This is how you choose the optimal gear motor for your pharmaceutical applications.
What exactly is a Hygienic Design gear reducer and why is it so important for the pharmaceutical industry?
A Hygienic Design gear reducer is specifically designed to prevent contamination and allow for easy cleaning. For the pharmaceutical industry, it is essential to ensure the highest product quality and patient safety by minimizing the accumulation of bacteria and meeting regulatory requirements.
What materials and surfaces are crucial for Hygienic Design gears in pharmaceutical applications?
Typically, corrosion-resistant stainless steel (e.g., AISI 316L or 1.4404) is used. The surfaces must be very smooth (recommended roughness Ra ≤ 0.8 µm) and ideally electropolished to minimize adhesion and optimize cleanability.
What does EHEDG compliance mean for gears and why should I pay attention to it?
EHEDG (European Hygienic Engineering & Design Group) establishes recognized standards for hygienically appropriate design. EHEDG-compliant gears meet stringent requirements for cleanability, material selection, and construction, significantly reducing the risk of contamination and facilitating the compliance with industry standards such as GMP.
What role do seals and protection classes such as IP69K play in Hygienic Design gears?
Seals made from FDA-compliant materials (e.g., EPDM, FKM) prevent the ingress of contaminants and aggressive cleaning agents. The protection class IP69K means that the gear is resistant to high-pressure and steam jet cleaning, which is necessary for intensive cleaning processes in the pharmaceutical industry.
Does ATEK Drive Solutions also offer custom Hygienic Design gears?
Yes, ATEK Drive Solutions specializes in custom drive solutions . With our modular system and our decades of experience in gear manufacturing, we can precisely adapt Hygienic Design gears to your specific requirements, even for small series and special solutions..
What lubricants are used in Hygienic Design gears for the pharmaceutical industry?
Only food-compatible lubricants (NSF H1 certified) are used. These are approved for applications where occasional, technically unavoidable contact with the product cannot be completely excluded, thus minimizing the contamination risk.
How does the use of Hygienic Design gears affect the total cost of ownership (TCO)?
Although the initial costs for Hygienic Design gears may be higher, they often lead to lower total operating costs (TCO). This results from significantly reduced cleaning times (up to 30%), lower consumption of water and chemicals, fewer production downtimes, and a longer lifespan of components..
What are the key design features of a dead space-free gear for the pharmaceutical industry?
A dead space-free design avoids gaps, undercuts, sharp corners, and horizontal surfaces where product residues or microorganisms could accumulate. It is characterized by smooth transitions, large radii, and self-draining surfaces to ensure easy, fast, and thorough cleaning.
Ein A Hygienic Design gear reducer for the pharmaceutical industry must meet stringent requirements: Materials such as stainless steel AISI 316L, surfaces with Ra ≤ 0.8 µm, dead space-free construction and EHEDG compliance are crucial for product safety and compliance.
The investment in Hygienic Design pays off through reduced cleaning times by up to 30% und up to 25% lower maintenance efforts, resulting in lower total operating costs (TCO) and improved plant effectiveness. ATEK Drive Solutions offers as a system provider
ATEK Drive Solutions bietet als Systemanbieter modular and custom Hygienic Design gear solutions, which enable fast delivery times and high variant diversity for the pharmaceutical industry. Discover how Hygienic Design gears meet the highest demands of the pharmaceutical industry and optimize your production processes.
The pharmaceutical industry sets the highest standards for hygiene and safety. Learn how ATEK Drive Solutions optimizes your processes with innovative Hygienic Design gears and minimizes contamination risks. Contact us for personalized advice and tailored drive solutions:
Entdecken Sie, wie Hygienic Design Getriebe die höchsten Ansprüche der Pharmaindustrie erfüllen und Ihre Produktionsprozesse optimieren.
Die Pharmaindustrie stellt höchste Ansprüche an Hygiene und Sicherheit. Erfahren Sie, wie ATEK Drive Solutions mit innovativen Hygienic Design Getrieben Ihre Prozesse optimiert und Kontaminationsrisiken minimiert. Kontaktieren Sie uns für eine individuelle Beratung und maßgeschneiderte Antriebslösungen: Get in touch now!Do you need a Hygienic Design gear that meets your high pharmaceutical requirements?
Let us advise you now!
Introduction to Hygienic Design gears for the pharmaceutical industry.
Hygiene and sterility are fundamental in the pharmaceutical industry. Choosing the design for hygienic gear reducers, often in critical zones, is a strategic decision for product safety and efficiency. Non-EHEDG compliant gears can cause audit issues; Hygienic Design gears are the solution here. A carefully selected A Hygienic Design gear reducer for the pharmaceutical industry can make the difference here. Given the increasing demands and cost pressure, thoughtful Hygienic Design reduces cleaning times and agents (up to 30% time savings), providing a competitive advantage for applications in food and medicine. The role of gears in pharmaceutical production facilities
Die Rolle von Getrieben in pharmazeutischen Produktionsanlagen
Gears in mixers, filling and packaging machines are potential contamination risks. Every component in product contact, such as drives in tablet presses, requires careful selection, e.g., stainless steel planetary gears for clean rooms. Here, gears in Hygienic Design for pharmaceutical facilities play a key role.
The necessity of Hygienic Design for contamination prevention
Hygienic Design is essential for the prevention of cross-contamination and product recalls. It protects against microbial hazards and particles, supported by smooth surfaces (Ra ≤ 0.8 µm) that minimize bacterial adhesion. ATEK Drive Solutions provides solutions, especially in the area of germ-free gear units for pharmaceutical production.Requirements for Hygienic Design gears in the pharmaceutical industry
Materials such as stainless steel AISI 316L resist aggressive cleaning and SIP cycles; electropolished surfaces reduce adhesion. A food-compliant gear with NSF H1 lubricant is often a prerequisite for a A Hygienic Design gear reducer for the pharmaceutical industry. Multi-stage, FDA-compliant seals protect up to IP69K, even against chemicals like VHP (e.g., WITTENSTEIN). For wet zones, IP69K classified gears are relevant.
Material selection and surface quality
Stainless steel 1.4404 (AISI 316L) offers good weldability and corrosion resistance, ideal for hygienically appropriate gears. A surface roughness of Ra ≤ 0.8 µm (EHEDG compliant, e.g., Neugart HLAE) minimizes biofilm formation.
Sealing concepts and protection classes
Multiple sealing systems (e.g., radial shaft seals, O-rings made of EPDM/FKM), often IP69K certified, are common. ATEK uses robust solutions in stainless steel gears, which can be used as cleanroom-compatible gears for the pharmaceutical industry.
Dead space-free construction
Dead space-free designs with large radii and smooth transitions (e.g., Nabtesco Neco®) prevent product accumulations and facilitate cleaning, a must for any A Hygienic Design gear reducer for the pharmaceutical industry.
Lubrication and contamination risk
NSF H1 lubricants are standard in cases of possible product contact. Long-term or lifetime lubricants reduce maintenance; lubricant-free magnetic gears are an alternative for special gears for hygienic applications in the pharmaceutical industry.Design features of Hygienic Design gears
Modular system designs allow for variant diversity and quick adaptation of Hygienic Design gears (e.g., ATEK with flexible flanges). The division into hygiene zones (product contact, splash, non-product zone) optimizes costs through adapted materials and design features (e.g., GEORGII KOBOLD), which is particularly important when designing a Hygienic Design gear reducer for the pharmaceutical industry . A hygienic motor with smooth surfaces can complement the solution.
- Using modular system designs for high variant diversity and quick adaptations in Hygienic Design gears for pharmaceutical facilities.
- Cost optimization through division into hygiene zones and adapted design features for hygienically suitable gears.
- Combination of predefined, hygienically appropriate components into customized solutions.
- Reduction of development times and costs through modular approaches for hygienic gear reducers.
- Risk analysis to define specific requirements for each hygiene zone for the A Hygienic Design gear reducer for the pharmaceutical industry.
- consideration of EHEDG guidelines and IP protection classes for different zones.
- Availability of specialized product lines from manufacturers like Neugart, ATEK, and WITTENSTEIN for germ-free gear units for pharmaceutical production.
Modular system
Modular systems (e.g., ATEK for hygienic gear reducers) combine predefined, hygienically appropriate components into customized solutions, reducing development times and costs.
Adjustment to hygiene zones
A risk analysis determines requirements: EHEDG guidelines for product contact zones, IP69K and cleanability for splash zones (e.g., WITTENSTEIN HDV). Open planetary gears can be relevant when it comes to gears for hygienic applications in the pharmaceutical industry.
Examples of Hygienic Design gears
Providers have specialized lines:
- Neugart HLAE
- ATEK HDV/HDVS
- WITTENSTEIN HDV
- Nabtesco Neco®
The selection is based on application requirements, similar to stainless steel worm gears, and is critical for the successful implementation of a Hygienic Design gear reducer for the pharmaceutical industry.Economic aspects and ROI of Hygienic Design
Although the initial investment for Hygienic Design may be higher, the total cost consideration (TCO) for a A Hygienic Design gear reducer for the pharmaceutical industry often advantageous due to reduced downtime and maintenance costs (e.g. 15% less unplanned downtime). It improves product quality and safety, lowers scrap rates, and avoids recalls (e.g. by preventing biofilm formation). ATEK assists in selecting the appropriate Gear Boxes for hygienic applications in the pharmaceutical industry.
Reduction of downtime and maintenance costs
Robust Hygienic Design gears allow for longer maintenance intervals and fewer downtimes, which can reduce maintenance times by up to 25% per facility. This is a significant advantage of cleanroom-compatible Gear Boxes for the pharmaceutical industry.
Optimization of product quality and safety
Improved product safety (fewer germ tests, lower particle contamination) supports compliance with FDA/EMA requirements. A A Hygienic Design gear reducer for the pharmaceutical industry is central to this.
Reduction of cleaning costs and environmental impact
Easily cleanable, dead space-free designs, as found in a high-quality Gear Box in Hygienic Design for pharmaceutical systems, shorten cleaning cycles, reduce the consumption of water, energy, and chemicals by up to 20-30%, and protect the environment.Training and further education in Hygienic Design
Expertise is essential for the correct specification, installation, operation, and maintenance of Hygienic Design components, especially with a A Hygienic Design gear reducer for the pharmaceutical industry, to avoid errors (e.g. improper sealing installation). ATEK invests in training. Organizations such as EHEDG offer courses and certifications on materials, design principles, and regulatory requirements for hygienic Gear Boxes.
- Essential expertise for correct specification, installation, operation, and maintenance of Hygienic Design Gear Boxes.
- Avoidance of errors, such as improper sealing installation, through expertise in handling Gear Boxes for hygienic applications in the pharmaceutical industry.
- Need for trained personnel for adequate cleaning and maintenance processes, specifically for the A Hygienic Design gear reducer for the pharmaceutical industry.
- Ensuring hygiene integrity, e.g. through proper sealing inspection in low-germ Gear Box units for pharmaceutical production.
- Availability of training and certifications from organizations such as EHEDG on topics related to hygienic Gear Boxes.
- Training content includes materials, design principles, and regulatory requirements for Gear Boxes in Hygienic Design for pharmaceutical systems.
- Minimization of compliance risks through recognized, individual qualifications when using hygienic Gear Reducers.
Importance of qualified personnel
Trained personnel are necessary for correct cleaning and maintenance processes as well as maintaining hygiene integrity (e.g. sealing inspection) when using hygienic Gear Reducers.
Training programs and certifications
EHEDG certifications and individual qualifications confirm expertise and minimize compliance risks (e.g. UT EHEDG Test Institute), which is of great importance for the use of cleanroom-compatible Gear Boxes for the pharmaceutical industry.Conclusion and outlook
Hygienic Design Gear Boxes are integral to quality assurance in the pharmaceutical industry. Careful, EHEDG-compliant selection of materials, design, and seals is critical for any A Hygienic Design gear reducer for the pharmaceutical industry. This leads to higher product safety, lower operating costs, and optimized processes. In the future, smarter solutions, e.g. with integrated sensors, are to be expected for hygienic gear reducers and other Gear Boxes for hygienic applications in the pharmaceutical industry.
For individual advice on Gear Box solutions, especially regarding the optimal A Hygienic Design gear reducer for the pharmaceutical industry, contact ATEK Drive Solutions.
