Tool-free disassembly reduces maintenance effort and downtime

In the food industry, the ease of cleaning machinery and equipment is crucial. However, the carriages of many linear guides are cumbersome to disassemble. To reduce downtime, Igus has developed a new linear guide in the drylin W series featuring a polymer carriage that can be removed without tools for cleaning. As the world's first linear guide to do so, the system has received EHEDG certification, thereby gaining official approval for use in food processing technology.

Almost every design engineer working on automation solutions for the food industry uses linear guides. They enable, for example, the movement of sealing stations in thermoforming packaging machines, the positioning of dosing heads in filling systems, and the guidance of blade units in bread-slicing machines. Yet, indispensable as they are, linear guides present a challenge in hygiene-critical applications, as lubricants, wear debris, and dirt can accumulate in gaps, contact surfaces, and hard-to-reach areas. "When thorough cleaning is required, disassembling conventional systems is often time-consuming and constrained by their design," says Mira Loges, a drylin development engineer at Igus.

There is, therefore, a demand for linear guides that are designed for hygiene and allow for quick cleaning. "We have launched just such a solution with the new drylin W series linear guide—the first linear guide worldwide to receive certification from the European Hygienic Engineering and Design Group (EHEDG)." The EHEDG is an international organization that develops standards for hygienic equipment design to enhance food safety. An EHEDG certificate confirms that a component is easy, thorough, and safe to clean—a significant advantage for operators with the strictest requirements regarding process and product safety. The certificate provides recognized proof that the design of the drylin W linear guide helps minimize the risks of contamination and system failure. Quick and easy disassembly for reduced downtime

Linear guides often complicate the cleaning of machinery and equipment in the food industry. "Conventional recirculating ball guides, for instance, frequently require tools for disassembly and must be removed via the end of the rail," says Mira Loges. "This results in unnecessary maintenance effort and downtime—issues that some users find problematic." Igus has therefore designed the new linear guide to allow for tool-free disassembly. The system consists of two stainless steel shafts and a single-piece sliding carriage made of high-performance plastic, onto which users can bolt their assemblies. "When the system requires a full cleaning, the carriage can simply be pulled off the rail and cleaned separately. The rail itself is cleaned in place, without needing to be dismantled," explains Mira Loges.

Lubrication-free hygienic design reduces contamination risk

Many conventional recirculating ball guides rely on lubricants that can trap dust, wear debris, and dirt particles. This can create an abrasive mixture that impairs smooth movement and poses a potential contamination risk. Igus therefore designed the new linear guide in strict accordance with EHEDG guidelines. The electropolished round shafts feature a surface roughness of less than 0.8 micrometers, facilitating effective cleaning as germs and product residues struggle to adhere to the smooth surface.

"During development, we consistently adhered to EHEDG guidelines. One challenge was the transition between the shafts and the shaft supports or rail connectors. However, we managed to comply with the guidelines here as well. The transition points are milled to ensure that minimum radii of three millimeters are maintained throughout," explains Mira Loges. A floor seal made of FDA-certified silicone also prevents dirt or microorganisms from accumulating between the rail and the surface.

Another distinctive feature is the carriage made from the blue high-performance polymer Iglidur A160. It is PTFE-free and PFAS-tested, while integrated, microscopic solid lubricants ensure particularly hygienic, lubrication-free dry running. "We also ensured that the material has low water absorption. This allows the carriage to retain its shape and functionality even after many intensive cleaning cycles."