Connection technology in the food industry
Sensor cabling for hygiene and wet areas
In the food industry, sensors and actuators are only as reliable as their connection technology. High-pressure cleaning, foam, steam (CIP/SIP) and cleaning chemicals stress connectors, sensor cables and transitions just as much as housings and seals. The following sections show what matters when selecting sensor cabling for hygiene and wet areas and how to avoid typical failures after cleaning.
The key points at a glance
Clarify the zone first:
Technical area vs. splash/foam area vs. direct cleaning zone (high pressure/hot water/steam).
Protect the seal:
For wet and cleaning zones, a robust sealing system with mechanical stop is essential.
Vibration during system operation?
Plan for vibration-resistant locking.
CIP/SIP means repetition:
Temperature cycles + chemicals + cycles – material and seal durability become critical.
With compact designs:
A profile seal concept can increase tightness and protection class in highly stressed areas.
Why connection technology in the food industry is particularly demanding
Connection technology in the food and beverage industry must withstand regular cleaning cycles with foam, high pressure and chemicals without compromising tightness or signal transmission. Surfaces and geometries must be designed so that product residues and biofilms have no chance to settle. At the same time, signal transmission must not be affected by cleaning cycles or environmental stress.
Typical stress combinations
Moisture + pressure (splash water/high-pressure jets)
Risk of water ingress
Cleaning chemicals
Sheath and seal materials must match the profile
Temperature cycles (hot water/steam, cooling)
Material moves, seals age faster
Vibration/movement
Screw connections loosen, cables suffer at bending points
Typical application areas along the process chain
Along the process chain – from raw material intake through processing to filling – measurement points are often located where it is wet, warm or mechanically moving. The closer a connection is to open product areas or cleaning zones, the higher the requirements for tightness, material durability and assembly quality.
Practical examples
Raw material intake:Fill level and temperature sensors in silos/tanks; sensor cables often in splash zones.
Processing:Mixers/pasteurisers/separators – CIP/SIP cycles, temperature cycling and vibration.
Filling/packaging:Splash water/foam and movement act simultaneously on cables and connectors.
CIP/SIP and high-pressure cleaning: What this means for connectors and cables
CIP (Clean-in-Place) and SIP (Sterilize-in-Place) stress connection technology cyclically: seals, transitions and sheath materials must maintain their function through countless repetitions, with changing temperatures, steam, foam and chemicals.
What matters in practice
Tightness across cycles:
Sealing systems must remain reliably tight even after repeated cleaning.
Chemical and temperature resistance:
Sheath and seal materials must resist the cleaning media used.
Assembly reliability:
Tool-free assembly requires a closure principle (section 2.7) that limits torque reproducibly.
Installation position:
Keep connection points out of the direct spray if possible; if not, design consistently for the cleaning zone.
IP67, IP68, IP69K: Meaning and limits in practice
The IP rating describes protection against dust and water ingress. In food plants, the key question is: what real stress does the connection face – and how often? The IP rating alone does not determine the practical suitability of a connection. Equally important are the seal concept, assembly quality and installation position, such as whether the connection point is in the direct cleaning spray. Further information on protection ratings can be found under IP protection ratings in sensor technology.
IP rating guidance
| Rating | Practical significance in food environments | Typical application scenario |
|---|---|---|
| IP67 | Basic protection against temporary submersion; often sufficient in many splash water areas | Splash/foam area without high-pressure nozzle directly at connection point |
| IP68 | Relevant with longer standing liquid / regular medium contact | Areas with standing moisture, frequent water accumulation |
| IP69K | Designed for high-pressure/hot water cleaning; target for open cleaning zones | Direct cleaning zone (high pressure/hot water) |
TECHNICAL AREA
SPLASH AREA
HIGH PRESSURE
autosen connectors: Sealing & locking principle (Features)
Whether a connection point remains reliably tight after many cleaning cycles depends largely on the closure principle. With autosen connectors, the mechanical stop, locking contour and seal geometry are coordinated so that assembly errors are constructively limited.
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Feature 1: Mechanical stop protects the O-ring
A mechanical stop limits the tightening of the union nut. This prevents over-compression of the sealing ring – the O-ring works continuously in the optimal pressure range. With tool-free assembly or changing personnel, the risk of permanently damaging the seal by over-tightening is eliminated.
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Feature 2: Vibration-resistant screw connection (sawtooth/form-fit contour)
Continuous vibration on conveyor systems, packaging machines or drive areas can gradually loosen screw connections. A form-fit contour on the union nut counteracts this and keeps the screw connection in position even under shock and vibration loads. Without this safeguard, leaks often only become visible after the next cleaning cycle, when moisture has already entered.
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Feature 3: Profile seal for highly stressed zones
Here a profile seal complements the O-ring: its larger contact area between seal and housing increases resistance to high pressure and temperature cycling. With daily or multi-stage CIP cycles, this additional sealing layer is a relevant factor for connection service life.
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Feature 4: Tool-free assembly
Connectors can be assembled and disconnected without tools. Combined with mechanical stop and vibration-resistant locking, the seal function remains stable even after replacement. For maintenance, this means: sensor replacement or cable replacement during operation, without additional tools.
Materials and seals: What you should pay attention to
Material selection affects service life and hygiene. In product-adjacent or splash water exposed areas, it matters that surfaces offer no possibility for deposits, are easily accessible and corrosion-resistant – and that seals remain permanently resistant to typical cleaning and disinfection agents. In addition to material selection, the constructive closure principle (section 2.7) influences long-term tightness. Further information on materials can be found under PUR or PVC?.
Checklist: Material & seal
Cable sheath:
Smooth, easy-to-clean surface; resistant to the actual cleaning profile (chemicals, temperature, cycles).
Seals:
O-rings/profile seals made from durable elastomers – suitable for temperature cycling and medium contact.
Union nut/housing:
Corrosion-resistant materials facilitate cleaning and reduce rust risk.
| Zone | Real stress | Priority in selection | Quick check |
|---|---|---|---|
| Technical area | low: dry/protected | Cable routing, strain relief, appropriate length | Signal type/connector type |
| Splash/foam area | medium: wet + chemicals | Seal system (O-ring), corrosion-resistant parts, easy-to-clean surface | Note cleaning profile |
| Direct cleaning zone | high: high pressure/hot water/steam | IP69K-like design + mechanical stop/profile seal + assembly concept | Connection in spray? |
| Moving machine | high: bending/vibration | Bend radii, strain relief, mechanical protection, vibration-resistant locking | Movement profile/drag chain |
Further information from autosen (discrete product bridge)
You can find matching categories directly through the following entry points. Please check technical details such as protection rating, material and length on the respective product page.
Sensors for the food industry
Food & beverage industry – hygienic, reliable, CIP/SIP compatible and ideal for IO-Link.
High Resistance Class sensor cables (PVC)
For food and wet areas – robust, hygienic and reliable in daily use.
Frequently asked questions (FAQ) about connection technology in the food industry
The zone determines the real stress: technical area (dry), splash/foam area (wet + chemicals) or direct cleaning zone (high pressure/hot water/steam). This determines priorities such as IP orientation, seal system and assembly reliability.
IP is important, but not the only factor. In addition, seal system, constructive protection against over-compression and correct assembly are important.
It limits the tightening of the union nut and stabilises seal function through many cycles.
Through vibration-resistant locking plus proper strain relief and maintenance schedule checks.
The device usually determines the interface. In practice, handling, accessibility and secure locking are decisive, especially if connections are frequently mated/de-mated or the location is difficult to inspect.
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