connection Stainless steel and food, a good Creating the future with stainless steel Richard Clemens, VDMA November 8, 2012

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1 Creating the future with stainless steel Stainless steel and food, a good connection Richard Clemens, VDMA November 8, 2012 Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

2 Mechanical engineering in Germany Facts & figures 2011 Production Exports 189 bn. 142 bn. Export ratio 75 % No. of employees 931,000 Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

The Association: Largest network of the mechanical engineering industry More than 3,000 member companies 45,000 visitors per year 1,500 events per year 400 dedicated employees 39 professional

3 The Association: Largest network of the mechanical engineering industry More than 3,000 member companies 45,000 visitors per year 1,500 events per year 400 dedicated employees 39 professional associations Present in Europe and the world Berlin Office European Office Brussels Liason Offices: China (Beijing and Shanghai) India Japan Russia Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

4 Our specialised industries One stop for diversity Agricultural technology Air-handling technology Building control and management Cleaning systems Compressors, compressed air and vacuum technology Construction equipment and building materials machines Electrical automation Engines and systems Equipment for metallurgical plants and rolling mills Fire fighting equipment Fluid power Food processing & packaging machinery Foundry machinery Garment and leather technology Lifts and escalators Machine tools and manufacturing systems Machine vision Materials handling and logistic technology Micro technology Mining equipment Municipal equipment Plastics and rubber technology Power systems Power transmission engineering Precision tools Printing & paper equipment and supplies Process plant and equipment Productronics Pumps + Systems Robotics + Automation Security systems Software Testing technology Textile machinery Thermo process and waste treatment technology Valves Weighing technology Welding Woodworking machinery Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

5 Food Processing and Packaging Machinery Who we are and what we do Networked Technology thinking, networked actions for people Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

6 German machine production food processing and packaging machinery, 2011: 10.5 billion Euro Source: National Statistics, VDMA Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

58,000 Companies 650 Rank* 4 *among the 34 branches of the German mechanical engineering industry

7 Facts and figures 2011 German food processing and packaging machinery Machinery production 10.5 billion Exports 6.7 billion Export quota > 80 % Import 1,2 Mrd. Euro Employees ca. 58,000 Companies 650 Rank* 4 *among the 34 branches of the German mechanical engineering industry (according to turnover) Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

World exports food processing and packaging machinery 2000-2011 Euro billion 32.000 30.000 28

8 World exports food processing and packaging machinery Euro billion Source: National Statistics of 47 Industrial Countries Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

9 World exports food processing and packaging machinery 2011 Great Britain 3% Denmark 3% Japan 4% France 4% China 5% Others 15% Switzerland 6% Netherlands 6% US 8% Germany 23% Italy 23% Source: VDMA, National Statistics of 47 Industrial Countries Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

10 Introduction Why is it so important to consider hygienic aspects of food processing and packaging? today, 7 billion people have to be fed In 2030, 75% of the world population is expected to live in cities by FAO*) In 2050, a world population of 9 billion people is expected by FAO *) Food and Agriculture Organization of the United Nations Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

11 What we are talking about Open processes and components Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

12 What we are talking about Closed processes Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

13 Why stainless steel? Why stainless steel is used as a main construction and contact material in food processing machinery? Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

14 Why stainless steel? 1. Corrosion resistance 2. Surface and whole material well suited for mechanical treatment 3. Cleanability Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

15 Milk processing machinery: Typical cleaning conditions acc. to DIN (example 1/2) Cleaning, desinfection and/or sterilization procedure max. conzentration aktive substance (mass ration) in application solution [%] max. contact time [min] max. temperature [ C] Alcaline intermediate cleaning 2,5 % NaOH based on caustic soda Alcaline intermediate cleaning 5,0 % NaOH based on caustic soda Alcaline intermediate cleaning 2,5 % NaOH based on caustic soda Combined cleaning and 1,0 % NaOH desinfection based on caustic soda plus Na-Hypochlorit 0,1 % NaOCl Acid intermediate cleaning based 4,0 % H 3 PO on phosphoric acid Acid intermediate cleaning based 4,0 % H 3 PO on phosphoric acid Acid cleaning based on nitric acid 1,0 % HNO Acid cleaning based on nitric acid 1,5 % HNO Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

16 Milk processing machinery: Typical cleaning conditions acc. to DIN (example 2/2) Cleaning, desinfection and/or sterilization procedure max. conzentration aktive substance (mass ration) in application solution [%] max. contact time [min] max. temperature [ C] Acid cleaning based on nitric acid 1,5 % HNO Desinfection based on Na- 0,3 % NaOCl Hypochlorit Desinfection based on peracetic 0,15 % CH 3 COOOH acid Desinfection based on peracetic 0,2 % CH 3 COOOH permanent 60 acid Desinfection based on hydrogene 0,5 % H 2 O peroxyd Desinfection based on hydrogene 35,0 % H 2 O peroxyd Staem (water vapour) 100,0 % H 2 O Hot water 100,0 % H 2 O Ozone (active oxygene) 0,001 % (10 ppm) O Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

Micro-organisms In some cases (yoghurt, cheese, meat) wanted and useful In most cases unwanted and the main reason for food getting spoiled or people getting ill Sometimes only one package / batch

17 Micro-organisms In some cases (yoghurt, cheese, meat) wanted and useful In most cases unwanted and the main reason for food getting spoiled or people getting ill Sometimes only one package / batch affected, e.g. if the equipment was cleaned early enough and well enough Worst case: Complete machine or processing line is infected Micro-organisms are very small and able to live or to survive under diverse conditions They live also in biofilms with several species If human beings were as small as microorganisms, all 7 billion people of the world would fit into one glass of yoghurt! Image: Regina Zschaler Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

18 Yeast cells on stainless steel Source: Research Project AiF N II, Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

19 Micro-organisms: differences between bacteria and humans Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

4435 Source: HENKEL Neustadt-Glewe Cells on a surface Source:

20 Pay attention to: Surfaces Surface defect on the inside surface of a seamless pipe, material Source: HENKEL Neustadt-Glewe Cells on a surface Source: PathogenCombat Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

21 Cleaning: Influencing factors ( Sinner-Circle ) Mechanics Time Chemistry Temperature Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

22 Cleaning: Procedures and methods 1. pre-cleaning superficial soil is removed by brushing or pre-cleaning 2. main cleaning removing of soil with detergents 3. rinsing loose soil and residual detergents are removed 4. disinfection elimination of micro-organisms 5. rinsing removal of residual disinfectant 6. drying removal of residual moisture Image: Regina Zschaler Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

Cleaning: Conclusion Cleaning is a complex procedure Adaption to expected soil necessary Consideration of item(s) which are to be cleaned is necessary Right choice of detergents (chemistry) and

23 Cleaning: Conclusion Cleaning is a complex procedure Adaption to expected soil necessary Consideration of item(s) which are to be cleaned is necessary Right choice of detergents (chemistry) and procedure (temperature, mechanics, time) is necessary Source: Rainer Sturm / pixelio.de Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

24 Hygienic design What is hygienic design? Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

25 What is hygienic design? Hygienic design is understanding how a certain product can be processed and packed, within a production plant and production site, with food processing and packaging machinery, by skilled (!) operators, in a way that ensures the product is not affected by unwanted objects (e.g. insects) harmful substances (e.g. machine oil or glass particles) pathogen micro-organisms (e.g. salmonella) quality affecting micro-organisms Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

Standards and Documents (examples) Documents, which contain some specific details, are e.g.

Food processing machinery - Basic concepts - Part 2: Hygiene requirements Code of Federal

g. Doc. 8, Hygienic equipment design criteria, 2d Ed. 2004 Doc.

Materials of construction for equipment in contact with food, 2005 Stainless steel and food, a

26 Standards and Documents (examples) Documents, which contain some specific details, are e.g. EN ISO 14159, Safety of machinery - Hygiene requirements for the design of machinery EN , Food processing machinery - Basic concepts - Part 2: Hygiene requirements Code of Federal Regulations of the United States of America, e.g. part 177, polymers Documents of the EHEDG (European Hygienic Engineering & Design Group), e.g. Doc. 8, Hygienic equipment design criteria, 2d Ed Doc. 10, Hygienic design of closed equipment for the processing of liquid food, 2nd ed Doc. 32. Materials of construction for equipment in contact with food, 2005 Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

27 Pay attention to: Welding Source: Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

28 Pay attention to: Welding Pictures by courtesy of Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

29 Pay attention to: Seals Food sector ( product side ). Non-food sector Expansion possible under thermal impact Seal is aligned towards product side Best possible alignment of sealing components Definite free space available for expansion under thermal impact Firm compression through axial stop Source: Process Engineering Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

30 Pay attention to: Radius, corners, screws Pictures: EHEDG Doc.13 Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

31 Pay attention to: Lubricants, soil entry Pictures: EHEDG Doc.13 Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

32 Challenging Availability of stainless steel, e.g. X5CrNi18-10 / X6CrNiMoTi / X2CrNiMo / Different standards in Europe (DIN, EN) and USA (AISI, ASME), e.g. W.-Nr. DIN AISI JIS (Japan) UNS X2CrNiMo L SUS 316 L S X2CrNiMo L SUS 316 L S Source: ISER : S % (semi-finished: 0.03 %), but 316L ASME BPE: controlled sulfur % If would get to a lower Delta-Ferrit, in pharma applications would not longer be needed and could be listed out Different testing criteria and documents for EU and USA Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

Papers Now you may understand better, why we need inspection documents declaration of complinance type 2.1 Test report type 2.2 Inspection certificate type 3.

33 Papers Now you may understand better, why we need inspection documents declaration of complinance type 2.1 Test report type 2.2 Inspection certificate type 3.1 Inspection certificate type 3.2 Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

34 Other reasons to choose hygienic design Other reasons to choose hygienic design? Cleaning duration takes about % *) of the available production time if hygienic design basics are used if not, the duration will be longer! if the design is improved, the duration can be shorter!!! Source: Rainer Sturm / pixelio.de save time, save money *) Estimation 2012 from VDMA Food Processing and Packaging Machinery Association. Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

35 Other reasons to choose hygienic design Other reasons to choose hygienic design? Water is the most important food. if hygienic design basics are used less water is needed for cleaning if not, water consumption will be higher! if the design is improved, water consumption can be reduced!!! Also detergent consumption can be reduced Source: Katharina Wieland Müller / pixelio.de save resources! Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

36 Today: Food spoilage Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

37 The future: Over 9 billon people in 2050 need to eat and drink Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

38 Stainless steel and food, a good connection Thank you for your attention! Stainless steel and food, a good connection 2012 VDMA Food Processing and Packaging Machinery Association Page

European Hygienic Engineering & Design Group

Why EHEDG? European Hygienic Engineering & Design Group Food-born diseases (1990 10Mio) as a result of not hygienically designed food processing equipment, process lines or plants forced the EU to react