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What does hygienic design mean?
Hygienic design is more than just a buzzword in the field of hygiene control. It encompasses an indispensable management system that guarantees that food and beverages are produced safely and hygienically, from the planning of the production plant and the cleaning process right through to the employees.
Hygienic weak point in the production process: Defective seal on a sight glassHygienic design is more than just cleanable construction
The concept of hygienic design has proven to be extremely effective in recent decades in ensuring the safety and quality of products. It involves designing machines, equipment and production environments in such a way that they are easy to clean and minimise the risk of contamination.
With the requirement of the EU Machinery Directive that food production plants must be constructed in accordance with hygienic design, for a long time this topic was focussed purely on the easy-to-clean design of individual components, fittings and machines. However, beverage manufacturers often have specific needs that go beyond the general requirements of the EU Machinery Directive. Close cooperation between the plant manufacturer and the beverage producer is therefore necessary in order to fulfil these requirements.
Bottle conveyor from below with biofilmBeverage manufacturers' specific requirements for hygienic design
The beverage manufacturer itself must carry out a risk analysis in order to determine the specific requirements for hygienic design. This involves looking not only at the machines and individual components, but also at the processes, the process environment and the packaging of the beverages. Both the EU Machinery Directive and the corresponding standards prescribe such a risk analysis.
Hygienic design is therefore a comprehensive management system that ensures that beverages and food can be produced safely in terms of food safety. It is the responsibility of the operator of the plant to deal intensively with the topic of hygienic design and to take the appropriate measures to ensure the hygiene and safety of their products.
What aspects does hygienic design cover in food production? It includes machines and equipment, their cleaning, supply systems, production rooms and also the operating personnel. An interdisciplinary approach is essential.
Develop a clear zone concept
For production rooms in particular, it is crucial to develop a zone concept in order to define the different hygiene requirements. This affects the choice of materials and surfaces in the rooms as well as the drainage system and ventilation. The division into zones has an impact on which machines are located in which area and need to be cleaned and equipped accordingly.
The supply systems also play an important role in food safety. Think of outdated pipework or disused pipes, which can be a source of contamination. Ventilation in the filling area also has a direct influence on the quality of the beverages.
The components and fittings as well as the containers and their fixtures must also fulfil the requirements of hygienic design. The basic design principles have been published in relevant guidelines and standards for many years. Depending on the production process, additional requirements may be necessary, e.g. in aseptic filling.
Proof of easy cleanability is essential for beverage manufacturers to ensure that existing systems can be cleaned reliably and completelyHygienic design starts with planning
The planning and design of production facilities have a direct influence on the efficiency of cleaning and disinfection. As part of efforts to achieve sustainability and energy savings, a cleaning-optimised installation is crucial. However, the cleaning time of existing systems should not simply be shortened, as this has an impact on the cleaning result and the cleanliness of the system.
Another important aspect is the employees. They must operate, clean and maintain the systems properly. Attentive employees who monitor the systems and report damage in good time can prevent unplanned downtime. It is therefore necessary to train staff and sensitise them to hygienic design issues.
Construction materials
The correct choice of construction materials depending on the application during production and cleaning is a central theme of hygienic design.
It is essential to use food-safe materials for production systems in contact with food. However, this alone does not guarantee that the equipment is easy to clean. Materials that are approved for contact with food are not harmful to the health of the consumer. Nothing more is said in this context.
The availability of corresponding certificates from the FDA or declarations of conformity in accordance with the EU Plastics Regulation are mandatory. The nature of the surfaces and the type of installation play a decisive role in cleaning. Smooth surfaces without gaps and indentations are easier to clean and therefore fulfil the requirements of hygienic design. It is also important that the cleaning agents used do not cause any damage to the surfaces and materials.
Surface coatings can minimise the adhesion of dirt, but must be mechanically stable so that no foreign bodies can get into the food.
The EHEDG test laboratories with all the relevant experts from all over the world meet regularly, here a group photo of a meeting at the Weihenstephan BGT research centreAdvantages of hygienic design
In the food industry, microbiological safety is particularly important to ensure that products can be handed over to consumers without risk. Product recalls are very costly and can cause high financial losses and, above all, lasting damage to a company's image.
Comprehensive hygienic design management can significantly improve productivity and efficiency in food production. By designing machines and equipment that are easy to clean and maintain, unnecessary downtime is reduced. This enables continuous production and optimum utilisation of the equipment. At the same time, hygienic design also supports efficient process management, as a smooth material flow is ensured and production bottlenecks are avoided.
The simple cleaning of the systems ensures shorter cleaning times, lower temperatures and lower flow velocities. These physical parameters contribute to energy savings, which is particularly important in terms of sustainability. By ensuring that their systems meet the hygienic design requirements for the respective production process, companies can minimise their carbon footprint.
Although the implementation of hygienic design may initially involve certain investments, it leads to considerable cost savings in the long term. The ease of cleaning and maintenance of the systems reduces the need for cleaning agents and personnel. In addition, the reduced risk of contamination reduces the risk of recalls and legal consequences, which can lead to savings.
Maintaining high standards of hygiene through the use of hygienic design can improve a company's image and increase consumer confidence. Customers increasingly value safely manufactured products.
The international organisation EHEDG offers practical information with its guidelines. The aim of the organisation is to be the leading resource for hygienic design and technical know-how and to improve food safety and quality throughout the industry.
Conclusion
Hygiene in food and beverage production encompasses product hygiene, process hygiene and personnel hygiene. In addition to preventive maintenance and repair, sustainable concepts such as hygienic design and hygienic processing are indispensable.
In particular, ensuring a high level of microbiological safety is a central concern in quality assurance for beverages. In this context, compliance with high, comprehensively designed hygiene standards and, in particular, the use of well-designed systems offers numerous advantages such as improved system availability, increased efficiency and energy savings. Taking hygienic design into account in the food industry reduces risks in production processes and ultimately increases productivity.
This article is based on an article first published in BRAUWELT No. 33, 2023, pp. 829-831.
