Expert knowledge for machine builders and plant operators in the food, pharmaceutical, and cosmetics industries.
What material requirements are crucial for hygienic design gearboxes?
For hygienic design gearboxes, stainless steel 1.4404 (AISI 316L) is standard due to its excellent corrosion resistance, chemical resistance, and temperature resistance. Its smooth surface (often Ra ≤ 0.8 µm) prevents the adhesion of contaminants and facilitates cleaning.
How do hygienic design gearboxes ensure effective cleaning?
Through a dead space-free design, smooth surfaces, and rounded edges, accumulations of product residues and microorganisms are prevented. This allows for a quick and thorough cleaning, often even under high pressure.
What does the protection class IP69K mean for a hygienic design gearbox?
IP69K means that the gearbox is protected against intensive cleaning with high-pressure water and steam cleaners , even at high temperatures. This is essential for industries with the strictest hygiene regulations..
Are the lubricants used in hygienic design gearboxes food-safe?
Yes, in general, NSF H1-certified lubricants are used. These are approved for occasional, unexpected contact with food and thus ensure the highest product safety..
What are EHEDG guidelines and why are they relevant for hygienic design gearboxes?
The EHEDG (European Hygienic Engineering & Design Group) develops guidelines for the hygienic design of machines and components. Compliance ensures that gearboxes are easy to clean and minimize contamination risks..
Can hygienic design gearboxes be tailored to specific application requirements?
Yes, many manufacturers, including ATEK Drive Solutions GmbH, offer custom modifications. This may include modifications to shafts, flanges, or special coatings to ensure optimal integration and performance. .
What advantages do hygienic design gearboxes offer beyond mere hygiene?
In addition to avoiding contamination, they lead to reduced downtime due to robust construction, a longer lifespan thanks to corrosion-resistant materials, and thus to lower total operating costs (TCO)..
How do the ATEK HDV/HDVS series specifically address hygiene requirements?
The ATEK HDV/HDVS series uses stainless steel for corrosion resistance, comply with EHEDG design principles with optimized surfaces (Ra ≤ 0.8 µm), use NOTOX food lubricants , and are designed to avoid dirt pockets.
Hygienic design gearboxes are characterized by specific design principles such as stainless steel 1.4404, dead space-free design, and high-quality seals that ensure maximum product safety and cleanability.
Compliance with standards such as EHEDG, FDA compliance, and protection class IP69K is essential for use in sensitive industries and ensures reliability and international marketability..
The use of hygienic design gearboxes leads to significant economic benefits, including up to 30% shorter cleaning times, an increased plant availability and thus reduced total operating costs (TCO)..Learn all about the selection, design, and benefits of hygienic design gearboxes. Avoid costly production downtimes and ensure the highest hygiene standards.
In sensitive industries such as the food or pharmaceutical industry, hygienic design gearboxes are essential. They minimize contamination risks and ensure a smooth production process. Need a customized solution? Contact our experts now!
Do you need a hygienic design gearbox for your plant?
Get advice now!Hygienic design gearboxes: Understanding the basics and unlocking potential.
Knowledge of Hygienic design gearboxes enables smooth production, high hygiene standards, and the prevention of costly failures, thereby securing processes.
What are hygienic design gearboxes?
Hygienic design gearboxes are designed for the highest hygiene standards in industries such as food, pharmaceutical, and cosmetics. Their nature minimizes, for example, bacterial growth. They ensure product safety and consumer health through optimized cleanability and elimination of contamination sources. More about HD gearboxes.
Why are they necessary?
In industries with strict cleanliness regulations, avoiding contamination is essential. The slightest contamination (e.g., in the pharmaceutical industry; components from ATEK Drive Solutions GmbH ensure product purity) can have serious consequences. Hygienic design prevents the accumulation of product residues/microorganisms, supports legal compliance, and avoids recalls. Special gearboxes for pharmaceutical.Design features optimize for maximum hygiene and efficiency.
Stainless steel 1.4404: The standard
Stainless steel 1.4404 (AISI 316L) offers high resistance to corrosion, chemicals, and temperatures (e.g., during daily cleaning in food plants). The choice of stainless steel 1.4404 is crucial for longevity/hygiene; its smooth surface minimizes adhesion and optimizes cleaning intervals. Details on stainless steel gearboxes.
- Use of stainless steel 1.4404 (AISI 316L) as standard material for maximum corrosion resistance.
- The decisive role of stainless steel 1.4404 for longevity and maintaining hygiene.
- Smooth surface texture to minimize adhesion and optimize cleaning intervals.
- Principle of dead space-free design to avoid hard-to-reach areas.
- Standardization of smooth surfaces (often Ra ≤ 0.8 µm) and rounded edges for maximum cleanability.
- Critical significance of sealing technology for hygienic conditions and longevity, especially with wet cleaning.
- Use of high-quality, FDA-compliant sealing materials that are resistant to aggressive cleaners and temperatures.
Design principles
Hygienic design gearboxes require dead space-free design without hard-to-reach areas. In Neco® gearboxes from Nabtesco, transitions are smooth. Smooth surfaces (often Ra ≤ 0.8 µm) and rounded edges are standard for maximum cleanability and minimal dirt adhesion. Easily cleanable gearboxes.
Sealing technology
High-quality seals prevent the ingress of liquids/particles and are resistant to aggressive cleaners/temperatures. FDA-compliant materials, for example, maintain integrity over hundreds of cycles. Sealing technology is critical for hygienic conditions and longevity, especially with wet cleaning. Discover IP69K gearboxes.Mastering standards and guidelines for guaranteed product safety.
EHEDG guidelines
The EHEDG provides guidelines for hygienic design, primarily in the food industry. EHEDG-compliant gearboxes (e.g., WITTENSTEIN models) are easy to clean. Compliance minimizes contamination risks, enhances food safety, and is often a prerequisite for export. Food-compliant gearboxes.
FDA compliance
The US FDA requires strict compliance for materials in contact with food (plastics, seals, NSF H1 lubricants). Seals must be free of contaminants. FDA compliance ensures consumer protection and is essential for US market access.. Gearboxes for breweries.
IP protection classes
In splash zones or during intensive cleaning, a high level of protection is needed. IP69K denotes components resistant to high-pressure hot water cleaning (e.g., Eisele EHPL gearboxes). IP69K guarantees reliability/longevity under the harshest conditions, reduces failures, increases operational safety. All about IP69 gearboxes.Analyze application fields and implement suitable solutions.
Food industry
The food industry presents diverse requirements: meat processing, dairies, beverage industry. Conveyors for unpackaged items, for example, require smooth surfaces and food-grade lubricants. The correct gearbox selection is crucial for product quality/safety.. Compact stainless steel gear motors.
- Considering the diverse requirements of specific areas of the food industry (e.g., meat processing, dairies).
- The necessity of smooth surfaces and food-grade lubricants, particularly for conveyors for unpackaged products.
- The crucial role of correct gearbox selection in ensuring product quality and safety.
- Meeting the highest hygiene requirements in the pharmaceutical industry through specialized gearbox solutions.
- Use of electropolished stainless steel and special seals to eliminate contamination in sterile environments.
- Importance of uncompromising hygienic design, especially in cleanroom applications.
- Exemplary implementation through solutions such as the Neugart HLAE planetary gearbox, which combines cleanability, FDA materials, and IP69K protection.
Pharmaceutical industry
The pharmaceutical industry demands the highest hygiene. Specialized gearboxes (e.g., electropolished stainless steel, special seals; ATEK HDV/HDVS series) exclude contamination. In sterile environments, uncompromising hygienic design is required.. Planetary gearboxes for clean rooms.
Example: Neugart HLAE
The Neugart HLAE planetary gearbox: cleaning-friendly design, FDA materials, NSF H1 lubricants, no radial housing screws, IP69K protection for wet areas. Such integrated solutions simplify the design of hygienic machines..Realize economic advantages through smart hygienic concepts.
Reduction of contamination risks
Hygienic design gearboxes minimize contamination risks, product residue accumulations; for safer products, fewer recalls. Optimized hygiene processes can increase OEE by up to 5%. Investment in hygienic design strengthens production reliability, market protection..
Efficient cleaning
Hygienic design components enable quick, thorough cleaning (smooth surfaces, no dead spaces), save time (up to 30%), water, and cleaning agents (e.g., WITTENSTEIN axenia value actuators). Less cleaning effort lowers operating costs and increases production time..
Longer lifespan.
High-quality materials (stainless steel 1.4404), robust seals protect gear boxes from aggressive conditions, enable longer lifespan, less maintenance (e.g., ATEK stainless steel gear boxes). Higher reliability and fewer failures reduce total operating costs (TCO)..Recognizing future trends and using innovations in hygienic design.
Intelligent gear boxes.
Sensors for condition monitoring in hygienic design gear boxes enable predictive maintenance, avoid costly downtimes. Intelligent gear boxes increase plant availability and optimize maintenance processes..
- Use of sensors for continuous condition monitoring.
- Facilitating predictive maintenance.
- Avoidance of costly, unplanned plant downtimes.
- Increase in overall plant availability.
- Optimization of all maintenance processes and intervals.
- Increasing importance of sustainable materials and biodegradable lubricants.
- Focus on resource-conserving manufacturing processes in line with sustainability goals.
Sustainability.
Sustainable materials/lubricants (e.g., biodegradable), resource-conserving processes (e.g., ATEK Drive Solutions GmbH) are gaining importance. The combination of hygienic design/sustainability becomes a more important competitive factor..
Selection and implementation of hygienic design gear boxes optimize production processes. A systemic view is often crucial. We are ready for individual consultation on plant optimization.
