Estimated reading time: 4 minutes
By applying a risk-based approach during the design phase, potential sources of contamination can be identified and eliminated before they become challenges.
Food contaminated with pathogens or other harmful substances poses a serious risk to consumers. As a result, equipment manufacturers and food processors have a shared responsibility to manage every aspect of food safety. One of the most effective ways to address food safety risks is through hygienic design, which can be incorporated from the earliest stages of equipment development.
According to Peet Grobler, chairperson of the South African regional branch of the European Hygienic Engineering and Design Group (EHEDG), manufacturers and processors are committed to protecting their brands and ensuring consumers can use their products safely. Food manufacturing and processing are about delivering safe, high-quality food.
To achieve this, companies implement a range of processes and control measures throughout their facilities. These include adherence to international standards such as those developed by the International Organization for Standardization (ISO), as well as food safety certifications such as Food Safety System Certification (FSSC) and International Featured Standards (IFS). The primary objective is to identify, manage, and mitigate food safety risks.
Grobler discussed these principles during a webinar hosted by the Dairy Standard Agency (DSA), focussing specifically on the role of hygienic design in improving food safety within dairy processing operations.
Global standards driving safety
The EHEDG has supported role-players across the food value chain since 1989, including food producers, processors, equipment manufacturers, universities, research institutes, and public health authorities. A key part of this work involves developing practical guidelines authored by international experts with specialised knowledge in relevant fields.
The South African regional branch of the EHEDG was established in 2019. Its activities are supported through membership and ongoing support from participating companies. The organisation’s long-term objective is to advance food hygiene through hygienic engineering.
The role of hygienic design
Grobler describes hygienic design as a strategic investment that promotes food safety, improves operational efficiency, and reduces expenses over time. By applying a risk-based approach during the design phase, potential sources of contamination can be identified and eliminated before they become challenges. This helps prevent cross-contamination between products during processing and handling.
He highlights several key principles of hygienic design:
- Equipment should be manufactured from non-reactive, non-toxic, and corrosion-resistant materials.
- Smooth surfaces minimise residue build-up, reducing the risk of microbial contamination and biofilm formation.
- Equipment should be designed to allow drainage of water and product residues after cleaning.
- Hidden or inaccessible areas should be eliminated. Poorly executed welds and metal-to-metal contact points can trap residues and create environments conducive to pathogen contamination.
- Effective process flow and physical separation within facilities are essential in preventing cross-contamination.
Research and industry reports demonstrate a range of measurable benefits associated with effective hygienic design, including:
- Improved food safety outcomes: Reductions in contamination by pathogens such as Listeria (which causes listeriosis) and Salmonella.
- Greater cleaning efficiency: Shorter wash cycles during clean-in-place processes can result in a 20 to 40% time saving; it also reduces water, energy, and chemical usage.
- Extended equipment lifespan: Reduced wear and mechanical damage result in lower maintenance costs and longer service life.
- Operational reliability: Fewer production interruptions and maintenance-related stoppages contribute to better production efficiency.
Although certified hygienically designed equipment and components, such as valves and pumps, often require a higher initial investment, Grobler notes that the long-term financial benefits outweigh the upfront costs. Reduced maintenance requirements, longer replacement intervals, and savings in labour, energy, water and cleaning chemicals all contribute to a strong return on investment.
A lifecycle approach to design
Hygienic design, he says, should be viewed as a comprehensive process that extends from initial concept development through to verification. The model, developed by EHEDG working groups, provides a framework for managing and evaluating each phase of the process. This approach encompasses equipment design, manufacturing, installation, and operational performance.
EHEDG publishes several valuable guidance documents on its website to support the food industry and ensure successful design and food safety outcomes. Through collaboration with internationally recognised organisations such as 3-A and FSSC, the EHEDG ensures that the information it makes available to members is relevant and aligned with global food safety standards. – Christal-Lize Muller, Stockfarm
For more information, contact Peet Grobler at 083 301 8033 or peet.grobler@oftgroup.co.za, or visit www.ehedg.org
