Keywords: Industrial Ethernet, Molex
Abstract: The introduction of robots and automated equipment in the food and beverage industry has brought about improvements in safety, product quality, productivity, and profit margins in many aspects.
How can industrial Ethernet at the device level help reduce downtime and improve operational safety and real-time information flow?
The introduction of robots and automation in the food and beverage industry has brought improvements in safety, product quality, productivity, and profit margins in many ways. Continuous advancements in automated process control and robotics, sensors for automated quality and safety control, and the development of equipment vision systems are leading to a more sustainable food industry. However, the food and beverage industry still lags behind in introducing innovative connected factory technologies, and much work remains to be done.
Several factors have prompted manufacturers and processors to adopt a more cautious approach to upgrading their automation systems. Many have been using the same products for over 20 years and hesitate to upgrade to better solutions until their outdated equipment is no longer usable. While the industry is highly competitive, it has been less affected by the global economic downturn compared to other sectors, resulting in a lower willingness to make changes. Furthermore, food and beverage manufacturers face unique challenges that make implementing new systems more difficult. These challenges include preventing product contamination, ensuring consumer and worker safety, environmental conditions such as temperature, humidity, and vibration, stringent cleaning and rinsing procedures, and compliance with local government regulations.
However, as manufacturers seek to improve operational efficiency and bottom-line profits, they must adopt more advanced factory floor networking technologies.
Connectivity is crucial
Some key components of these advanced automation systems are cables, connectors, and communication systems that connect everything. In many cases, hard-wired solutions remain common in factory floors due to their lower cost. However, this approach is extremely labor-intensive, so the connection systems must be easy to install, reliable, and secure. Pre-wired patch panels can save time and help prevent incorrect wiring, making them suitable for applications with high-density input and output connections. In both cases, robustness is crucial for withstanding the harsh environment of food and beverage factory floors, where electrical short circuits caused by moisture ingress into electrical and electronic equipment and devices are a primary concern on food and beverage production lines.
Similarly, communication systems such as DeviceNet, an open device-level control and information network system for industrial equipment; Profibus, a standardized global open network communication system; and Modbus, a popular industrial communication protocol, all require cables, connectors, and sockets that offer versatility, reliability, and signal integrity in harsh environments.
Advantages of migrating to Ethernet
Ethernet was originally designed for office environments, but it gained momentum in factory floors as businesses required the collection and transmission of real-time data from the factory floor back to the enterprise. This is particularly important for the food and beverage industry, which typically needs to continuously monitor production processes to maximize uptime and meet regulatory requirements. For companies looking to gain a competitive edge by connecting factory floor equipment to their manufacturing network, Industrial Ethernet often offers several unique advantages:
Accessing information across the enterprise to improve enterprise intelligence.
Achieve faster information flow by leveraging faster data transmission speeds.
Cost savings through improved energy efficiency and resource management
Reduce factory downtime by enhancing equipment performance.
Optimize equipment performance through collaborative monitoring and control.
Major industrial Ethernet solutions include EtherNet/IP, used for industrial automation, process control applications, and robotics , and whose standards are managed by the Open Device Vendor Association ( ODVA); PROFINET, an open industrial Ethernet protocol for advanced manufacturing and automation; and Modbus TCP/IP, an extension of the popular Modbus protocol, widely used in industrial manufacturing environments. In any case, the underlying infrastructure, including cables, connectors, switches, protocol stacks, interface cards, and I/O modules, must be highly reliable for a successful industrial Ethernet network implementation. Moving these components out of the rack and onto the shop floor exposes them to extremely harsh environments. General commercial products used in offices are insufficient to handle these conditions; therefore, selecting appropriate and reliable cables and connectors is crucial and a key factor in maintaining normal shop floor operations.
Choose suitable materials that can be used in harsh environments.
The extreme conditions in the food and beverage industry are a major reason why companies are delaying the migration of Ethernet from offices to food and beverage plant floors. One of the biggest obstacles is the rinsing process, a critical factor in preventing contaminants from negatively impacting product quality; however, extremely high water temperatures and corrosive cleaning and disinfecting agents can easily damage sensitive electronic equipment. Another factor is the risk of rust and corrosion, which could potentially disrupt manufacturing processes or contaminate products. Finally, extreme temperatures, humidity, and vibrations can all affect the performance and reliability of communication infrastructure.
By selecting the right products, food and beverage manufacturers can safely transition to Industrial Ethernet. Some characteristics to consider when evaluating different devices, components, and wiring options include:
Rated Ingress Protection ( IP) Rating: IP rating is an internationally recognized standard. The first digit indicates protection against solid substances (such as dust particles), while the second digit defines protection against liquids. In many areas of food and beverage factory premises, an IP67 rating is acceptable, indicating dust protection and protection against short-term immersion. However, an IP69K rating is ideal, indicating protection against dust, high temperatures, and high-pressure water, suitable for applications where equipment requires careful cleaning.
Stainless steel construction: The smooth-surfaced 316-grade stainless steel connection system limits the area where bacteria can accumulate, helping to prevent bacterial growth, and can withstand harsh chemicals and high water temperatures without rusting. Furthermore, the robust overmolded cable sheath can withstand extreme temperature conditions, providing additional protection.
Push-to-lock technology: Connectors incorporating a mechanical locking design provide a secure connection not found in threaded wire assemblies. This inherent reliability reduces connector-related intermittent signals in the most demanding environments. Fewer intermittent signals mean shorter downtime and better productivity.
DIN Rail Mount/Machine Mount: By migrating Ethernet switches to factory floor equipment, manufacturers can save rack space, reduce cabling costs, and simplify installation. The heavy-duty enclosure provides protection against water and temperature variations, making it suitable for demanding industrial applications.
A well-thought-out industrial Ethernet migration allows food and beverage companies to maintain relevant legacy systems while developing innovative applications that support future business growth.
