In a food industry production environment, nothing can be left to chance. Safety, hygiene, and reliability are non-negotiable values.
A Finnish food industry company faced the situation where their old switched power sockets no longer met modern technical requirements. Production line modernization was underway, and at the same time, the need for solutions to multiple critical requirements emerged.
One of the biggest problems was electromagnetic interference (EMI), which disrupted the operation of bus control systems and caused unreliability in production processes. Since the existing switched power sockets were not EMC-protected, an immediate solution was required.
Additionally, the solution needed to be compact and made of stainless steel by also considering the environment. From a maintenance perspective, it was crucial that motors could be disconnected without an electrician. In practice, the connection had to allow safe and easy disconnection by production personnel.
The end customer, who had a long-standing cooperation with Sonepar, contacted them at the start of the project. For the customer, it was important to find a complete solution from one supplier rather than sourcing separate individual components from multiple suppliers. Kari Pirttimäki from Sonepar began investigating who could provide an integrated solution while meeting the special requirements. One name quickly stood out:
“KATKO was the first one that came to mind – I knew their ability to adapt and tailor solutions.” – Kari Pirttimäki, Sonepar.
The project moved swiftly into technical discussions, with a clear shared goal from the outset: to solve the customer’s challenges without compromising safety, quality, or usability.
KATKO was closely involved from the beginning, forming a tripartite collaboration: the end customer defined the technical requirements, Sonepar ensured the feasibility and coordination of the complete solution, and KATKO designed and implemented the final solution.
The customer faced challenges with electromagnetic interference. Their existing switched sockets were not EMC-protected, causing disruptions in bus control systems. They wanted a solution that would reduce or eliminate electromagnetic interference and ensure stable system operation.
The product was also needed to meet the customer’s requirement for a compact size, driven by the dimensions of the multipole connector used. Another key requirement was the enclosure material: it had to be stainless steel (AISI 304). In the food industry, stainless steel is not just a choice, but a hygiene requirement. AISI 304 stainless steel withstands repeated cleaning, chemicals, and provides corrosion protection in demanding production environments.
At the core of the solution was a multipole industrial connector replacing the old, fixed outlet. The industrial connector met EMC requirements while also addressing mechanical and chemical durability challenges in the environment, as it is mostly metal and highly durable. In addition to meeting EMC requirements, the connector was crucial for usability: motors no longer needed to be disconnected by an electrician. Production personnel can safely disconnect power via the connector, and reconnecting a new motor is just as easy. This reduces maintenance time and speeds up responses to production interruptions.
No ready-made solutions were available, so the project required a fully customized product. Design was carried out in close co-operation between the end customer, Sonepar, and KATKO. KATKO’s product development and procurement team began mapping out and designing the implementation, creating a solution tailored to the customer’s needs.
The first challenge was mechanical fitting: a compact, EMC-protected stainless steel enclosure was needed. KATKO’s team decided to order a custom enclosure, precisely sized according to the project requirements.
“We drew a couple of versions with different sizes, which started a technical feedback round. There were several iterations, but the customer’s feedback was always precise and well-justified, which helped us a lot in the design process.” – Simo Kettunen, KATKO.
The end customer particularly appreciated the visual documentation. Illustrative images and 3D models made it easier to understand and approve the plans, ensuring the design phase proceeded smoothly.
“With the images, we easily understood what was being done. They spoke more than a thousand words – discussions and planning started efficiently when we could easily grasp the solution.” – End Customer.
Special attention was given to the connection solution. The traditional fixed outlet was replaced by an industrial connector that met EMC requirements and enabled maintenance-friendly operation. The steel structure met both hygiene and durability requirements. The Phoenix Contact multipole connector chosen inside the switch allowed safe motor disconnection without an electrician, which is a significant practical benefit for the customer.
Clear division of responsibilities was also key to the project’s success. Sonepar procured components, such as Phoenix Contact connectors, and delivered them to KATKO’s production. KATKO focused on preparing and assembling the products. This reduced intermediaries, accelerated the process, and made the project agile.
“We didn’t purchase all the components ourselves. Kari ordered the connectors and delivered them to us – this worked very well and was cost-effective.” – Simo Kettunen, KATKO.
Component delivery schedules were tight, and KATKO proactively managed the situation. The production team prepared assembly even before all parts arrived. Components were pre-tested, and everything possible was done in advance to allow final assembly to start immediately once the remaining parts arrived.
“We did as much as possible without the final enclosures. We tested auxiliary contacts and terminal blocks in advance. Our rhythm was good, and communication worked in every direction.” – Simo Kettunen, KATKO.
Rapid responsiveness and planning were key factors in the project, praised by both the customer and Sonepar.
“The responsiveness has been incredibly fast, which made our job easier and more efficient”, said Kari Pirttimäki, Sonepar.
The outcome was a complete solution that precisely addressed and resolved the customer’s original challenges.
“It was important for us that the complete solution came from a single supplier. Sonepar handled it well – we got everything in one go without needing to coordinate multiple vendors.” – End Customer.
With the new EMC-protected safety switches, bus control system interference was brought under control, and the electrical reliability of production improved. Disturbance sources and system operation were stabilized. The metal enclosure ensures that the solution withstands the demanding conditions of the food industry. Maintenance was also significantly simplified: motors can now be safely disconnected via the connector without an electrician.
The project progressed smoothly because the entire solution was delivered through a single partner. Components did not need to be sourced from multiple manufacturers, keeping schedules manageable and the design process clear. KATKO’s local production and agile product development in Finland provided flexibility and ensured delivery within tight deadlines.
Collaboration among all parties was exceptionally smooth. The customer knew what was needed, Sonepar built the bridge between need and solution, and KATKO shaped the requirement into a complete solution—quickly, clearly, and reliably.
“Reliable partners make it easier to work for the customer – and in this project, it worked seamlessly and commendably. – Kari Pirttimäki, Sonepar.”
This project was not just about delivering components; it was about deeply understanding the customer’s challenge and solving it through close collaboration. The project required precision, trust, and active listening – which is why it stands out as a successfully executed solution.
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