What Are Some New IP69K Sensor Options for Food, Beverage, and Pharmaceutical Processing Lines?

Sanitation is mandatory in food, beverage, and pharmaceutical processing. Like all Industry 4.0 operations, those processing lines require high levels of automation supported by numerous sensors.

That means using environmentally hardened ingress protection (IP) 69K-rated sensors that can withstand high-pressure washdowns and routine clean-in-place (CIP) procedures to maintain a sanitary operating environment while ensuring efficient operation.

In addition to an IP69K rating, sensors in these applications are often required to be constructed using materials that meet the Food and Drug Administration (FDA) requirements, like the SAE 360 L stainless steel alloy that’s highly resistant to corrosion and can withstand routine CIP procedures. In other applications, a housing made with FDA-grade plastic is suitable.

This article begins with an overview of the requirements of IP69K as defined in DIN 40050-9, reviews the performance of various FDA stainless steels, including SAE 200, 300, and 400 series, and considers available FDA-grade plastics and when they can be used.

Next, it presents several new sensors from Banner Engineering that are suited for use in food, beverage, and pharmaceutical processing lines, along with some application and installation suggestions. It closes by looking at a bottle capping application that needs IP69K sensor performance but not a housing made with an FDA-approved material.

Do IP69K sensors also meet IP68?

A sensor can be designed to meet both standards. The “6” in these IP ratings means that these devices are dust-tight and there’s no dust ingress.

However, meeting IP69K does not automatically mean the sensor meets IP68. International Electrotechnical Commission (IEC) 40050-9 is based on a German standard that extends the IEC 60529 IP rating system to add IP69K for high-pressure, high-temperature washdown applications that diverge somewhat from the other IP ratings.

The water ingress protection of IP68 is based on IP67. IP67 requires temporary immersion in water up to one meter deep for at least 30 minutes. IP68 also involves immersion in water with the test conditions set by agreement between the device maker and the user, and it must be more severe than IP67. For example, Banner Engineering IP68-rated sensors can handle at least 24 hours of continuous immersion in two meters of water.

IP69K does not require immersion in water. Testing for IP69K includes three elements:

• Ability to spray the device with +80°C water at a flow rate of 14 to 16 liters per minute (L/min) and a pressure of 10 MPa (1500 pounds per square inch, psi)
• The spray nozzle must be held 10 to 15 cm from the device at angles of 0°, +30°, +60°, and +90° for 30 seconds each, for a total of 120 seconds
• The device is rotated on a turntable once every 12 seconds

Banner Engineering IP69K-rated sensors are additionally tested to at least one-meter immersion in water, a requirement that exceeds the standard IP69K testing (Figure 1). After testing, the sensor is inspected to see if water is inside. No water should be inside, and the sensor must continue functioning normally to pass the test.

Figure 1: Sensors rated for IP69K, like this one, can withstand high-pressure, high-temperature washdowns. (Image source: Banner Engineering)

Corrosion also matters

The IP rating system indicates how well an enclosure protects against solid particles and liquid ingress. It does not consider operation in a corrosive environment. FDA requirements cover that.

The FDA regulates the enclosure housing materials to ensure they are safe for use with food and pharmaceuticals. For example, food-grade stainless steel must meet the following requirements:

• It must have a minimum chromium content of 16%. A chromium-oxide film that self-heals in the presence of oxygen makes stainless steel resistant to corrosion.
• It must be from the SAE 200, 300, or 400 series of stainless steels that include chromium-nickel-manganese alloys, chromium-nickel alloys, and chromium alloys, respectively.
• It must have a smooth, easy-to-clean surface.
• It must resist pitting, chipping, crazing, scratching, and scoring and be thick enough to withstand repeated high-pressure, high-temperature washdowns.
• It must not impart orders, tastes, or colors to food.

For a lighter-weight solution, anodized aluminum is considered “generally recognized as safe” by the FDA. Proper handling and processing are necessary when using aluminum.

There are a variety of FDA-approved plastics. Common characteristics include high resistance to wear, flexing, and dimensional changes. A few examples are:

• Polycarbonate is a lightweight, transparent, and exceptionally strong material.
• Polybutylene terephthalate (PBT polyester) has high strength, stiffness, and dimensional stability. It's resistant to chemicals, oxidation, and water and is heat resistant up to 150 °C.
• Acrylic is a nontoxic, transparent plastic that's approved for materials handling. It’s also heat resistant and suitable for use in harsh environments.
• Nylon has exceptional oxygen and moisture barrier properties. It’s used to protect parts from the outside environment.

Photoelectric sensors in FDA-grade stainless steel

Banner Engineering's Q4X series photoelectric sensors offer a sensing range from 25 to 610 mm, depending on the model. For example, model Q4XFKLAF310-Q8 has a detection range of 35 to 310 mm.

The housing is made with 316 L FDA-grade stainless steel and is rated IP68 per IEC60529 and IP69K per DIN 40050-9. It’s compatible with acidic or caustic cleaning and disinfecting chemicals commonly used in equipment cleaning and sanitation and is ECOLAB-certified.

When the sensor is in run mode, the 4-digit, 7-segment display shows the current measurement reading or corresponding analog output value (Figure 2). Additional features include:

• Discrete, analog (0 V to 10 V or 4 mA to 20 mA), clear object, and IO-Link models
• High-resolution models with analog output and a higher excess gain for more challenging applications
• Detects a variety of target colors, materials, and surfaces depending on the distance
• Dual-teach mode (intensity + distance) can be used for error-proofing applications and enables clear object detection with no retro-reflector required

Figure 2: This IP69K and IP68-rated photosensor is packaged in FDA-grade stainless steel. (Image source: Banner Engineering)

Speeding configuration and changeovers

The optional RSD1QP remote sensor display (RSD) can be used with the Q4X series and other sensor families from Banner for configuration and monitoring (Figure 3). It can speed product changeovers in Industry 4.0 factories and remain connected or removed after configuration is completed. It also simplifies the monitoring of sensors in difficult-to-access locations. Other uses for the RSD include:

• Copying settings between sensors
• Supports rapid replacement of sensors
• RSD can store up to six configurations for different operations

Figure 3: The RSD1 can be used for remote configuration and monitoring of sensors like Banner’s Q4X series. (Image source: Banner Engineering)

Photosensors in plastic housings

The T18-2VPRL-2M (T18-2) washdown sensor is a self-contained photoelectric sensor designed for use in harsh environments, such as food production lines, poultry processing, box detection, and triggering the operation of a check weight station.

The case is made with black and yellow PBT polyester, and the indicator light pipes and window are made using translucent white acrylic. The plastic case is ultrasonically welded to ensure complete sealing, and the electronics are encapsulated in an IP69K-rated epoxy, providing a redundant seal (Figure 4). These sensors are also IP68-rated.

Figure 4: This IP69K and IP68-rated photosensor is packaged in FDA-approved plastics. (Image source: Banner Engineering)

IP69K radar sensors in aluminum

Radar sensors like the Q90R series can benefit applications like protecting people from machines, working with collaborative robots (cobots), or for tank-level measurements in food, beverage, and pharmaceutical processing lines. The IP69K-rated aluminum housing is sturdy and lightweight. These sensors have an operating temperature range of -40°C to +65°C, making them suitable for use in challenging environments like wet and misty areas.

For example, model Q90R-4040-6KDQ ranges from 150 mm to 20 m and has two outputs, one PNP/NPN with IO-Link communication and one 1 PNP/NPN. All Q90R sensors can customize sensing parameters like window shape and target setpoints. IO-Link can support real-time data transfers.

Object detection can be based on distance, speed, and angular position relative to the sensor, providing configurable, multidimensional performance. Two independent zones can detect and measure multiple targets simultaneously (Figure 5).

Figure 5: This aluminum-housed radar sensor can be used for tank-level monitoring in food, beverage, and pharmaceutical processing lines. (Image source: DigiKey)

Lighting for vision systems

Vision systems for quality control and inspection applications need good lighting for optimal operation. Banner’s BL60 sealed LED bar lights provide bright, focused illumination. Models that produce four high-intensity visible wavelengths plus infrared (IR) and two ultraviolet (UV) wavelengths are available. By selecting the most suitable lighting option, vision system performance can be further enhanced.

The oil-, chemical- and water-resistant aluminum housings are IP69K rated and available in 340 and 640 mm lengths. There are three window options: clear or diffused polycarbonate and borosilicate glass. They have a 1 to 10 V dimming control and an adjustable pulse width modulation (PWM) strobe function. Examples of available light colors for the 340 mm LED bar lights include:

• Daylight white (5000K), BL60W340L14ASQ
• Red, BL60R340L14ASQ
• Green, BL60G340L14ASQ
• Blue, BL60B340L14ASQ
• Infrared, BL60I340L14ASQ.
• 365 nm ultraviolet, BL60UV365-340GL30ASQ
• 395 nm ultraviolet, BL60UV395-340L30ASQ

IP69K nickel-plated zinc laser sensor for bottle caps

Not every sensor application in food, beverage, and pharmaceutical processing lines requires an FDA-approved housing material. Bottle capping is a good example.

Bottle caps are often delivered in bulk and require sorting before being used on the filling line. Misaligned caps, like upside-down ones, can result in uncapped bottles or jam the capper machine, reducing productivity. A laser sensor like the Q3XTBLD-Q8 (Q3X) can quickly identify if any caps are facing the wrong way before they reach the cap delivery system.

The Q3X has 100 mm background suppression, which makes it well-suited for orientation detection applications. With fixed background suppression, Q3X sensors can be set to recognize a specific distance and ignore anything outside the setpoint.

In a bottle cap sorting application, the Q3X can be set up to detect when the top of a cap is facing toward the sensor. If the cap is facing away, it’s ignored. If it’s facing toward the sensor, a failed output is sent, and the cap is rejected. It can be recycled into the cap sorter for another try.

The rapid detection rate of the Q3X is important in high-speed filling lines. This sensor can detect a part in just 250 µs and capture up to 2,000 events per second. The angled 3-digit display provides user feedback and speeds setup and commissioning. The nickel-plated zinc housing is IP67 and IP69K rated, making it suitable for wet environments (Figure 6).

Figure 6: This IP69K-rated laser sensor is in a nickel-plated zinc package suitable for bottle-capping processes. (Image source: Banner Engineering)

Conclusion

Robust sensors that meet IP69K and can withstand high pressure and high-temperature CIP operations are needed in food, beverage, and pharmaceutical processing lines. Many of these sensors are also designed to meet the requirements of IP68 for submersion in water. In most instances, they must be packaged in FDA-approved materials, but there are exceptions like bottle capping operations.