strength when the fitting is tightened.
Flexicon uses different inserts depending on the conduit type, i.e. non-metallic conduits or metallic
conduits. This provides the benefit to the installer of increased performance and ease of installation,
with the simplicity that the fitting performance has been optimised for the specific conduit.
The integrity of the system has been tested to ensure continued performance. The system offers
tensile strength performance of 70kg for non-metallic LPC-FG conduits and 130kg for metallic LTP-
FG conduits.
The seals, of which there are 3, are critical to the performance of the fitting.
The conduit seal (a.) is made from blue polyamide and fills the gap between the conduit and fitting
when tightened. There is a blue polyester elastomer seal (b.) between the compression nut and the
fitting body which is retained in an undercut in the nut. This prevents any food or bacteria getting inside
the compression nut thread.
a. b. c.
There is a blue polyester elastomer retained
face seal (c.), it is a larger diameter than
the terminating thread, the same size as
the OD of the fitting and it’s compression is
controlled, all to give optimum sealing onto
any surface.
flexiconsales@atkore.com www.atkore.com/flexiconLTP-FG and LPC-FG fittings have IP performances of IP66 and IP67 and IP68 and IP69. Each of these
IP ratings are tested in a different way and you cannot assume that a higher rating automatically
confirms a lower rating.
▲ IP66 is a high pressure water jet
▲ IP67 in immersion under 1m of water
▲ IP68 is 2 or 5 bar water pressure
▲ IP69 is a very high pressure jet of hot water (176°F / 80°C), similar to steam cleaning
The combination of these IP ratings covers all food equipment cleaning methods.
Flexicon LTP-FG and LPC-FG Hygienic fittings are easy to assemble and do not require any special
tools for assembly or maintenance.
The Hygienic fittings are also available with a reduced thread length, designed specifically for use with
the Hygienic Round Connection Boxes to provide maximum internal wiring space.
Flexible conduits may also be an easier and more cost effective
installation method than using food grade cable glands. Multiple
cables can be run through one conduit meaning that fewer glands
are required meaning less installation time and fewer equipment
interfaces.
It also means that individual cables can be used rather than circular
over-sheathed multi-core cables.
Flexicon offer a handy installer pack (I-Pack) which contains 3
metres of conduit and two SS Hygienic fittings and SS locknuts
under one part number.
Summary:
Hygienic Flexible Conduit systems can offer numerous benefits for Food & Beverage installations to
protect critical power and data cabling. Time saving, simplicity of installation and future proofing can
all be achieved by using Hygienic Flexible Conduits to group cables from end to end.
With multiple and diverse hazards, cabling needs protection to maintain system and process
functionality and safety. How are you currently achieving this? What would happen if your Cabling
systems failed?
This tutorial highlights termination methodologies for cabling within Food & Beverage applications
and compares the merits of Hygienic Flexible Conduit installation versus Hygienic Cable Glands.
Allied Tube
& Conduit
flexiconsales@atkore.com www.atkore.com/flexiconCable Protection Solutions for Food &
Beverage Applications
Q1) Name 3 benefits of using Flexible Conduit when protecting Power and Data Cabling within
Hygienic Applications?
Q2) Name 3 categories of potential hazards specific for Food Safety & Hygienic Applications?
Q3) How many Flexible Conduit Systems from Flexicon are suitable for use in Hygienic Applications?
Q4) What does FDA stand for?
Q5) What is the recommended IP requirement for equipment exposed to high pressure washdown
processes.
Q6) What is the European Standard number for Hygiene Requirements for the Design of Food
Machinery.
Q7) Which coating material offers limited resistance to chemical breakdown if your cleaning
processes involve chlorine’s?
Q8) Why should your conduit systems have a smooth outer surface?
Q9) Which one of these five statements below are incorrect;
• Product recalls are expensive resulting in fines, litigation, damage to brand reputation
• No roll marking as this would disturb the outer smoothness of the fitting
• LPC is a smooth flexible PVC conduit with rigid uPVC reinforcement spiral for strength
• Materials must be able to withstand cleaning chemicals and be corrosion resistant
• Materials should be toxic
Flexicon have published a range of tutorials to help inform and educate in the application and understanding of Flexible Conduit for Cable
Protection. We are an Industry leading UK Manufacturer, and a Technical Specialist when it comes to Cable Protection, with proven knowledge
and experience across the world. If you would like more details regarding other tutorials please email: clegg@atkore.com
About the Author:
Our Technical Director, Alex Smith, works with Ian Gibson, who is the chairman of both the IEC (worldwide) and CENELEC (European)
committees that prepare conduit standards.
BS EN ISO9001 2015 EN 61373 Cat2 EN ISO 14159
Approved BS EN IEC 61386 EU Regulation 10/2011 EN 1672-2
Ingredients
flexiconsales@atkore.com www.atkore.com/flexiconNotes
Allied Tube
& Conduit
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