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CUSTOMER MAGAZINE
Edition 01-2019
PFLITSCH builds Cable Trunking
Competence Centre Pages 4-5
Orca relies on
blueglobe CLEAN Plus Pages 13-15
Customer Magazine
PFLITSCH-Kundenmagazin · 01-2019
· 01-2018
PFLITSCH celebrates 100-year
companyPFLITSCH
anniversary
Technik im Pages 20-21
Rennwagen
Der neue S3-11e Seite 12-13
Hygiene-compliant cable routeing on industrial bakery machines
The company MKW
PFLITSCH
Pages 10-12
1 · Messe Sonderausgabe Messe Sonderausgabe · 1
Company
YOUTUBE
Edition LOGO SPECS
01-2019
PRINT on light backgrounds on dark backgrounds
main red gradient bottom
standard standard Contents
PMS 1795C PMS 1815C
C0 M96 Y90 K2 C13 M96 Y81 K54
PFLITSCH creates space for further company growth
white
WHITE
black
BLACK no gradients no gradients
New plant becomes Cable Trunking Competence Centre 4
C0 M0 Y0 K0 C100 M100 Y100 K100
Hygienic Design Expo 2019
watermark watermark
Success with EHEDG-certified products 6
eltefa 2019 – industry and trades under one roof
Solutions to prevent moisture inside control cabinets 7
stacked logo (for sharing only) stacked logo (for sharing only)
HANNOVER MESSE 2019 – in the midst of integrated energy
>> Visit us on
social networks Surprising solutions in the area of cable routeing 8
SMART 2019 – PFLITSCH exhibits in Austria
Automation in the foothills of the Alps –
perfect solutions for industry 9
Hygiene-compliant cable routeing on industrial bakery machines
Prefabricated component assemblies for more
efficient manufacture 10
Not just clean, but sterile
orca relies on hygiene and design with
stainless steel cable glands 13
Cable glands
Springtime innovations 16
The new VARiOX-Trunking system
Manageable – easy to assemble – economical 18
PFLITSCH celebrates 100-year company anniversary
Position as technological leader always maintained 20
The “automated small parts warehouse”
Modern hub for warehousing and logistics 22
Environmental protection and energy management
Consuming continuously less energy 23
Splittable cable gland for use in automation applications
Secure entry of preassembled cables 24
Exclusive for PFLITSCH portal users
Coming immediately: your comprehensive quotation 25
Recipient of the Grand Prize for Medium-sized Enterprises
Overall development of PFLITSCH acknowledged 26
Trade fairs at home and abroad 27
2 · Customer Magazine
Company
Edition 01-2019
Editorial
Dear Customers, dear Readers,
A very warm welcome to our anniversary year! It’s hard to be-
lieve, but after 100 years in existence PFLITSCH is perfectly po-
sitioned and has gained an excellent reputation for its high level
of problem-solving expertise.
In this issue of our customer magazine we will provide you with
information on current product trends, give you an insight into
the company, report on interesting customer projects and pre-
sent an outlook on the future of PFLITSCH.
During this year we will be commissioning a cutting-edge com-
petence centre for cable trunking manufacture at our newly
acquired site.
What will the latest PFLITSCH products to be launched – LevelEx
and VARiOX – be able to offer you? How can you become more
efficient by using our comprehensive services? How can coope-
rating with PFLITSCH make a difference to you? These are just
a few of the key issues that are dealt with in the magazine.
Be inspired by our “passion for the best solution!” We would
love to meet up and chat with you at the forthcoming trade
fairs such as the HD Expo, eltefa and HANOVER FAIR in
Germany or at one of the over 20 international exhibitions –
come and celebrate our 100th anniversary with us.
We hope you enjoy reading our magazine!
Warmest regards,
&
Roland Lenzing and Mathias Stendtke
Managing Partners
PFLITSCH GmbH & Co. KG
Kundenmagazin 02-2012 · 3
Customer Magazine
Company
Edition 01-2019
PFLITSCH creates space for further company growth
New plant becomes Cable Trunking
Competence Centre
With the acquisition of a factory site on the Winterhagen Industrial Estate in Hückeswagen PFLITSCH is also
paving the way for the future in terms of space. A competence centre for the fast-growing cable trunking
product range is under construction here. The space this is freeing-up at the parent plant is being reserved
for expanding the cable gland product range.
On-time for the 100-year anniversary PFLITSCH is set- framework conditions for the equally fast-growing
ting its sights on further milestones for its cable trunking range. “This gives us the space and ca-
future@pflitsch strategy. A key component and prere- pabilities we need for optimising our production pro-
quisite for the further growth of the company is spatial cesses and further expanding our component assembly
enlargement. With the acquisition of the new company operations”, explains Roland Lenzing. Particularly in
premises, which includes office space and a production view of our new, highly promising VARiOX cable trun-
building, PFLITSCH is creating further opportunities for king range, this is more than necessary.
expansion. The decision to take on a second site is
therefore the logical conclusion to for allowing the 1,300 m2 of office plus 7,000 m2 of produc-
family-run company to be steered toward a successful tion space are available
future. “At our current company premises we would
only be able to continue with our current rate of growth A modern ensemble of buildings offering 1,300 m2 of
for a further one or two years”, according to Roland office and 7,000 m2 of production space are located on
Lenzing and Mathias Stendtke, who, as Managing Part- the plot which measures some 52,000 m2. With the
ners in the 4th generation, are leading the company start-up of the modern PFLITSCH cable trunking pro-
with 100 years of successful history behind it. duction facility in autumn the family-run company will
have made an overall capital investment running into
Thanks to the new, cutting edge automated small parts the millions.
warehouse, the company's headquarters is already op-
timally prepared for expanding the cable gland range. PFLITSCH intends to set up a modern, automated pro-
The new site now practically creates the perfect duction facility in the new halls that will deliver benefits
4 · Customer Magazine
Company
Edition 01-2019
in terms of both technical manufacturing and logistics
perspectives and will also offer further opportunities
for expansion. “This means that further increases in
growth can be achieved over the next ten years with
the two plants. Fully digitalised, sophisticated processes
are intended to ensure greater efficiency”, is how Ma-
thias Stendtke gives an insight into the status of ideas
and planning. The figures have not been pulled out of
thin air: in the past financial year alone PFLITSCH has
far exceeded the ambitious sales target.
The premises in Winterhagen, also offer the potential
to further expand the site as necessary and create even
more space.
The benefits at a glance:
· Establishment of automated processes in the
warehouse for sheet metal and punched parts
· Warehouse technology adapted to suit the respective
type of stored goods
· Low waste processes thanks to cutting edge WMS
· Ergonomic provision of work equipment
· Establishment of lean and paperless production
· Free-up capacities for further expansion
The time schedule
1) Technical planning: December 2018 to the begin-
ning of August 2019
2) Construction phase: January to mid-June 2019
3) Relocation of factory equipment and material:
August/September 2019
4) Relocation of personnel: September 2019
5) Completion and commissioning: October 2019
Customer Magazine · 5
Company
Edition 01-2019
Hygienic Design Expo 2019
Success with EHEDG-certified
products
The HD EXPO entered the 3rd round. From 5–7 February 2019 eve-
rything revolved around the subject of hygienic design. The trade fair
organisers view the creation of practical solutions for the food and
pharmaceuticals sector as a particular challenge. In this context, the
HD Expo serves as an ideal discussion platform for experts and users from this sector. This is where the use
of certified components and their benefits in operation are discussed. The general assumption is that a po-
tential production stoppage or product recall campaign caused by contaminated foodstuffs would be more
expensive for a company than adhering to and implementing the hygienic design guidelines.
PFLITSCH is a new
EHEDG Company Member
As was already the case in previous years, PFLITSCH
product management was involved in the technical
committees of the EHEDG and had contributed its ex-
pertise. PFLITSCH has now joined the alliance as a com-
pany and can now officially call itself an “EHEDG Com-
pany Member”. “This now allows us to clearly signal
our intention of focusing on the strategic alignment of
the Food & Pharma segment over the long term”, exp-
lains Heiko Emde, market segment manager for the
Food & Pharma sector. “Applying for active EHEDG
company membership was therefore the logical
consequence.”
Product solutions from PFLITSCH in
accordance with EHEDG standards
As a forum for hygienic design specialists, the HD Expo is Over previous years, PFLITSCH has already successfully
a fixed date in the annual PFLITSCH trade fair calendar. brought to market product solutions designed to
The particular focus here is the blueglobe CLEAN Plus EHEDG standards. Well-known manufacturers and sup-
cable gland in stainless steel and plastic. We will also be pliers of production machinery for the meat and milk
providing information on our open and closed cable processing sectors, as well as packaging machine ma-
trunking product range made of high quality stainless nufacturers, beverage bottlers and suppliers of cleaning
steel that is also utilised in the food and pharmaceuti- machines have now become PFLITSCH customers. To
cals industry. quote an example: PFLITSCH now supplies all of the
subsidiaries of a global bottling plant manufacturer
with cable glands and cable trunking in the capacity of
“component supplier”.
6 · Customer Magazine
Company
Edition 01-2019
eltefa 2019 – industry and trades under one roof
Solutions to prevent moisture inside
control cabinets
From 20–22 In terms of cable glands, PFLITSCH will be exhibiting its
March 2019 ex- UNI Dicht and blueglobe ranges with various industry
perts from the variants such as for EMC, hygiene and fire protection
trade, industry, applications, together with split systems for modern
commerce, planning and architecture will be meeting modular installation concepts. In focus here will be the
at the eltefa exhibition in Stuttgart, the largest regional new pressure equalisation elements (PEE) that prevent
trade fair for the electrical industry. The event peaked the formation of moisture inside enclosures.
with some 24,000 trade visitors and the fair organisers
believe that no end is in sight to the upward trend for
2019 either. The reason for this lies partly with the typi-
cal Stuttgart trade visitor mix of representatives from
industry, trades, commerce, local authorities, energy
service providers, architects and planners.
For the first time, industrial technology will be exhibited
in a dedicated hall. PFLITSCH will also be represented at
the fair with its stand. One key focal point on show is
the new VARiOX Trunking. As with all PFLITSCH trun-
king, the easyRoute CAD tool can also be used to plan
the VARiOX system on-screen. At the fair we will be
providing customers who want to free themselves of
! Information
the complicated manual work associated with trunking
preassembly with information about the PFLITSCH
component assembly service: Using the planning data,
PFLITSCH prepares preassembled trunking component eltefa in Stuttgart: 20–22 March 2019:
assemblies at the factory and delivers them to the PFLITSCH can be found in hall 10, stand 10F15
customer’s assembly site on-time and at a fixed price.
This allows installation to take place quickly, safely and
at high quality.
Customer Magazine · 7
Company
Edition 01-2019
HANNOVER MESSE 2019 – in the midst of integrated energy
Surprising solutions in the area of
cable routeing
“Energy sent on its way” – with this industry slogan PFLITSCH fits perfectly into the lea-
ding Integrated Energy trade fair at Hanover. Sweden is the fair’s partner country in 2019.
With 6,500 exhibitors and over 1,400 events in the exhibition halls, the world’s largest in-
dustrial trade fair at the beginning of April aims to attract over 220,000 visitors
Suitable for every cable: mounting in production bays, through the compact
many sealing inserts available PIK-Trunking for small volumes of cables, right up to
the open Wire-tray Trunking system. In addition to the
In order to improve quality and minimise production comprehensive Industrial-Trunking system, PFLITSCH is
times, industry is increasingly using completed compo- also exhibiting the new VARiOX-Trunking, which is fo-
nent assemblies, modules and preassembled and tes- cused on standard applications: With just a small num-
ted system cables. To ensure reliable cable entry into ber of components it is possible to realise custom cable
control cabinets and enclosures, splittable systems are trunking layouts that are extremely assembly-friendly.
therefore used, such as the ones PFLITSCH is exhibiting
in Hanover. In comparison with many standard pro- All PFLITSCH trunking can be designed using the easy-
ducts, the UNI flange and UNI Split Gland solutions, on Route CAD tool. The easyRoute data is compatible with
the basis of the UNI Dicht cable gland, impress with that of other common CAD systems. On request
their high type of protection up to IP 67, above-average PFLITSCH can preassemble the layouts designed in this
strain relief values and simple assembly. In addition to manner into ready-to-install component assemblies
the plastic variant, both product lines are also available that are delivered to the customer’s installation site.
in die-cast zinc: this heavy-duty solution is designed for Customers who want to put together the trunking
increased mechanical demands. themselves will find perfectly matched tools and machi-
nes at the PFLITSCH stand – where they can be tried
For the UNI Split Gland and UNI flange PFLITSCH has far out in “hands-on” fashion.
more than one hundred sealing inserts in its range that
are suitable for various cable cross-sections and requi- Celebrate our 100th anniversary together with us in
rements. Multiple sealing inserts allow multiple cables Hanover.
– even of differing diameters – to be fed through a
single gland in a space-saving manner. Inserts for flat PFLITSCH will present a special product solution to the
and special cables can also be supplied. global public for the first time in Hanover. A surprise
awaits you!
Trunking systems route different cables
perfectly and safely
A large number of the most diverse types of cable –
from thin glass fibre cables to thick energy cables –
! Information
need to be safely routed through production plants. At HMI in Hanover: 1–5 April 2019:
the fair, PFLITSCH is exhibiting a wide spectrum of pro- PFLITSCH can be found in hall 13, stand E97
ducts, from its walkable Automobile-Trunking for floor
8 · Customer Magazine
Company
Edition 01-2019
SMART 2019 – PFLITSCH exhibits in Austria
Automation in the foothills of the
Alps – perfect solutions for industry
SMART Automation Austria is the country’s only trade fair for industrial automation.
This year it takes place from 14–16 May in Linz. The focus is placed on factory and
process automation. Over 180 exhibitors and 200 represented brands are a sign of
growth. More than 7,300 trade visitors are expected.
The scope of the exhibition stretches from the compo- PFLITSCH is expecting a high rate of growth in the mar-
nent level right through to complete systems and inte- ket for preassembled cable trunking component as-
grated automation solutions. It encompasses all pro- semblies that are delivered to the customer’s assembly
duct areas of industrial automation technology. “We site on-time and ready for installation. “This allows
will be exhibiting PFLITSCH solutions on the product companies to reduce costs, deploy their workers opti-
level”, says Stephan Kadanka, the new sales expert mally and improve process workflows,” says Stephan
for Austria. Kadanka, underlining the PFLITSCH philosophy of ser-
ving customers comprehensively in a way that creates
“Among cable glands the UNI Dicht range takes centre value for them.
stage, with its special split solutions that are needed for
modern modular construction.” For safe and practical
cable routeing through plants and machines PFLITSCH
is exhibiting a selection of products from its cable trun-
king range in Linz. “This allows our customers to install The direct line to PFLITSCH in Austria:
sensitive glass fibre cables just as reliably as thick cross-
section energy cables or a large number of control Stephan Kadanka
cables.” Mobile: +43 664 1673537
E-mail: stephan.kadanka@pflitsch.at
Stephan Kadanka is the on-site contact for PFLITSCH
customers and users of cable glands and trunking. ...or meet Stephan Kadanka at the
PFLITSCH is furthermore expanding its dealer network SMART Linz.
through which products are delivered rapidly. At the
parent plant in Hückeswagen a team has been looking
after customers from the Alpine republic since 2016.
“In Austria PFLITSCH already enjoys a good reputation
for supplying high quality cable glands – not mass-pro-
duced goods. These products are therefore used in ap-
! Information
plications where standard solutions are overburdened.
My aim is to further strengthen awareness of the
PFLITSCH brand in Austria”, explains Stefan Kadanka.
“During visits by industrial users and meetings at trade SMART in Linz: 14–16 May 2019:
fairs such as Linz I will be able to convince decision- PFLITSCH can be found in hall DC, stand 505
makers of the benefits offered by PFLITSCH solutions.
Customer Magazine · 9
Case study
Edition 01-2019
Hygiene-compliant cable routeing on industrial bakery
machines
Prefabricated component assemblies
for more efficient manufacture
The company MKW is an expert in the manufacture of special machines. New technologies and optimisa-
tions are always at the company’s focus of attention. With the takeover of the industrial bread cutting ma-
chine product line from manufacturer Rego Herlitzius, MKW is opening up a further field of activity for itself.
Instead of making the cable trunking – necessary for the uncluttered routeing of cables within these machi-
nes – by hand, MKW is using the service package offered by PFLITSCH, the manufacturer from Hückeswagen.
With its component assembly service, hygiene-compliant cable trunking is designed to the correct dimensi-
ons, manufactured, preassembled and supplied as a ready-to-install cable trunking system.
MKW stands for Maschinen-Kooperation-Wuppertal subsequent commissioning of plants and machines,”
(Wuppertal Machine Cooperation). It encompasses se- says Marco Horn, Company Secretary. “Furthermore,
ven specialist companies that have joined forces to we are also capable of mapping the digitisation of the
bundle their expertise and allow them to operate more machines through to complete production planning
successfully in the market as special machine manufac- with the aid of our in-house MES (Manufacturing Exe-
turers. In 2018 they formed a German limited company cution System = a level of a multi-tiered manufacturing
with some 70 employees. “We are experts in the fields system operating on the factory floor). We are further-
of planning, development, design, manufacture, more constantly pursuing innovative new
programming, component manufacture, assembly and technologies.”
10 · Customer MagazineCase study
Edition 01-2019
Bakery machines are currently supplemen- Within the machine, stainless steel Wire-tray Trunking
ting the range ensures orderly cable routeing. The PFLITSCH Wire-tray
Trunking is easy to clean and is resistant to high-pressu-
“We have many years of experience with industrial re cleaners and common detergents. It can be fitted
baking machines and have, as partner to Rego Herlitzi- with a roof-shaped cover to protect the inserted cables
us, completed the programing and commissioning of from media dripping from above. The mounting bra-
the machines,” explains Marco Horn. “With the takeo- ckets are also designed taking hygiene aspects into
ver of this product line we are now directly supplying consideration.
industrial bakeries with a complete solution – starting
with bakery product feed systems, the slicing and por- “Instead of having to adapt the various trunking sys-
tioning of the products and ending with their removal tems to the machine environment and assemble them
from the machine. We furthermore integrate palleti- by hand, we now order already completed prefabrica-
sing systems using robots from well-known ted trunking from PFLITSCH,” says Janine Kölven. “This
manufacturers.” fits in with our optimisation concepts because it allows
us to concentrate fully on our core competences. Fur-
A current example is the “SBA Rotec 3000” bread sli- thermore, manual work is complicated, expensive and
cing plant. This is capable of cutting practically every ties up valuable manpower and material resources.”
type of bread. “An ideal cutting result is achieved
thanks to an individual knife lubrication system,” exp- Design trunking layouts using CAD
lains designer Janine Kölven. Fully automated bread
feed, memories for various recipes and automatic bread PFLITSCH is a member of EHEDG and has developed a
height adjustment are further features of the plant. component assembly service for its trunking systems
that encompasses consulting, design, preassembly and
Preassembled trunking systems instead of installation of customer-specific trunking layouts, inclu-
expensive manual work ding the manufacture of special components. The be-
nefits to customers such as MKW are plain to see:
reduced costs, better manufacturing plannability,
consistently high quality, reduced inventory costs
and the optimised deployment of employees are
the result.
Trunking design starts either with taking measurements
on the machine or on the basis of existing CAD data.
Using the PFLITSCH easyRoute design tool – in which all
components of the Industrial-, PIK-, VARiOX- and Wire-
tray Trunking systems are stored in an intelligent data-
base – the trunking components are put together on-
The “Rotec 3000” is of modular design. Its individual screen in three dimensions to achieve the required
modules are connected together from above using cable trunking layout. The resulting CAD data forms
data and energy cables running in stainless steel trun- the basis for parts and order lists and for production
king. In addition to the straight trunking sections MKW planning at PFLITSCH. It can be imported into the
also uses T and corner accessory fittings to route the customer’s own CAD system and further processed
cables to the respective machine modules and control there. The data can also be used for completing the
cabinet. The trunking sections are securely bolted to- machine documentation.
gether and are therefore resistant to the machine’s
vibrations.
Customer Magazine · 11Case study
Edition 01-2019
Manufacture of the component assemblies Savings potential of up to 20 %
under consistent conditions
“With our component assembly service mechanical en-
Following prefabrication using its cutting edge and fle- gineering firms always achieve the optimum, high qua-
xible machine fleet, PFLITSCH preassembles the ready- lity trunking layout through their plants and machinery,
to-install component assemblies. Edge protection, se- regardless of whether the installation is large or small,”
parating walls and other equipment features are promises Heiko Emde from PFLITSCH. “Experience gai-
pre-installed upon request. Even special components, ned with projects indicates that customers’ throughput
such as the connection of the trunking to the control times for producing cable trunking are reduced by half
cabinet, are implemented economically. “This keeps and costs are reduced by up to 20 %. At the same time,
our production clean, relieves the pressure on our em- installation results are better than those achieved with
ployees and facilitates cost-transparent planning,” manual processing.”
sums up MKW Company Secretary Marco Horn.
The 100 %-checked trunking components are preas-
sembled in this manner into handy component assem- Cable glands complying with EHEDG hygienic
blies so that they fit inside common transport contai- design criteria are a mandatory part of the
ners and boxes and onto pallets. In this way, PFLITSCH machine fittings
makes the customer’s logistics, warehousing and requi-
rements planning exceptionally simple. The component “In order to feed cables into the stainless steel enclosu-
assemblies are delivered on-time – together with com- res of food production plants in a hygienically compa-
prehensive documentation. The complete shipment of tible manner, cable glands complying with hygienic
parts also includes all connectors and fasteners. “Be- design criteria – such as our bluebloge CLEAN Plus –
cause the components are consecutively numbered as- are absolutely necessary,” says Heiko Emde, expert for
sembly is rendered easy and safe for us,” says Janine hygienic design applications. PFLITSCH meets these re-
Kölven. quirements by complying with EHEDG and BGN guide-
lines. The cable gland has smooth surfaces with round-
Once a component assembly has been designed it can ed transitions. For the cable gland body we use high
always be called-up at the press of a button and can be quality stainless steel and polyamide. The sealing in-
easily modified in case changes are necessary. “This is serts and sealing rings are made of TPU or silicone; ma-
an important feature because the positioning of the terials that are suitable for contact with foodstuffs.
control cabinet is different for every installation loca-
tion,” adds the experienced MKW designer. The stainless steel blueglobe CLEAN Plus achieves high
types of protection of IP 66, IP 68 (up to 15 bar) and
IP 69 and can be used in temperatures from -40 °C to
+85 °C with TPU and from -60 °C to +180 °C with sili-
cone. It can also be combined with hygienic hoses.
Heiko Emde (market segmant manager from PFLITSCH) and Marco
Horn (Company Secretary MKW)
12 · Customer MagazineCase study
Edition 01-2019
Not just clean, but sterile
orca relies on hygiene and design
with stainless steel cable glands
In foodstuffs and pharmaceuticals industry processes, air, water and surfaces must be disinfected and kept
free of bacteria. In the field of UVC disinfection orca places a strong emphasis on technology, hygiene and
design. To ensure reliable cable entry, the specialist company uses the elegant PFLITSCH hygienic cable gland
– designed in accordance with EHEDG guidelines.
“For over 20 years we have been supporting our custo- separate ways. “We had created the basis for develop-
mers with solutions for surface, air and water disinfec- ing our own product range that is now known on the
tion using UVC,” explains Dr. Michael Calenberg, CEO market as UVpro devices.” The UVC disinfection of sur-
of orca GmbH and acknowledged industry expert. faces ensures constantly hygienic contact surfaces
“In 1998 we exclusively served the German market as throughout the whole production day. Conveyors and
the sales subsidiary of a Swiss company. Back in 2004 rollers can be kept permanently free of bacteria using
we had already realised the first large-scale projects in the orca Type BD 2016 conveyor belt disinfectors dur-
the field of air disinfection for meat processing plants ing ongoing production. “We offer solutions with con-
as an independent sales partner and installed the first veyor widths from 40 cm to 1 m,” explains Dr. Calen-
conveyor belt disinfector at a meat cutting plant.” berg. “The modular system can be individually adapted
to meet the needs of any plant. We take into consid-
Since 2014 Dr. Michael Calenberg and his partner eration the suitability of the materials used and the out-
Rainer Orbach, the two owners of orca GmbH, head- put that is actually required, for instance.”
quartered in Kürten close to Cologne, have gone their
Customer Magazine · 13Case study
Edition 01-2019
Conveyor belt disinfectors destroy the DNA High IP 69 type of protection demanded
of microorganisms
The UVpro conveyor belt disinfectors are normally placed beneath the orca initially leads the protected cable through the stainless steel handle
conveyor belts. The whole unit can be folded down to facilitate easy before it is securely fed through the blueglobe CLEAN Plus cable gland
cleaning. (Photo: orca) into the enclosure of the conveyor belt disinfector with IP 69.
The orca conveyor belt disinfectors operate with invisi- All of the plug connectors on the UVpro conveyor belt
ble radiation having a wavelength of around 254 nm. disinfector are suitable for use in wet rooms, have been
This destroys the microorganisms that pose a risk of specially developed for high-pressure wet cleaning and
contamination. “This allows us to bring bacteria, yeast at least meet the requirements of IP 69. “We therefore
and fungal spores under control,” explains Dr. Calen- need a secure IP 69 solution for the cable entries,” says
berg. He relies on high quality tubes with a service life Dr. Calenberg. “We looked at various systems available
of 12,000 operating hours. “In order to design the tu- on the market and then decided to go with the
bes for the respective application, we perform tests un- PFLITSCH solution, because its design, functionality and
der the customer’s environmental conditions and co- quality are top class.” The orca boss views the fact that
operate with conveyor manufacturers in order to the headquarters of the manufacturer from Hückeswa-
achieve the required disinfection rate of up to 99 % and gen is only some 20 km from Kürten as a special bonus.
more, with the lowest system performance possible.” The blueglobe CLEAN Plus is used on the conveyor belt
disinfectors, control cabinets and tube covers.
The design of the BD devices consistently follows the
hygienic design guidelines and also avoids hygienically EHEDG design for perfect hygiene
problematic cavities. The special tubes are PTFE-coated
and are compliant with HACCP and IFS requirements “Achieving hygiene compliance with cable glands is a
relating to shatter protection. “With our novel corrosi- special challenge. Because with traditional solutions ex-
on-free reflector and the use of special emitters our ternal threads and gaps between the pressure screw
devices achieve a significantly higher UVC output,” and insert seal are normal design features,” comments
says Dr. Calenberg, highlighting further benefits of his Thomas Hillebrand from Wagner, the PFLITSCH repre-
current development. A special tilting mechanism al- sentative in Wülfrath that serves orca.
lows the UVpro conveyor belt disinfector to be folded
away in order to facilitate optimum cleaning of the belt “In order to prevent the formation of deposits that can
environment. With a single movement the device, encourage the build-up of bacteria, cavities, gaps and
which is normally positioned beneath the conveyor open threads are absolutely taboo.”
belt, can be moved back into its operating position af-
ter cleaning.
14 · Customer MagazineCase study
Edition 01-2019
As an EHEDG company member, pressure screw is then screwed into place, the cable
PFLITSCH has broken new ground with pushed through and the pressure screw tightened to its
the blueglobe CLEAN Plus: This cable stop – i.e. with no gaps.
gland that complies with hygienic de-
sign criteria was designed from the very A flush sealing ring made of an FDA-approved
beginning in accordance with the de- elastomer material securely seals the cable gland
manding EHEDG standard and to BGN guidelines. This against the enclosure. “The complete assembly of the
resulted in success – with it being the first complete cable entries takes place from the outside without the
cable gland solution to be certified on the market, need for special tools, thereby minimising assembly
while others are solely certified in terms of their times,” reports Silvio Brand. “Because we have to re-
material. main flexible with the cable entries, our latest generati-
on has a second drill hole in its enclosure which we
Challenging from a technical manufacturing close using a PFLITSCH hygienic design blind plug.”
perspective too
Appearance underscores high quality
For the cable gland body PFLITSCH uses high quality
1.4404/AISI 316L stainless steel that is processed on a The blueglobe CLEAN Plus is currently available in sizes
machining centre to produce a very smooth surface M8 to M63 for cable diameters of up to 56.5 mm. It
(roughness of Ra < 0.8 μm) together with rounded, achieves the high types of protection IP 66 (up to 15
seamless transitions to the spanner flats. Instead of the bar) and IP 69 and therefore remains sealed under high
required 3° radii, PFLITSCH generally achieves 6° radii, pressure cleaning. These cable glands can be used in
which ensures more reliable hygiene. For the sealing temperatures of -40 °C to +85 °C and the high tempe-
inserts and sealing rings plastics that meet the require- rature version can be used in temperatures of -60 °C to
ments of FDA 21 CFR §177.2600 are used. These are +180 °C.
suitable for contact with food in accordance with EU
Regulation 10/2011. The hygienic cable gland is also available as an EMC
variant as the blueglobe TRI CLEAN Plus, with higher
“In comparison with other cable glands that comply than average screening attenuation values, and now –
with hygienic design criteria, the blueglobe CLEAN Plus most recently – in a plastic version made of polyam-
is of compact and low-build design,” says Dr. Calenberg, ide,” adds Thomas Hillebrand. “Connection to hygienic
naming a further benefit. The gentle-action cable seal hoses – in order to bundle individual cables and route
with simultaneously high strain relief must also be them perfectly hygienically through plants – is also pos-
highlighted. “It is amazing how PFLITSCH manages to sible using this system.”
realise the high ingress protection rating and strain reli-
ef from a design perspective, without irreparably crus-
hing the cable,” says Dr. Calenberg, giving credit to the
PFLITSCH concept.
Fewer components – easier assembly
“We are equally impressed with the PFLITSCH solution
when it comes to assembly,” says Silvio Brand, who is
responsible for purchasing and production planning at
orca. With its low component count this cable gland
requires very little space and it is also easy to install. Its
cable gland body is screwed into the stainless steel en-
Purchasing Manager Silvio Brand and orca Managing Director Dr. Mi-
closure wall of the conveyor belt disinfector. The chael Calenberg are impressed with the PFLITSCH product.
Customer Magazine · 15Cable glands
Edition 01-2019
Cable glands
Springtime innovations
Multiple cable glands are now available for Pressure equalisation elements to prevent
larger temperature ranges from -55 °C to condensation from forming inside
+200 °C enclosures
With the invention of the multiple sealing insert Inside enclosures that are subject to large temperature
PFLITSCH has created a solution for highly space-saving variations it is possible for water to condense or for
cable entry: depending upon the size of the cable gland pressure to build up that can cause stress on the enclo-
and the cable diameter in use, it is possible to feed sure seals. The result is that components can be dam-
multiple cables, even of differing thicknesses, through aged and contamination may penetrate inside. The
a single drill hole in the enclosure. new pressure equalisation elements (PEE) from
PFLITSCH can effectively prevent this. They ensure a
Thanks to the PFLITSCH sealing principle the UNI Multiple constant flow of air in and out of the enclosure so that
cable gland achieves the high types of protection IP 65 the average leakage threshold of the enclosure seal of
to IP 68 (up to 10 bar). As the pressure screw tightens, 70 mbar is not exceeded. A high quality membrane in
the sealing insert makes gentle and even contact around the PEE allows moisture to escape from the enclosure
and over a large area of the cable, an action which pre- and prevents the ingress of fluids and particles.
vents the cable sheath from being irreparably cut into,
thereby causing leaks over the long term. The PEE is available in brass, stainless steel and polyami-
de plastic housings for temperature ranges of between
PFLITSCH manufactures the multiple sealing insert to -40 °C to +105 °C. Depending upon the type, they
the customer’s specification from TPE-V plastics as stan- achieve the high types of protection IP 66, IP 68 and
dard. This material allows the inserts to be used at wor- IP 69 in accordance with IEC 60529. This protects them
king temperatures of between -40 °C and +135 °C. against the ingress of dust, water jets and steam clea-
With the new black silicone material variant working ners. They remain sealed even when permanently sub-
temperatures of -55 °C to +200 °C have been facilita- merged. They are furthermore resistant to chemicals
ted for the first time with the brass and stainless steel and solvents. The M12 pressure equalisation elements
cable glands. With the PVDF plastic types temperatures are available with 6 mm and 10 mm connecting th-
of -40 °C to +150 °C can be achieved, therefore multi- reads. They can be obtained with two air throughputs:
ple cable glands can be reliably used in hot and cold SL for 16 l/h and HL for 150 l/h.
conditions while simultaneously offering a long service
life. The UNI Multiple silicone cable gland is currently
available in four sizes from M20 to M40.
16 · Customer MagazineCable glands
Edition 01-2019
The robust ventilation elements are temperature and Large spanner flats facilitate secure assembly using
UV-resistant (chemically inert and hydrolytically stable). spanners. An o-ring – fitted in a special groove – de-
An o-ring ensures a secure seal in the screwed-in posi- forms in a defined manner when the double nipple is
tion. PFLITSCH furthermore offers versions with UL Cer- tightened, thereby ensuring a secure seal between the
tification in polyamide and stainless steel. cable gland and the enclosure.
A pressure equalisation insert that can be used in Many sizes – wide temperature range – inter- na-
UNI Dicht standard and multiple sealing inserts with tional approvals
sealing ranges of 12 mm is also available – certified for
working temperatures of between -30 °C and +100 °C. LevelEx cable glands are available in sizes ranging from
M16 to M63 and with NPT threads from 3/8” to 2 1/2”.
LevelEx – greater safety in potentially The cable gland bodies are available either in galva-
explosive atmospheres on ships and off- nised brass or stainless steel. Cable diameters from 7
shore installations mm to 56 mm can be securely sealed thanks to the
large sealing range. With their broad temperature ran-
ge of -60 °C to +130 °C and ATEX, IECEx, EAC and
DNV GL certifications, they can also be used under ext-
reme environmental conditions. In accordance with
VDE approval 62444 the LevelEx can also be used in the
industrial sector.
Since February 2019 the LevelEx now also has CNEX
certification for the Chinese market. It therefore meets
the standards applicable there for use in potentially ex-
plosive areas.
With the LevelEx, PFLITSCH has brought to market an The minimum requirement of 30 bar is significantly ex-
innovative cable gland for use in potentially explosive ceeded, which means that the LevelEx can be used at a
atmosphere zones “Ex-d” and “Ex-e” which impresses reference pressure of 20 bar and a temperature of
with its compact design for space-saving installation -60 °C.
and its captive parts. The LevelEx has the DNV GL Cer-
tificate especially for customers in the maritime sector.
Following comprehensive testing, the suitability of the
cable gland for use on ships and offshore installations
has now been certified. The LevelEx therefore meets
the requirements relating to safety, reliability and envi-
ronmental protection regulations for international
waters.
www.levelex.de/en
Completely new and unique is the LevelEx seal: The
sealing inserts are made of a high-quality silicone ma-
terial of red/brown colour and a transparent pressure
sleeve that deforms the seal over a large area as the
pressure screw is tightened, thereby achieving highly
effective sealing and strain relief on the cable. LevelEx
achieves the high types of protection IP 66 and IP 68.
Customer Magazine · 17Cable Trunking
Edition 01-2019
The new VARiOX-Trunking system
Manageable – easy to assemble
– economical
With the new VARiOX-Trunking system PFLITSCH offers a future-oriented installation solution for standard
applications in international machinery and equipment: with just a few system components and a special
connector, a custom cable trunking layout can be easily and rapidly realised.
Many clever ideas make up the new VARiOX system: trunking 2,000 mm long in four cross sections from
thanks to optimised wall thicknesses the trunking is 100 mm x 100 mm to 300 mm x 100 mm – with either
light, but still keeps its shape. Using the multifunctional solid or perforated bases. Various 90° accessory fit-
metal connector, trunking bodies and accessory fittings tings, tees, end caps and connectors are also available
are easily assembled into the desired trunking layout. to match. With just 42 components, the VARiOX range
The self-engaging cover is a further special feature: This is designed to be concise, which minimises the cost of
is simply clipped onto the trunking body via a special ordering, stocking and assembly for the customer.
contour. It can be easily removed again at any time with-
out using tools, to allow the cable installation to be Combination with the Industrial-Trunking
changed. PFLITSCH manufactures the VARiOX system allows versatile applications
with a low-burr finish from high quality, galvanised
sheet steel. Because VARiOX is compatible with the well-known
PFLITSCH Industrial-Trunking, its components can, if
A manageable level of component diversity desired, be combined with all components and acces-
minimises effort sories in the PFLITSCH Industrial-Trunking range to in-
clude features such as edge protection. Through this
The low number of components make the VARiOX sys- compatibility with PFLITSCH Industrial-Trunking, the
tem a manageable one: It consists of straight lengths of options for all sorts of trunking layouts are almost
unlimited.
18 · Customer MagazineCable Trunking
Edition 01-2019
It may look like this in practice: While the VARiOX-Trun-
king is used for installing cables in the mechanically-
protected machine, the Industrial-Trunking takes over
for routeing cables between plant components – e.g.
also in the form of walkable floor-mounted trunking.
From individual trunking to complete
component assembly: cost-transparent and
on-time
Multifunctional VARiOX Quick connector – can also be used as a tool
This level of compatibility also means that users can use
the same PFLITSCH services, tools and machines from
the Industrial-Trunking segment for the VARiOX sys-
tem. This allows custom trunking layouts to be simply,
quickly and safely realised.
For the processing of cable trunkings, PFLITSCH has a
wide range of different machines and tools that are
precisely matched to the cable trunkings. In addition to
higher quality and greater safety during processing, this
also offers the customer the advantage of cost
reduction.
VARiOX Quick connector: the smart all-rounder
VARiOX-Trunking can also be designed and supplied as
component assemblies – and, if requested, even ins-
talled for you at your premises. Its system components
are stored in an intelligent database in the PFLITSCH
easyRoute 4.0 design tool. This allows the trunking
components to be put together on screen, three-di-
mensionally, to create the required trunking layout. The
CAD data are used to generate order and parts lists
which are then used by PFLITSCH to flexibly manufac-
ture the customer’s component assembly.
VARiOX: compatible with Industrial-Trunking
www.VARiOX.net/en
Customer Magazine · 19Company
Edition 01-2019
PFLITSCH celebrates 100-year company anniversary
Position as technological leader al-
ways maintained
By harnessing inventiveness, high-level problem-solving expertise and “Made in Germany” quality, the fa-
mily-run business PFLITSCH has developed a good reputation in demanding sectors over the past 100
years.
This is the only way to explain how a small electrical More from the inventor of the modern cable
engineering factory has turned into a global player with gland
well-known product solutions in the fields of cable
glands and cable trunking. It all began in July 1919 Technology from this region of inventors is famous –
when Ernst Pflitsch established the company. Following take X-rays or Mannesmann tubes for instance – and,
Hans-Georg and Otto Pflitsch (2nd generation) and of course PFLITSCH, as a problem solver in the field of
Harald Pflitsch and Ute Pflitsch-Stendtke (3rd generati- cable entries and routeing for industrial applications.
on) the flourishing family-run business is now being
steered further into the future by the 4th generation of Always driven by the pledge to do things better and to
Roland Lenzing and Mathias Stendtke. For instance, optimise processes, the breakthrough came in the
PFLITSCH is currently constructing a competence centre 1960s with the invention of the modern cable gland
for cable trunking with automated design and manu- and its development into the modular UNI Dicht system
facturing processes at a new site, in order to supply with thousands of types, designs and sizes ranging
customers worldwide with products and individual from M4 to M120. The PFLITSCH key feature: Thanks
component assemblies. The parent plant, with modern to the special sealing inserts, high types of protection
CNC machining centre, innovative plastic injection and strain relief values are achieved, without irrepa-
moulding facilities and an automated small parts rably cutting into the cable sheath. Today, splittable
warehouse is well-prepared for further growth in the cable entries on the basis of this concept are the com-
cable gland sector. panions of modern modular design.
20 · Customer MagazineCompany
Edition 01-2019
Cable trunking protects the lifelines of Broad range of social media activities: 100
technology stories from the history of PFLITSCH
During the 1980s PFLITSCH successfully introduced In its anniversary year PFLITSCH is starting a broad-
cable trunking with industrial capability. For instance, based image campaign on the social media channels.
the Industrial-Trunking is a modern-day solution for Its core is a microsite. “We will be looking back into the
creating safe and customised cable routeing layouts in history of PFLITSCH and daring to look into the future,”
the field of machinery and equipment. While the com- explains marketing expert Frauke Ulrich, who manages
pact PIK-Trunking is designed for smaller cable installa- the PFLITSCH channels on Facebook, Twitter, Xing, Lin-
tions, PFLITSCH is focusing on standard applications kedIn and YouTube. “We will be using a colourful com-
with the new VARiOX-Trunking. And the variable, open bination of historic information and current facts to tell
Wire-tray Trunking provides the perfect solution for the history of PFLITSCH.” There are 10 defined catego-
manageable cable routeing through machines and buil- ries and in each of them 10 contributions will be pos-
dings, especially where a large number of cables – the ted. These will be divided among the social media
lifelines of technology for energy and data – need to be channels in the form of image and text contributions.
cleanly installed. One category will be presented every month and distri-
buted worldwide.
Design tools, machines and tools make work
easy “On the occasion of our anniversary
year we will set up a profile on Insta-
PFLITSCH has never questioned the fact that products gram,” says Frauke Ulrich. “We are
alone are not enough. This has repeatedly led to the naturally looking forward to receiving
creation of useful aids, ergonomic machines and tools, contributions from our partners, customers and follo-
cutting edge design tools and matching accessories. wers under #PFLITSCH100.” The perfect opportunity
for a PFLITSCH related snapshot will be, for instance on
For instance, an increasing number of customers world- one of our celebrations throughout the year.
wide are using our CAD service. This makes the design
data for PFLITSCH products available online at all times,
thereby facilitating both design and documentation. So
that plant and mechanical engineering firms can con-
centrate on their core competencies, PFLITSCH offers
its component assembly service. This is a unique con-
cept in the field of cable trunking: Using the easyRoute
CAD tool, trunking layouts can be designed on-screen,
which PFLITSCH then prefabricates and delivers to cus-
tomers worldwide, on-time and at a fixed price.
Customers who still wish to preassemble their cable
trunking themselves will find useful machines and tools
for processing the trunking components easily, rapidly
and safely.
Customer Magazine · 21Company
Edition 01-2019
The “automated small parts warehouse”
Modern hub for warehousing and
logistics
EMC, hygiene or automation applications – some
40,000 parcels containing cable glands and with a total
weight of over 600 tons left the plant in Hückeswagen
last year on their way to customers. This is far higher
than the already ambitious annual target.
During ongoing daily operations further optimisations
are being gradually undertaken in order to make the
ASPW processes even more efficient. “For instance, we
have been able to reduce throughput times by bringing
operations together at a single workstation.” Further-
more, savings have also been made in terms of hand-
ling and walking distances during order picking for
assembly.
The automated small parts warehouse – or ASPW
for short – has been operating at the PFLITSCH The goods come to people
site in Hückeswagen for a year. Thousands of sys-
tem components for the UNI Dicht and blueglobe Alongside the automated warehouse system with its
cable gland ranges are stored here in over 25,000 five rack aisles, lifts and ten micro-shuttles, an order
bin storage spaces, ready for assembly and picking and assembly area also adjoin the ASPW.
dispatch. Instead of having to fetch parts from a warehouse, the
goods arrive directly at the workstation on roller con-
veyors in quiet-running plastic containers with sound-
The result for the first year of operation of the ASPW is absorbing double bases. The 24 assembly stations are
extremely positive: Almost 700,000 putaways and al- equipped with height-adjustable work tables. The or-
most the same number of picks took place over the der-related assembly instructions appear on PC screens.
past 12 months. “This amounts to some 2,800 move- Thanks to the mobile, lockable drawer units for private
ments per day,” calculates Sascha Schier, Assembly Ma- utensils, employees are easily able to change assembly
nager, whose team is responsible for smooth opera- stations if necessary.
tions in the PFLITSCH automated small parts warehouse.
“The daily peak last year reached around 4,200 The picking stations are located upstream of this. The
movements.” cable gland parts are brought together here on an or-
der-related basis before being sent for assembly. The
Over 40,000 parcel shipments throughout intelligent PFLITSCH system “remembers” the
the world customer’s desired delivery date and manages the pro-
cesses in the ASPW accordingly. “Despite the large
“Without the ASPW we would not be able to achieve number of different orders, we are achieving a high
the same rate of growth,” agree managing partners degree of dispatch reliability of over 90 %,” Sascha
Roland Lenzing and Mathias Stendtke. Whether stan- Schier is pleased to report.
dard types or individual solutions for fire protection,
22 · Customer MagazineCompany
Edition 01-2019
Environmental protection and energy management
Consuming continuously less energy
are avoiding energy losses by permanently searching
for leaks.” The machine compressors are also dimensi-
oned such that they operate in the ideal range and are,
therefore, energy-efficient.
In its offices and production areas PFLITSCH is conver-
ting the lighting to energy-saving LED technology. Mo-
dern heat pumps with deep bore holes ensure the right
level of warmth in the administration building. Thermal
insulation and insulated doors in unheated areas, such
as the warehouse and logistics area, are also part of the
energy-saving measures. “This year we have decided to
look at the cooling equipment in the machining depart-
ment,” explains Olaf Brentzek. We are expecting an
enormous energy-saving potential here. The strategic
Improving across the board – for PFLITSCH this also objective of PFLITSCH is to achieve average specific
means optimising production processes in terms of energy savings of 1.3 % per annum, despite growth
energy and environmental aspects. Our corporate ener- and expansion.
gy policy therefore states “We endeavour to achieve
dependable, cost-effective, environmentally friendly After completing the initial phase of the project,
and energy-efficient solutions for our products and ma- Tobias Fahl, project manager, sums up:
nufacturing processes.” We are therefore focusing all From a project perspective we had little time overall,
of our activities in the area of environmental protection and we had to invest much of that time at the begin-
and energy management on state-of-the art solutions. ning, namely in planning. It has, however, allowed us to
We include our suppliers and contract partners in these achieve a remarkable result, despite the high level of
considerations and when setting the objectives. production line utilisation. The team came together
quickly and was able to implement the requirements as
“Our aim is to optimise our energy consumption over planned. We are carefully investing in sustainability and
the long term,” says PFLITSCH QA expert Olaf Brent- further corporate growth.
zek. “We have therefore introduced an energy ma-
nagement system.” Most energy is consumed by the In addition, Mathias Stendtke, managing partner,
large CNC machining centre, plastic injection moulding says:
and cable trunking production – together these depart- We have taken a further step into the future with the
ments account for almost 80 % of electricity consump- integration of the energy management system. At this
tion at PFLITSCH. “In these areas we are successively juncture we would like to express our gratitude to the
fitting more efficient motors and pumps and, in the project team in particular, for successfully implemen-
case of new capital investments, are placing great em- ting this issue in just a short time.
phasis on plants and machines that are highly energy
efficient.” The way in which pneumatics are used in
various processes is also under scrutiny. “In this area we
Customer Magazine · 23Cable glands
Edition 01-2019
Splittable cable gland for use
in automation applications
Secure entry of
preassembled
cables
In order to easily and securely feed preassembled cables into control cabinets PFLITSCH sets the standard
with fully splittable cable glands and flanges: The solutions based on the proven UNI Dicht system offer
above average types of protection and strain relief values, can be very easily fitted and ensure a high level
of operational reliability and long service life of the installation.
In order to improve quality, reduce assembly times and The flange plate is securely bolted to the control cabi-
save costs companies are increasingly using prefabricat- net via through holes. The plastic variant is also avail-
ed and tested modules that are already fitted with con- able with four internal threaded bushes to allow instal-
nectors, sensors, cable lugs etc. But how can such pre- lation from the inside. This results in full protection
assembled cables be fed into control cabinets and against electric shock in accordance with protection
enclosures without having to pause the whole produc- class 2 (DIN EN 61140, VDE 0140-1).
tion process, possibly for a longer period? For this ap-
plication the UNI flange is available with 3 integrated A continuous, injected foam lip provides the seal be-
cable glands, together with the UNI Split Gland single tween the flange plate and the enclosure wall. This pro-
cable gland – in both plastic and metal respectively. tects the system against jets of water from all directions
They show their excellence with simple assembly, high and prevents the penetration of dust. The UNI flange
types of protection up to IP 67 and high strain relief can be used in temperatures between -20 °C and
values. +80 °C.
Flange system seals connector cut-outs in Splittable cable gland for individual drill
the enclosure holes
The UNI flange comprises a two-part frame plate that In order to be able to feed preassembled cables through
fits exactly into standard 112 mm x 36 mm panel cut- a single drill hole PFLITSCH has developed the comple-
outs for 14-pole heavy-duty connectors. Three cable tely splittable UNI Split Gland. The component halves of
gland bodies are integrated into the frame plate which the cable gland body and pressure screw interlock with
are similar in construction to those of the UNI Dicht each other securely during installation. PFLITSCH offers
system. PFLITSCH has developed pressure screws for versions in polycarbonate in sizes M20 to M32 as well
this flange that are also splittable, thereby also allowing as an M25 HD in diecast zinc. This heavy-duty solution
preassembled cables to be fed through. is designed for higher mechanical loads and increased
operating temperatures of between -20 °C and
+80 °C.
24 · Customer MagazineYou can also read
