Cable Entry for hygienic zones in the Food Industry – How to design a hygienic cable entry
For the designer, this means having to reconcile several requirements at the same time. The cable entry should be sealed, resistant to cleaning agents, and easy to keep clean. At the same time, not every area of the machine requires the most advanced and costly hygienic solutions. There are also issues related to installation, subsequent servicing, and routing cables that are already terminated with connectors.
The CABseal clean system from Pflitsch addresses exactly this set of challenges. It is a cable entry system designed for washdown zones and non-product hygienic areas. Its design makes it possible to increase the level of hygiene where needed, without introducing the unnecessary complexity typical of complete hygienic systems. In this article, we explain which design challenges this product line helps solve.
Problem 1: the cable entry should not make the machine harder to clean
In an environment that is regularly washed down, every gap, protruding edge, or hard-to-reach recess can make effective cleaning more difficult. From a designer’s point of view, this means that choosing a cable entry is not only about routing cables into a cabinet or enclosure. The design of CABseal clean was developed in accordance with hygienic design principles based on EHEDG guidelines. Reducing areas where contamination can accumulate makes it easier to clean the entire area around the cable entry. Importantly, the system does not require additional covers or extra components to improve hygiene. For the designer, this means fewer elements to account for in the design, and for the operator, fewer places that require special attention during cleaning.
Problem 2: cable entries must withstand regular washdown processes
In machinery used in the food industry, sealing alone may not be enough. Components located in hygienic areas are repeatedly exposed to water and cleaning agents used during washdown. If a material loses its properties over time, the result may be leaks, faster wear of components, or the need for more frequent replacement. That is why the frame and cable inserts of CABseal clean are made from materials compliant with FDA requirements.
Material resistance to commonly used cleaning agents has been confirmed in Ecolab tests. As a result, the system retains its function even during repeated cleaning cycles. In addition, the cable entry provides IP65/66 protection and can operate within a temperature range from -40°C to +100°C.
Problem 3: the cable already has a connector, and installation becomes a challenge
Pre-assembled cable harnesses and cables with connectors are standard in modern machinery. Routing them through conventional cable glands may, however, require removing the connector, making a large opening, or using a more complex solution. In the case of CABseal clean, the frame is split and the flexible cable inserts have a side slit. This allows cables that are already terminated with plugs or connectors to be routed through the entry. Installation comes down to placing the cables in the inserts, closing the frame, and screwing it in place. No specialist tools are required. This is important not only when building a new machine. The benefit is even greater when modernizing existing installations, because there is no need to interfere with finished cables and harnesses.
Problem 4: six cables are needed today, but there may be eight next year
The configuration of an electrical installation rarely remains unchanged throughout the entire service life of a machine. Additional sensors, drives, automation components, or new equipment modules may be added. In a traditional solution, adding more cables may require making additional openings or replacing the entire cable entry. CABseal clean can be reopened and reconfigured. The system is available in four frame sizes that can accommodate 4, 6, 8, or 10 cable inserts. The inserts allow cables with diameters from 3 to 16 mm to be sealed, and their fitted shape also provides mechanical strain relief for the cable.
Unused positions can be closed with suitable plugs made from polyamide compliant with FDA requirements. In practice, this means that the cable entry can evolve together with the machine. When the installation is expanded, the entire system does not automatically need to be replaced.
Problem 5: the design requires hygiene, but not an elaborate solution
One of the more common design challenges is selecting the right level of hygiene for a specific machine zone. In areas without direct contact with the product, using a complete hygienic system may be technically possible but economically unjustified. On the other hand, a standard solution may not provide sufficient ease of cleaning. CABseal clean fills the gap between these two approaches. The system was designed primarily for washdown zones and non-product hygienic areas where an easy-to-clean design is needed, but where a full solution intended for the most demanding production zones is not necessarily required.
Three versions are available: a frame with standard stainless-steel screws, a version with hygienic screws, and a complete version with hygienic screws and a mounting kit. In the hygienic versions, screws made of 1.4404 stainless steel are used. The designer can therefore match the version to the requirements of a specific part of the machine instead of applying one maximum standard everywhere.
Not sure whether the CABseal clean cable entry system will work in your installation? Contact us and we will recommend the optimal solution.
Fewer components also mean fewer potential problems
In hygienic design, simplifying the construction has very practical significance. Every additional component may mean another connection, a surface that needs cleaning, or a potential leakage point. That is why in CABseal clean, the seal on the rear part of the frame is already integrated into the design. There is no need to add a separate gasket during installation. This detail translates into fewer components, simpler installation, and a lower risk of installation errors.
Especially useful for retrofits
Modernizing an existing machine in a hygienic area can be much more difficult than designing a new solution from scratch. The cables are already routed, terminated with connectors, and connected to devices. Any major intervention means additional work and longer downtime. The split design of CABseal clean allows the system to be installed around existing cables. As a result, during a retrofit there is no need to dismantle entire harnesses or replace the complete cable entry whenever the configuration changes. For maintenance teams, this means simpler modifications, and for the operator, shorter machine downtime.
Cable entries matched to actual operating conditions
Good design in the food industry is not about using the most advanced solution in every part of the machine. It is about selecting the level of protection that genuinely matches the operating conditions. In the case of cable entries, this means combining hygienic design with washdown resistance, sealing performance, easy installation, and the ability to modify the installation later.
CABseal clean combines these requirements in one system: it allows cables with connectors to be routed, facilitates cleaning, withstands regular washdown processes, and can be reopened when the machine is expanded.
Frequently asked questions about designing machinery for the food industry
What EHEDG requirements must a cable entry meet in a washdown zone?
The design must minimize gaps and hard-to-reach areas and be easy to clean without additional covers. CABseal clean meets these requirements, as it was designed specifically for washdown zones.
What is the difference between a product zone and a non-product zone?
A product zone comes into direct contact with food and requires the highest level of hygiene, while a non-product zone (e.g. a washdown zone) only requires regular cleaning without product contact. For the latter, an intermediate solution such as CABseal clean is sufficient instead of a full hygienic system.
Is there a cable entry resistant to cleaning agents and tested according to Ecolab?
CABseal clean is made from materials compliant with FDA requirements, and its resistance to standard cleaning agents has been confirmed in Ecolab tests.
How can a cable with an already installed connector be routed without removing it?
A split frame with inserts featuring a side slit is required, allowing the cable to be inserted without removing the connector. That is how CABseal clean works — installation involves placing the cable, closing the frame, and fastening it together.
Can additional cables be added without drilling new holes?
Yes, if the cable entry uses modular inserts in a split frame — CABseal clean offers frames for 4, 6, 8, or 10 inserts, with plugs for unused positions. The frame can be reopened when the installation is expanded.
What materials are permitted in hygienic zones without food contact?
Materials compliant with FDA requirements and resistant to moisture and cleaning agents are required, such as TPE inserts and polyamide plugs in CABseal clean. Full compliance with food-contact standards is not necessary here.
Is there a more affordable alternative to full hygienic systems?
Yes, intermediate solutions such as CABseal clean combine ease of cleaning and washdown resistance without the cost of a full hygienic system. They are suitable for zones without direct contact with the product.
What IP rating is required for a cable entry exposed to pressure washing?
Usually, at least IP65/66 is required, meaning dust-tight protection and resistance to water jets. CABseal clean provides this level of protection within a temperature range from -40°C to +100°C.
Looking for a cable entry that can withstand daily washdown while avoiding the need to invest in a full hygienic system? Check the full CABseal clean specification and contact us. We will help you select the right version, frame size, and number of inserts for the specific zone of your machine.
