HYGIENIC DESIGN

REQUIREMENTS FOR
FOOD PROCESSING
MACHINERY

Emma Maguire
Food Manufacturing Technologies
Department – Campden BRI
 INTRODUCTION

• Over view of Campden BRI

• Hygienic design
• Regulations
• Examples
• Other considerations
• Summary
 CAMPDEN BRI
• Membership based: 2,400
members
• Independent, Non-profit distributing
• International – clients in 75
countries
• Turnover: c. £21 m
• Staff: 390
• Industry and Government Clients

• Member involvement and influence

- Governance
- Scientific & Technical Strategy
- Project development & selection

• Largest in the world

 VISION
To be the partner of choice for the development and
application of technical knowledge and commercially
relevant solutions for the food and drink supply chain

MISSION
The practical application of technical excellence for the food
and drink supply chain
 HYGIENIC DESIGN IN FOOD
PRODUCTION:
Quality
The art of producing a product without
(unintentionally) changing it - good hygienic design
maintains product in the main product flow
Safety
The art of producing a product without adding
anything to it - good hygienic design prevents the
transfer of hazards
Efficiency
The ability to (dismantle) access all product contact
areas to facilitate cleaning in an economic time
frame
 I have to clean this for
LIFE CYCLE FOR EQUIPMENT
the next 20 years?!!
What were they
thinking?
Proactively we will need to:
•Redesign to improve
effectiveness
•Educate management on
risks
•Spend capital to reduce risks
•Redesign to improve cleaning
•Redevelop cleaning
procedures
IN A FOOD PRODUCTION
PLANT
During the 20 year life cycle we
2014 will:
•Produce 2 billion meals
•Train 250 employees on how to clean
•Introduce and train 80 production
supervisors
•Spend up to 33,000 hours cleaning it
•Spend 2500 hours doing pre-op
inspections
•Waste up to 295 Million lbs. of food
2034 •Generate 15 million gallons of effluent
+ BOD
•Generate 78 million lbs of rework
•Generate 17 million lbs. of inedible
waste
 Early recognition

Product hold-up causes

product deterioration
SCHEMATIC
FOOD Hazard analysis
FACTORY
Specified raw
materials
HACCP

Hygienic design Process

development

Prerequisites ISO 9000

Hygienic practices Process control

ISO/TS 22002-1:2009 ISO 22000

Safe, wholesome
Food
 HYGIENIC
DESIGN

Hazard analysis

Buildings Equipment People

Site Lines Medical screening

Fabric Equipment Labs and toilet location
Segregation Utensils
Size Bins
Flows Robots
Services
Housekeeping
Sanitation
Waste control
Pest control
Maintenance Sanitation Personal hygiene
GHP Maintenance Return-to-work
Audit Audit Training

Buildings Equipment People

Hazard analysis

Hygienic
practices
REGULATIONS AND
STANDARDS
Reg. (EC) no 178/2002
European Food Law
 Food hygiene:
EU Regulation 852/2004
Requires companies to implement a quality
control system and proposes the Hazard
Analysis and Critical Control Points
(HACCP) system most appropriate.

• Surfaces and equipment should be:

• Easy to clean and disinfect.
• Smooth, washable, corrosion-resistant and non-
toxic materials are desired.
• kept in good order, repair and condition, so as to
minimise any risk of contamination
• Installed so as to allow ample cleaning of the
equipment and the surrounding area.
 Food contact
• EU Regulation 10/2011 plastic materials
and articles intended to come into contact
with food
• EU Regulation 1935/2004 on materials
and articles intended to come into contact
with food
• EU Regulation 2023/2006 on good
manufacturing practice for materials and
articles intended to come into contact with
food
 MACHINERY
•EC Directive 2006/42/EC, or the Machinery
Directive.
•EN 1672-2 (2009), Food processing
machinery - Basic concepts - Part 2:
Hygiene requirements
•BS EN ISO 14159:2008 Safety of
machinery. Hygiene requirements for the
design of machinery
•Doc 8, 10 and 13 of the EHEDG.
 EC DIRECTIVE 2006/42/EC, or the
MACHINERY DIRECTIVE.

Annex 2.1: ‘Machinery

intended for use with
foodstuffs or with cosmetics
or pharmaceutical products
must be designed and
constructed in such a way as
to avoid any risk of infection,
sickness or contagion’
 EN 1672-2 (2009), Food processing
machinery - Basic concepts - Part 2:
Hygiene requirements
Materials of construction
Surface finish
Joints
Fasteners
Drainage
Internal angle and corners
Dead spaces
Bearings and shaft entry points
Instrumentation
Panels, covers and doors
Covers
• European Hygienic Engineering & Design
Group
– Best practice guidance on hygienic
engineering and design for food equipment
manufactured in or imported into Europe
– Knowledge on the design, installation and
cleanability of components
– Best practices for hygienic operations, supply
and maintenance
 PREVENTING BARRIERS TO
TRADE - EUROPE
EHEDG 1989
www.ehedg.org

Directive 2006/42/EC on machinery – machinery directive

CEN/TC 153 - Machinery intended for use with foodstuffs and feed
BS EN 1672-2:2005+A1:2009
-Food processing machinery. Basic concepts. Hygiene requirements
 PREVENTING BARRIERS TO
TRADE - USA
3-A Sanitary Standard- 1920
International Association of Food industry Suppliers (IAFIS)
International Association for Food Protection (IAFP)
Milk Industry Foundation (MIF)

National Sanitation Foundation NSF -1944

NSF International Standard for Food Equipment –NSF/ANSI
2-2007
ANSI/NSF/3-A 14159-1999 Safety of Machinery
NSF 3A 14159-1-2010- Hygiene Requirements for the Design
of Meat and Poultry Processing Equipment
 HYGIENE
PRINCIPLES/RULES
 HYGIENE RULES
1. Relevant ‘materials in contact’ rules.
Machinery designed such that these
materials can be clean before use. Where
this is not possible, disposable parts must
be used
2. All surfaces, including their joints, must be
smooth, and must have neither ridges nor
crevices which could harbour organic
materials
3. Projections, edges and recesses must be
minimised,
2. Surface finish (RA) and
cleanability

RA = 0.5

RA = 1.0

RA = 3.0
2. Staphylococcus aureus
 3. Projections, edges and
recesses must be minimised

! !
 HYGIENE RULES
CONTINUED...
4. All surfaces in contact with food must be easily cleaned
and disinfected, where possible after removing easily
dismantled parts. Inside surfaces curves must be
reduced to facilitate cleaning
5. Liquids, gases and aerosols derived from foodstuffs....
and cleaning should be completely discharged (if
possible, in a cleaning position) - Drainable
6. Design and construction should prevent the entry of
liquids or animals and prevent accumulation of soil in
areas that cannot be cleaned – No Niches
7. Design and construction such that no ancillary
substances (e.g. lubricants) can come into contact with
foodstuffs... Compliance should be able to be checked
 4. Inside surfaces curves must
be reduced to facilitate cleaning
5. Drainable
6. No niches or dead spaces
Listeria in sliced meats (2001)
7. Design and construction such that no
ancillary substances (e.g. lubricants)
can come into contact with foodstuffs
OTHER CONSIDERATIONS
Siting of equipment
 HYGIENIC DESIGN
VALIDATION
• 2/3 dimensional drawings
• Computer aided CFD modelling
• Equipment visualization and inspection
• Third party approvals
– EN 1672, ISO 14159, EHEDG, 3-A
• Cleanability tests (primarily for closed equipment)
– Microbiological tests, organic tests, commissioning
tests
• Specific tests
– Pasteurizability, sterilizability, bacterial ingress
• EHEDG Certification
 CERTIFICATION
CRITERIA

• Hygienic design to meet the

requirements of EHEDG Guideline No. 8
Hygienic Equipment Design Criteria
• If appropriate, cleanability assessment is
required to meet the requirements of
EHEDG Guideline No. 2 A method for the
in-place cleanability of food processing
equipment
• In all cases, the requirements of the
machinery directive 2006/42/EC, via EN
1672-2 should be met
 RETAILER REQUIREMENTS
• “Product contact surfaces, including those not in
direct contact with food, must be constructed of
materials that will not contribute a food safety risk” –
SQF (Annex 1: Guidance-premises and equipment
construction and design)
• “All materials used for maintenance and repair shall
be fit for the intended use” – IFS, Version 5, 2007
• “Certificates of conformity or other evidence shall be
available for equipment in direct contact with food to
confirm its suitability for use, e.g. Conveyor belts” –
BRC,
FINAL CONSIDERATIONS
HYGIENIC DESIGN?
BUT SAFETY?
 SUMMARY: Hygienic design in
food production:
Quality
The art of producing a product without
(unintentionally) changing it - good hygienic design
maintains product in the main product flow
Safety
The art of producing a product without adding
anything to it - good hygienic design prevents the
transfer of hazards
Efficiency
The ability to (dismantle) access all product contact
areas to facilitate cleaning in an economic time
frame
 Campden BRI
‘The partner of choice for the development and application of
technical knowledge and commercially relevant solutions for
the food and drink supply chain’

Questions
Emma Maguire

Contact details: 01386842038

Emma.Maguire@campdenbri.co.uk

no. 1079 no. 1207

 SANITARY PRINCIPLES
1. Cleanable to a Microbiological Level
2. Made of Compatible Materials
3. Accessible for Inspection, Maintenance, Cleaning
and Sanitation
4. No Product or Liquid Collection
5. Hollow Areas Should be Hermetically Sealed
6. No Niches
7. Sanitary Operational Performance
8. Hygienic Design of Maintenance Enclosures
9. Hygienic Compatibility With Other Plant Systems
10. Validated Cleaning and Sanitizing Protocols