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Stainless Steel Enclosed Trunking v Stainless Steel Wire Basket Tray – which works the best?

Stainless Steel Enclosed Trunking v Stainless Steel Wire Basket Tray – which works the best?

The wiring infrastructure throughout a production facility plays a crucial role in ensuring operational efficiency, durability, and compliance with both hygiene and safety standards. The same considerations must also apply to installed equipment, as production machinery maybe be in either direct or indirect contact with any product. It is essential when evaluating any cable management solutions several key factors must be considered such as environment, positioning, and cable routing. In addition practical limitations such as cable fill rates, electrical noise, ventilation and site specific requirements.  While various containment systems, such as ladder racks, perforated trays, and conduit, are available, this article focuses on low-level machine installations for equipment within a food / beverage production environment. Given the hygienically sensitive nature of these areas, choice is generally between traditional stainless steel enclosed trunking system, either IP30 / IP4X /  IP66, or an open system such as stainless steel basket tray.

Here we evaluate the merits of the traditional IP3X / IP4X enclosed system, IP66 Waterproof Trunking system and open wire basket tray relative to food and beverage applications

Stainless Steel Trunking

Stainless steel Trunking is a traditional enclosed cable management system designed too mechanically protect electrical wiring from physical damage and environmental exposure. Lasnek have been manufacturing these systems for over 25 year.

Advantages

Protection & Hygiene

  • Suitable for non-contact food environments (304)
  • Available in 316 for direct contact or aggressive environments
  • Provides very good corrosion resistance
  • Good Mechanical protection of internal cabling
  • Allows for easy cleaning of all external surfaces.

Installation

  • Easy to install with basic hand tools
  • Supplied in 3m lengths
  • Lengths can be cut onsite using standard cutting equipment and practices
  • Available with a wide range of pre-made bends
  • A wide range of widths and heights is available,EMI & Cable Segregation

EMI & Cable Segregation

  • Good protection from radiated EMC interference internal or external
  • Cable barriers available for segregation of cables for both lengths and fittings.

Disadvantages

Installation

  • Additional layout planning its typically required
  • Requires specific cover fitting and pre-set angles
  • Onsite cutting restrictions in live production areas
  • Increased labour costs for any site specific fabrication
  •  Bracket and support positioning requirements

Heat Management

  • Stainless steel is a poor conductor for heat dissipation
  • Compliance with wire fill rate regulations may facilitate the use of larger trunking
  • Potential de-rating of conductors may be necessary to prevent localised overheating

Cost Implications

  • Increased product material leads to higher initial purchase costs
  • 3 metre Trunking lengths are volumetric, leading to higher logistics costs for shipping  and storage.

Stainless Steel IP66 (Waterproof) Trunking 

Stainless steel IP66 Trunking are a significant advancement of the IP3X/4X, offering both the installer and end user a reliable watertight solution for protecting cables from any dust or water ingress.  With a fixed hinged cover and welded connecting flanged at each end, this is commonly referred to as a pull through system, rather than the lay in system use in the traditional trunking systems. As the name implies, the cables are pulled through both fittings and lengths, similar to conduit, except this trunking system allows for periodic access via the hinge cover.

Advantages

Installation

  • Easily Assembled using basic hand tools
  • Tested to IP66 / UL870 NEMA 4X
  • Lengths can be mounted with opening on any side  
  • Repeatable by using silicon gasket flanges and cover
  • Provides a high degree of cable protection
  • Supplied in Pre-cut lengths 2ft thru 10ft
  • Cable access through hinged cover

Hygiene and Protection

  • Guaranteed Ingress Protection against liquids and solids
  • Smooth Matt Finish
  • Suitable for high pressure wash-down environments
  • High degree of mechanical protection
  • Fittings designed for reduced debris collection
  • FDA approved seals and gaskets

EMC & Cable Segregation

  • High degree of protection from radiated EMC interference (internal or external)

  • Cable barriers available for segregation of cables – lengths only

Disadvantages

Installation

  • Additional layout planning its typically required
  • Hinged lengths cannot be cut / reduced on site
  • Limited mounting bracketry
  • Additional installation volume required due to the external flanges
  •  Limited sizes 2.5, 4”, 6”, 8” square

Heat Management

  • Stainless steel is a poor conductor for heat dissipation
  • Compliance with NEC wire fill rate regulations may require larger trunking
  • Potential de-rating of conductors may be necessary to prevent localised overheating

Cost Implications

  • Higher purchase costs due to design
  • Additional shipping cost due to increased weight and volume
  • Additional Installation design costs

Stainless Steel Wire Basket Tray

Wire basket trays, constructed from stainless steel wires, is an open cable tray system.  Originally designed for high level applications for the building services industry, these systems are increasingly used at low level on machinery within production areas. Typically supplied as lengths only, any fittings such as bends or tees, are typically fabricated on site by cutting set pattern of wire sections from the lengths.

Advantages

Installation

  • Lengths require purchasing only
  • Lasnek tray provide free location of couplers relative to support bracketry
  • Option of welding lengths ore using purchased connectors
  • On site forming of bends and tees
  • Flexibility to form complex angles
  • Can be cut in live areas using bolt croppers or pneumatic cutting equipment
  • Easy to ship and store
  • Multiple freight options available for smaller dimensions or quantity
  • Available in a wide range of dimensions up to 24” / 600mm

Ventilation

  • Typically, cables do not need de-rating
  • Higher fill rate compared to equivalent enclosed trunking
  •  Excellent usable volume capacity area

Cost

  • Reduced cost due to less material used per length
  • Indirect savings through fewer parts required and ordered
  • Reduced logistic costs for shipping and storage

Disadvantages

Protection & Hygiene

  • Open design leaves cables exposed to damage, contamination, or electrical interference
  • An open system is more susceptible to unwanted debris and debris trap areas
  • Cables will require appropriate gland techniques for control enclosures
  • Cables should be installed individually with minimal bundling to prevent debris build up
  • Careful consideration of hygiene practice and external environmental factors  

Installation

  • Requires individuals experienced with wire basket products.
  • Bends need manufacturing on site adding to labour time.
  • Some tray brands require couplers are positioned within a set distance of the supports
  • Inferior trays manufactured may have limited carrying capacity or reduced spans
  • The removal of wires may reduce earth continuity, external bonds may be required
  •  With visible cables aesthetics need to be considered during installation

Cost

  • Higher labour cost has to be offset against lower material costs 
  • Additional costs for clamps, joiners, brackets and fixing hardware can increase costs
  • Length costs are generally proportional to number and thickness or wires used.

Comparison summary

Feature
Stainless Steel Trunking

Stainless Steel Wire Basket cable Tray
Ingress Protection 
High; Enclosed system protects against objects, dust, liquids (IP66)
Low; Open design offers limited protection
Electromagnetic Interference (EMI) – Radiated
High; Reduced transmitted and receiving (radiated). Internal barriers available
Medium; Partial reduction (radiated) Requires additional barriers and routing practices
Wire Fill
Moderate; 40% of cross-sectional area
Moderate; 50% of cross sectional area
Heat Dissipation
Limited; Limited airflow, potential cable de-rating maybe required
Excellent; Potentially Unrestricted airflow
Hygiene Compliance
High; Smooth, cleanable surfaces
Moderate; May require specific cleaning procedures
Flexibility/Modularity
Low; Rigid and fixed bends
High; Highly modular and site adaptable bends
Installation Complexity
Moderate; Requires precision and specific cutting tools ( S/Steel)
Moderate; Cutting, bends and cable clipping
Cost
Moderate / High; High material content / pre-made bends
Low/Moderate; Lower material content / fabrication of bends

Summary

The final choice between wire basket or enclosed Trunking system should be guided by the facility’s operational needs, regulatory requirements, and budget. It is advised that those tasked with overseeing any decision on which type of system used should consider both the commercial and technical aspects of each solution.  For Machine builders the choice may be clearer, however site specifications may need checking. While it is not unusual to have different solutions within one facility, it’s important to account for future expansions and product compatibility, especially on machinery supplied from multiple vendors that is interconnected with existing equipment. Ultimately, whatever the decision on which system or brand to implement, this should be communicated to those responsible for purchasing and procurement.

Lasnek Ltd.
1 President Way, Luton, Bedfordshire, LU2 9NR

Tel: +44 (0) 1582 425 777
Fax: +44 (0) 1582 425 776
Business Hours
Monday - Friday: 08:30 - 17:00 (GMT)
Closed Saturdays and Sundays
Closed for UK Public Holidays