Yearbook 2013/2014 - ehedg
Yearbook 2013/2014 - ehedg
Yearbook 2013/2014 - ehedg
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EHEDG<br />
<strong>Yearbook</strong> <strong>2013</strong>/<strong>2014</strong><br />
European Hygienic<br />
Engineering & Design Group
EHEDG<br />
<strong>Yearbook</strong> <strong>2013</strong>/<strong>2014</strong><br />
European Hygienic<br />
Engineering & Design Group
European Hygienic Engineering & Design Group<br />
Contents<br />
Articles<br />
Page<br />
Greeting from the President, Knuth Lorenzen, EHEDG President 5<br />
News from the Treasurer, Piet Steenaard, EHEDG Treasurer 6<br />
News from the Secretariat, Susanne Flenner, EHEDG Secretariat 7<br />
EHEDG Executive Committee members 8<br />
EHEDG Company and Institute members 10<br />
EHEDG membership 15<br />
Test and Certification Institutes 16<br />
Legal requirements for hygienic design in Europe, by Hans-Werner Bellin, BELLINconsult 17<br />
The importance of hygienic design: A process facility case study and checklist, 20<br />
by Carolina López Arias, Kraft-Foods España (part of Mondelēz International)<br />
Solving concrete kerb challenges to ensure hygiene and food safe wall protection 26<br />
in manufacturing environments, by Nick Van den Bosschelle, PolySto<br />
Hexagonal tile floors: The hygienic foundation of production areas, 28<br />
by Volker Aufderhaar, Argelith Bodenkeramik<br />
Research on hygienic flooring systems: Particle and VOC emissions, 30<br />
chemical and biological resistance, and cleanability,<br />
by Markus Keller and Udo Gommel, Fraunhofer Institute for Manufacturing Engineering<br />
and Automation IPA, Department of Ultraclean Technology and Micromanufacturing<br />
Hygienic design of floor drainage components, by Martin Fairley, ACO Technologies plc 42<br />
Hygienic design of high performance doors for utilisation in the food industry, 47<br />
by Daniel Grüttner-Mierswa, Albany Door Systems GmbH<br />
Performance testing of air filters for hygienic environments: 50<br />
Standards and guidelines in the 21st century,<br />
by Thomas Caesar, Freudenberg Filtration Technologies SE & Co. KG<br />
Spray cleaning systems in food processing machines and the simulation of CIP-coverage tests, 54<br />
by André Boye, Marc Mauermann, Daniel Höhne, Jens-Peter Majschak, Fraunhofer Application Center<br />
for Processing Machinery and Packaging Technology AVV, and Technische Universität Dresden,<br />
Faculty of Computer Science, Institute of Software- and Multimedia-Technology, Dresden, Germany<br />
Environmentally friendly water based surface disinfectants, 60<br />
by Stephan Mätzschke, BIRFOOD GmbH & Co. KG<br />
Flow behaviour of liquid jets impinging on vertical walls, 66<br />
by Ian Wilson, Tao Wang and John F. Davidson, Department of<br />
Chemical Engineering and Biotechnology, University of Cambridge<br />
Optimisation of tank cleaning, by René Elgaard, Alfa Laval Tank Equipment A/S 70<br />
Effective tank and vessel cleaning: How different systems can help meet today’s demands, 76<br />
by Falko Fliessbach, GEA Breconcherry<br />
Practical considerations for cleaning validation, by Hein Timmerman, Diversey 83<br />
Integrated hygienic tamper-free production, by Stefan Åkesson, Tetra Pak 85<br />
Damage scenarios for valves: Identifying the potential for optimisation, 87<br />
by Willi Wiedenmann, Krones AG<br />
Infection-free preparation of bacterial cultures, by Ludger Hilleke, amixon GmbH 92<br />
Modern level detection and measurement technologies, by Daniel Walldorf, Baumer GmbH 94
Contents 3<br />
An example of the development process of hygienic process sensors: A hygienic level switch, 96<br />
by Holger Schmidt, Endress+Hauser<br />
Storage in silos and pneumatic conveying of milk powder with up to 60% fat content, 99<br />
by Hermann Josef Linder, Solids Solutions Group, S.S.T.-Schüttguttechnik Maschinenbau GmbH<br />
Material and design optimisation calculated by EHEDG: Tubing systems, 103<br />
by Torsten Köcher, Dockweiler AG<br />
Improved hygienic design and performance of food conveyor belts, by Olaf Heide, Habasit AG 106<br />
Smart hygienic solutions for the food industry, 108<br />
by Peter Uttrup, Interroll España S.A and Lorenz G. Koehler, Interroll (Schweiz) AG<br />
Examination of food allergen removal from two flat conveyor belts, 110<br />
by Zhinong Yan, Gary Larsen, Roger Scheffler, and Karin Blacow. Intralox, L.L.C.<br />
The future of food-grade lubrication, by Taco Mets, Van Meeuwen Groep B.V. 115<br />
Hygienic automation technology in food production, by Alexander Wagner, Festo AG & Co. KG 117<br />
Cleanability test of a hygienic design-compatible washer, 120<br />
by Julia Eckstein, Application Consultant, Freudenberg Process Seals GmbH & Co. KG<br />
Aspects of compounding rubber materials for contact with food and pharmaceuticals, 122<br />
by Anders G. Christensen, AVK GUMMI A/S<br />
New developments for upgrading stainless steel to improve 124<br />
corrosion resistance and increase equipment hygiene,<br />
by Siegfried Piesslinger-Schweiger, POLIGRAT GmbH<br />
International Hygienic Study Award 2012, by Peter Golz, VDMA 128<br />
EHEDG Regional Sections 130<br />
EHEDG Armenia 132<br />
EHEDG Belgium 133<br />
EHEDG Czech Republic 134<br />
EHEDG Denmark 135<br />
EHEDG France 136<br />
EHEDG Germany 137<br />
EHEDG Italy 138<br />
EHEDG Japan 140<br />
EHEDG Lithuania 141<br />
EHEDG Macedonia 141<br />
EHEDG Mexico 144<br />
EHEDG Netherlands 145<br />
EHEDG Russia 147<br />
EHEDG Serbia 148<br />
EHEDG Spain 148<br />
EHEDG Switzerland 150<br />
EHEDG Taiwan 150<br />
EHEDG Thailand 151<br />
EHEDG Turkey 152<br />
EHEDG Ukraine 153
4 Contents<br />
EHEDG Guidelines 154<br />
EHEDG Congresses 163<br />
EHEDG Subgroups 164<br />
EHEDG Subgroup “Air Handling” 164<br />
EHEDG Subgroup “Hygienic Building Design” 165<br />
EHEDG Subgroup “Chemical Treatment of Stainless Steel” 166<br />
EHEDG Subgroup “Cleaning Validation” 167<br />
EHEDG Subgroup “Conveyor Systems” 168<br />
EHEDG Subgroup “Dry Materials Handling” 168<br />
EHEDG Subgroup “Fish Processing” 169<br />
EHEDG Subgroup “Materials of Construction for Equipment in Contact with Food “ 170<br />
EHEDG Subgroup “Hygienic Design of Meat Processing Equipment” 170<br />
EHEDG Subgroup “Open Equipment” 171<br />
EHEDG Subgroup “Pumps, Homogenisers and Dampening Devices” 172<br />
EHEDG Subgroup “Seals” 172<br />
EHEDG Subgroup “Separators” 173<br />
EHEDG Subgroup “Tank Cleaning” 173<br />
EHEDG Subgroup “Test Methods” 174<br />
EHEDG Subgroup “Training and Education” 175<br />
EHEDG Subgroup “Valves” 176<br />
EHEDG Subgroup “Welding” 177<br />
EHEDG application forms 178<br />
Imprint 180
European Hygienic Engineering & Design Group<br />
Greeting from the President<br />
Knuth Lorenzen, President of the European Hygienic Engineering and Design Group (EHEDG),<br />
E-mail: knuth.lorenzen@<strong>ehedg</strong>.org<br />
EHEDG values the cooperation and positive relationship<br />
with 3-ASSI (www.3-a.org). In our shared commitment we<br />
work together to advance hygienic equipment design. Both<br />
organisations exchange their draft guidelines and standards.<br />
The contents of all EHEDG guidelines are cross-referenced<br />
with those of the 3-ASSI standards and are summarised in<br />
a matrix. In order to ‘talk the same language’ and to further<br />
harmonise the documents, EHEDG and 3-ASSI experts<br />
have jointly drafted the new issue of the EHEDG Glossary.<br />
To complement the scope of our services, we offer you<br />
seminars, symposia and workshops worldwide which impart<br />
and disseminate the EHEDG Hygienic Engineering & Design<br />
expertise.<br />
The core business of the EHEDG, Hygienic Engineering &<br />
Design, is still an unknown territory for many target groups.<br />
State-of-the-art machinery and processing plant can only<br />
fulfil the today’s needs of the food industry and meet with<br />
the existing legal requirements if they are designed, built,<br />
installed and maintained according to hygienic design<br />
principles.<br />
University graduates are highly qualified experts trained to<br />
solve complex engineering tasks and they are expected<br />
to design and build innovative machinery that is safe to<br />
operate. Nevertheless they are often unaware of Hygienic<br />
Engineering & Design as it is not a mandatory part of their<br />
course contents.<br />
Machines used in the food industry need to be safe and<br />
highly productive, but at the same time they have to meet<br />
food hygiene requirements.<br />
In answer to these needs, the EHEDG expert network<br />
was established to close the existing knowledge gaps<br />
by developing teaching aids for practical use as well as<br />
education material for students, engineers and operators<br />
who are interested in learning more about the field of<br />
hygienic design & engineering.<br />
The specific and profound EHEDG expertise is collated in our<br />
guidelines, in our training material and in other publications<br />
which are developed by our motivated volunteers – all of<br />
them aiming to raise the awareness in food hygiene worldwide.<br />
EHEDG training courses on hygienic engineering & design<br />
are meanwhile offered by various authorised institutes and<br />
universities in Denmark, Germany, Japan, the Netherlands,<br />
Spain, Thailand, UK and in the USA. Attendees who<br />
successfully passed their exam are given the opportunity to<br />
have their name published on the EHEDG webpage www.<br />
<strong>ehedg</strong>.org.<br />
University lecturers involved in the EHEDG are filling the<br />
gaps in hygienic engineering & design education and have<br />
integrated such contents in their seminars.<br />
I invite you to benefit from our knowledge which reflects the<br />
expertise of all volunteers involved into EHEDG, and I hereby<br />
express my sincere thanks to these enthusiastic experts for<br />
their tireless contribution and excellent input. Last but not<br />
least, I should like to thank the EHEDG member companies<br />
who support us – without them we would not be in a position<br />
to offer our wide range of educational services.<br />
Yours<br />
Knuth Lorenzen<br />
President of EHEDG
European Hygienic Engineering & Design Group<br />
News from the Treasurer<br />
Piet Steenaard, Dr. Catzlaan 19, NL-1261 CE Blaricum, e-mail: steenaard@kpnmail.nl<br />
Apart from covering our administration costs, the positive<br />
income was partly used for giving the growing number of<br />
experts the possibility of joining Subgroup meetings and<br />
EHEDG congresses. In most cases we have been able to<br />
fund the attendance of Subgroup members without financial<br />
back-up from a company or institute.<br />
At the end of each year, all Regional and Subgroup Chairmen<br />
are asked to send in their activity and budget planning for the<br />
year to come and if in need of financial support for upcoming<br />
EHEDG activities, we have approved most inquiries in the<br />
past. Resulting from the growing number of Subgroups and<br />
Regions, about 50 regular EHEDG meetings plus many local<br />
events, workshops and training courses are held annually.<br />
From a financial point of view, the period 2011 - 2012<br />
was successful for the EHEDG. It was characterised by<br />
an increase in income thanks to a significant growth in<br />
membership and by more revenues from certification. On the<br />
other hand, as company members benefit from downloading<br />
the guidelines free-of-charge from the EHEDG website,<br />
document sales have been decreasing at the same time.<br />
Institutes have been offered an advantageous membership<br />
fee and since then, the EHEDG has gained more universities<br />
and institutions. This increase helps to strengthen the<br />
scientific recognition of the EHEDG. As a result, we are now<br />
in a position to involve more scientists into the development<br />
of our state-of-the-art guidelines, along with our experts from<br />
mechanical engineering with their essential know-how. Many<br />
institutes adopt and organise our regional activities and<br />
they translate the EHEDG guidelines and our website into<br />
the local languages. They are active in various Subgroups<br />
and hold seminars and workshops to disseminate EHEDG<br />
knowledge.<br />
The EHEDG Subgroups are ideally composed of mechanical<br />
engineers, microbiologists, food producers and academia.<br />
However, sometimes it is not easy to find the right experts<br />
who can jointly provide the well-balanced and comprehensive<br />
know-how on the topic in question. Therefore, active expert<br />
input and EHEDG Subgroup participation on behalf of all<br />
related industries is always highly welcome – as long as it<br />
is considered on a basis of ‘give-and-take’. The EHEDG can<br />
offer many benefits to the industry if it actively joins our work:<br />
companies are offered the opportunity to feed their interests<br />
into the discussion and they can provide influence on setting<br />
global standards by actively contributing to the Subgroup<br />
work. EHEDG helps to enhance the reputation of its member<br />
companies and makes them knowledge leaders in hygienic<br />
design and processing.<br />
Most companies encourage and support their employees<br />
to participate in EHEDG activities, so they can develop or<br />
revise guidelines, training material and test methods for<br />
equipment. We are thankful to all these companies for their<br />
continued support.<br />
In recent years, we brought all our Chairmen together on<br />
the occasion of our annual Plenary Meetings to provide<br />
updated information from EHEDG International, enhance<br />
networking and cooperation in our fast growing organisation<br />
and offer them an opportunity for experience exchange and<br />
networking.<br />
EHEDG participation in international exhibitions helps to<br />
establish the new relationships and to expand our network<br />
and we invite you to visit us on the occasion of e.g. Drinktec,<br />
Anuga FoodTec and other important events.<br />
We are interlinking more than 200 companies and 30<br />
academic institutions. To date, about 1,000 persons have<br />
joined the EHEDG and more than 350 experts are actively<br />
involved in our Subgroup work. They are aiming to develop<br />
state-of-the art documents and teaching aids for hygienically<br />
designed machinery and equipment as well as for safe food<br />
production processes. Any new members are welcome in<br />
order to keep up this good work.<br />
It was an honour and a pleasure to take care of the EHEDG<br />
finances and to work with such highly committed people.<br />
Piet Steenaard<br />
EHEDG Treasurer
European Hygienic Engineering & Design Group<br />
News from the Secretariat<br />
Susanne Flenner, EHEDG Secretariat, susanne.flenner@<strong>ehedg</strong>.org<br />
Apart from these virtual options, the EHEDG network is<br />
real and we continue to bring the experts together in our<br />
Subgroups to help them learn from each other. All who have<br />
ever attended an EHEDG seminar, workshop or congress<br />
will not only have experienced the high quality of lectures<br />
but also the ‘EHEDG spirit’ of those who are enthusiastic in<br />
disseminating our expertise.<br />
In our meetings and events, you will find an open atmosphere<br />
far away from competition. We are not only enhancing the<br />
expert dialogue and dissemination of specific Hygienic<br />
Design knowledge but are also streamlining our activities<br />
and knowledge exchange with other organisations such as<br />
our strong counterpart 3-ASSI Standards Inc. in the USA.<br />
Having experienced a strong growth in membership and an<br />
increasing awareness of the EHEDG for its highly recognised<br />
expertise in the past years, this is to express our sincere<br />
thanks to all those who are involved in our activities today –<br />
whether on the part of our Subgroups, our Regional Sections<br />
or our members at large who support the EHEDG work.<br />
While global economic growth seems to be stagnating,<br />
at EHEDG we are continuing to expand and build our<br />
wolrdwide network in Hygienic Engineering & Design. This<br />
continuous development is certainly seen as a success<br />
story.<br />
On the part of the Secretariat, we are aiming to provide<br />
service excellence and although our organisation is lean, it is<br />
highly efficient and we can make our experts share the knowhow<br />
they wish to have accessible – without overloading them<br />
with information they don’t need. A major part of the EHEDG<br />
knowledge is available from our website with its huge data<br />
base where additional member information is available and<br />
where the EHEDG Subgroups build up and share their<br />
working files.<br />
By providing individual access rights to the different<br />
database sections, we can help our members find exactly<br />
what they need and want to know. The webpage is going to<br />
be continuously built-up by additional features and add-ons<br />
like i.e. an extended certificate database offering uploading<br />
options to company members for their pictures and the<br />
product information of their EHEDG-certified components.<br />
Meanwhile, the webpage is available in 15 languages thanks<br />
to having been translated by our regional experts. We<br />
welcome about 8,000 visitors on the web monthly and our<br />
Newsletter is sent out 6 times a year to keep our members<br />
up-to-date on the most important recent and upcoming<br />
EHEDG activities.<br />
World-wide education in Hygienic Engineering & Design<br />
is our credo which is well reflected by the many Regional<br />
Sections established to date and those which are going to be<br />
established in the future – all of them aiming to disseminate<br />
the EHEDG know-how in their countries.<br />
Our members do not only recognise hygienic design as a<br />
knowledge advancement, but we help them to find design<br />
solutions which save both cost and time by ensuring high<br />
food safety at the same time.<br />
About 400 EHEDG certificates issued by our accredited<br />
testing and certification institutes to date speak their own<br />
language. EHEDG certification is sought by many companies<br />
as a proof of their capability in building easy to clean and<br />
maintain equipment and machinery. The EHEDG helps<br />
these companies to become leaders in hygienic design and<br />
- hand in hand with our members from the food industry and<br />
from academia - this know-how is continuously developed.<br />
If you are not a member of the EHEDG network already, we<br />
herewith invite you on board. Thanks again to all members for<br />
their commitment and welcome to those who are convinced<br />
of the benefits of joining the EHEDG after reading this book.<br />
Contact:<br />
Susanne Flenner<br />
Head Office Manager<br />
EHEDG Secretariat<br />
Lyoner Str. 18<br />
60528 Frankfurt am Main<br />
Germany<br />
Phone: +49 69 6603-1217<br />
Fax: +49 69 6603-2217<br />
E-mail: secretariat@<strong>ehedg</strong>.org<br />
susanne.flenner@<strong>ehedg</strong>.org<br />
Web: www.<strong>ehedg</strong>.org
European Hygienic Engineering & Design Group<br />
EHEDG Executive Committee members<br />
Mr Andrew Batley *<br />
Nestlé Product Technology Center<br />
NESTEC LTD.<br />
SWITZERLAND<br />
Phone (+41 31) 7 90 15 86<br />
E-mail: andrew.batley@rdko.nestle.com<br />
Mr Erwan Billet *<br />
Hydiac<br />
FRANCE<br />
Phone (+33 61) 2 49 85 84<br />
E-mail: e.billet@hydiac.com<br />
Professor Olivier Cerf *<br />
Alfort Veterinary School<br />
FRANCE<br />
Phone (+33 1) 43 96 70 34<br />
E-mail: ocerf@vet-alfort.fr<br />
Nicolas Chomel *<br />
Laval Mayenne Technopole<br />
EHEDG France<br />
FRANCE<br />
Phone (+33 243) 49 75 24<br />
E-mail: chomel@laval-technopole.fr<br />
Lyle W. Clem **<br />
ESC<br />
Electrol Specialties Company<br />
UNITED STATES OF AMERICA<br />
Phone (+972 815) 3 89-22 94<br />
E-mail: lyleclem@att.net<br />
Susanne Flenner ***<br />
EHEDG Secretariat<br />
GERMANY<br />
Phone (+49 69) 66 03-12 17<br />
E-mail: susanne.flenner@<strong>ehedg</strong>.org<br />
Dr. Peter Golz *<br />
VDMA<br />
Fachverband Nahrungsmittelmaschinen<br />
und Verpackungsmaschinen<br />
GERMANY<br />
Phone (+49 69) 66 03-16 56<br />
E-mail: peter.golz@vdma.org<br />
Mr Richard Groenendijk *<br />
Stork Food & Dairy Systems B.V.<br />
NETHERLANDS<br />
Phone (+31 20) 6 34 86 48<br />
E-mail: richard.groenendijk@sfds.eu<br />
Christophe Hermon **<br />
Conservation des Produits Agricoles<br />
CTCPA - Centre Technique de la<br />
FRANCE<br />
Phone (+33 2) 40 40 47 41<br />
E-mail: chermon@ctcpa.org<br />
Dr. Jürgen Hofmann *<br />
Ingenieurbüro Hofmann<br />
Hygienic Design Experte<br />
GERMANY<br />
Phone (+49 8161) 8 76 87 99<br />
E-mail: jh@hd-experte.de<br />
Dr. John Holah *<br />
Campden BRI<br />
GREAT BRITAIN<br />
Phone (+44 1386) 84 20 41<br />
E-mail:j.holah@campden.co.uk<br />
Jana Alicia Huth ***<br />
EHEDG Secretariat<br />
GERMANY<br />
Phone (+49 69) 66 03-14 30<br />
E-mail: jana.huth@<strong>ehedg</strong>.org<br />
Salwa El Janati **<br />
Lactalis RD<br />
FRANCE<br />
Phone (+33 24) 3 59 52 18<br />
E-mail: salwa.eljanati@lactalis.fr<br />
Ludvig Josefsberg *<br />
Tetra Pak Processing Systems<br />
SWEDEN<br />
Phone (+46 46) 36 60 01<br />
E-mail: ludvig.josefsberg@tetrapak.com<br />
Mr Jacques Kastelein *<br />
TNO - Quality of Life<br />
NETHERLANDS<br />
Phone (+31 30) 6 94 46 85<br />
E-mail: jacques.kastelein@tno.nl<br />
Huub Lelieveld *<br />
NETHERLANDS<br />
Phone (+3130) 2 25 38 96<br />
E-mail: huub.lelieveld@inter.nl.net<br />
Knuth Lorenzen *<br />
GERMANY<br />
Phone (+49 4173) 83 64<br />
E-mail: knuth.lorenzen@ewetel.net<br />
Dirk Nikoleiski *<br />
Kraft Foods R&D Inc.<br />
Product Protection & Hygienic Design<br />
GERMANY<br />
Phone (+49 89) 6 27 38 61 14<br />
E-mail: dnikoleiski@krafteurope.com<br />
Susanna Norrby *<br />
Alfa Laval Tumba AB<br />
SWEDEN<br />
Phone (+46 85) 3 06 56 33<br />
E-mail: susanna.norrby@alfalaval.com
EHEDG Executive Committee members 9<br />
Andres Pascual *<br />
ainia centro tecnológico<br />
SPAIN<br />
Phone (+34 96) 1 36 60 90<br />
E-mail: apascual@ainia.es<br />
Arno Peter *<br />
GEA TDS GmbH<br />
Niederlassung Büchen<br />
GERMANY<br />
Phone (+49 4155) 49-24 27<br />
E-mail: arno.peter@geagroup.com<br />
Timothy R. Rugh **<br />
3-A Sanitary Standards, Inc.<br />
UNITED STATES OF AMERICA<br />
Phone (+1 703) 7 90 02 95<br />
E-mail: trugh@3-a.org<br />
Satu Salo *<br />
VTT<br />
Industrial Contamination Control<br />
FINLAND<br />
Phone (+358 20) 7 22 71 21<br />
E-mail: satu.salo@vtt.fi<br />
Tracy Schonrock *<br />
UNITED STATES OF AMERICA<br />
Phone (+1 703) 5 03 29 71<br />
E-mail: ftracy1@cox.net<br />
Piet Steenaard *<br />
EHEDG Treasurer<br />
NETHERLANDS<br />
Phone (+31 35) 5 38 36 38<br />
E-mail: steenaard@kpnmail.nl<br />
Hein Timmerman *<br />
Diversey Europe BV<br />
BELGIUM<br />
Phone (+32 495) 59 17 91<br />
E-mail: hein.timmerman@sealedair.com<br />
Dr. Gun Wirtanen *<br />
VTT<br />
FINLAND<br />
Phone (+358 20) 7 22 52 22<br />
E-mail: gun.wirtanen@vtt.fi<br />
Mr Patrick Wouters *<br />
Unilever Research Laboratory<br />
NETHERLANDS<br />
Phone (+3110) 4 60 50 28<br />
E-mail: patrick.wouters@unilever.com<br />
This shows the Executive Committee as listed in<br />
December 2012:<br />
* regular members<br />
** liaison members<br />
*** EHEDG Secretariat<br />
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European Hygienic Engineering & Design Group<br />
EHEDG Company and Institute members<br />
EHEDG thanks its members for their continued support<br />
ACO Technolgies plc,<br />
United Kingdom<br />
AFM Sensorik GmbH, Germany<br />
www.aco.co.uk<br />
www.afmsensorik.de<br />
Aviatec, Denmark<br />
AVK GUMMI A/S, Greece<br />
aviatec@aviatec.dk<br />
www.avkgummi.dk<br />
AFRISO-EURO-INDEX GmbH,<br />
Germany<br />
AGORIA Federation<br />
Multisectorielle de L’Industrie<br />
Technologique, Belgium<br />
Agus Innovation Sp. z o.o.,<br />
Poland<br />
www.afriso.de<br />
www.agoria.be<br />
www.agus.com.pl<br />
AZO GmbH & Co. KG, Germany<br />
Nordischer Maschinenbau<br />
Rud. Baader GmbH & Co. KG,<br />
Germany<br />
Balluff GmbH, Germany<br />
Bari Samaratsi LLC, Armenia<br />
www.azo.de<br />
www.baader.com<br />
www.balluff.com<br />
www.barisamaratsi.am<br />
ainia centro tecnológico, Spain<br />
AK System GmbH, Germany<br />
Akvatekhavtomatika CJSC,<br />
Austria<br />
Albany Door Systems GmbH,<br />
Germany<br />
www.ainia.es<br />
www.ak-processing.com<br />
www.akvatekh.narod.ru<br />
www.albint.com<br />
Barry Callebaut Manufacturing<br />
(UK) Ltd., United Kingdom<br />
BASF Stavebni hmoty Ceska<br />
republika s.r.o., Czech Republic<br />
Baumer GmbH, Germany<br />
Bawaco AG, Switzerland<br />
g.benguiries@barrycallebaut.com<br />
www.basf.com<br />
www.baumergroup.com<br />
www.bawaco.com<br />
Alfa Laval Tumba AB, Sweden<br />
Alvibra A/S, Denmark<br />
AMEC, Spain<br />
AMH Technologies Sdn Bhd,<br />
Malaysia<br />
amixon GmbH, Germany<br />
AMMAG GmbH, Austra<br />
www.alfalaval.com<br />
www.alvibra.com<br />
www.amec.es<br />
www.amh.com.my<br />
www.amixon.de<br />
www.ammag.com<br />
Birfood GmbH & Co. KG,<br />
Germany<br />
BJ-Gear A/S, Denmakr<br />
Blücher Metal A/S, Denmark<br />
Joh. Heinr. Bornemann GmbH,<br />
Germany<br />
Robert Bosch Packaging<br />
TechnologyB.V., Netherlands<br />
www.birfood.de<br />
www.bj-gear.com<br />
www.blucher.dk<br />
www.bornemann.com<br />
www.boschpackaging.com<br />
Ammeraal Beltech srl, Italy<br />
www.ammeraalbeltech.it<br />
Bosch Rexroth Pneumatics<br />
GmbH, Germany<br />
www.boschrexroth.com<br />
Anderol BV, Netherlands<br />
www.anderol.com<br />
BOSSAR - Rovema Ibérica S.A.,<br />
Spain<br />
www.bossar.com<br />
Anderol Europe BV, Netherlands<br />
Andreasen & Elmgaard A/S,<br />
Denmark<br />
Argelith Bodenkeramik, Germany<br />
Armaturenbau GmbH, Germany<br />
Armaturenwerk Hötensleben<br />
GmbH, Germany<br />
Arol Spa, Italy<br />
www.anderol-europe.<br />
comwww.chemtura.com/<br />
petadds<br />
www.aoge.as<br />
www.argelith.com<br />
www.armaturenbau.com<br />
www.awh.de<br />
www.arol.it<br />
BP Biofuels UK Ltd,<br />
United Kingdom<br />
Brabender Technologie KG,<br />
Germany<br />
Brinox Engineering d.o.o., SLO<br />
Bühler AG, Switzerland<br />
Bürkert GmbH & Co. KG,<br />
Germany<br />
Burggraaf & Partners B.V.,<br />
Netherlands<br />
www.bp.com/biofuels<br />
www.brabendertechnologie.com<br />
www.brinox.si<br />
www.buhlergroup.com<br />
www.buerkert.com<br />
www.burggraaf.cc<br />
ARSOPI S.A., Portugal<br />
www.arsopi.pt<br />
Campden BRI<br />
www.campden.co.uk<br />
Aseptomag AG, Switzerland<br />
www.aseptomag.ch<br />
Cargill, Belgium<br />
www.cerestar.com<br />
Cederroth AB, Sweden<br />
www.cederroth.com
EHEDG Company and Institute members 11<br />
CENTA Centre of New Food<br />
Technologies and Processes<br />
www.centa.cat<br />
Elmar Europe GmbH, Germany<br />
www.elmarworldwide.com<br />
CFT S.p.a., Italy<br />
www.cftrossicatelli.com<br />
Endress + Hauser Japan, Japan<br />
www.jp.endress.com<br />
Chronos BTH, Netherlands<br />
www.chronosbth.com<br />
Esenda Ingeniería, S.C., Spain<br />
esenda@esenda.es<br />
Ciptec Services, Finland<br />
www.ciptec.fi<br />
Eurobinox S.A., France<br />
www.eurobinox.com/<br />
Clyde Process Limited, United<br />
Kingdom<br />
CMS S.p.A., Italy<br />
The Coca-Cola Company, USA<br />
Cocker Consulting Ltd., Ireland<br />
Consulting & Training Center KEY,<br />
Macedonia<br />
cool it Isoliersysteme GmbH,<br />
Germany<br />
Coperion Waeschle GmbH & Co.<br />
KG, Germany<br />
www.clydematerials.com<br />
www.gruppocms.com<br />
www.coca-cola.com<br />
www.cocker.ie<br />
www.key.com.mk<br />
www.coolit.de<br />
www.coperion.com<br />
Festo AG & Co. KG<br />
FIRDI Food Industry Research<br />
and Development Institute,<br />
Thailand<br />
Food Coating Expertise SAS,<br />
France<br />
Food Masters Ltd. Engineering &<br />
Equipment Supply, Israel<br />
FRAGOL Schmierstoff GmbH+Co.<br />
KG, Germany<br />
Fraunhofer- Anwendungszentrum<br />
Verarbeitungsmaschinen und<br />
Verpackungstechnik, Germany<br />
http://www.festo.de<br />
www.firdi.org.tw<br />
www.food-coating.com<br />
www.foodmast.com<br />
www.fragol.de<br />
www.avv.fraunhofer.de<br />
John Crane GmbH<br />
Gleitringdichtungssysteme,<br />
Germany<br />
www.johncrane.de<br />
Fraunhofer Institut für<br />
Produktions-technik und<br />
Automatisierung (IPA), Germany<br />
www.ipa.fraunhofer.de<br />
CSF Inox S.p.A., Italy<br />
www.csf.it<br />
Freudenberg Filtration<br />
Technologies KG, Germany<br />
www.freudenberg.dewww.<br />
freudenberg-filter.de<br />
Ing. Johann Daxner GmbH,<br />
Austria<br />
Derichs GmbH, Germany<br />
DGL Deutsche Gesellschaft für<br />
Lebensmittelsicherheit, Wasserund<br />
Umwelt, Germany<br />
www.daxner-international.<br />
com<br />
www.derichs.de<br />
www.dgl-com.de<br />
Freudenberg Process Seals<br />
GmbH & Co. KG, Germany<br />
Friesland Foods, Netherlands<br />
Funke Wärmeaustauscher<br />
Apparatebau GmbH, Germany<br />
www.freudenberg.de www.<br />
freudenberg-process-seals.<br />
de<br />
www.frieslandcampina.com<br />
www.funke.de<br />
DIL Deutsches Institut für<br />
Lebensmitteltechnik e.V.,<br />
Germany<br />
Dinnissen BV, Netherlands<br />
Diversey Europe BV EMA<br />
Headquarters, Netherlands<br />
DMN Machinefabriek<br />
NoordwykerhoutB.V., Netherlands<br />
Dockweiler AG, Germany<br />
www.dil-ev.de<br />
www.dinnissen.nl<br />
www.diversey.com<br />
www.dmnwestinghouse.<br />
com<br />
www.dockweiler.com<br />
Galleon Rus ltd., Russia<br />
GEA Group<br />
GEMÜ Gebr. Müller Apparatebau<br />
GmbH & Co. KG, Germany<br />
Gericke GmbH, Germany<br />
Gida Güvenligi Dernegi - TFSA -<br />
Turkish Food Safety Association,<br />
Turkey<br />
www.galleon-rus.ru<br />
www.geagroup.com<br />
www.gemue.de<br />
www.gericke.net<br />
www.ggd.org.tr<br />
Dofra bv, Netherlands<br />
www.dofra.nl<br />
Gram Equipment A/S, Denmark<br />
www.gram-equipment.com<br />
DTU Technical University of<br />
Denmark National Food Institute,<br />
Denmark<br />
Döinghaus cutting and more<br />
GmbH &Co. KG, Germany<br />
www.food.dtu.dk<br />
www.cuttingandmore.de<br />
Grontmij Industrial Division,<br />
Netherlands<br />
Habasit AG, Switzerland<br />
häwa GmbH & Co. KG, Spain<br />
www.grontmij.nl<br />
www.habasit.com<br />
www.haewa.de<br />
Eaton Industries GmbH, Germany<br />
Ecolab Deutschland GmbH,<br />
Germany<br />
www.eaton.com<br />
www.ecolab.com<br />
HECHT Technologie GmbH,<br />
Germany<br />
H.J. Heinz & Co Ltd, United<br />
Kingdom<br />
www.hecht.eu<br />
www.hjheinz.ie/
12 EHEDG Company and Institute members<br />
Hengesbach GmbH & Co. KG,<br />
Germany<br />
www.hengesbach.biz<br />
K-Tron Schweiz AG, Switzerland<br />
www.ktron.com<br />
HENKEL Lohnpoliertechnik<br />
GmbH, Germany<br />
www.henkel-epol.com<br />
Kuipers Woudsend B.V.,<br />
Netherlands<br />
www.kuiperswoudsend.nl<br />
Herding GmbH Filtertechnik,<br />
Germany<br />
www.herding.de<br />
LABOM Mess- u. Regeltechnik<br />
GmbH, Germany<br />
www.labom.com<br />
HES-SO University of Applied<br />
Sciences Western Switzerland,<br />
Switzerland<br />
www.hevs.ch<br />
LAEUFER International AG Food<br />
Processing, Germany<br />
Lamican, Finland<br />
www.laeufer-ag.de<br />
www.lamican.com<br />
Hochschule Fulda - FB<br />
Lebensmitteltechnologie<br />
Fachgebiet<br />
Lebensmittelverfahrenstechnik<br />
www.lt.hs-fulda.de<br />
LECHLER GmbH, Germany<br />
Leibinger GmbH, Germany<br />
www.lechler.de<br />
www.leibinger.eu<br />
IDMC Limited, India<br />
www.idmc.coop<br />
Lely Industries N.V., Netherlands<br />
www.lely.com<br />
Ilinox Srl, Italy<br />
www.ilinox.com<br />
LEWA GmbH, Germany<br />
www.lewa.de<br />
Interroll (Schweiz) AG,<br />
Switzerland<br />
Intralox L.L.C. Europe Modular<br />
Plastic Conveyor Belts,<br />
Netherlands<br />
www.interroll.ch<br />
intralox.com<br />
GEBRÜDER<br />
LÖDIGEMaschinenbau GmbH,<br />
Germany<br />
Jürgen Löhrke GmbH, Germany<br />
www.loedige.de<br />
www.loehrke.com/<br />
Jentec GmbH Ingenieurbüro &<br />
Maschinenbau, Germany<br />
www.jentec24.de<br />
D. Iordanidis S.A, Greece www.iordanidis-pumps.gr<br />
J-TEC Material Handling, Belgium<br />
Kanto Kongoki Industrial Ltd.,<br />
Japan<br />
Kek-Gardner Ltd, United Kingdom<br />
KHS GmbH Werk Bad Kreuznach,<br />
Germany<br />
G.A. KIESEL GmbH, Germany<br />
Kieselmann GmbH, Germany<br />
King Mongkut’s Institute of<br />
Technology Ladkrabang, Faculty<br />
of Engineering Department of<br />
Food Engineering<br />
Maschinenbau Kitz GmbH,<br />
Germany<br />
Klüber Lubrication München KG,<br />
Germany<br />
www.j-tec.com<br />
kanto-mixer.co.jp<br />
www.kekgardner.com<br />
www.khs.com<br />
www.kiesel-online.de<br />
www.kieselmann.de<br />
www.kmitl.ac.th<br />
www.maschinenbau-kitz.de<br />
www.klueber.de<br />
Lübbers Anlagen und<br />
Umwelttechnik GmbH, Germany<br />
M & S Armaturen GmbH,<br />
Germany<br />
Maga Metalúrgica, S.L., Spain<br />
Magnetrol International N.V.,<br />
Belgium<br />
Marel Food Systems B.V.,<br />
Netherlands<br />
MBA Instruments GmbH,<br />
Germany<br />
Metal Industries Research &<br />
Development Centre, Taiwan<br />
METAX Kupplungs- und<br />
Dichtungstechnik GmbH,<br />
Germany<br />
Mettler Toledo AG Process<br />
Analytics, Switzerland<br />
MGT Liquid Process Systems<br />
Industrial Area Maalot, Israel<br />
Microzero Corporation, Japan<br />
www.luebbers.org/<br />
www.ms-armaturen.de<br />
www.maga-inox.com<br />
www.magnetrol.com<br />
www.marel.com<br />
www.mba-instruments.de<br />
www.mirdc.org.tw<br />
www.metax-gmbh.de<br />
www.mt.com<br />
www.mgt.co.il<br />
www.microzero.co.jp<br />
KNOLL Maschinenbau GmbH,<br />
Germany<br />
www.knoll-mb.de<br />
MikroPul GmbH, Germany<br />
www.mikropul.de<br />
KOBOLD Messring GmbH,<br />
Germany<br />
www.kobold.com<br />
Mondelez / Kraft Foods R&D Inc.,<br />
Germany<br />
www.kraftfoods.com<br />
Koninklijke Euroma B.V.,<br />
Netherlands<br />
www.euroma.com<br />
MOOG Cleaning Systems,<br />
Switzerland<br />
www.moog.ch<br />
Kraft Foods R&D Inc., Germany<br />
www.kraftfoods.de<br />
MQA s.r.o., Czech Republic<br />
www.mqa.cz<br />
Krones AG, Germany<br />
www.krones.com<br />
MST Stainless Steel Sdn. Bhd.,<br />
Malaysia<br />
www.minox.biz
EHEDG Company and Institute members 13<br />
Müller AG Cleaning Solution,<br />
Switzerland<br />
info@muellercleaning.com<br />
Reitz Holding GmbH & Co. KG,<br />
Germany<br />
www.reitz-ventilatoren.de<br />
MULTIVAC Sepp Haggenmüller<br />
GmbH & Co. KG, Germany<br />
www.multivac.de<br />
REMBE GmbHSafety + Control,<br />
Germany<br />
www.rembe.de<br />
Municipality of Karpos, Macedonia<br />
National Institute of R&D for<br />
Machines & Installations for<br />
Agriculture and Food Industries,<br />
Romania<br />
www.karpos.gov.mk<br />
www.inma.ro<br />
Gebr. Rieger GmbH + Co. KG,<br />
Germany<br />
Rittal GmbH & Co. KG, Germany<br />
RONDO Burgdorf AG, Switzerland<br />
www-rr-rieger.de<br />
www.rittal.de<br />
www.rondo-online.com<br />
Negele Messtechnik GmbH,<br />
Germany<br />
www.anderson-negele.com<br />
Rondotest GmbH & Co. KG,<br />
Germany<br />
www.rondoshop.de<br />
Nestlé S.A.Nestlé Headquarters,<br />
Switzerland<br />
www.nestle.com<br />
RULAND Engineering &<br />
Consulting GmbH, Germany<br />
www.rulandec.de<br />
Nocado GmbH & Co. KG,<br />
Germany<br />
www.nocado.de<br />
SAMSON REGULATION S.A.,<br />
France<br />
www.samson.fr<br />
Novozymes A/S, Denmark<br />
www.novozymes.com<br />
Scanjet Systems AB, Sweden<br />
www.scanjetsystems.com<br />
Pack4Food, Belgium<br />
www.pack4food.be<br />
Scan-Vibro A/S, Denmark<br />
www.scan-vibro.com<br />
Packo Inox nv, Belgium<br />
Parker Hannifin Corporation<br />
Pneumatics Div. Europe/<br />
Automation Group, United<br />
Kingdom<br />
www.packo.com<br />
www.parkermotion.com/<br />
pneu/food<br />
SED Flow Control GmbH,<br />
Germany<br />
seepex GmbH, Germany<br />
SEITAL Separatori Italia Srl, Italy<br />
www.sed-flowcontrol.com<br />
www.seepex.com<br />
www.seital.it<br />
PAYPER, S.A., Spain<br />
Pepperl+Fuchs GmbH<br />
PepsiCo, USA<br />
www.payper.com<br />
www.pepperl-fuchs.com<br />
www.pepsico.com<br />
SEW Food & Process bv,<br />
Netherlands<br />
SGS INSTITUT FRESENIUS<br />
GmbH, Germany<br />
www.seworks.nl<br />
www.de.sgs.com,<br />
www.institut-fresenius.de<br />
Pneumatic Scale Angelus, USA<br />
PNR Italia, Italy<br />
Poligrat GmbH, Germany<br />
PolySto, Belgium<br />
www.psangelus.com<br />
www.pnr.it/<br />
www.poligrat.de<br />
www.polysto.com<br />
Shanghai AOFUDE Fluid<br />
Equipment Science Technology<br />
Co., Ltd<br />
SICK AG, Germany<br />
“SIS Natural” LLC Canneryvil.<br />
Aghtsk Aragatsotn Region,<br />
Armenia<br />
www.chinaavm.com<br />
www.sick.de<br />
www.sisnatural.am<br />
POWER Engineers, Inc., United<br />
Kingdom<br />
www.powereng.com<br />
SISTO Armaturen S.A.,<br />
Luxembourg<br />
www.sisto.de<br />
Proaseptic Technologies S.L.,<br />
Spain<br />
www.proaseptic.com/<br />
SKF Sverige AB, Sweden<br />
www.skf.com<br />
ProCert Mexico / USA, Mexico<br />
www.procert.ch<br />
SMC Pneumatik GmbH<br />
www.smc-pneumatik.de<br />
Produsafe B.V., Netherlands<br />
Protek Engineering Solutions Ltd,<br />
United Kingdom<br />
Purdue University, USA<br />
www.produsafe.com<br />
www.protekengineering.<br />
co.uk<br />
www.purdue.edu<br />
Sociedad Mexicana de Inocuidad<br />
y Calidad para Consumidores de<br />
Alimentos AC (SOMEICCAAC),<br />
Mexico<br />
Solids Components Migsa, S.L.,<br />
Spain<br />
www.someicca.com.mx<br />
www.migsa.es<br />
QUIMIPRODUCTOS, S.A. de<br />
C.V., Mexico<br />
Radar process S.L., Spain<br />
www.quimiproductos.com.<br />
mx<br />
www.radarprocess.com<br />
Solids system-technik s.l., Spain<br />
Sommer & Strassburger GmbH &<br />
Co. KG, Germany<br />
www.solids.es<br />
www.sus-bretten.de<br />
Rattiinox srl, Italy<br />
www.ratiinox.com<br />
SONTEC Sensorbau GmbH,<br />
Germany<br />
www.sontec.de
14 EHEDG Company and Institute members<br />
SORMAC B.V., Netherlands<br />
S.S.T. Schüttguttechnik GmbH,<br />
Germany<br />
SPX Flow Technology Rosista<br />
GmbH, Germany<br />
Steeldesign GmbH, Germany<br />
Gebr. Steimel GmbH & Co.<br />
Maschinenfabrik, Germany<br />
www.sormac.nl<br />
www.solids.de<br />
www.apv.com<br />
www.steeldesign.de<br />
www.steimel.com<br />
Van Meeuwen Smeertechniek<br />
B.V., Netherlands<br />
VDMA Fachverband<br />
Nahrungsmittelmaschinen und<br />
Verpackungsmaschinen, Germany<br />
VEGA Grieshaber KG, Germany<br />
Vienna University of Technology /<br />
Institute of Chemical Engineering,<br />
Austria<br />
www.vanmeeuwen.nl<br />
www.vdma.org<br />
www.vega.com<br />
www.vt.tuwien.ac.at<br />
Stephan Machinery GmbH,<br />
Germany<br />
Stork Food & Dairy Systems B.V.,<br />
Netherlands<br />
Stranda Prolog AS, Norway<br />
www.stephan-machinery.<br />
com<br />
www.fds.storkgroup.com<br />
www.stranda.net<br />
Vikan A/S, Denmark<br />
VISCO JET Rührsysteme GmbH,<br />
Germany<br />
Volta Belting Technology Ltd.,<br />
Netherlands<br />
www.vikan.com<br />
www.viscojet.com<br />
www.voltabelting.com<br />
STW – Stainless Tube Welding<br />
GmbH, Germany<br />
www.stw-gmbh.de<br />
von Rohr Armaturen AG,<br />
Switzerland<br />
www.von-rohr.ch<br />
Südmo Components GmbH,<br />
Germany<br />
www.suedmo.de<br />
VTT Technical Research Centre of<br />
Finland, Finland<br />
www.vtt.fi/<br />
Food Industry Swisslion Ltd.,<br />
Macedonia<br />
Taiwan Filler Tech. Co., Ltd,<br />
Thailand<br />
Tanis Food Tec b.v., Netherlands<br />
TBMA EUROPE B.V., Netherlands<br />
Tetra Pak Packaging Solutions<br />
AB, Sweden<br />
www.swisslion.com.mk<br />
www.twftc.com<br />
www.tanisfoodtec.com<br />
www.tbma.com<br />
www.tetrapak.com<br />
WAM GmbH, Germany<br />
Wennekes Welding Support BV,<br />
Netherlands<br />
Wenzhou Aomi Fluid Equipment<br />
Science & Technology Co., Ltd.,<br />
Peoples Rep. of China<br />
Hans G. Werner Industrietechnik<br />
GmbH, Germany<br />
Wilco PM, Lebanon<br />
www.wamgroup.com<br />
www.weldingsupport.nl/<br />
www.wzaomi.com<br />
www.werco.de<br />
www.wilcopm.com<br />
TMR Turbo-Misch und<br />
Rühranlagen, Germany<br />
Tokachi-zaidan, Japan<br />
www.tmr-ruehrtechnik.de<br />
www.tokachi-zaidan.jp<br />
Wipotec Wiege- und<br />
Positioniersysteme GmbH,<br />
Germany<br />
www.wipotec.com<br />
TPI Chile S.A., RCH<br />
www.tpi.cl<br />
Wire Belt Co Ltd, United Kingdom<br />
www.wirebelt.co.uk<br />
Forschungszentrum<br />
Weihenstephan für Brau- und<br />
Lebensmittelqualität Technische<br />
Universität München, Germany<br />
www.blq-weihenstephan.de<br />
WITTENSTEIN alpha GmbH,<br />
Germany<br />
Wright Flow Technologies Ltd,<br />
United Kingdome<br />
www.wittenstein-alpha.de<br />
www.idexcorp.com<br />
Faculty of Agriculture - Institute of<br />
Food Technology -<br />
www.bg.ac.rs<br />
Xylem, Inc., Germany<br />
www.xylemflowcontrol.com<br />
Dep. of Micobiology<br />
University of Belgrade, Serbia<br />
ULMA Packaging Technological<br />
Center, Spain<br />
www.ulmapackaging.com/<br />
Zeppelin Reimelt GmbH, United<br />
Kingdom<br />
Zürcher Hochschule für<br />
Angewandte Wissenschaften,<br />
Switzerland<br />
www.reimelt.de<br />
www.lsfm.zhaw.ch<br />
Unilever Research Laboratory<br />
Vlaardingen, Netherlands<br />
www.unilever.com<br />
University of Cambridge<br />
www.www.cam.ac.uk<br />
University of Osijek, Faculty of<br />
Food Technology, Hungary<br />
www.ptfos.unios.hr<br />
University of Parma, Italy<br />
www.unipr.it<br />
URESH AG, Switzerland<br />
www.uresh.ch<br />
List status as of December 2012
EHEDG membership 15<br />
EHEDG membership<br />
• The EHEDG network is open to individuals,<br />
companies and institutes and comprises almost 1000<br />
persons who are the representatives of<br />
• Companies for the manufacturing of food or of<br />
equipment for the production of food, pharmaceuticals<br />
and/or cosmetics<br />
• Companies supplying engineering services<br />
• Scientific and research organisations<br />
• Health authorities<br />
EHEDG is an “Institution for General Benefit” and donations<br />
may be fully deducted from tax.<br />
Good reasons to become an<br />
EHEDG member<br />
• EHEDG creates a central, internationally recognized<br />
source of excellence on hygienic engineering<br />
• EHEDG provides networking on an international level,<br />
opportunities for the establishment of global contacts<br />
and are interlinking our Regional Sections<br />
• EHEDG is a platform for an exchange of state-ofthe-art<br />
know-how and offer advancement in hygienic<br />
engineering knowledge<br />
• EHEDG provides influence in setting global standards<br />
and rules and have impact on regulatory bodies<br />
• EHEDG offers a legal basis by practically<br />
demonstrating how to follow existing requirements<br />
and standards<br />
• EHEDG guidelines are referenced by international<br />
organisations and provide practical know-how<br />
• EHEDG guidelines are created by gathering the<br />
expert know-how of our members who are equipment<br />
manufacturers of food and packaging machinery<br />
as well as food processing companies, research<br />
institutes and health authorities<br />
• EHEDG follows up new trends and help to share,<br />
disseminate and canalize hygienic design expertise<br />
• The EHEDG mission is extended to ‘environmental<br />
issues’ and aiming to support food safety and<br />
sustainability<br />
• EHEDG evaluates hygienic design in relation to shelflife<br />
• EHEDG provides international, high-level training &<br />
education and our training material is developed by<br />
recognized experts in the field<br />
• EHEDG provides equipment certification by EHEDGaccredited<br />
test institutes<br />
• The EHEDG certification methods are continuously<br />
further developed and complemented by new test<br />
methods<br />
• EHEDG provides reference publications like the<br />
EHEDG <strong>Yearbook</strong> and press articles in scientific<br />
journals and trade magazines<br />
• EHEDG enhances the reputation of our member<br />
companies and help them to become leaders in<br />
hygienic design and processing<br />
• EHEDG provides an information and meeting platform<br />
at the EHEDG Congress, an international event held<br />
biannually in varying countries.
European Hygienic Engineering & Design Group<br />
Test and Certification Institutes<br />
The following institutes and organisations are authorised by EHEDG to test and certify equipment:<br />
DENMARK<br />
DTU National Food Institute<br />
Dr. Jens Adler-Nissen<br />
Søltoftsplads 221<br />
Dk-2800 Kgs. Lyngby<br />
Phone: +45 4525 2629 / E-mail: <strong>ehedg</strong>@food.dtu.dk<br />
www.dtu.dk/English.aspx<br />
Testing and Evaluation:<br />
Dr. Per Væggemose Nielsen<br />
Phone: +45 4525 2631<br />
E-mail: <strong>ehedg</strong>@food.dtu.dk, pvn@ipu.dk<br />
Mr Jon J. Kold<br />
Phone: +45 8870 7515<br />
E-mail: jon.kold@staalcentrum.dk<br />
FRANCE<br />
Adria Normandie<br />
Dr. Nicolas Rossi<br />
Adria Normandie – Centre d’ Expertise Agroalimentaire, Dpt.<br />
Research<br />
Boulevard 13 Juin 1944<br />
14310 VILLERS BOCAGE<br />
Phone: +33 2 31 25 43 00<br />
E-mail: nrossi@adrianie.org<br />
www.adria-normandie.com<br />
GERMANY<br />
TU München Forschungszentrum Weihenstephan für<br />
Brau- und Lebensmittelqualität<br />
Dr. Jürgen Hofmann<br />
Alte Akademie 3<br />
D-85354 Freising<br />
Phone: +49 8161 87 68 799<br />
Fax +49 8161 71 41 81<br />
E-mail: jh@hd-experte.de, juergen.hofmann@<strong>ehedg</strong>.org<br />
www.blq-weihenstephan.de/leistungen/hygienic-design.html<br />
NETHERLANDS<br />
TÜV Rheinland Nederland B.V.,<br />
Ilse Wasim-Moestaredjo<br />
P.O. Box 541<br />
NL-7300 AM Apeldoorn<br />
Phone: (+31 88) 8 88 78 88<br />
E-mail: Ilse.Wasim@nl.tuv.com<br />
www.tuv.com/nl/index.html<br />
Testing and Evaluation:<br />
Jacques Kastelein<br />
TNO<br />
P.O. Box 360, 3705 MJ Zeist,<br />
Phone: +31 88 86 61877<br />
E-mail: Jacques.kastelein@tno.nl<br />
www.tno.nl/<br />
SPAIN<br />
AINIA Centro tecnológico<br />
A. Pascual Vidal<br />
Departamento de Calidad y Medio Ambiente,<br />
Parque Tecnológico de Valencia,<br />
c/Benjamin Franklin, n° 5-11<br />
ES-46980 Paterna (Valencia)<br />
Phone: +34 961 366 090<br />
Fax +34 961 318 008<br />
E-mail: apascual@ainia.es<br />
www.ainia.es/web/acerca-de-ainia<br />
UNITED KINGDOM<br />
Campden BRI<br />
Lawrence Staniforth<br />
Station Road<br />
GB-Chipping Campden, GLOS , GL55 6LD<br />
Phone: +44 1386 842042<br />
E-mail: l.staniforth@campden.co.uk<br />
www.campden.co.uk/<br />
Mr Andy Timperley<br />
Phone: +44 1789 490081<br />
E-mail: andy.timperley@tesco.net<br />
USA<br />
PURDUE University<br />
Professor Mark T. Morgan, P.E.<br />
Food Science Building, Room 1161<br />
745 Agriculture Mall Drive<br />
USA-West Lafayette, IN 479072009<br />
In addition to the certification organisations above, the<br />
following research institutes participate in the development<br />
of EHEDG test methods:<br />
• Agence Francaise de Sécurité Sanitaire des Aliments,<br />
France<br />
• Institut Nationale de la Recherche Agronomique,<br />
France<br />
• Lund University, Department of Food Engineering,<br />
Sweden<br />
• SIK - Swedish Institute for Food Research<br />
• Unilever Research Vlaardingen, The Netherlands<br />
• VTT Biotechnology and Food Research, Finland<br />
For further information on EHEDG Test and Certification<br />
Institutes please refer to www.<strong>ehedg</strong>.org.<br />
List status as of December 2012
European Hygienic Engineering & Design Group<br />
Legal requirements for hygienic design in Europe<br />
There are European requirements for food safety to protect consumers. ‘Hygienic design’ is one<br />
of the elements that is needed to produce safe food and fulfil all of these requirements. This<br />
article presents an overview of the food safety and hygiene regulations in Europe that provide<br />
machinery and food producers with essential guidance.<br />
Hans-Werner Bellin, BELLINconsult, Aarbergen, Germany, e-mail: hans-werner.bellin@bellinconsult.de,<br />
www.bellinconsult.de<br />
Most people in Europe buy their food in supermarkets. It is<br />
likely that the majority of these consumers do not know the<br />
conditions under which the products they purchase have<br />
been produced, processed, packed, stored and distributed.<br />
They do not know what has happened, or even what can<br />
happen to a product during its travel from its place of origin<br />
to the point of sale. Consumers do not always know what<br />
chemical, biological, environmental or other factors can spoil<br />
the product, or what the potential negative health impacts<br />
such contamination of their foods may pose.<br />
Both EU Regulation 852/2004 of the European Parliament<br />
and of the Council of 29 April 2004 on the hygiene of<br />
foodstuffs and EU Regulation 2073/2005 of 15 November<br />
2005 on microbiological criteria for foodstuffs focus on the<br />
product and the process.<br />
Food safety professionals, however, realise that there are<br />
many possibilities for negative influences on food products<br />
as they travel from farm to fork. For this reason, vigilence<br />
along the entire food supply chain is vital to ensure that all<br />
possible risks are reduced to acceptable levels.<br />
Food laws and regulations provide food producers and food<br />
equipment manufacturers with the requirements to manage<br />
potential food safety risks. The globally influential international<br />
food standards Codex Alimentarius (www.codexalimentarius.<br />
org), published by the Food and Agriculture Organisation<br />
(FAO) of the United Nation (www.fao.org) and the World<br />
Health Organization (WHO, www.who.int), sets up a global<br />
framework of general principles of food hygiene. Supporting<br />
this target, the European Commission (EC) has developed<br />
several European regulations and directives that primarily<br />
address the food processor and require that food is produced<br />
in a safe manner.<br />
The overarching food safety regulation in the European<br />
Union (EU) is EU Regulation 178/2002 of the European<br />
Parliament and of the Council of 28 January 2002 laying<br />
down the general principles and requirements of food law,<br />
which established the European Food Safety Authority<br />
and regulates procedures in matters of food safety. The<br />
regulation enables the European member states to require a<br />
certain quality management system in each food processing<br />
plant. The main points are:<br />
• Basic hygiene principles<br />
• Food and feed business operators’ legal<br />
responsibilities for ensuring product safety<br />
• Unsafe foodstuffs may not be placed on the market<br />
• Traceability<br />
• Consideration of long-term, cumulative effects<br />
Figure 1. The CE mark, which identifies industrial equipment as<br />
in compliance with all the safety requirements established by the<br />
European Union, must appear on each unit.<br />
EU Regulation 852/2004 requires companies to implement a<br />
quality control system and proposes the Hazard Analysis and<br />
Critical Control Points (HACCP) system as an appropriate measure<br />
to ensure the quality of the process. The following steps are<br />
necessary to fulfil this requirement:<br />
• Conduct hazard analysis<br />
• Determine critical control points (CCPs)<br />
• Establish critical limit(s)<br />
• Establish system to monitor CCPs<br />
• Establish corrective action<br />
• Establish verification procedure<br />
• Establish documentation<br />
In addition, EU Regulation 852/2004 mentions in Annex 1 that<br />
all the equipment must be cleaned, and where necessary,<br />
disinfected in an appropriate manner. In Annex II, Chapter V,<br />
there is a requirement for hygienic design and cleanability<br />
for the entire facility.<br />
EU Regulation 2073/2005 requires the following:<br />
• Determining limits for safe food<br />
• Food safety criteria for best before date (BBD)<br />
• Process hygiene criteria during manufacturing
18 Legal requirements for hygienic design in Europe<br />
EU Regulation 1935/2004 on materials and articles<br />
intended to come into contact with food covers the following<br />
equipment: processing machinery and filling equipment, and<br />
kitchen equipment, containers, and packaging materials. The<br />
regulation specifically requires that food-contact materials<br />
and equipment comply with the following:<br />
• No human health hazards<br />
• No indefensible modification of food composition<br />
• No detraction from organoleptic food properties<br />
• No misdirection of customers<br />
• Use of ‘for food contact’ or the symbol (Figure 2). (This<br />
symbol is only needed, if there is no instruction manual<br />
and if it is not obvious that this is for food contact).<br />
• Traceability on all manufacturing and distribution steps<br />
EU Regulation 2023/2006 of 22 December 2006 on good manufacturing<br />
practice (GMP) for materials and articles intended to come<br />
into contact with food requires that the following must be set up and<br />
installed for all producers of materials intended to come into contact<br />
with food and are covered by EU Regulation 1935/2004:<br />
• Quality assurance system<br />
• Quality control system<br />
• Documentation<br />
According to Article 2 of EC 2023/2006: “This regulation shall<br />
apply to all sectors and all stages of manufacture, processing<br />
and distribution of materials and articles, up to but excluding<br />
the production of starting substances.” This means that,<br />
for example, all producers of plastic materials must have a<br />
quality system that includes the required documentation if<br />
they produce materials intended to come in food contact.<br />
Depending on the risk assessment, this documentation must<br />
be more or less detailed, corresponding to the known or<br />
potential risk.<br />
To prevent consumers from absorbing toxic substances<br />
that may leach from plastics that come into contact with<br />
foods, the European Commission has issued EU Regulation<br />
10/2011 on plastic materials and articles intended to come<br />
into contact with food. Rubber and silicone materials are not<br />
covered by this regulation. Since there is nothing specific<br />
for seals in Europe, the US Food and Drug Administration<br />
(FDA) Code of Federal Regulations (CFR) 21 is commonly<br />
used in Europe.<br />
Food safety is the core interest of the European Commission.<br />
EC Directive 2006/42/EC, or the Machinery Directive, which<br />
came into force at the end of 2009, sets up the essential<br />
requirements for machinery. All machines brought to the<br />
European market must fulfil these requirements. The CE<br />
mark, which identifies industrial equipment as in compliance<br />
with all the of safety requirements established by the<br />
European Union must appear on each unit (Figure 1).<br />
Annex I of the Machinery Directive describes in detail what<br />
has to be taken into consideration to build safe machines.<br />
Of particular interest to the food industry is Chapter 2.1 of<br />
Annex I, entitled ‘Foodstuffs machinery and machinery for<br />
cosmetics or pharmaceutical products.’ This chapter not only<br />
takes into consideration potentially hazardous situations<br />
for equipment operators and the environment in which the<br />
machine is used, but it is the only chapter in this directive<br />
that refers to the potential hazards for the consumer of the<br />
product produced on these machines. Essentially, this means<br />
that mistakes caused by neglecting these requirements can<br />
have a strong impact on public health.<br />
The Machinery Directive states that all surfaces (with the exception<br />
of disposable parts), including joining areas that come into product<br />
contact must:<br />
• Be smooth, without ridges or crevices<br />
• Reduce projections, edges and recesses to a minimum<br />
• Be easily cleaned and disinfected<br />
• Inside surfaces must have curves of a radius sufficient<br />
to allow sufficient cleaning<br />
From a hygienic design perspective, the following re quirements<br />
are particularly noteworthy:<br />
• It must be possible for liquids, gases and aerosols<br />
deriving from products and from cleaning, disinfecting<br />
and rinsing fluids to be completely discharged from the<br />
machinery.<br />
• Machinery must be designed and constructed in such<br />
a way as to prevent any substances or living creatures,<br />
in particular insects, from entering, or any organic<br />
matter from accumulating.<br />
• Machinery must be designed and constructed in such<br />
a way that no ancillary substances that are hazardous<br />
to health, including the lubricants used, can come into<br />
contact with products.<br />
Figure 2. EU food contact symbol used for marking materials<br />
intended to come into contact with food in the European Union as<br />
defined in EU Regulation 1935/2004.<br />
For food processing machines, so-called “C-Standards”<br />
also are provided in some detail, including how the design<br />
of the machine (e.g., the roughness of the surfaces)<br />
should be addressed in machines used in contact with<br />
specific products. The standards EN ISO 14159, “Safety<br />
of machinery - Hygiene requirements for the design of<br />
machinery” and EN 1672-2, “Food processing machinery -<br />
Basic concepts - Part 2: Hygiene requirements” describe the<br />
aim of the Directive through examples.<br />
In addition to these standards, the European Hygienic<br />
Engineering & Design Group (EHEDG) Guideline 8 criteria<br />
and the EHEDG Guideline 13, Hygienic design of equipment<br />
for open processing, offer additional guidance. The content
Legal requirements for hygienic design in Europe 19<br />
of these two guidelines is comparable with the two European<br />
Committee for Standardisation (CEN) standards, and in<br />
some cases, the examples used are the same. There are<br />
some minor differences in the definition of the food zone,<br />
but the design of the units should be such that they can be<br />
readily cleaned within an appropriate time. Ultimately, every<br />
machine has to be cleaned, and depending on the overall<br />
cleanability of a machine and its components, this can be<br />
time-consuming. For this reason it is much cheaper for food<br />
processors to invest in machines that are designed properly<br />
with high cleanability rather than buying cheaper machines<br />
with low cleanability, which might cause product spoilage or<br />
contamination triggered by product residues and/or cleaning<br />
agents left behind.<br />
For machines that do not meet the “easy to clean”<br />
requirements of the Machinery Directive and the relevant<br />
standards, the CE conformity is not valid. The only question<br />
is, who decides if something is cleanable or not? For this,<br />
EHEDG provides certification for various types of equipment.<br />
This is a voluntary approval scheme that provides a high<br />
level of confidence that the equipment conforms with the<br />
Machinery Directive. EHEDG is working on new certification<br />
schemes and guidelines to improve the machines for more<br />
efficient cleanability.<br />
3-A Sanitary Standards, Inc.<br />
Promoting Food Safety Through Hygienic Design<br />
<br />
<br />
<br />
Leads the development of modern hygienic design standards<br />
for equipment and accepted practices for processing systems.<br />
Oversees the comprehensive Third Party Verification inspection<br />
program required for 3-A Symbol authorization and voluntary<br />
certificates for processing systems and replacement parts.<br />
Provides specialized education resources to enhance the knowledge<br />
of equipment fabricators, processors and regulatory professionals.<br />
Learn, network, and share insights on hygienic design with some of<br />
the most qualified and trusted authorities from around the world.<br />
3-A Sanitary Standards Inc.<br />
6888 Elm Street, Suite 2D • McLean, Virginia • 22101-3829<br />
PH: 703-790-0295 • FAX: 703-761-6284 • EMAIL: 3-ainfo@3-a.org<br />
3-A Sanitary Standards, Inc.<br />
www.3-a.org
European Hygienic Engineering & Design Group<br />
The importance of hygienic design:<br />
A process facility case study and checklist<br />
The hygienic design of food processing facilities and equipment is becoming more important<br />
to the food industry, since it allows for a maximisation of the efficiencies of manufacturing lines<br />
and minimises the cleaning processes without penalising the operation’s effectiveness.<br />
Carolina López Arias, QA Coordinator Sanitation, Mondelēz International<br />
email: clopeza@mdlz.com<br />
Figure 1. Processing steps of a cream cheese manufacturing line.<br />
In this practical case study of a new cream cheese<br />
manufacturing line installed in an existing facility (Figure 1),<br />
the hygienic design principles that should be incorporated<br />
into the operations of food processing facilities are described<br />
within the framework of the phases of a project management<br />
approach. A checklist of the elements of hygienic design<br />
under this construct is presented.<br />
Project Management<br />
Figure 2. Project management phases.<br />
Every project consists of four phases (Figure 2). There are<br />
common functions involved in these phases, which include<br />
the project manager, and the quality assurance, sanitation,<br />
conversion, research and development, and supply change<br />
departments. The inverted pyramid in Figure 2 shows that<br />
more resources and time are required to accomplish Phases<br />
1 and 2 of a project (i.e., development and pre-engineering<br />
design) than Phases 3 and 4. It is critical to allocate the right<br />
amount of time and resources to each phase to successfully<br />
implement a project.<br />
Phase 1. Project development:<br />
feasibility and risk assessment<br />
The goals of Phase 1 are to evaluate the feasibility of the<br />
project idea and estimate the risks, costs, benefits and<br />
resources associated with the project. By using tools that<br />
allow for the evaluation and measurement of the risks<br />
associated with a project, such as brainstorming or failure<br />
modes and effect analysis (FMEA), the project team can<br />
effectively consider the elements that involve all of the<br />
different key functions of the project.<br />
In this phase, it is imperative that the project team cover in<br />
its risk assessments, at a minimum, the following aspects of<br />
the production facility and operations:<br />
• Microbiological safety assessment<br />
• Allergen assessment<br />
• Cleaning and hygiene (covering both clean-in-place<br />
[CIP] and clean-out-of-place [COP]<br />
• Production capacity<br />
• Utilities capacity
The importance of hygienic design: A process facility case study and checklist 21<br />
Phase 2. Project pre-engineering: Design<br />
The objective of this phase is to have hygienic design<br />
principles established for location and layout, piping and<br />
instrumentation, and supplier specifications.<br />
1. Location and layout determination. This involves three<br />
hygienic design principles, as follows:<br />
a. Hygienic design principle 1:<br />
Separation. In the case of the cream cheese facility, a new<br />
layout of the facility was needed in order to meet the the<br />
hygienic design principles. Determining a new layout, in this<br />
example, took into account the following considerations:<br />
• Space availability within the existing facilities.<br />
• Physical separation between the raw area and<br />
pasteuriser area.<br />
• Allergens segregation.<br />
b. Hygienic design principle 7:<br />
Proper ventilation and utility air. In order to ensure the<br />
proper ventilation of the different areas of the facility, the<br />
following considerations need to be taken into account:<br />
• Air quality (i.e., filtration requirements according to<br />
product sensitivity).<br />
• Proper design of the installation that prevents<br />
condensation.<br />
• Location of the supply and extraction systems are<br />
properly located to avoid product contamination, and<br />
ventilation system (i.e., fans) are properly located<br />
(Figure 5).<br />
▬► Entrances for people to the manufacturing line<br />
Figure 5. Ventilation map.<br />
▬► Entrances for people to the manufacturing line<br />
Figure 3. Initial layout of the cream cheese manufacturing facility.<br />
As a result of the evaluation, a new layout was proposed for<br />
the facility (Figures 3 and 4).<br />
c. Hygienic design principle 2:<br />
Cleanability. It is essential that the position of the drains in<br />
the processing room is 100% compatible with the layout of<br />
the processing line. For this specific case, it was possible<br />
to fit the layout of the processing line to the drains location<br />
in the room (Figure 6).<br />
▬► Entrances for people to the manufacturing line<br />
Figure 4. Final layout of the facility after hygienic design<br />
evaluation.<br />
▬► Entrances for people to the manufacturing line<br />
Figure 6. Processing line and room layout in alignment with proper<br />
positioning of drains in processing room.
22 The importance of hygienic design: A process facility case study and checklist<br />
2. Piping and instrumentation diagram (P&ID). This<br />
involves one significant hygienic design principle:<br />
d. Hygienic design principle 2:<br />
Cleanability. During the definition of the P&ID for the<br />
processing line, the following aspects should be considered<br />
and included:<br />
• Identify all of the different equipment that are part of<br />
the process.<br />
• Establish cleaning methods (i.e., CIP, manual, etc.)<br />
and cleaning regimes.<br />
• Evaluate restrictions inw the process and determine<br />
alternative solutions to ensure that effective cleaning is<br />
achieved.<br />
In the cream cheese facility during the P&ID definition phase,<br />
it was determined that for the CIP cleaning of the scraped<br />
surface heat exchangers (SSHE), a reinforcement was<br />
needed to ensure effective cleaning of the system (Figure<br />
7). The red arrows represent the product flow and the pink<br />
ones CIP reinforcement.<br />
During the CIP cleaning additionally to the main route (red<br />
arrows) there is a flip that makes a closed loop with the<br />
SSHE, supported by a centrifugal pump.<br />
Figure 7. CIP cleaning route for the scraped surface heat exchangers (SSHE).<br />
3. Specifications for different suppliers. Once the P&ID is<br />
completed, the next step is to define the detailed function of<br />
the line (FDS), as well as the specifications for the quality of<br />
the materials to be used. Once all this information is compiled<br />
the specifications can be sent to the different suppliers in<br />
order to get an estimated quotation for the installation.<br />
Some hygienic design principles that are important to be<br />
considered when defining the specifications are:<br />
e. Hygienic design principle 2:<br />
Cleanability.<br />
• Identify the method of cleaning (e.g., CIP, clean-out-ofplace<br />
[COP], foam, manual cleaning).<br />
• Assess the capability of the equipment to handle<br />
frequent CIP temperature exposure.<br />
• Determine whether all of the equipment components,<br />
such as valves, are designed to be cleaned in place.<br />
• Ensure that the process connections of all the<br />
measurement devices are hygienically designed.<br />
• Decide how many process connections are needed.<br />
f. Hygienic design principle 3:<br />
Compatible materials. All materials that may come into<br />
contact with food should not be able to make the food unfit<br />
for consumption (e.g. toxic). As such, all materials used in<br />
the composition of food manufacturing equipment should be:<br />
• highly resistant to corrosion;<br />
• nonporous with smooth surfaces;<br />
• highly resistant to thermal variations;
The importance of hygienic design: A process facility case study and checklist 23<br />
• resistant to mechanical tensions;<br />
• absent of protective fragile coverings or coatings that<br />
easy deteriorate; and<br />
• of an ideal cleanliness capacity, which translates to a<br />
high degree of elimination of microorganisms.<br />
g. Hygienic design principle 4:<br />
Smooth and accessible surfaces. Considerations<br />
include:<br />
• Roughness of the material (i.e., 0.8 mm for product<br />
contact surfaces and 3 mm for non-product contact<br />
surfaces).<br />
• Smooth and continuous welding.<br />
• Equipment accessibility for cleaning effectiveness<br />
check (e.g., spray balls and agitators).<br />
• Cleanability of the space around the equipment.<br />
h. Hygienic design principle 5:<br />
Self draining. The following actions should be taken:<br />
• Minimise horizontal surfaces.<br />
• Process and CIP piping should be sloped to allow<br />
drainage (20 mm per meter).<br />
• Equipment/installation is self-draining (Figure 8).<br />
Figure 9. Examples of hygienic design issues identified in FAT.<br />
In this specific case during the FAT of the filling machine,<br />
niches in the frame and exposed treats were found that<br />
could promote dirtiness harbourage<br />
2. Start with the construction of the line. The first step to<br />
be taken prior to construction is to determine the traffic<br />
patterns. The production and personnel traffic patterns<br />
are established in order to minimise the risks and prevent<br />
product contamination.<br />
▬► Entrances for people to the manufacturing line<br />
Figure 10. The traffic patterns of personnel through the production<br />
area can have a big impact on the hygiene of the plant.<br />
In the case of the cream cheese production facility, a<br />
new entrance for construction workers was established,<br />
isolating the area under construction from the production<br />
area (Figure 10).<br />
Figure 8. Self-draining installation.<br />
During the CIP cleaning the direction of the flow is opposite<br />
to the one shown in the figure 8 (pink arrows). At the end of<br />
the last step of the cleaning the pump changes the rotation<br />
direction thus ensuring the complete drainage of the pipe.<br />
Once the installation of the equipment begins it is important<br />
to perform a regular review of the installation to ensure all<br />
hygienic design principles and goals are and continue to be<br />
implemented and met (Figure 11).<br />
Phase 3. Project Execution: Building<br />
In Phase 3, the building and execution step, there are a few<br />
important tasks to be done. These include:<br />
1. Perform a factory acceptance test (FAT) at all suppliers’<br />
sites in order to:<br />
• Confirm that all of the hygienic design principles are<br />
met.<br />
• Identify potential needs that were not considered in<br />
the previous project development phases (Figure 9).<br />
Figure 11: Equipment hygienic design issues.<br />
Both pictures show hygienic design issues, the first one a<br />
syphon that promotes water stagnation and the second one<br />
the presence of a screw that could drop into the product.
24 The importance of hygienic design: A process facility case study and checklist<br />
Phase 4. Project Commission:<br />
Accept and installation<br />
This is the last phase of the project. Once this phase<br />
is completed, the installation will be approved by all of<br />
the functions involved and production can begin. The<br />
commissioning, under a sanitation point of view, consists of:<br />
• An entire review of the hygienic design of the<br />
installation once it is completely built.<br />
• Validation of the effectiveness of the cleaning<br />
(e.g., visual inspection + swabbing, enzyme-linked<br />
immunosorbent assay [ELISA]) during the start-up<br />
phase.<br />
• Training of the operators on how to clean the new<br />
installation.<br />
After the line has been running for a certain period of time,<br />
the site acceptance test (SAT) will take place to approve the<br />
final handover of the installation to the plant. During the SAT,<br />
a complete tear-down of the line will be carried out by the<br />
sanitation team to confirm the absence of product residues,<br />
biofilms, allergen residues, and other potential contaminants.<br />
This verification will be performed using the same tools used<br />
in the start-up phase.<br />
Conclusion<br />
• In addition to the takeaway messages that can<br />
be gleaned from this example of the application<br />
of hygienic design principles to the design and<br />
construction of a cream cheese manufacturing facility,<br />
there are some that are worth reiterating:<br />
• Allocate the proper amount of time/resources for the<br />
feasibility and pre-engineering phases. The more the<br />
work is developed during these phases, the higher the<br />
likelihood of successful implementation of the project.<br />
• Sanitary design expertise has to be present in the FAT<br />
in order to identify potential sanitary design issues that<br />
equipment suppliers should modify before bringing the<br />
systems on site.<br />
• During the execution phase it is really important to<br />
perform a frequent (i.e., daily) assessment of the<br />
building and processing areas to identify potential<br />
design “issues” that can still be fixed at this stage but<br />
not in further stages in the process.<br />
• Unexpected “surprises” may arise during the execution<br />
and commissioning phase. Be ready to proactively<br />
look for feasible alternatives that can be implemented<br />
without significant impact to the efficiency of the line.
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European Hygienic Engineering & Design Group<br />
Solving concrete kerb challenges to ensure hygiene and<br />
food safe wall protection in manufacturing environments<br />
Using chemical- and water-resistant polymer composite kerbs and plinths help ensure that food<br />
production facilities remain hygienic.<br />
Nick Van den Bosschelle, PolySto, Lokeren, Belgium, e-mail: nick@polysto.com, www.polysto.com<br />
For the past 25 years, sandwich panel constructions have<br />
been the most popular way to construct food safe rooms in<br />
Europe, because it offers fast installation, is easy to clean<br />
and provides good insulation value. Nevertheless, sandwich<br />
panels are very weak and quickly damaged. Often, kerbs in<br />
this scheme have been made onsite in the manufacturing<br />
plant during construction, composed of concrete and covered<br />
by the floor finishing. This system has some important<br />
disadvantages with regard to food safety, impact resistance<br />
and maintenance.<br />
Concrete covered by any kind of flooring material is never a<br />
monolithic system and after some period of time, the bonding<br />
between the concrete and the floor material will break as the<br />
concrete deteriorates due to exposure to humidity and acids<br />
in the air and other physical impacts to the surface. Physical<br />
impacts from trollies, forklifts, hand pallets and cleaning<br />
machines cause cracks to appear in the floor covering<br />
(Figures 1 and 2). The result is that dirt and cleaning water<br />
starts to leak through those cracks, building up behind the<br />
floor covering and absorbed by the concrete. This trapped<br />
dirty water will eventually begin to evaporate, creating a high<br />
pressure of humidity behind the floor covering. The pressure<br />
eventually breaks the bonding between the concrete and<br />
the floor finishing, exposing the concrete and creating food<br />
safety issues as dirt builds up in the resulting crevices and<br />
provides harbourage to harmful bacteria.<br />
Figures 1 and 2. Damaged concrete kerbs, as shown, create<br />
harbourage niches for dirt and bacteria in food processing<br />
environments.<br />
Figures 3 and 4. Kerbs and plinths for food safe environments.
Solving concrete kerb challenges to ensure hygiene and food safe wall protection in manufacturing environments 27<br />
Another problem that frequently arises when using<br />
concrete kerbs is that the sealant between the panel and<br />
concrete kerb can break. The difficulty is that there is no<br />
bonding with water-resistant glues or sealant between the<br />
concrete and sandwich panel. As such, dirty water will start<br />
to accumulate behind the concrete kerbs creating a niche<br />
where microorganisms can survive and grow – and become<br />
a real cross-contamination risk in the food production<br />
environment.<br />
Prefabricated polymer composite kerbs and<br />
plinths for food safe environments<br />
For these reasons, kerbs used in food processing<br />
environments where hygiene is a priority should be<br />
constructed with materials that are chemical-, impact- and<br />
water-resistant. Polymer composite kerbs and plinths<br />
provide a solution to the hygiene challenges posed by kerbs<br />
composed of concrete. Prefabricated polymer composite<br />
kerb systems are made by mixing polyester resins and<br />
quartz granulates with the surface and then finished with a<br />
bacteriostatic and shock-resistant polyester gel coat surface.<br />
In the production of these kerbs, a monolithic system is<br />
created by moulding together the polyester quartz mass<br />
with the polyester gel coat covering. Both materials have the<br />
same chemical structure (polyester), which creates a strong<br />
kerb that is easy to clean, water- and chemical-resistant and<br />
repairable.<br />
In addition to their fabrication from hygiene-promoting<br />
materials, polymer composite kerbs can be installed to<br />
improve hygiene in the food manufacturing environment.<br />
Polymer composite kerbs are bonded to the sandwich<br />
panel with a flexible; water-resistant polymer glue. The<br />
joints can be finished with a food-safe flexible sealant that<br />
is easy to dismantle for cleaning, or with a two-component<br />
polyurethane finish. Even if the joints become damaged, the<br />
polymer glue creates a secondary water barrier so that water<br />
cannot infiltrate or become trapped behind the kerb. If the<br />
gel coat is damaged by heavy impacts over a period of time,<br />
the high water-resistance of the polymer composite mass<br />
will prevent water absorption. Damage or scratches to these<br />
types of kerbs can be easily repaired with a cleaner or a twocomponent<br />
repair kit. Finally, polymer composite kerbs can<br />
be delivered with a food-safe curving for renovations or with<br />
a rebate in the front to create a seamless connection with<br />
the floor curving.<br />
Fig. 5. Sectional drawing showing hygienic advantages of polymer<br />
composite kerbs.
European Hygienic Engineering & Design Group<br />
Hexagonal tile floors:<br />
The hygienic foundation of production areas<br />
Producers of food and beverages expect their industrial floors to remain hygienic over many<br />
years despite chemical and mechanical influences. Industrial floors build the foundation of<br />
the total production area. Every machine is connected and attached to it. In case of damage,<br />
replacement is often difficult and costly. Good planning before construction avoids this problem.<br />
Volker Aufderhaar, Argelith Bodenkeramik, Bad Essen, Germany, e-mail: aufderhaar@argelith.com,<br />
phone +49-151-1262 3575<br />
A hexagonal tile floor is an excellent solution for flooring in<br />
three production areas: locations in which hygiene is a top<br />
priority, locations that are wet, and areas that experience<br />
high levels of pallet truck or forklift traffic.<br />
Hygienic areas. Practical experience recommends the use<br />
of 18-mm thick tiles in areas with high pallet truck and forklift<br />
traffic. A tile of this thickness will increase safety in the<br />
event of additional stress from chemical cleaning agents or<br />
acids inherent to products manufactured onsite. As for the<br />
cleaning features of these flooring materials, tiles should be<br />
easy to clean. The density of a floor finishing product is the<br />
key for long-term cleaning. Frequently, flooring materials<br />
show undesirable features such as gas bubble holes or<br />
cracked-off aggregates in resin floors, sponge structures<br />
in polyurethane resin floors, or cracks at tile aggregates. It<br />
is essential to choose a flooring material that has density<br />
and is durable, so that harmful bacteria do not have an<br />
opportunity to remain on the floor surface. Modern fully<br />
vitrified porcelain tile fired to highest density meets these<br />
requirements and increases resistance to high mechanical<br />
point loads. 1<br />
Wet areas. A hexagon-shaped floor tile performs very well in<br />
wet areas. Its near-round shape fits any kind of slope, which<br />
solves one major problem associated with ceramic floors<br />
from the past: wide joints and overlipping on high and low<br />
points often caused tile chipping, creating areas vulnerable<br />
to alkaline solutions and acids (Figure 1). Furthermore,<br />
wastewater would stay in the wide joints so that chemicals<br />
such as lactic acid or caustic soda could damage the joints<br />
on a sustained basis. Also, wide joints are an ideal breeding<br />
ground for all kinds of bacteria.<br />
The exact calibration of hexagonal floor tiles allows reduction<br />
of the joint size to a required minimum of approximately<br />
2.5mm (Figure 2). In this way all types of residue run directly<br />
across the tiles into the drains. Joints are the weakest point<br />
of a ceramic floor. Therefore, joints should be stressed as<br />
little as possible.<br />
Temperature shocks often cause splits between the floor<br />
and subsurface. Different thermal expansion coefficients of<br />
building materials separate thinner tiles from the screed or<br />
create breaks in coatings. Fully vitrified porcelain tiles of 18-<br />
mm thickness slowly absorb heat and warm up continuously.<br />
Due to the thickness of the tile, the underside remains at<br />
a more consistent temperature and therefore prevents<br />
fractures from forming.<br />
Figure 1. Constant wet areas are hygienic problem zones if a floor<br />
is failing. The risk of damage is minimised by choosing the right tile<br />
and a professional contractor.<br />
Traffic areas. Areas with high heavy pallet truck and forklift<br />
traffic on a daily basis will need to reliably sustain dynamic<br />
and heavy loads. Extruded tile floors frequently cause<br />
significant noise due to their 6- to 10-mm wide joints. These<br />
familiar clattering noises continuously impact tile edges,<br />
causing damage after a short time. Such damage not only<br />
makes the floor unhygienic, but it looks shabby as well.<br />
Resin-based floors are often considered too thin and<br />
incapable of permanently resisting these loads; they<br />
would break off the substrate. Compared with resin floors,<br />
hexagonal tiles offer optimal protection for the total floor<br />
system. Dynamic loads from rolling vehicles occur at acute<br />
angles to tile edges minimising vibrations and impacts (e.g.,<br />
from hardened plastic wheels). A floor made of hexagonal<br />
tiles creates the smoothest possible rolling surface with extra
Hexagonal tile floors: The hygienic foundation of production areas 29<br />
damage resistance. Additionally, 18-mm thick fully vitrified<br />
porcelain tiles are capable of resisting heavy mechanical<br />
point loads. They distribute these loads conically into the<br />
ground, minimising stress on the screed.<br />
or beverage production, it may be essential to use resins<br />
for grouting, as these provide chemical resistance of the<br />
joints in the final floor finish – cement based joints would not<br />
withstand the daily chemical loads in a factory and would<br />
cause failure of the whole floor accordingly. From a hygienic<br />
point of view it is also recommended to install resin based<br />
joints, as these are much more dense than relatively porous<br />
cement joints.<br />
Additionally, the technical advantages of the ‘small tile’ cannot<br />
be ignored. Hexagonal tiles can be installed in funnel shapes<br />
to fit almost any slope leading towards drainage systems or<br />
channels without overlipping and minimise cutting of tiles.<br />
The mechanical load resistance is also far higher than with<br />
other flooring solutions (Figures 3 and 4).<br />
Figure 2. To receive a virtually seamless floor with small joints that<br />
minimise the opportunity for bacteria to find harbourage, hexagonal<br />
tiles need to be perfectly accurate in size.<br />
Safety and size: Other important flooring<br />
factors affecting hygiene<br />
Slip resistance in wet areas is also important as slip and trip<br />
injuries are a major safety issue in the food industry. Meeting<br />
both requirements equally well has been a challenge in the<br />
past. Older generations of tiles, such as extruded tiles, were,<br />
due to their coarse ceramic characteristics, optically smooth<br />
and slip-resistant, but very hard to clean. Floors used to turn<br />
black after only a few years due to chemicals and abrasion<br />
of forklift tires. Resin floors may not retain their anti-slip<br />
values from the time of installation due to abrasion and may<br />
become a hazard for the workforce over time. In addition,<br />
resin floors are hand-made and do not give a constant tread<br />
safety as industrial-made tiles do. Densely-fired, fully vitrified<br />
porcelain tiles effectively fulfil both requirements in one<br />
product. The hardness of these tiles makes them extremely<br />
resistant to abrasion.<br />
One might think that hexagonal 10cm² floor tiles would be<br />
too small and consequently, that joint proportion would be<br />
too high. Therefore, tiles must be accurate to size so that<br />
they can be installed butt jointed via vibration or conventional<br />
method. This means the area of the joints, calculated in m²,<br />
will be significantly smaller, resulting in less grouting material.<br />
A hexagonal tile floor will require approximately 0.5 kg of<br />
the expensive epoxy grouting material. Using an extruded<br />
or split tile in 24x11.5 cm format of the same thickness and<br />
normal 6mm-wide joints requires approximately four times<br />
more epoxy grouting material. To install tile floors in food<br />
Figure 3.A floor in a bakery has to be hygienic and withstand high<br />
thermal and mechanical loads daily.<br />
Figure 4.Well-designed details at expansion joints or at floordrain-connections<br />
are essential for the lifetime of a floor covering,<br />
no matter if tile or resin floor.<br />
Reference<br />
1. Carpentier, B. 2011-2012. A suggested method for<br />
assessing the cleanability of flooring materials. EHEDG <strong>Yearbook</strong><br />
2011-2012, p. 16.
European Hygienic Engineering & Design Group<br />
Research on hygienic flooring systems<br />
Particle and VOC emissions, chemical and biological<br />
resistance, and cleanability<br />
In the food industry, a hygienic manufacturing environment is an absolute necessity in order to<br />
minimise reject rates due to contamination and ensure low-germ or sterile conditions. Product<br />
quality is especially impaired by microorganisms but also by other forms of contamination, such<br />
as particles and chemical residues. Today, some foods are already produced and packaged<br />
under cleanroom conditions in the same way as practised by the pharmaceutical industry.<br />
Cleanroom technology guarantees the necessary controlled conditions, fulfilling air quality<br />
requirements such as those stated in the EU-GMP Guideline Annex 1 for the manufacture of<br />
sterile pharmaceutical products. In order to minimise contamination risks during manufacturing<br />
processes, cleanroom environments need to be carefully planned to ensure that no sources<br />
of contamination will be present during later production. Materials used to make walls, floors,<br />
housings, joins and equipment systems need to be taken especially into consideration. Using<br />
the qualification of industrial flooring as an example, this article describes an assessment and<br />
classification procedure that will help planners to make objective decisions about the choice of<br />
materials.<br />
Markus Keller and Udo Gommel, Fraunhofer Institute for Manufacturing Engineering and Automation IPA,<br />
Department of Ultraclean Technology and Micromanufacturing, Stuttgart, Germany.<br />
e-mail: markus.keller@ipa.fraunhofer.de<br />
To create controlled hygienic environments, appropriate<br />
room solutions in suitable locations are needed with minimum<br />
microbiotic base levels. To achieve this, the concentration of<br />
particles in the air has to be drastically reduced. In a normal<br />
urban atmosphere, a particle concentration of 0.5 to 35 billion<br />
particles with a diameter of >0.5 µm is typical per cubic meter<br />
air volume. Cost-intensive filtration technology can reduce<br />
such particulate concentrations to less than 3520 particles/<br />
m 3 >0.5 µm diameter. This is required, for example, in sterile<br />
pharmaceutical manufacturing environments and equates<br />
approximately to Cleanroom Class International Standards<br />
Organisation (ISO) 5 in accordance with the cleanroom<br />
classification standard ISO 14644-1. 1 The pharmaceutical<br />
industry uses its own standard for the production of sterile<br />
medicinal products, which also defines different zones for<br />
hygienic manufacturing environments and extends the<br />
considered contamination sources including particles to<br />
microorganisms. 2 In the food industry, microbiological<br />
contamination is also especially relevant. 3 Particles between<br />
10 and 20 µm in size make up the majority of airborne<br />
microorganisms. 4 Another hygiene-related classification<br />
system is based on the so-called “hospital guideline” DIN<br />
1946-4. 5 The food industry is currently implementing more<br />
and more of the existing good manufacturing practice (GMP)<br />
pharmaceutical guidelines. A targeted reduction in airborne<br />
particles >0.5 µm automatically means a reduction in airborne<br />
microorganisms. However, in hygienic manufacturing<br />
environments, additional parameters regarding the materials<br />
used are also of interest: chemical resistance, biological<br />
resistance, cleanability and antimicrobial properties. 6<br />
Solutions from other areas:<br />
Pharmaceutical industry<br />
As many foods are produced and/or packaged under almoststerile<br />
conditions (milk products, meats, beverages), the<br />
following section gives some brief background information<br />
about manufacturing environments in the pharmaceutical<br />
industry. In the process, many of the aspects mentioned<br />
can be applied directly to manufacturing environments in the<br />
food industry. A cross-industry viewpoint can be very helpful<br />
when implementing clean and hygienic manufacturing<br />
environments because both the pharmaceutical and food<br />
industries have to combat the same sources of contamination:<br />
particles and microorganisms.<br />
EU-GMP Guideline<br />
The European Commission Guide to Good Manufacturing<br />
Practice (EU-GMP Guideline) is implemented as a<br />
statutory standard in the manufacture of sterile drugs and<br />
other contamination-sensitive products. In Annex 1 of the<br />
EU-GMP guideline, a special emphasis is placed on the<br />
requirements of hygienic manufacturing environments.<br />
Clean zones for the manufacture of sterile products<br />
are graded according to the environmental conditions<br />
required. In order to minimise the risk of contaminating<br />
the product or material concerned with particles or<br />
microorganisms, each manufacturing process requires a<br />
corresponding degree of environmental cleanliness in an<br />
operating state. In order to fulfil operating state conditions,<br />
the zone has to be designed to achieve a certain degree<br />
of air cleanliness when in a resting state. The resting<br />
state is the state whereby the entire technical equipment
Particle and VOC emissions, chemical and biological resistance, and cleanability 31<br />
is installed and ready for operation but no employees<br />
are present. The operating state is the state when all<br />
equipment is being correctly operated by the prescribed<br />
number of employees.<br />
In compliance with the current EU-GMP Guideline Annex 1,<br />
Figure 2 gives information about the classification of GMP<br />
cleanliness classes according to the number of airborne<br />
particles detected.<br />
EU-GMP Guideline Annex 1: Cleanliness Classes<br />
In the manufacture of sterile drugs, there are four cleanliness<br />
classes for the zones required:<br />
• Cleanliness Class A: sterile zones. These are<br />
localised zones where high-risk work processes are<br />
carried out (e.g., for filling processes, or areas where<br />
containers with stoppers, open ampoules and bottles<br />
are kept or sterile connections produced). Such<br />
conditions are ensured using a laminar unidirectional<br />
airflow system with a flow rate of 0.45 m/s + 20%.<br />
• Cleanliness Class B: sterile zones. Unless an<br />
insulator is used, this is where aseptic products are<br />
prepared and filled; they form the antechamber of a<br />
Cleanliness Class A zone.<br />
• Cleanliness Classes C and D: clean zones.<br />
Laboratories and manufacturing areas for less-critical<br />
steps in the manufacture of sterile products.<br />
• Cleanrooms of GMP Class E and F and CNC zones:<br />
areas without defined particle or biocontamination<br />
level. These may be manufacturing areas,<br />
laboratories, documentation areas, offices, break<br />
rooms and other room types. Recently, a new type of<br />
cleanroom class is also mentioned: CNC (controlled<br />
but not classified). These controlled zones do not<br />
require stringent tests to be classified. Depending<br />
on the official assessment, CNC areas may be<br />
installed in hermetically separate sterile manufacturing<br />
environments; for example, by using insulators, in<br />
order to keep the extremely expensive tests and<br />
documentation involved in classifying zones as low as<br />
possible. 7<br />
Figure 1 contains examples of work processes carried out in<br />
the different cleanliness classes.<br />
GMP Cleanliness<br />
Class<br />
A<br />
B<br />
C<br />
D<br />
Examples of work processes<br />
for sterilised products in closed<br />
end-containers<br />
Aseptic preparation and filling<br />
of products where the work step<br />
represents an unusual risk<br />
Environmental condition of Cleanliness<br />
Class A unless an insulator<br />
is used<br />
Preparation of solutions where the<br />
work step represents an unusual<br />
risk, filling products<br />
Preparation of solutions and ingredients<br />
for subsequent filling<br />
GMP<br />
Cleanliness<br />
Class<br />
Maximal<br />
permissible count<br />
of particles per m 3<br />
-resting state-<br />
> 0.5 µm > 5 µm > 0.5 µm > 5 µm<br />
A 3,520 20 3,520 20<br />
B 3,520 29 352,000 2,900<br />
C 352,000 2,900 3,520,000 29,000<br />
D 3,520,000 29,000 Not fixed Not fixed<br />
Figure 2. Classification of air quality in the manufacture of sterile<br />
products: airborne particles in compliance with EU-GMP Annex 1.<br />
In Figure 2, particle concentrations in the column “in a resting<br />
state” must be attained in an area in an unmanned state<br />
after a short clean-up phase of approximately 15-20 minutes<br />
on completion of work processes. Particle concentrations in<br />
the table for Cleanliness Class A in an operating state must<br />
be observed in the immediate product area if the product or<br />
open container is exposed to the environment. In hygienic<br />
manufacturing environments, the number of microorganisms<br />
on surfaces and in the air also plays a major role. Figure 3<br />
shows the classification of cleanliness classes according to<br />
the number of microorganisms detected.<br />
GMP<br />
Cleanliness<br />
Class<br />
Recommended limiting value for<br />
microbiological contamination<br />
Air sample<br />
[CFU/m 3 ]<br />
Maximal permissible<br />
count of particles<br />
per m 3<br />
- operating state-<br />
Sedimentation<br />
plates<br />
(Ø 90 mm)<br />
[CFU/4 hours]<br />
Contact<br />
plates<br />
(Ø 55 mm)<br />
[CFU/plate]<br />
A
32 Particle and VOC emissions, chemical and biological resistance, and cleanability<br />
Hygienic materials suitable for use<br />
in the food industry using the example<br />
of flooring systems<br />
All surfaces in a clean manufacturing environment that are<br />
in contact with the ambient air are capable of contaminating<br />
it. Consequently, they significantly affect the attainment<br />
and maintenance of a required degree of cleanliness. For<br />
example, if process water accumulates in the joint of a<br />
flooring system sealed with poor quality sealing material, any<br />
mould spores present could flourish there due to the good<br />
local growing conditions (humidity, temperature, nutrients)<br />
and become a major source of infection. If a material<br />
corrodes as a result of the effect of an aggressive cleaning<br />
agent, it not only loses its required material properties but<br />
may become a dangerous source of particulate emissions.<br />
Chemical influences may cause a flooring material to<br />
become brittle. If mechanical action is subsequently applied<br />
(transport rollers of a heavy preparation tank, etc.), cracks<br />
could form, representing a microscopic hazard because it<br />
would be impossible to remove or inactivate effectively any<br />
microorganisms accumulating in the cracks. Among others,<br />
this aspect was considered in the requirements of the EU-<br />
GMP Guideline Annex 1 illustrated in Figure 4:<br />
Extract from EU-GMP-guideline Annex 1:<br />
» … in clean areas, all surfaces should be smooth, imperious and unbroken in<br />
order to minimize the shredding or accumulation of particles or<br />
microorganisms and to permit repeated application of cleaning agents and<br />
desinfectants where used … «<br />
» … The manufacture of sterile products is subject to special requirements in<br />
order to minimize risks of microbiological contamination, and of particulate<br />
or pyrogen contamination.«<br />
Particle<br />
Biol. Resistance and<br />
Microbizidity<br />
Cleaning and<br />
Chem. Resistance<br />
Figure 4. Extract from EU-GMP Annex 1 with derivable material<br />
requirements.<br />
Therefore, flooring systems installed in a hygienic<br />
manufacturing environment need to be resistant to the<br />
chemicals used in cleaning and disinfection agents.<br />
Microorganisms may not colonise there or interact with them.<br />
Surfaces must be thoroughly cleanable. No substances may<br />
migrate from materials to the product and the material may<br />
not host any form of contamination. In some industries,<br />
material surfaces are treated with an antimicrobial agent.<br />
In such cases, it is not only important to be sure that the<br />
antimicrobial coating functions in practice but also that the<br />
material does not represent a hazard to human health in any<br />
way.<br />
Due to the large surface area and associated contamination<br />
risk of flooring systems, they are now discussed in more<br />
detail. First of all, the under-surface of a flooring system<br />
must be permanently sealable. Liquid residues from a<br />
previous cleaning or disinfection process may remain on the<br />
surface for a long time, making it extremely important for the<br />
system to be highly resistant to the chemicals used. To be<br />
able to clean edges and corners effectively, flooring must be<br />
laid so that it extends upwards to cover the bottom section<br />
of walls. The mechanical properties of the system must be<br />
designed to prevent damage from occurring as a result of<br />
typical stresses (e.g., rollers of transport trolleys, high point<br />
loads). To generally aid cleanability, roughness levels must<br />
be kept as low as possible. However, the need for a nonslip<br />
coating, if required, may not be forgotten in the process.<br />
Where possible, the transmission between floor and wall<br />
systems should be seamless.<br />
The biomaterial regulations in Annex 2 state that, for all<br />
protective categories, surfaces are to be impermeable to<br />
water and easy to clean. From Level 2 upwards, biomaterial<br />
regulations require adequate resistance to acids, alkalis,<br />
disinfection agents and solvents. 8<br />
In the case of reactive systems (e.g., epoxy resin floors),<br />
care must be taken to ensure that the outgassing of organic<br />
contamination is kept to a minimum in order to protect<br />
employees and, if sensitive processes are concerned, also<br />
the product. No critical airborne particulate contamination<br />
may be generated on subjecting the flooring system to<br />
tribological stress (e.g., rollers, stress due to walking,<br />
etc). Comparative tests need to be carried out on a wide<br />
range of materials to determine outgassing behavior and<br />
particulate emission due to tribological stress, and the<br />
results appropriately classified. 9,10 It must be possible to<br />
clean flooring systems effectively using dedicatedl cleaning<br />
methods and agents.<br />
Material and methods:<br />
Comparative tests to classify materials<br />
Particulate emission<br />
If a material is subjected to mechanical stress due to<br />
friction from another material, material abrasion in the form<br />
of particle generation occurs. This also can be caused by<br />
sliding friction from rollers or static friction from walking over<br />
a flooring system wearing shoes. To obtain comparative<br />
information about particulate emission from various flooring<br />
systems due to tribological stress (friction), a special<br />
tribological test bench has been constructed (Figure 5). It is<br />
operated in a Class ISO 1 reference cleanroom to eliminate<br />
measurement errors caused by potential foreign particles<br />
in the environmental air. 2 In the comparative classification,<br />
only sliding friction is considered. The counter sample<br />
used in the tests is a standardised polyamide-6 roller that<br />
simulates the sliding friction caused by transport rollers.<br />
Both applied force and angular velocity are kept constant.<br />
The laminar unidirectional airflow with a velocity of 0.45<br />
m/s, which flows from the cleanroom ceiling to the raised<br />
floor in accordance with ISO specifications for a Class 1<br />
cleanroom, ensures that particles generated during the test<br />
are transported downwards in a vertical direction towards<br />
the sampling probe installed downstream that detects<br />
the airborne particles (Figure 2). Using the principle of<br />
scattered light, a particle counter detects all particles with<br />
a diameter >0.2 µm and classifies the number of particles<br />
into predefined particle size channels according to their<br />
size. To take single events appropriately into account, the<br />
test is performed for a minimum of one hour. On cumulating<br />
the data and transforming coordinates, a result is obtained<br />
that gives an assessment of the test material with regard to<br />
particulate abrasion due to tribological stress. The procedure
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34 Particle and VOC emissions, chemical and biological resistance, and cleanability<br />
is standardised and explained in detail in the guideline VDI<br />
2083 Part 17. The material value obtained enables a direct<br />
comparison of flooring systems to be made and shows<br />
how much the system potentially contributes to particulate<br />
contamination of the cleanroom environment when subjected<br />
to tribological stress.<br />
layered construction also is accounted for in the planned<br />
application. Glass dishes made of borosilicate glass are<br />
used as VOC-free carriers. Samples are preconditioned for a<br />
period of 30 days under controlled climatic conditions (room<br />
temperature 22+/-1°C, relative humidity of 45%. 12,13 Crosscontamination<br />
of the samples during storage is prevented<br />
through the use of mini-environments with VOC filtration. The<br />
VOC-reduced quality of the environment must be at least<br />
one class better than the anticipated VOC assessment of the<br />
test piece. 9 After storage, material samples are heated in a<br />
microchamber at atmospheric pressure and a standardised<br />
temperature of 22°C +/-1°C for one hour. The VOCs emitted<br />
from the material sample are then advanced to a sorption<br />
tube by a rinsing gas where they are adsorbed. The sorption<br />
tube is then analysed via TD-GC/MS. Thermodesorption<br />
causes the VOC to be desorbed from the sorption tube and<br />
made available for the subsequent analysis carried out in<br />
compliance with VDA 278. The SER m of the material is then<br />
ascertained from the results, which in turn can be expressed<br />
as a simple standardised material value ISO AMC m . 14,15<br />
Figure 5. Cleanroom-suitable tribological test bench at Fraunhofer<br />
IPA to ascertain particulate emission from material surfaces. To<br />
avoid cross-contamination, the test bench is installed in an ISO<br />
Class 1 cleanroom.<br />
VOC outgassing<br />
In addition to particulate emission, the outgassing behaviour<br />
of hygienic flooring systems due to mechanical stress also<br />
is becoming a more important issue. When using suitable<br />
materials, statutory limiting values for workplace stress<br />
(MAK values) must be observed. Substances outgassing<br />
from materials (e.g., softeners, solvents, and other volatile<br />
constituents of materials) contribute significantly toward<br />
contaminating the ambient air with airborne molecules (i.e.,<br />
airborne molecular contamination, AMC). Here, organic<br />
airborne contamination (volatile organic compounds, VOCs)<br />
is the most relevant. 11 Airborne molecular contamination<br />
has been identified as being the main cause of the socalled<br />
“sick building syndrome.” The procedure, outlined<br />
here, enables different flooring systems to be compared<br />
with regard to the emission of VOCs; a ranking list has been<br />
derived for their selection and classification. The quantity<br />
of organic compounds released into the atmosphere is<br />
dependent upon surface area, outgassing time, age, and<br />
temperature of the test material. The specific emission rate<br />
(SER) ascertained for each material is related to these<br />
parameters and is expressed as mass per surface area and<br />
time [g/m 2 s] at room temperature. To obtain comparable<br />
results, a standardised test procedure using a microchamber<br />
is applied (Figure 6).<br />
Outgassing is assessed by collecting and accumulating<br />
volatile compounds in an adsorber, followed by analysis using<br />
thermodesorption with gas chromatography coupled with<br />
a mass spectrometer (TD-GC/MS). Samples are selected<br />
representatively according to their geometry and surface<br />
quality, taking the later application of the flooring system<br />
into consideration. In the case of multilayered materials, the<br />
Figure 6. Microemission chamber to ascertain VOC emissions from<br />
a material surface at Fraunhofer IPA.<br />
Biological resistance<br />
The international test standard Deutsches Institut<br />
für Normung (DIN) EN ISO 846 has proven useful in<br />
determining the biological resistance of materials to bacteria<br />
and moulds. 16 Under the test conditions prescribed in the<br />
standard, test materials are assessed to find out if they are<br />
inert to moulds (Procedure A) and bacteria (Procedure C),<br />
or if microorganisms are able to interact with them. Test<br />
samples are incubated at 24°C and 95% relative humidity<br />
in accordance with the parameters stated in ISO 846 and<br />
visually evaluated after a period of four weeks. The numerical<br />
ISO assessment of both Procedure A and Procedure C<br />
enables classification according to a rating value based on a<br />
worst case of both procedures.<br />
The problem with the standard ISO 846 is the complicated<br />
and time-consuming incubation procedure for the test<br />
microorganisms if the procedure is done completely<br />
according to the standard. Also ISO 846 lacks a standardized<br />
objective assessment matrix for Procedure C to evaluate<br />
bacterial growth as the stated assessment matrix is only<br />
applicable for the evaluation of mould growth according to
Particle and VOC emissions, chemical and biological resistance, and cleanability 35<br />
procedure A. So how bacterial growth should be evaluated?<br />
There is no method described in ISO 846. Therefore,<br />
as defeat strategy the majority of test laboratories and<br />
Fraunhofer IPA use the assessment matrix for Procedure A<br />
for the evaluation of procedure C. This lack has prompted<br />
the Deutsches Institut für Normung (DIN – German Institute<br />
for Standardisation) at ISO level to initiate a revision of the<br />
standard. The aim is to replace subjective visual assessment<br />
with objective mechanical assessment through the use of<br />
more cost-efficient automated image analysis methods. The<br />
guideline series ISO 4628-1 to -6 gives an example of an<br />
automated analysis method that uses reference images and<br />
their black-and-white binarized images for comparison. 17<br />
As mentioned before, the ISO 846 standard – which has<br />
remained unchanged since 1997 – is currently being<br />
revised. Interested institutes are invited to add their skills and<br />
technical knowledge to the discussion and are requested to<br />
contact the author.<br />
Chemical resistance<br />
There are several internationally-recognised standards for<br />
assessing chemical resistance. Tests in accordance with<br />
the DIN EN ISO 2812-1 immersion process have proven<br />
especially useful in assessing the suitability of materials and<br />
surfaces for use in hygienic manufacturing environments. 18<br />
To compensate for the fact that future cleaning or disinfection<br />
agents are not known at this point, materials are tested with<br />
a representative spectrum of possible groups of chemicals.<br />
This approach permits a general assessment about the<br />
chemical resistance of materials to be made but not a specific<br />
assessment regarding defined cleaning or disinfection<br />
agents. The concept was developed by the industrial<br />
alliance CSM under the management of Fraunhofer IPA and<br />
is standardised in VDI 2083 Part 17 and VDI 2083 Part 18. 9,19<br />
The resulting standard test assesses chemical resistance<br />
to the following 10 representative reagents in dependence<br />
upon their anticipated later maximum concentration in<br />
cleaning and disinfection media:<br />
With regard to outgassing:<br />
• Formalin (37%)<br />
• Hydrogen peroxide (30%)<br />
• Peracetic acid (15%)<br />
With regard to alcohols:<br />
• Isopropanol (100%)<br />
With regard to alkalis as constituents of alkaline cleaning<br />
agents:<br />
• Caustic soda (5%)<br />
• Ammoniac (25%)<br />
With regard to acids as constituents of acid cleaning agents:<br />
• Sulfuric acid (5%)<br />
• Hydrochloric acid (5%)<br />
• Phosphoric acid (30%)<br />
With regard to cleaning agents containing chlorides:<br />
• Sodium hypochlorite (5%)<br />
In accordance with the ISO 2812-1 immersion procedure,<br />
the entire material sample is placed in a receptacle filled with<br />
the chemical, which is then hermetically sealed. If a coating<br />
applied to a substrate requires testing, care is to be taken to<br />
ensure that all surfaces and edges of the carrier material are<br />
sealed with the coating concerned. In the modified spotting<br />
method according to VDI 2083-18, the test substance is<br />
placed in a glass vessel. The test surface and a seal are<br />
placed over it and then clamped into a device to create a<br />
hermetic seal. The test apparatus is then rotated 180° so<br />
that the test chemical is in contact with the surface of the<br />
sample.<br />
The modification made to ISO 2812-4 requires a much<br />
larger volume of test chemical. 20 If only a droplet is applied,<br />
evaporation phenomena cannot be excluded. Test pieces<br />
are exposed to the respective reagents at room temperature<br />
for a period of one, three, six and 24 hours and subsequently<br />
examined to see if there any visiible alterations. Using 10-<br />
fold magnification, the test surface is visually assessed<br />
conform to ISO 4628-1 to -5 with regard to the following<br />
criteria: type of damage (alteration in degree of shine,<br />
discolouring or yellowing, swelling, softening or reduced<br />
scratch resistance); amount of damage (N-value); size<br />
of damage (S-value) and intensity of alteration (I-value). 17<br />
The analysis is carried out as follows: “blistering, N2-S2” or<br />
“discolouring, I1”. The poorest value (N, S, I) obtained after<br />
24 hours is taken for the comparative assessment. In the<br />
CSM procedure, the mean of all 10 values from each of<br />
the previously mentioned chemicals gives the rating value,<br />
which is used for classification and comparison.<br />
Microbicidal properties<br />
Some flooring systems have microbicidal properties;<br />
these can be divided into bactericidal properties (effect on<br />
bacteria) and fungicidal properties (effect on moulds). One<br />
method of assessing bactericidal effects is to implement the<br />
international test standard ISO 22196. 21 In the standard, the<br />
recommended bacteria strains Staphylococcus aureus and<br />
Escherichia coli are incubated on a surface sample treated<br />
with a bactericide and also on another sample without the<br />
bactericide. Other bacterial strains may also be utilised but<br />
this must be clearly mentioned in the test report. Using the<br />
contact plate method, the once-only assessment of the<br />
logarithmic reduction factor R = log(CFU untreated /CFU treated ) is<br />
made after a period of 24 hours by determining the number of<br />
bacteria present on the reference surface, as well as on the<br />
surface treated with bactericide. 22 CFU stands for “colonyforming<br />
units” because bacteria can only be detected and<br />
counted if they have grown during incubation to form visible<br />
colonies. With the contact plate method, a solid incubation<br />
medium (casein-soya-peptone-agar or similar) with a surface<br />
area of approximately 50 cm 2 is applied to a flat surface with<br />
a defined pressure over a defined period of time; specifically,<br />
5 seconds, where possible, with sufficient force so that the<br />
entire surface is in contact with the medium but without<br />
any air bubbles forming. An application weight of 1 kg has<br />
proved effective. Samples are incubated in the same way as
36 Particle and VOC emissions, chemical and biological resistance, and cleanability<br />
other cultivation test procedures. The efficacy of fungistatic<br />
or fungicidal coatings can be assessed on implementing<br />
Procedure B outlined in ISO 846. Fungistatic or fungicidal<br />
effects can be assessed if an inhibition zone is formed after<br />
application of the material sample to a fully-colonised Petri<br />
dish.<br />
Cleanability<br />
In order to assure hygienic processes and give products<br />
a maximum shelf life, adequate cleanability is generally<br />
necessary from a hygienic aspect. 23 A clean manufacturing<br />
environment is capable of minimising factors that could have<br />
a negative effect on sensitive products. 24 A standardised<br />
test procedure verifies the degree of effectiveness with<br />
which particles can be removed from a flooring system by<br />
wipe-cleaning. A linear wiping simulator is used to ensure<br />
reproducibility of the cleaning (Figure 7). Before being<br />
cleaned, test surfaces are reproducibly contaminated with<br />
a defined quantity of particles. Before and after the cleaning<br />
process, the concentration of particles present is determined<br />
by a measuring device that detects particles on surfaces<br />
(PMT Partikel-Messtechnik GmbH, Heimsheim, Germany).<br />
This enables the relative cleaning success of different<br />
surfaces to be calculated, and gives a comparative value<br />
based on standardised surface cleanliness classes. 9,25,26<br />
Figure 15 shows the results of a cleanability test on a<br />
material surface.<br />
Particulate emission<br />
The classification of particulate emission is based on the air<br />
cleanliness classes defined in ISO 14644-1 (Figure 8). 2 It is<br />
principally assumed that all particles generated by a flooring<br />
system as a result of tribological stress are released into a<br />
surrounding volume of air of 1 m 3 . 9 The ISO class calculated<br />
according to VDI 2083 Part 17 is, however, only a material<br />
classification value and cannot be directly correlated with<br />
the cleanroom class in which the flooring system can<br />
be implemented. To do this, the anticipated tribological<br />
stress also has to be taken into consideration. However,<br />
the material classification value established does enable<br />
the abrasion resistance of different flooring systems to be<br />
directly compared.<br />
Figure 8. Classification of air cleanliness in accordance with ISO<br />
14644-1. The classification of particulate emission behaviour from<br />
material samples is based on this classification..<br />
VOC outgassing<br />
Figure 7. Linear wiping simulator.<br />
Classification<br />
Classifications regarding particulate emission, outgassing,<br />
chemical and biological resistance, antimicrobial properties<br />
and cleanability are explained below in detail as developed<br />
by the industrial alliance CSM and standardised in the<br />
guideline VDI 2083 Part 17. The clear comparability and<br />
simple communication of information enables suitable<br />
materials to be rapidly selected according to their future<br />
conditions of use.<br />
To convert the SER value into an ISO AMC m class for<br />
the type of contamination concerned (in this case volatile<br />
organic compounds) the value is normed. The classification<br />
is based on ISO AMC cleanroom classes in accordance with<br />
ISO 14644-8 (Figure 9). 27 The actual detection limit is ISO<br />
AMC m (VOC) = -9.6. This material classification calculated<br />
in accordance with VDI 2083 Part 17 does not correlate<br />
with the corresponding ISO AMC cleanroom class. It does<br />
however permit the outgassing behavior of different flooring<br />
systems to be directly compared with one another. Based on<br />
the material classification value ISO AMC m , the anticipated<br />
ISO AMC class can be estimated if all relevant operating<br />
parameters are known (e.g., surface area, air-conditioning<br />
technology, volume of the manufacturing environment,<br />
etc.). 10,14
Particle and VOC emissions, chemical and biological resistance, and cleanability 37<br />
Results<br />
Particulate emission,<br />
VOC outgassing and microbiological resistance<br />
Figure 11 shows the results from an assessment of the<br />
floor covering Sikafloor 390 in accordance with ISO 846<br />
Procedures A and C.<br />
Figure 11: Assessment of the floor covering Sikafloor 390 in<br />
accordance with ISO 846 Procedure A and C.<br />
Figure 9. Cleanroom classification in accordance with ISO 14644-<br />
8 and classification of the outgassing behavior of volatile organic<br />
compounds (VOC) from material samples.<br />
Chemical and biological resistance,<br />
microbicidity<br />
Chemical and biological resistance and microbicidity are<br />
classified according to Figure 10:<br />
Figure 12 shows a summary of concrete material<br />
results regarding particulate emission, outgassing and<br />
microbiological resistance. Detailed data are available to<br />
the public in the database at the websites www.ipa-csm.com<br />
and www.ipa.qualification.com.<br />
Figure 10. Classification of chemical and biological resistance and<br />
antimicrobial properties.
38 Particle and VOC emissions, chemical and biological resistance, and cleanability<br />
Figure 14 shows the results from an assessment of the<br />
chemical resistance of a flooring system with various<br />
exposure times (Exp.) in accordance with ISO 2812-1 and<br />
ISO 4628-1 to -5:<br />
Figure 12. Overview of examples of tested flooring systems,<br />
wall coatings and sealants with regard to outgassing, particulate<br />
emission and microbiological resistance. Note: Not all tests were<br />
carried out on all materials. Key: Type “P” means panel material,<br />
“E” is epoxy-system, “F” is floor system, “S” is sealant, “P” is PUsystem<br />
and “A” is acrylic system.<br />
Chemical Resistance.<br />
Figure 13 shows an example of a classification of the<br />
chemical resistance of another flooring system.<br />
Figure 14. Assessment of the chemical resistance of a material<br />
sample in accordance with ISO 2812-1 and ISO 4628-1 to -5.<br />
Photographic examples of the effects of two chemicals.<br />
Cleanability<br />
Figure 13: Example of assessment of chemical resistance of a<br />
material sample in accordance with VDI 2083 Part 17.<br />
The cleanability of a material surface is currently expressed<br />
as a relative cleaning success. If, for example, a surface<br />
cleanliness class of SPC = 6 (SPC class in accordance with<br />
ISO 14644-9 [26]) is ascertained before cleaning and SPC<br />
= 4 after cleaning, the relative cleaning success is two SPC<br />
classes. One method of standardisation would be to have a<br />
defined level of initial contamination. As no valid standards<br />
apply at the moment, the relative cleaning success is<br />
used as a comparable material value. For the purposes<br />
of comparison, an identical level of contamination was<br />
applied to the test materials listed below, which was then<br />
measured, removed and the surface inspected again after<br />
cleaning. Surface roughness values Ra in accordance with<br />
ISO 4287 along and across the direction of grinding were
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40 Particle and VOC emissions, chemical and biological resistance, and cleanability<br />
also recorded. 28 Figure 15 shows a graphical illustration of<br />
the test results and corresponding SPC class of a material<br />
surface before and after cleaning. Figure 16 shows the final<br />
results from different material surfaces tested.<br />
Figure 15. Graph showing the test results and corresponding SPC<br />
class of a material surface before and after cleaning. Particle sizes<br />
are shown on the x-axis. Particle concentrations are shown on the<br />
y-axis. SPC class values have been taken from ISO/FDIS 14644-9.<br />
Figure 16. Overview of examples of material surfaces tested and<br />
relative cleaning efficiency.<br />
Summary<br />
A comprehensive understanding of the various aspects of<br />
cleanliness in hygienic manufacturing is required in order to<br />
select suitable flooring systems for cleanroom constructions.<br />
Reliable procedures for testing and assessing the cleanliness<br />
suitability of materials make it possible to compare materials<br />
objectively. The procedure has been standardised in the<br />
guideline VDI 2083 Part 17. The ISO standardisation<br />
currently being carried out at international level is based on<br />
the VDI guideline. By carrying out numerous tests on flooring<br />
systems, a pool of knowledge has been created regarding<br />
the cleanliness suitability of materials for use in hygienic<br />
manufacturing environments.<br />
Under www.tested-device.com and www.ipa-csm.com, the<br />
world’s first public database has been set up by Fraunhofer<br />
IPA for materials and operating utilities suitable for use in<br />
cleanrooms and hygienic manufacturing environments.<br />
The materials and results accessible to the public can<br />
be viewed at any time. This enables appropriate flooring<br />
systems to be selected for use in clean and hygienic<br />
manufacturing environments even during the design phase<br />
of a manufacturing environment.
Particle and VOC emissions, chemical and biological resistance, and cleanability 41<br />
References<br />
1. EU-GMP Guide to Good Manufacturing Practice, Annex 1. (2008).<br />
Manufacture of sterile medicinal products. Brussels: European<br />
Commission.<br />
2. ISO 14644-1. Cleanrooms and associated controlled environments<br />
– Part 1: Classification of air cleanliness. Geneva: International<br />
Organization for Standardization, 1999.<br />
3. Keller, Markus. Hygiene and Training (in German). In: Lothar Gail,<br />
Udo Gommel and Hans-Peter Hortig. Reinraumtechnik. 3. Auflage.<br />
Berlin, Heidelberg: Springer Verlag, 2011.<br />
4. USP 30 . The United States Pharmacopeia. Rockville MD:<br />
United States Pharmacopeial Convention, 2003.<br />
5. DIN 1946-4. Ventilation and air conditioning – Part 4: Ventilation<br />
in buildings and rooms of health care. Berlin: Beuth Verlag, 2007.<br />
6. Bürger, Frank and Schweizer, Marion. Equipment Design in<br />
clean and hygienic environments (in German). In: Lothar Gail, Udo<br />
Gommel and Horst Weißsieker. Projektplanung Reinraumtechnik.<br />
Heidelberg: Hüthig Verlag, 2009, pp. 84-85.<br />
7. Chalk, Simon, et al. (2011). Challenging the cleanroom paradigm<br />
for biopharmaceutical manufacturing of bulk drug substances.<br />
BioPharm International. 2011, Vol. 24, 8, pp. 44-60.<br />
8. BioStoffV. Ordinance on safety and health protection at work<br />
involving biological agents. Federal Gazette I p. 50. Berlin: Federal<br />
Ministry of Justice, 1999.<br />
9. VDI 2083 part 17 (draft). Cleanroom technology – Compatibility<br />
of materials with required cleanliness class and surface cleanliness.<br />
Berlin: Beuth Verlag, 2012.<br />
10. Keller, Markus. Molecular Emissions from cleanroom suitable<br />
materials (in German). ReinRaumTechnik. Darmstadt: GIT Verlag<br />
GmbH & Co. KG, 2010. Vol. 12, 3, pp. 14-17.<br />
11. ISO 16000-6. Indoor air – Part 6: Determination of volatile organic<br />
compounds in indoor and test chamber air by active sampling on<br />
Tenax TA ® sorbent, thermal desorption and gas chromatography<br />
using MS or MS-FID. Geneva: International Organization for Standardization,<br />
2006.<br />
12. ISO 16000-11. Indoor air – Part 11: Determination of the emission<br />
of volatile organic compounds from building products and furnishing<br />
– Sampling, storage of samples and preparation of test specimens.<br />
Geneva: International Organization for Standardization, 2006.<br />
13. VDI 2083 part 9.1. Clean room technology – Compatibility with<br />
required cleanliness and surface cleanliness. Berlin: Beuth Verlag,<br />
2006.<br />
14. Keller, Markus. (2011). VOC emissions test method: Calculating<br />
VOC emissions. Cleanroom Technology. 19:19-23.<br />
16. ISO 846. Plastics – Evaluation of the action of microorganisms.<br />
Geneva: International Organization for Standardization, 1997.<br />
17. ISO 4628-1 to -5. Paints and varnishes – Evaluation of degradation<br />
of coatings – Designation of quantity and size of defects, and of<br />
intensity of uniform changes in appearance. Geneva: International<br />
Organization for Standardization, 2003.<br />
18. ISO 2812-1. Paints and varnishes – Determination of resistance<br />
to liquids – Part 1: Immersion in liquids other than water. Geneva:<br />
International Organization for Standardization, 2007.<br />
19. VDI 2083 part 18. Biocontamination control. Berlin: Beuth Verlag,<br />
2011.<br />
20. ISO 2812-4. Paints and varnishes – Determination of resistance<br />
to liquids – Part 4: Spotting methods. Geneva: International Organization<br />
for Standardization, 2007.<br />
21. ISO 22196. Measurement of antibacterial activity on plastics and<br />
other non-porous surfaces. Geneva: International Organization for<br />
Standardization, 2011.<br />
22. DIN 10113-3. Determination of surface colony count on fitment<br />
and utensils in foodareas – Part 3: Semiquantitative method with<br />
culture media laminated taking up equipment (squeeze method).<br />
Berlin: Beuth Verlag, 1997.<br />
23. Bobe, U. The cleanability of techical surfaces in immersed<br />
systems (in German). Technical University Munich: Department<br />
of Apparatus and Plant Design; Center of Life and Food Sciences<br />
Weihenstephan, 2008.<br />
24. Gommel, Udo. Method for the determination of the cleanroom<br />
suitability of material pairings. In: IPA-IAO research and practice<br />
Volume 445. University of Stuttgart, Institute for Industrial Manufacturing<br />
and Management, Dissertation, ISBN 3-936947-8, 2006.<br />
Heimsheim: Jost-Jetter Verlag, 2006<br />
25. Keller, Markus and Waldner, Alina. (2011). How effective ist he<br />
cleaning of different surfaces? (in german). Der Lebensmittelbrief.<br />
Vol. 22, 9/10, pp. 53-58.<br />
26. ISO 14644-9. Cleanrooms and associated controlled environments<br />
– Part 9: Classification of surface cleanliness by particle<br />
concentration. Geneva: International Organization for Standardization,<br />
2012.<br />
27. ISO 14644-8. Cleanrooms and associated controlled environments<br />
– Part 8: Classification of airborne molecular contamination.<br />
Geneva: International Organization for Standardization, 2006.<br />
28. ISO 4287. Geometrical Product Specifications (GPS) – Surface<br />
texture: Profile method – Terms, definitions and surface texture<br />
parameters. Geneva: International Organization for Standardization,<br />
2010.<br />
15. Gommel, Udo, Bürger, Frank and Keller, Markus. Cleanroom and<br />
Cleanliness suitability – definitions, test methods and assessment<br />
(in German). In: Lothar Gail, Udo Gommel and Hans-Peter Hortig.<br />
Reinraumtechnik. Berlin, Heidelberg: Springer Verlag, 2011.
European Hygienic Engineering & Design Group<br />
Hygienic design of floor drainage components<br />
Drainage is a critical component affecting the hygienic performance of food production facilities.<br />
This article considers surface drainage holistically at site level initially before focusing internally<br />
to look at how features within the drain component itself might elevate hygienic performance.<br />
Martin Fairley, ACO Technologies plc, e-mail: mfairley@aco.co.uk, www.aco.co.uk<br />
Drainage is a critical component that affects the hygienic<br />
performance of food production facilities. Effective drainage<br />
helps mitigate hazards from the external environment and<br />
is central to the safe and hygienic operation internally.<br />
Floor drainage specifically provides three basic functions<br />
– interception, conveyance of fluids, and the ability to act<br />
as a barrier. Despite its importance, relatively few academic<br />
studies have focused on hygienic attributes of floor drains.<br />
Of greater concern are the numerous examples of drainage<br />
installations that exhibit some capacity to be termed<br />
hazardous. This is often a result of a floor-drain interface<br />
issue, but can equally apply to the component design<br />
itself. This article considers surface drainage holistically at<br />
site level initially before focusing internally to look at how<br />
features within the drain component itself might elevate<br />
hygienic performance.<br />
Such holistic consideration of drainage is necessary for<br />
any operation, but becomes critical where hygiene is of<br />
importance. While surface water sewers are now more<br />
common, many countries have a substantial legacy of<br />
combined surface and foul drainage systems of fixed<br />
and often inadequate capacity. Should such a system<br />
surcharge – due to influx of large amounts of surface water<br />
— sewer backflow may occur. The risk can be managed<br />
through specification of adequate backflow prevention<br />
devices. Optimally, these sense backflow and automatically<br />
close, re-opening once the event has subsided. Figure 1<br />
illustrates such a device with the necessary twin valves,<br />
one operated by external power, in accordance with EN<br />
13564 type 3,<br />
Site level drainage consideration<br />
Of course, drains serve both internal and external<br />
requirements and it is worthwhile reviewing the increasing<br />
focus on external drainage design. Many countries now<br />
acknowledge the impact of changing weather patterns and<br />
the implications for surface water management. The EU<br />
Flood Directive (2007) initiated local flood risk management<br />
plans that spurred specific legislation related to this growing<br />
external hazard. In England and Wales, for example, the<br />
Flood and Water Management Act (2010) empowers local<br />
government to coordinate flood risk management, and this<br />
translates directly to planning requirements that must be<br />
satisfied before building work commences.<br />
The implication for newly built construction is far more focused<br />
on mitigating flood risk to people and property. At site level<br />
this requires consideration of a number of potential (model)<br />
storm events and drainage design to accommodate them.<br />
Ultimately, the degree to which the risk is managed is a choice<br />
of the building operator. Storm events are commonly specified<br />
by their frequency, duration and intensity; for example,<br />
it is necessary to consider the impact of a 1:100-year (1%<br />
probability) storm in England, the duration and intensity of<br />
which will depend upon the geographical area selected in<br />
the model. The building operator may choose to manage<br />
less probable events; in other words, a 1:200-year (0.5%<br />
probability) event logically produces greater water volumes,<br />
and therefore an appropriate drainage design should follow.<br />
As may be appreciated, these new challenges to site design<br />
are accommodated in newly built construction. Existing<br />
facilities may well benefit from an engineering assessment<br />
of their drainage via a qualified professional conversant with<br />
local regulation, as many of the techniques used in a newly<br />
built construction can be retrofitted to existing sites.<br />
Figure 1. A sewer backflow prevention device.<br />
In more modern schemes, site connection will be to surface<br />
water sewer only, and in many cases, no sewer at all. In<br />
such situations the risk of building flooding can be reduced<br />
by accommodating more storm water in the now ubiquitous<br />
underground geocellular storage devices as shown in Figure<br />
2. Furthermore, the building operator may request that his<br />
or her designer does not allow car parks or other areas of<br />
the production facility to be designated as ‘flood storage’,<br />
which is becoming a common approach. Although in many<br />
cases this may be entirely justified on the grounds of cost<br />
avoidance, food production facilities may prefer to adopt<br />
alternative measures. In any case, it is necessary to specify<br />
adequate freeboard over the expected flood level with<br />
respect to the building floor.
Hygienic design of floor drainage components 43<br />
Figure 2. Geocellular storage systems provide efficient<br />
underground capacity to manage flood risk to the building and to<br />
meet local volume discharge consents.<br />
Internal floor drainage<br />
It is well recognised that drainage is an essential component<br />
of effective hygienic operation. Global initiatives such as the<br />
Global Food Safety Initiative (GFSI 2012) and European<br />
Economic Community legislation (EC 852) highlight the<br />
requirement for adequate drainage. Further definitions<br />
can be sourced from the various European standards<br />
as referenced in this article, as well as local building or<br />
construction regulations.<br />
Within the food production facility, surface fluids present a<br />
hazard for which an appropriate risk assessment strategy<br />
can be devised. Fluids may be part of the cleaning process,<br />
or may originate from specific equipment discharge points,<br />
or be simply the result of accidental spillage. Quite often<br />
the fluid contains other components – organic matter being<br />
prevalent. Floor drainage components cater for these<br />
situations through three core functions:<br />
• Interception<br />
• Conveyance<br />
• Barrier capability<br />
The main categories of floor drainage, gullies and linear<br />
channels, differ in their performance of these functions.<br />
The property of interception can be related to the efficiency<br />
of surface fluid removal, a function equally influenced by the<br />
source: Point discharges can be most efficiently intercepted<br />
by a gully, often with a tundish or funnel component on the<br />
cover or grate to minimise splashing. In cases in which large<br />
volumes of fluid discharge over a wider area, wide channel<br />
systems provide interception along their length and prevent<br />
bypass. Examples of both are shown in Figure 3.<br />
Figure 3. Fluid interception and conveyance illustrated on the left in<br />
a slot linear channel, and localised point interception is shown on<br />
the right through a tundish connected to a floor gully.<br />
Conveyance relates to fluid movement or transport. While<br />
fluid conveyance across floors should be minimised it is<br />
clear that linear channels exhibit good conveyance attributes<br />
with the benefit of generally keeping the drainage invert<br />
higher than with a pure gully system. This is especially so in<br />
larger areas. This attribute is also useful in drainage retrofit<br />
schemes, where construction depths might be minimised<br />
with subsequently less disruption. Gullies on the other hand,<br />
convey only to the ongoing drain pipe.<br />
The ability to create a barrier that prevents fluid bypass<br />
may be important at specific locations, such as doorways.<br />
As such, drainage layout may be part of the wider scheme<br />
of segregation or zoning within the facility as illustrated in<br />
Figure 4.<br />
Figure 4. A common position for floor drainage.
44 Hygienic design of floor drainage components<br />
That drains might contribute to segregation or zoning, and<br />
indeed their impact hygienically on the facility, is a matter<br />
for debate, though reference to drainage is made in a<br />
number of EHEDG derived publications (Lelieveld, Mostert,<br />
Holah: 2003; 2005; 2011). Zhoa et al. (2006) in their study<br />
of Listeria in poultry plants noted the importance of drains:<br />
“Floor drains in food processing facilities are a particularly<br />
important niche for the persistence of Listeria and can be a<br />
point of contamination in the processing plant environment<br />
and possibly in food products” (ibid, p. 3314).<br />
However, even when the provisions contained in component<br />
standards are adopted, these are not necessarily aligned<br />
with best hygienic practice. For example, the standard EN<br />
1253 permits the design of gullies with an effective sump, as<br />
illustrated in Figure 6. Here, the obvious sump provides all of<br />
the potential ingredients for bacterial growth.<br />
More recent work by Berrang et al. (2012) studied Listeria<br />
mobilization from the drain by inadvertent water spray during<br />
cleaning operations, with subsequent potential to transfer to<br />
food contact surfaces. Of note, Berrang cites studies where<br />
such bacteria have been detected in floor drainage even<br />
after extensive plant sanitation (ibid p. 1328).<br />
Reducing the potential for harbourage of such pathogens<br />
should be a key concern of any floor drainage product<br />
manufacturer concerned with hygienic principles.<br />
Floor drainage issues in practice<br />
Generally, two main issues give rise to hygienic concern:<br />
issues related to installation, and in particular the floor-todrain<br />
interface, and issues related to the component design<br />
itself. Here, the latter is considered.<br />
The choice of materials for drainage component manufacture<br />
is extensive and not necessarily constrained by the key<br />
European standard (EN 1253). Typically, where hygienic<br />
considerations apply, stainless steels are advocated. With<br />
the readily available supply of appropriate grade sheet,<br />
it should come as no surprise that many components are<br />
fabricated by none drainage-specific companies. Linear<br />
channels in basic form, especially, can be easily fabricated,<br />
as can simple ‘box’ type gullies. It is estimated that more<br />
than 200 suppliers fabricate drainage components in the<br />
European Union (EU) alone (ACO 2009), the vast majority<br />
of which are primarily fabrication companies with no specific<br />
expertise in drainage. Consequently, there is huge variation<br />
in how floor drains are fabricated, two examples are shown<br />
in Figure 5.<br />
Figure 6. Horizontal gully as portrayed in BS EN 1253.<br />
It thus becomes necessary to supplement general standards<br />
with further guidance. In the case of the floor gully, many<br />
of the design aspects of European Hygienic Engineering<br />
Design Group (EHEDG) guidance documents, particularly<br />
Document 13, may be economically incorporated in product<br />
design.<br />
ACO has sought to incorporate in its components:<br />
• Continuous welding of joints<br />
• Radiused corners<br />
• Drainability<br />
The new horizontal gully in Figure 7 shows a floor drain<br />
body that addresses the above points.<br />
Figure 5. A case for improved drainage component design.<br />
For the facility operator, specification of components that<br />
meet appropriate standards – Euronorms or their regional<br />
counterparts – ensures compliance with a number of criteria,<br />
not the least of which are load bearing and hydraulic capacity.<br />
As a matter of course, certification should be requested from<br />
component suppliers (e.g., for the internal floor gully the<br />
recommended reference is EN 1253 [2003]).<br />
Figure 7. Floor gully body addressing key principles of hygienic<br />
design.
ACO. The future of drainage.<br />
We take hygienic performance one step further.<br />
Deep-drawn body ensures smooth<br />
contours eliminating crevices that can<br />
nest dangerous bacteria.<br />
All radiuses are larger<br />
than 3mm which greatly<br />
increases the cleaning<br />
effectiveness.<br />
Edge in-fill ensures stable and<br />
durable transmission between<br />
the gully and surrounding floor<br />
and helps to minimize the risk<br />
of floor cracks that prevents<br />
bacteria growth.<br />
Dry sump design, completely drainable<br />
- eliminating potential problems<br />
of bacteria growth.<br />
ACO gully ACO pipe ACO slot channel<br />
ACO tray channel<br />
ACO gully design takes hygienic performance one step further. We focus on the exacting<br />
requirements in the food production industry, applying standards reserved for food contact<br />
surfaces EN 1672 and EN ISO 14159 to the gully design. All our building drainage products<br />
are tested according to European standards EN 1253, EN 1433 or EN 1124.<br />
More than 60 years of drainage experience makes ACO the world class supplier of<br />
drainage systems.<br />
www.aco-buildingdrainage.com
46 Hygienic design of floor drainage components<br />
A further step necessary to ensure hygienic design and<br />
one that is not always taken in drain fabrication is the pickle<br />
passivation process. The benefits of the process are well<br />
understood. Given the nature of drains, passivation helps<br />
prevent corrosion at points where inspection and cleaning is<br />
more difficult, and as such, it should be part of the standard<br />
checklist for any potential user.<br />
In summary it is useful to provide a quick checklist of the key<br />
aspects of hygienic floor drainage:<br />
Certified to EN 1253 or local equivalent<br />
Pickle passivated stainless steel Grade 304, 316<br />
or higher to specification<br />
Key hygienic design parameters of Document 13<br />
evident<br />
Specified according to the application requirements<br />
for traffic load<br />
Specified according to the application requirements<br />
for hydraulic flow<br />
Bibliography<br />
ACO (2009) Market survey of drainage component producers in<br />
Europe. Internal Report.<br />
Berrang, B.E. and J.E. Frank. (2012). Generation of airborne Listeria<br />
innocua from model floor drains. Journal of Food Protection, Vol.75,<br />
7:1328-1331.<br />
Directive 2007/60/EC of the European Parliament and of the Council<br />
of 23 October 2007 on the assessment and management of flood<br />
risks.<br />
EN (BS) 1253:2003. Gullies for buildings. British Standards<br />
Institution (BSI). London.<br />
EN (BS) 13564:2002. Anti-flooding devices for buildings. British<br />
Standards Institution (BSI). London.<br />
EHEDG Document 13. Hygienic design of open equipment for<br />
processing of food. May 2004.<br />
Flood and Water Management Act (2010 ) England and Wales,<br />
Chapter 29, (2010). London. HMSO<br />
GFSI Guidance Document Sixth Edition Issue 3 Version 6.2 (2012).<br />
www.mygfsi.com/technical-resources/guidance-document/issue-3-<br />
version-62.html.<br />
H. L. M. Lelieveld, M. A. Mostert, and J. Holah. Hygiene in food<br />
processing: Principles and practice. Woodhead Publishing Series in<br />
Food Science, Cambridge 2003<br />
H. L. M. Lelieveld, M. A. Mostert, and J. Holah. Handbook of hygiene<br />
control in the food industry. Woodhead Publishing Ltd. Cambridge<br />
2005<br />
H. L. M. Lelieveld, M. A. Mostert, and J. Holah. Hygienic design<br />
of food factories. Woodhead Publishing Series in Food Science,<br />
Cambridge 2011<br />
Regulation (EC) No. 852/2004 of the European Parliament and of<br />
the Council of 29 April 2004 on the hygiene of foodstuffs.<br />
Zhao, T., T.C. Podtburg, P. Zhao, B.E. Schmidt, D.A. Baker, B. Cords,<br />
M.P. Doyle. (2006). Control of Listeria spp. by competitive-exclusion<br />
bacteria in floor drains of a poultry processing plant. Applied and<br />
Environmental Microbiology, Vol. 72, 5:3314-3320.
European Hygienic Engineering & Design Group<br />
Hygienic design of high performance doors for utilisation<br />
in the food industry<br />
In order to protect human health stringent hygiene regulations are implemented throughout the<br />
food industry, from small- to large-scale food production operations, to kitchens and canteens.<br />
The most important hygiene regulations are comprised of mandatory requirements regarding<br />
food safety, many of which focus on ensuring that the design of and materials used in the<br />
manufacture of equipment, walls, floors, ceilings, and doors used in food production facilities<br />
meet hygienic standards. In this article, hygiene regulations pertaining to doors providing<br />
entrance and exit from food manufacturing operations are discussed, as well as a door system<br />
designed for hygienic ingress and egress from low-risk and high-risk areas.<br />
Daniel Grüttner-Mierswa, Albany Door Systems GmbH, D-59557 Lippstadt, Phone +49 (0 29 41) 766-644,<br />
e-mail: Daniel.Gruettner-Mierswa@assaabloy.com, www.albanydoors.com<br />
Doors regulate access to production, washing and storage<br />
areas, separate these safely from each other, and are<br />
beneficial for smooth-running logistical operations. They<br />
also can be used as entrances to airlocks, which separate<br />
clean and dirty areas from each other (Figure 1). For these<br />
reasons, the hygienic design of doors is critically important,<br />
and several European regulations and standards are in place<br />
to help ensure that these building components contribute to<br />
the sanitary conditions of food production facilities.<br />
The most important hygiene regulations are comprised of<br />
mandatory requirements regarding food safety, such as<br />
European Commission (EC) Regulation 1935/2004 for<br />
utilised materials, which regulates the general principles and<br />
the requirements of the hygiene regulations for all foods.<br />
It stipulates, among others, that doors have to be easily<br />
cleanable and, if applicable, easy to disinfect.<br />
Figure 1. Doors can be used as entrances to airlocks, separating<br />
clean from dirty areas in a food production facility.<br />
This high level of hygiene requires a special resistance of<br />
the utilised materials against aggressive cleaning agents,<br />
as well as smooth and water repellent surfaces. In addition,<br />
according to EC Regulation 852/2004, operators must<br />
integrate doors into their Hazard Analysis and Critical Control<br />
Points (HAACP) plans, the self-implemented food safety risk<br />
analysis and management system. Specifically, under Article<br />
5 of the regulation, food processors are obliged to introduce<br />
a permanent procedure based on this system.<br />
An example of a door meeting hygienic<br />
requirements<br />
The Albany Rapid Food Door is a good example of the type<br />
of door that meets regulatory and other hygiene standards<br />
criteria. The Rapid Food Door is certified with the Institute<br />
for Occupational Safety and Health of the German Social<br />
Accident Insurance (DGUV) test mark and has been<br />
hygiene tested by the test and certification body of the<br />
German Berufsgenossenschaft BG Expert Committee for<br />
Food and Drug. The hygienic suitability of the Rapid Food<br />
door also meets the requirements of the German Product<br />
Safety Act, the DIN EN 1672-2:2009 and EC Regulation<br />
852/2004 regarding the cleanability of the curtain and easy<br />
access for cleaning to all surfaces and components.<br />
The side frames and the bottom profile of the door are<br />
completely made of stainless steel (V2A). Additionally,<br />
the door offers a slanted top roll cover and motor cover<br />
to ensure drainage. The top roll cover is hinged for easy<br />
cleaning. The side columns are open at the bottom in order<br />
to avoid the collection of excess cleaning water. Due to<br />
the hinged side frames, it is possible to thoroughly clean<br />
and disinfect the inside of the side columns. The drain<br />
drip on the bottom profile ensures that no liquid enters the<br />
clearance between the door curtain and the floor in order to<br />
avoid the contamination of foods. Additionally it is possible<br />
to adjust the lower end position to stop the bottom profile<br />
from touching the floor. Therefore it is kept dry and clean<br />
just as the drain drip.<br />
The smooth door curtain made of transparent PVC with blue<br />
reinforcement stripes is resistant against cleaning aids and<br />
is not affected in its function or appearance by permanent<br />
cleaning, which meets the requirements of EC Regulation<br />
852/2004. The reinforcement stripes are available in an<br />
extensive variety of RAL colours, which means that the<br />
door can also be customised to its production surroundings.<br />
A curtain conforming to the regulations of the US Food<br />
and Drug Administration (FDA), which stipulates the<br />
requirements for PVC that come into contact with food, is<br />
also available.<br />
The Rapid Food Door also meets the requirements of the<br />
Global Food Safety Initiative (GFSI), which divides food<br />
production facilities into three hygiene zones. Hygiene
48 Hygienic design of high performance doors for utilisation in the food industry<br />
Zone 1 entails stringent requirements regarding hygiene<br />
and cleanability. Open products are processed in these<br />
areas. Wood and glass are strictly prohibited. Access is<br />
only granted in protective clothing after the disinfection of<br />
hands. In Hygiene Zone 2, prepacked products are stored.<br />
Wooden sheets are tolerated. Stringent hygienic-based<br />
access requirements similar to Zone 1 apply to this hygiene<br />
zone. In the third, the lowest risk hygiene zone, packed<br />
goods are stored. There are no stringent requirements for<br />
this area.<br />
Figure 2. The Albany airlock system is used to ensure hygienic<br />
and continuous material flow from low-care to high-care areas at<br />
Milupa’s Fulda, Germany processing plant.<br />
An example of an application: Milupa, Fulda<br />
The Rapid Food Door is utilised at Milupa, a member of<br />
the Danone Group, at its Fulda, Germany location. In the<br />
production of baby and infant foods, as well as clinical<br />
products, stringent hygiene regulations are observed in<br />
order not to endanger the health of children or adults.<br />
The company focuses on flawless hygienic conditions in<br />
its food production facilities that exceed the mandatory<br />
requirements. Complex air filters and airlocks protect against<br />
contamination and create perfect conditions in production.<br />
While the raw material warehouse of Milupa is classified<br />
as a ‘low care’ area, the production is classified as a ‘high<br />
care’ area due to the latter’s stringent hygienic requirements.<br />
This conforms to Hygiene Zone 1 of the GFSI (Global Food<br />
Saftey Intitiative). In order to ensure a continuous material<br />
flow from the low care area to the high care area, Milupa<br />
introduced the Albany airlock system into its Fulpa facility.<br />
• Due to the interlocking system, only one door at a<br />
time can be opened. Access to the high care area is<br />
not granted unless the opposite door has completely<br />
closed. This ensures additional hygiene and offers<br />
security to the warehouse staff. The red vertical<br />
reinforcement stripes indicate the change from the<br />
low care to the high care area, and mark the strict<br />
separation of the two areas. The stainless steel side<br />
frames of the door conform to the stringent hygiene<br />
regulations of the food industry. Just like the curtain,<br />
they can be cleaned easily and thoroughly due to the<br />
smooth surfaces. The company opted for this door<br />
type not only because it meets the requirements of<br />
the Good Hygiene Praxis (GHP), which refers to the<br />
hygienic conditions of the surroundings and includes<br />
hygienic measures regarding room climate, protection<br />
against pests and/or the surface design of the interior,<br />
but also matches the HACCP concept instituted by<br />
Milupa.
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featuring best mechanical and chemical resistance it is able to resist extreme process conditions during<br />
pharmaceutical and food production. trust the original: sealing compounds from Process Seals.
European Hygienic Engineering & Design Group<br />
Performance testing of air filters for hygienic environments:<br />
Standards and guidelines in the 21 st century<br />
Air filtration is the key technology that supplies air of the required cleanliness to hygienic<br />
production areas and to ensure sufficient air quality for processes, products and human<br />
beings. Increasing demands for high-filtration performance and energy-efficient operation<br />
have prompted recent updates of existing standards and guidelines and the definition of new<br />
international documents.<br />
Dr.-Ing. Thomas Caesar, Freudenberg Filtration Technologies SE & Co. KG, 69465 Weinheim, Germany<br />
e-mail: Thomas.Caesar@Freudenberg-Filter.com<br />
For the manufacturing, testing, classification, installation and<br />
operation of air filters in general, and in the food industry in<br />
particular, various standards and guidelines must be heeded.<br />
The hygienic requirements for general building ventilation<br />
are laid down in the European standard EN 13779. For<br />
cleanrooms and associated controlled environments the<br />
filter selection, installation, inspection and operation, in<br />
particular of high efficient particulate air (HEPA) and ultra low<br />
penetration air (ULPA) filters, is defined in the international<br />
series of standards International Standards Organisation<br />
(ISO) 14644. In the food industry, guidance documents of<br />
the Global Food Safety Initiative (GFSI) and of the European<br />
Hygienic Engineering and Design Group (EHEDG) have<br />
to be regarded, in particular EHEDG Document 30, which<br />
offers the defining guidelines on air handling in the food<br />
industry. This document is currently under revision.<br />
Unlike the hygienic requirements for building and production<br />
area ventilation, the manufacturer testing and classification<br />
of air filters has not yet been standardised on a global level.<br />
In Europe, air filters are tested and classified according to<br />
two standards, EN 779 for coarse and fine dust filters and<br />
EN 1822 for efficient particulate air (EPA), HEPA and ULPA<br />
filters. In the United States, this is standardised by the ANSI/<br />
ASHRAE standard 52.2. Currently, great efforts are made<br />
to harmonise these standards globally and to add additional<br />
aspects that have not yet been considered in the existing<br />
standards and guidelines; in particular, naming standards<br />
and guidelines on the energy performance of air filters.<br />
New ISO standard for filter high efficiency<br />
(EPA, HEPA and ULPA) filters<br />
In 2006, the ISO Technical Committee (TC) 142 “Cleaning<br />
Equipment for Air and Other Gases” was reactivated, with the<br />
aim to harmonise the world of standards and guidelines for<br />
air and gas filtration on a global level. The first international<br />
standard from this committee, ISO 29464 “Cleaning<br />
equipment for air and other gases - Terminology“ was<br />
published recently, and standardises the terminology around<br />
filtration. In October 2011, the standard ISO 29463 “Highefficiency<br />
filters and filter media for removing particles in air”<br />
followed, defining in five parts the testing and classification<br />
of high-efficiency air filters. This new international standard<br />
is based, in its essential elements, on the European standard<br />
EN 1822 and will likely replace it in the near future. As in<br />
EN 1822, high-efficiency filters are subdivided into three<br />
different groups by the new standard ISO 29463 (Table 1):<br />
EPA. Filters of this group can neither be leak-proof tested<br />
at the manufacturer’s premises nor after installation at the<br />
user’s site. The efficiency is ensured by test methods as<br />
part of the manufacturer’s quality control system based on<br />
statistical methods. EPA filters typically are used to remove<br />
yeast and mold from the air stream.<br />
HEPA. Filters of this group typically are used to effectively<br />
remove bacteria and viruses from the air stream, supplying<br />
sterile air, and have to be individually leakage tested by the<br />
manufacturer. The reference test method is the scan test<br />
procedure, where the whole surface of the filter element is<br />
scanned with particle counter probes measuring the local<br />
efficiency values. Alternatively, other test methods are<br />
defined, such as the oil thread leakage test method.<br />
ULPA. Filters of this group are individually leak-proof<br />
tested by the manufacturer, in cases where the scan test<br />
method is the only suitable test method. ULPA filters are<br />
used in the strictest of cleanroom applications, such as in<br />
microelectronics.<br />
Table 1: Filter class definitions according to ISO 29463.<br />
Group<br />
EPA<br />
(E)<br />
HEPA<br />
(H)<br />
ULPA<br />
(U)<br />
ISO<br />
Class<br />
Class to<br />
EN 1822<br />
Minimal efficiency<br />
for MPPS<br />
ISO 15 E E11 ≥ 95% —<br />
ISO 20 E ≥ 99% —<br />
ISO 25 E E12 ≥ 99,5% —<br />
ISO 30 E ≥ 99,9% —<br />
ISO 35 H H13 ≥ 99,95% ≤ 0,25%<br />
ISO 40 H ≥ 99,99% ≤ 0,05%<br />
ISO 45 H H14 ≥ 99,995% ≤ 0,025%<br />
ISO 50 U ≥ 99,999% ≤ 0,005%<br />
Maximum allowable<br />
local penetration<br />
(Leakage limits)<br />
ISO 55 U U15 ≥ 99,9995% ≤ 0,0025%<br />
ISO 60 U ≥ 99,9999% ≤ 0,0005%<br />
ISO 65 U U16 ≥ 99,99995% ≤ 0,00025%<br />
ISO 70 U ≥ 99,99999% ≤ 0,0001%<br />
ISO 75 U U17 ≥ 99,999995% ≤ 0,0001%<br />
After installation, HEPA and ULPA filters must be leakage<br />
tested again at the end-user’s premises to ensure airtight fit<br />
and freedom from leaks, as defined by ISO 14644, part 3.
Performance testing of air filters for hygienic environments: Standards and guidelines in the 21st century 51<br />
Similar to EN 1822, the new international standard ISO 29463<br />
defines the scan test method as the reference method, where<br />
the local and the integral particle collection efficiencies are<br />
measured for the most penetrating particle size (MPPS).<br />
Table 1 defines the ISO filter classes and the related collection<br />
efficiencies and penetrations, respectively. In total, the test<br />
and classification procedure consists of four individual steps:<br />
(1) Determination of the MPPS by measuring the fractional<br />
collection efficiency curve as a function of the particle size on<br />
flat sheet media samples (see part 3 of the standard); (2) leakproof<br />
testing of the filter element (see part 4 of the standard);<br />
(3) determination of the integral efficiency of the filter element<br />
(see part 5 of the standard); and (4) classification according to<br />
Table 1 (see part 1 of the standard). In part 3 of the standard,<br />
the required statistical methods are described.<br />
General ventilation air filters<br />
Coarse and fine dust filters ensure sufficient indoor air<br />
quality in less critical production areas and in general<br />
building and office ventilation. In high care production areas,<br />
cleanrooms and associated controlled environments, these<br />
filters are used as pre-filters to the EPA, HEPA and ULPA<br />
filters. Coarse and fine dust filters are tested and classified<br />
in Europe according to EN 779. In contrast to the testing<br />
of HEPA and ULPA filters, the procedure in EN 779 is a<br />
destructive test method, where the tested element is loaded<br />
with a synthetic test dust known as ASHRAE dust. The filter<br />
classes are determined from the average arrestance and<br />
the average efficiency as averaged over the dust loading.<br />
This standard has recently been revised and published as<br />
EN 779:2012. The main modification in this revision is the<br />
introduction of requirements for the minimum efficiencies to<br />
the filter classes F7 to F9, which gives higher operational<br />
safety to the end users with regard to the particle collection<br />
efficiency of filter elements (Table 2).<br />
Table 2. Class definitions to EN 779:2012.<br />
Group<br />
Coarse filter<br />
Fine filter<br />
G<br />
M<br />
Class<br />
G1<br />
Final test<br />
pressure<br />
drop<br />
Average<br />
arrestance A m<br />
to ASHRAE<br />
dust in %<br />
50 ≤ A m<br />
< 65<br />
G2<br />
250 Pa<br />
65 ≤ A m<br />
< 80<br />
G3 80 ≤ A m<br />
< 90<br />
G4<br />
M5<br />
90 ≤ A m<br />
Average<br />
efficiency E m<br />
to 0.4 µm in %<br />
Minimum<br />
efficiency to<br />
0.4 µm in %<br />
— —<br />
40 ≤ E m<br />
< 60<br />
M6 60 ≤ E m<br />
< 80<br />
F F7 450 Pa — 80 ≤ E m<br />
< 90 ≥ 35<br />
F8 90 ≤ E m<br />
< 95 ≥ 55<br />
F9 95 ≤ E m<br />
≥ 70<br />
To ensure a high confidence level of end users with regard<br />
to the quality and design specifications of fine air filters,<br />
the European Committee of Air Handling & Refrigeration<br />
Equipment Manufacturers (Eurovent) introduced some years<br />
ago a certification program, wherein the main performance<br />
characteristics of the products offered by the participants are<br />
verified by regular and independent checks (www.euroventcertification.com).<br />
On an annual base, the initial pressure<br />
—<br />
drop, the initial and minimum particle collection efficiency, the<br />
filter class, and the energy efficiency class of four randomly<br />
chosen fine filters from the participants’ product range are<br />
verified by independent laboratories.<br />
Figure 1. Eurovent certification mark.<br />
Energy efficient operation of air filters<br />
In the context of increasing energy prices and the imperative<br />
of reducing CO 2<br />
emissions, the energy consumption caused<br />
by air handling units has become the focus of attention. In<br />
an average industrial plant approximately 10-20% of the total<br />
energy is consumed by fans in heating, ventilation and air<br />
conditioning (HVAC) systems. In high care production areas<br />
and in cleanrooms and associated controlled environments,<br />
this percentage is even higher. Approximately one-third is<br />
related to the flow resistance (pressure loss) of air filters,<br />
depending on the size and the design of the HVAC units.<br />
Besides investments in energy-efficient fans and variable<br />
speed drives, for example, the optimisation of the filter<br />
efficiencies used and the use of high quality, energy efficient<br />
air filters is a comparably easy possibility to achieve significant<br />
energy savings. Hence, a reduction of the pressure loss of air<br />
filter systems can make a significant contribution to energy<br />
savings and reduction of carbon dioxide emissions when<br />
used in conjunction with variable speed drives. At the same<br />
time, the air quality targets have to be considered, which<br />
means that ultimately the individual optimum of sufficient<br />
filter efficiency with lowest possible energy consumption<br />
must be found.<br />
To guide the end user to the most energy efficient filter<br />
selection, Eurovent published a new document, Eurovent<br />
4/11, which defines an energy efficiency classification<br />
system for air filters.<br />
Under the assumption that the volume flow rate supplied<br />
by the fan is constant, and hence, does not depend on the<br />
filters‘ pressure drop, the energy consumption of air filters<br />
can be calculated by Equation 1 (Goodfellow, 2001).<br />
⎯<br />
q V ⋅ Δp ⋅ t<br />
W = ⎯⎯⎯<br />
η ⋅ 1000 (1)<br />
The abovementioned assumption is valid if the fan is<br />
controlled by a frequency inverter to operate at constant<br />
volume flow rate q V<br />
(in m³/s). In Eq. (1) W (in kWh) is the<br />
energy consumed in the time t (in h). Since the pressure loss<br />
of an air filter increases with the dust collected during the time<br />
of operation, in Eq. (1) the pressure loss Δp (in Pa) has to be<br />
introduced as integral average value over the time interval t.<br />
The overall electromechanical fan efficiency η depends on<br />
the design and the operating conditions of the fan. Modern<br />
fans can have an efficiency of 70%; while for older models<br />
or when utilised in disadvantageous operating conditions,<br />
realised efficiencies might be just 25% or even lower.
52 Performance testing of air filters for hygienic environments: Standards and guidelines in the 21st century<br />
In air handling units mostly pocket or rigid filters are used in<br />
two stages (Figure 2).<br />
group according to EN 779, different amounts of dust are<br />
used, considering the fact that filters of group F are typically<br />
used in the second filter stage where they are exhibited to<br />
smaller dust concentrations compared to filters of group G or<br />
M, which are typically used in the first filter stage.<br />
Figure 2. Examples of a pocket filter (left) and a rigid filter (right)<br />
used in air handling units.<br />
The energy performance of filters largely depends on the<br />
used filter media, the effective filtering area and the design<br />
and quality of converting. For example, progressively<br />
structured filter media made of polymer fibers, with a fiber<br />
density and fineness increasing in the air flow direction,<br />
store significantly higher amounts of dust compared to<br />
homogeneous structured nonwovens made of polymer or<br />
glass fibers. A higher dust holding capacity results in a slower<br />
increase of the pressure loss over the time of operation,<br />
and hence, a lower energy consumption. Additionally, a<br />
high stiffness of the filter media results in self-supporting,<br />
stabile filter pockets when no additional energy is required to<br />
open the pocket in the air stream and an optimal V-shape of<br />
the pocket is ensured. Also in rigid filters, in which the filter<br />
medium typically is pleated into six or eight thin pleat panels<br />
or one deep-pleated panel glued into a rigid filter frame, the<br />
stiffness of the filter medium and the pleat geometry strongly<br />
influence the energy consumption (Caesar, et al. 2002).<br />
The energy efficiency classification system defined by<br />
Eurovent 4/11 allows the end user to quantitatively compare<br />
the different design aspects of different air filters according<br />
to their energy-efficient operation. The laboratory test<br />
procedure used is mainly based on the filter test standard<br />
EN 779:2012, where the tested filter element is loaded<br />
with synthetic ASHRAE test dust at a constant flow rate of<br />
3400 m³/h (0.944 m³/s). The pressure loss curve measured<br />
in this procedure as a function of dust loading is used<br />
to determine the average pressure loss (Equation 1),<br />
representing one year of operation. Depending on the filter<br />
With the average pressure loss, determined from the loading<br />
curve measured according to EN 779, by using Equation<br />
1, the yearly energy consumption of an air filter can be<br />
calculated. As a convention in the Eurovent 4/11 document,<br />
the yearly operating hours are defined to 6000 h and the<br />
efficiency of the fan to 50%. Based on this calculated annual<br />
energy consumption, filters are classified depending on their<br />
filter class into energy efficiency classes given in Table 3.<br />
Additionally, Eurovent-certified filter suppliers can use an<br />
energy efficiency label in a design well-known in Europe to<br />
report and display the energy efficiency classification of their<br />
products (Figure 3).<br />
Freudenberg Filtration Technologies<br />
MaxiPleat filter<br />
MX95 1/1<br />
3400 m³/h<br />
62<br />
60<br />
1300<br />
F8<br />
Figure 3. Example of the energy efficiency label used by<br />
participants of the Eurovent certification program.<br />
A<br />
Table 3: class limits of energy efficiency in relation of filtration class according to EN 779 (established at bei 3400 m³/h) [6].<br />
Filter c las s<br />
G 4<br />
M5 M6 F 7 F 8 F 9<br />
MTE<br />
— — — MTE ≥ 35% MTE ≥ 55% MTE ≥ 70%<br />
M G = 350 g ASHRAE M M = 250 g ASHRAE M F = 100 g ASHRAE<br />
A 0 – 600 kWh 0 – 650 kWh 0 – 800 kWh 0 – 1200 kWh 0 – 1600 kWh 0 – 2000 kWh<br />
B > 600 kWh – 700 kWh > 650 kWh – 780 kWh > 800 kWh – 950 kWh > 1200 kWh – 1450 kWh > 1600 kWh – 1950 kWh > 2000 kWh – 2500 kWh<br />
C > 700 kWh – 800 kWh > 780 kWh – 910 kWh > 950 kWh – 1100 kWh > 1450 kWh – 1700 kWh > 1950 kWh – 2300 kWh > 2500 kWh – 3000 kWh<br />
D > 800 kWh – 900 kWh > 910 kWh – 1040 kWh > 1100 kWh – 1250 kWh > 1700 kWh – 1950 kWh > 2300 kWh – 2650 kWh > 3000 kWh – 3500 kWh<br />
E > 900 kWh – 1000 kWh > 1040 kWh – 1170 kWh > 1250 kWh – 1400 kWh > 1950 kWh – 2200 kWh > 2650 kWh – 3000 kWh > 3500 kWh – 4000 kWh<br />
F<br />
G<br />
> 1000 kWh – 1100 kWh > 1170 kWh – 1300 kWh > 1400 kWh – 1550 kWh > 2200 kWh – 2450 kWh > 3000 kWh – 3350 kWh > 4000 kWh – 4500 kWh<br />
> 1100 kWh > 1300 kWh > 1550 kWh > 2450 kWh > 3350 kWh > 4500 kWh
Performance testing of air filters for hygienic environments: Standards and guidelines in the 21st century 53<br />
Summary and outlook<br />
The world of filter standardisation is currently one of forward<br />
motion. Existing standards are being revised, updated and<br />
globalised. For example, the European standard EN 779<br />
for the testing and classification of coarse and fine dust<br />
filters recently has been revised and a new international<br />
standard ISO 29463 for the testing and classification of highefficiency<br />
filters and filter media has been published, which<br />
will likely replace European standard EN 1822 in the near<br />
future. With the new Eurovent document 4/11, a European<br />
energy efficiency classification system for air filters has been<br />
defined. This will likely also be the basis for future European<br />
legislation for air filters in the context of the Eco-Design<br />
guideline of the European Parliament and Commission<br />
(Directive 2009/125/EC).<br />
In the framework of ISO/TC 142, currently more than 30<br />
standardisation projects are in process. Among them are the<br />
series of standards ISO 10121 for the testing and classification<br />
of gas adsorption filters and the series of standards for coarse<br />
and fine dust filters (ISO 16890), which is written in four<br />
parts and will likely replace EN 779 in a few years. The final<br />
publication of ISO 16890, part 1, is planned for 2015.<br />
Bibliography<br />
American Society of Heating. Refrigerating and Air-Conditioning<br />
Engineers. 2007. ANSI/ASHRAE Standard 52.2-2007. Method of<br />
testing general ventilation air-cleaning devices for removal efficiency<br />
by particle size. Atlanta.<br />
Caesar, T. and T. Schroth. 2002. The influence of pleat geometry<br />
on the pressure drop in deep-pleated cassette filters. Filtration +<br />
Separation, 39(9):49-54.<br />
DIN EN 779. Particulate air filters for general ventilation. Determination<br />
of the filtration performance. Beuth Verlag, Berlin, 2012.<br />
DIN EN 1822. High efficiency air filters (EPA, HEPA and ULPA), Part<br />
1-5. Beuth Verlag, Berlin, 2011.<br />
DIN EN 13779. Ventilation for non-residential buildings - Performance<br />
requirements for ventilation and room-conditioning systems; German<br />
version EN 13779:2007, Beuth Verlag, Berlin, 2007.<br />
EHEDG Guideline DOC 30. Guidelines on air handling in the food<br />
industry, 2005<br />
ISO 29464. Cleaning equipment for air and other, Beuth Verlag,<br />
Berlin, 2011<br />
European Committee of Air Handling & Refrigeration Equipment<br />
Manufacturers (Eurovent), 2011. Eurovent 4/11: Energy efficiency<br />
classification of air filters for general ventilation purposes. Paris.<br />
Goodfellow, H. and E. Tähti. 2001. Industrial Ventilation. Academic<br />
Press.<br />
International Standards Organisation. ISO 14644: Cleanrooms and<br />
associated controlled environments. Series of standards. Beuth<br />
Verlag, Berlin. 1999-2012.<br />
International Standards Organisation. ISO 29463: High-efficiency<br />
filters and filter media for removing particles in air. Parts1-5. Beuth<br />
Verlag, Berlin, 2011.<br />
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European Hygienic Engineering & Design Group<br />
Spray cleaning systems in food processing machines and<br />
the simulation of CIP-coverage tests<br />
The intelligent usage of experimental and simulated cleanability tests is a further step toward<br />
the reduction of machinery development time and costs and time of machinery for the food and<br />
pharmaceutical industry.<br />
André Boye 1 , Marc Mauermann 1 , Daniel Höhne 2 , Jens-Peter Majschak 1<br />
1<br />
Fraunhofer IVV, Branch Lab for Processing Machinery and Packaging Technology AVV Dresden, Germany<br />
2<br />
Technische Universität Dresden, Faculty of Computer Science, Institute of Software- and Multimedia-Technology,<br />
Dresden, Germany<br />
e-mail: andre.boye@avv.fraunhofer.de<br />
Due to increasing hygienic requirements, more and more<br />
machinery for the food industry is delivered with automated<br />
clean-in-place (CIP) systems. By using such systems,<br />
hygienic risks may decrease and cleaning efficiencies may<br />
rise.<br />
The validation of the hygienic design of such systems, and<br />
thus the selection of specific nozzles for cleaning, their<br />
alignment and built-in position has so far been done so far<br />
only on a real prototype by means of CIP-coverage tests.<br />
The objective of this test is to verify that the cleaning systems<br />
associated with the machinery are capable of delivering<br />
cleaning solutions to all exposed product contact surfaces. If<br />
that is not the case, the cleaning system has to be adjusted<br />
and tested further until all surfaces are wetted with cleaning<br />
agent in the coverage test. This iterative optimisation is<br />
extremely time-consuming and has very high resource<br />
requirements (e.g., staff, material, etc.). Hence, many costs<br />
arise that are also hardly calculable when submitting a<br />
tender offer.<br />
An approach to improving the hygienic design of food<br />
processing machinery is to simulate the coverage test<br />
using the computer-aided design (CAD) data of the<br />
machinery and the cleaning system. This paper presents a<br />
software solution that is capable of simulating the coverage<br />
of relevant equipment surfaces with cleaning fluids from<br />
nozzles by means of ray tracing. The main differences<br />
between CAD and computational fluid dynamics (CFD)<br />
methods are that the simulation is much easier to handle,<br />
simpler in degree of detail of the results, works in real-time<br />
and can be used for optimising cleaning systems with a<br />
huge number of nozzles. The main requirements for the<br />
software design were that the software should not have high<br />
demands on construction engineers with regard to the level<br />
of simulating knowledge and should be very practicable for<br />
complex systems.<br />
For characterising the spray pattern as a precondition for<br />
integrating different nozzles in this software, an adequate<br />
cleanability test was found. By means of the test rig,<br />
characteristics of different cleaning nozzles can be<br />
analysed, classified and provided in an electronic format.<br />
In summary, the complete package consists of the software<br />
and new test method for spray pattern characterisation.<br />
Software for the simulation of spray shadows<br />
(a)<br />
(b)<br />
Figure 1. Screenshots of the developed (a) simulation software and<br />
(b) nozzle explorer for selecting a nozzle from the database.<br />
With the simulation software developed, engineers are<br />
given the opportunity to optimise their cleaning systems at<br />
computers before any components of a new machine have<br />
to be manufactured (Figure 1). Thereby, the presented tool<br />
gives an estimation for the spray pattern on complex parts in<br />
relation to the specific cleaning systems.<br />
Software usage and features<br />
Import CAD assembly<br />
Choose view<br />
Insert nozzles<br />
Figure 2. Flow chart for software usage.<br />
Export position of nozzles<br />
Inspection of cleaning<br />
results/ optimisation<br />
Positioning/ alignment<br />
As shown in Figure 2, there are a number of software usage<br />
functions and features. At first, the user opens a new project<br />
and loads the CAD assembly of the object to be cleaned<br />
by using standardised exchange formats. In the next step,<br />
the view can be chosen like in standard CAD software and<br />
the nozzles are inserted via drag-and-drop, with quantity and
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56 Spray cleaning systems in food processing machines and the simulation of CIP-coverage tests<br />
type as required, into the scene. The computer program is<br />
directly connected with a public nozzle database in which<br />
the specific characteristics of different nozzles are stored<br />
together with the related single spray pattern. Consequently,<br />
the same nozzle doesn’t have to be measured twice at the<br />
same operating parameters. The determination of a single<br />
spray pattern can be managed with an adequate cleaning<br />
test like that described below, or with impact measurements<br />
for example. After insertion, the nozzles can be positioned<br />
and aligned in the scene. The activated nozzle is marked<br />
with a pyramid. This pyramid shows the maximum nozzle<br />
distance in which the nozzle was measured. If the nozzle<br />
is moved outside this range, no cleaning effect is shown on<br />
the surface. The expected cleaning results are calculated<br />
and shown in real-time, so the cleaning system can be<br />
optimised (e.g., insert more nozzles or change their<br />
alignment) in an iterative way without large response time.<br />
After all, the nozzles positions can be exported for using in<br />
CAD software.<br />
Functional principles<br />
Depending on the application area, one could model the<br />
effect of a nozzle as a stream or as a spray of single particles<br />
– omitting particle-particle interaction. In our experiments the<br />
latter approach proved the most feasible. The behaviour of<br />
such an isolated particle could be approximated using the<br />
following formula:<br />
0<br />
Figure 3. Projection principle, from 3D space onto 2D plane with<br />
depth information (as Z). A brighter colour is equivalent to a shorter<br />
distance to the projection plane. Note the intersection of the ray<br />
with the 2D plane.<br />
After identifying where the particles collide with the surface,<br />
the exerted influences<br />
0<br />
on the surface have to be computed.<br />
For this, every nozzle gets a spate of spray masks that are<br />
determined by cleanability tests or impact measurements<br />
(Figure 4).<br />
z<br />
z<br />
where the forces are defined as<br />
•<br />
•<br />
•<br />
•<br />
Numerical algorithms for solving the time integration can be<br />
found in Press et al. (2007) and are efficiently computable<br />
on the GPU (graphics processing unit) as described by<br />
Nguyen (2007). 1,2 But, solving the equation of motion for<br />
millions of particles is just one step. For the interesting<br />
effect of a particle-surface interaction, the intersection of a<br />
particle with a surface has to be found. Despite several<br />
well-known acceleration techniques, a lot of work had to be<br />
done in every time step of the simulation. 3 But experiments<br />
showed that the process could be approximated as linear<br />
with respect to the input parameter domain in focus. These<br />
experiences effectively broke down the simulation to a onetime<br />
step at which the intersection occurs. In the field of<br />
computer graphics this is known as ray-tracing, but instead<br />
of tracing light, the ray’s linear particle paths are traced. 4 A<br />
first implementation produced reasonable results for further<br />
investigations, but it was too slow to be used in interactive<br />
applications. Therefore, the process was modelled as a<br />
projection of surface points in 3D space to 2D points on the<br />
escape plane of the nozzle which is exactly what graphics<br />
processing units (GPUs) are good at doing (Figure 3).<br />
Figure 4. (Left) 2D impact map. Red means high impact. (Right) 2D<br />
spray pattern. A black colour means a point got cleaned during the<br />
spray process.<br />
Thus, deciding whether a point is cleaned through the spray<br />
process becomes essentially the inversion of the projection<br />
mentioned before. This is equivalent to the functional<br />
principle of a slide or movie projector. Here the nozzle is the<br />
projector, the film or slide to be projected is the impact or<br />
spray pattern and the to-be-cleaned surface is the functional<br />
equivalent of the projection screen (Figure 5). In computer<br />
graphics this technique is known as projective texture<br />
mapping or perspective shadow mapping. 5-9<br />
(a)<br />
(a)
Spray cleaning systems in food processing machines and the simulation of CIP-coverage tests 57<br />
Soiling<br />
(a)<br />
(a)<br />
For the 3D soiling of surfaces from complex parts a method<br />
similar to spray paint processes was chosen (Figure 6). In<br />
that context, a model soil consisting of a polysaccharide<br />
and luminescent tracer was used and the surfaces of the<br />
test object were coated with the viscose test solution. The<br />
maximum layer thickness was limited by the avoidance of<br />
rinsing test soil.<br />
(b)<br />
(c)<br />
Test rig for cleaning<br />
For the experimental analyses a Washing Cabin test rig was<br />
used. With it, cleaning tests for open surfaces of complex<br />
parts up to a dimension of (1x1x1) m³ with several nozzle<br />
systems are practical. Furthermore, tank cleaning systems<br />
can be analysed by using a special test tank (Figure 7).<br />
Figure 5. (a) Principle of projective texturing and the application of<br />
projection for (b) a full cone nozzle; (c) and a flat fan nozzle.<br />
A characteristic of the presented approach is that a spray/<br />
impact map is only valid for a certain parameter configuration;<br />
i.e., nozzle model, pressure, distance and duration. To<br />
enhance this range further, spray patterns for different<br />
distances were interpolated linearly between each other.<br />
Cleanability test<br />
Figure 7. Test rig ‘Washing Cabin’ (left) and test tank (right).<br />
For a cleaning test the CIP station is started up by activating<br />
the bypass (Figure 8). When the steady state is reached,<br />
the threeway valve switches and the cleaning process starts.<br />
During it, a camera takes continuous pictures while an<br />
ultraviolet (UV) lamp system excites the remaining residual<br />
soil.<br />
Figure 6. Example for a cleaning test of a complex part: (1) Socket<br />
with spray shadow in detail; (2) soiled test object; and (3) test<br />
object after cleaning (green = soiled; black = clean).<br />
For verifying the simulated scenes in contrast to real<br />
experiments, an adequate cleaning test was developed.<br />
With this method, it is possible to differentiate clearly<br />
between areas with direct nozzle impact and spray<br />
shadows. Even rinsing water does not destroy the resulting<br />
spray pattern for a long period of time. Consequently, in<br />
this context the test rig ‘Washing Cabin’ at Fraunhofer<br />
AVV was used for testing single nozzles, different nozzle<br />
combinations and tank cleaning systems combined with<br />
different objects to clean.<br />
Figure 8. Scheme of the test rig Washing Cabin.
58 Spray cleaning systems in food processing machines and the simulation of CIP-coverage tests<br />
The adjustable pressure range of the test rig is 0 - 4 bar<br />
by a maximum flow rate of 16 m³/h. Both parameters were<br />
continuously measured. The highest frame rate is nine<br />
pictures per second but one frame per second has been<br />
determined as a useful value for the cleaning systems<br />
tested. Thereby, the exposure time of 0,35 s and aperture<br />
F4 were chosen. In order to exclude possible detection<br />
failures due to extraneous light, the test rig is completely<br />
darkened.<br />
Spray pattern analysis<br />
(a)<br />
(b)<br />
Figure 10. Comparison of (a) cleaning and (b) simulation result<br />
inside a test tank.<br />
In summary, the software gives a quite good estimation for<br />
the expected spray pattern, but the user must always be<br />
critical with the simulation results. For example, if a nozzle<br />
sprays into a deep gap. In the front area of the gap the<br />
estimation is quite good but deeper into the gap there aren’t<br />
any cleaning effects as the simulation shows.<br />
Figure 9. Detection principle.<br />
The model soil of the presented cleaning test contains a<br />
luminescent tracer, which is important for the detection<br />
of residual soil (Figure 9). In the cleaning processes, the<br />
surfaces are excited by UV radiation and areas with residual<br />
soil emit visible light. This is captured by taking pictures with<br />
a defined frame rate. After the cleaning test, the photos are<br />
rectified and a computer program checked to ascertain in<br />
which picture the stationary state of the spray pattern was<br />
reached. This picture is used for the next steps of analysis,<br />
where it is binarily divided in cleaned areas (with direct<br />
nozzle impact) and spray shadows (areas without direct<br />
nozzle impact). Hence, in single nozzle test, the spray<br />
masks are obtained and stored in the nozzle database. For<br />
this task, a semi-automated method also was developed<br />
and used.<br />
Conclusion<br />
The software presented in this paper gives engineers a<br />
computer aided constructive design and optimisation tool<br />
for complex spray cleaning systems for the first time. Spray<br />
shadows can be avoided preliminary in the constructive<br />
stage before any parts of prototypes are manufactured.<br />
Furthermore, the developed qualitative cleanability test<br />
is a practical method for the detection of weak points of<br />
spray cleaning systems and tank cleaners. Consequently,<br />
by combining the use of cleaning tests and simulation,<br />
hygienic risks are minimised and investment security is<br />
increased.<br />
The software and experimental methods will be further<br />
developed. For example, the implementation of tank<br />
cleaning systems with rotating nozzles is currently being<br />
investigated. In the near future, the achieved cleaning effect<br />
will be resolved quantitatively, and rinsing water, as a main<br />
cleaning component, will be considered.<br />
Acknowledgement<br />
Verification<br />
The simulation tool was verified by using specific geometrical<br />
phenomena, such as spraying with a nozzle over edges<br />
or into a gap between two plates. Therefore, the results<br />
from cleanability tests and simulation were compared<br />
qualitatively. In addition, the simulation was verified with<br />
complex parts, including a test tank that was cleaned inside<br />
with two full cone nozzles (Figure 10). The simulation and<br />
cleaning tests led to nearly the same result.
Spray cleaning systems in food processing machines and the simulation of CIP-coverage tests 59<br />
References<br />
1. Press, W.H., S.A. Teukolsky, W.T. Vetterling, and B.P. Flannery.<br />
2007. Numerical Recipes, 3rd Edition: The Art of Scientific Computing.<br />
Cambridge University Press. New York, NY, USA.<br />
2. Nguyen, H. 2007. GPU Gems 3. Addison-Wesley Professional.<br />
3. Langetepe, E. and G. Zachmann. 2006. Geometric Data Structures<br />
for Computer Graphics. A. K. Peters, Ltd. Natick, MA, USA.<br />
4.[PH04] Pharr, M. and G. Humphreys. 2004. Physically Based Rendering:<br />
From Theory to Implementation. Morgan Kaufmann Publishers<br />
Inc. San Francisco, CA, USA.<br />
6. EIsemann, E., M. Schwarz, U. Assarsson, and M. Wimmer. 2011.<br />
Real-time shadows. CRC Press. USA.<br />
7. Fernando, R. 2004. GPU Gems: Programming Techniques, Tips<br />
and Tricks for Real-Time Graphics. Pearson Higher Education.<br />
8. Stamminger, M. and G. Drettakis. July 2002. Perspective shadow<br />
maps. In Proceedings of ACM SIGGRAPH, J. Hughes, (Ed.), Annual<br />
Conference Series, ACM Press/ACM SIGGRAPH, pp. 557-562.<br />
9. Whler, C. 2009. 3D Computer Vision: Efficient Methods and Applications,<br />
1st Ed. Springer Publishing Co., Inc.<br />
5. Williams, L. 1978. Casting curved shadows on curved surfaces. In<br />
Proceedings of the 5th Annual Conference on Computer Graphics<br />
and Interactive Techniques. New York, NY, USA. SIGGRAPH ’78,<br />
ACM, pp. 270–274.<br />
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Environmentally friendly water based surface<br />
disinfectants<br />
Markets fluctuate. Requirements change. And this is especially true in the highly sensitive areas<br />
of cleaning and hygiene in the production and preparation arms of the food industry. Demand is<br />
for innovative solutions and cost-saving methods that conserve resources, are environmentally<br />
friendly, do not cause undue side effects to humans and are as safe as possible for the users.<br />
Stephan Mätzschke, Dipl.- Oecotrophologist (FH), Member of the Management Board at BIRFOOD GmbH & Co. KG<br />
E-mail: s. maetzschke@birfood.de, Tel.: + 49 421 489 960 17<br />
The cleaning and disinfection of production plants in the<br />
meat handling industry are two intrinsically linked processes<br />
required to guarantee the proper hygienic production of food<br />
in line with regulations. At a time when ultimate consumption<br />
date periods are getting longer and the requirements from<br />
legislators, trade and consumers are continually increasing,<br />
producers are forced to take the hygiene measures that<br />
accompany their production processes to a new level.1<br />
It is standard practice in the meat handling industry today that<br />
after thorough cleaning the production plant is chemically<br />
disinfected using either a foam or a spray. Currently a whole<br />
range of chemical disinfectants is available to the food<br />
industry, but despite the choice of products available, this<br />
article will highlight the difference between two disinfection<br />
methods: the inhibitive methods and the destructive methods.<br />
Some active agents like quaternary ammonium compounds<br />
or aldehydes, for example, have an inhibitive effect on<br />
bacterial cells. This means that these substances do not<br />
destroy the bacterial cells; instead, they prevent their<br />
reproduction by disrupting the cellular metabolism. Such<br />
substances are generally suitable for use on most surfaces<br />
and are user friendly; however, there are gaps in their<br />
effectiveness. Certain groups of germs are less susceptible<br />
to them and if the agents are used incorrectly, particularly if<br />
the wrong concentration is used over a long period of time,<br />
there is a risk that the bacteria will build up a resistance to<br />
them.<br />
The alternative group of active agents have a destructive<br />
effect; specifically, these agents destroy the bacterial cells.<br />
Active agents like peracetic acid, hydrogen peroxide and<br />
sodium hypochlorite belong to this group. This group of<br />
active agents has a broad spectrum of effectiveness and<br />
there is no danger of resistance if the products are used<br />
incorrectly. However, these agents are highly corrosive<br />
and are therefore dangerous to use on material (especially<br />
aluminium and non-ferrous metals) as well as for the user.<br />
A further disadvantage is their relative instability in the<br />
presence of organic matter.<br />
Non-hazardous water based surface<br />
disinfectants<br />
In contrast to the meat handling industry, the disinfection of<br />
drinking water and the drinking water supply network has<br />
been carried out for years using electrochemical activation<br />
(ECA) technology as an alternative to chemical disinfection.<br />
ECA technology frequently is used successfully in countries<br />
with precarious water supplies and in very warm climates, as<br />
well as in buildings with irregular water consumption where<br />
the water in the pipes must be held for longer periods (e.g.,<br />
hotels) as a reliable way of protecting against Legionella<br />
and other germs. The idea of using this technology as an<br />
environmentally or user-friendly alternative to the chemical<br />
disinfection of surfaces in the meat handling industry is<br />
relatively new.<br />
How ECA technology works<br />
The ECA technology is based on the treatment of drinking<br />
water by electrolysis. During the electrolysis process redox<br />
potential is generated by applying an electric voltage<br />
(Figure 1). This redox potential imparts the resulting flow of<br />
microbiocidal properties.<br />
Figure 1. Electrolysis process.<br />
During a redox reaction (effectively a reduction oxidation reaction)<br />
an electron from one reactant is transferred to the other. As one<br />
reactant is reduced, the other oxidises. The redox potential (in this<br />
case, 1200 mV) serves as an indicator of the extent to which such<br />
an electron transfer between reactants can take place. In doing so,<br />
it also demonstrates to a certain extent the level of the solution’s<br />
microbiocidal activity. When apparatus that has been treated with<br />
the solution produced with ECA technology comes into contact with<br />
bacterial cells, electrons will be transferred. The bacterial cell will<br />
oxidise and die.<br />
The ECA solution works in the same way as peracetic<br />
acid, hydrogen peroxide or sodium hypochlorite: that is,<br />
destructively. It oxidises the bacterial cell and with that, it<br />
dies. The advantage of ECA technology over these other<br />
solutions is that it is neither a corrosive nor an irritant for<br />
material or users. It complies with the German Drinking Water<br />
Directive because it does not contain anything dangerous.
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62 Environmentally friendly water based surface disinfectants<br />
Testing<br />
As a result of the limited number of surface disinfection<br />
available for use by the meat handling industry, there has<br />
been a lack of empirical scientific data allowing a judgment<br />
to be made on the suitability of the technology for application<br />
in this environment. A project was undertaken that aimed<br />
to identify maintenance and improvement in plant hygiene,<br />
taking into consideration conservation of resources,<br />
reduction in hazardous substances, optimisation of costs,<br />
and increased safety of food products.<br />
In September 2011, all relevant actual data such as water<br />
use and working times were included with the original<br />
cleaning methods (chemical disinfection). Over many<br />
years, certain factors regarding disinfectant use and the<br />
microbiological hygiene levels in the plant were recorded<br />
and provided historical data from which to benchmark results<br />
of the ECA technology trials. At the end of September 2011,<br />
ECA technology was installed in the plant rooms at Edeka<br />
Fleischwerk Nord GmbH. The concentrate produced using<br />
ECA technology was fed into the network in small amounts<br />
through an injection point in the cleaning line. As such the<br />
concentration was measured so that the amount of chlorine<br />
in the water did not exceed 0.3 ppm and the water quality met<br />
the requirements of the German Drinking Water Directive.<br />
The concentration was measured using a digital piston<br />
diaphragm pump connected to a contact water meter. From<br />
4 October 2011, ECA technology was installed in individual<br />
departments. The equipment classified as “hard to clean”<br />
was checked for organic residue using ATP bioluminescence<br />
after cleaning but prior to sanitising with ECA water. This<br />
ensured that the cleaning personnel had correctly completed<br />
the required steps for the use of ECA water and that any<br />
discrepancies in the results could not be attributed to human<br />
error.<br />
Each day, water consumption in each department was<br />
calculated using electronic contact water meters and<br />
ultrasonic measuring procedures in order that only small<br />
measuring tolerances occurred. Further, the concentration<br />
of ECA in the water that was used was checked daily to<br />
make sure it met the German Drinking Water Directive. This<br />
was done photometrically. Swab samples were taken daily.<br />
During the trial period, more than 1,000 swabs were taken<br />
and sent to an accredited laboratory for analysis. Tests were<br />
carried out on the mesophilic aerobic bacteria count and for<br />
enteric bacteria. The analysis of the swabs was performed in<br />
line with EC Decision 2001/471/EC.<br />
The project trials, which ran for six months, showed that the<br />
chemical disinfection and the subsequent neutralisation step could<br />
be replaced by ECA technology. Specifically, the foam cleaner<br />
may be rinsed from surfaces using ECA water and in doing so the<br />
meat handling plant can achieve surfaces that are cleaner from a<br />
microbiological perspective.<br />
A real-world study<br />
In August 2011, an initial risk analysis was done. Taking<br />
into account the fact that an ECA solution could have been<br />
similarly unstable in the presence of organic influences on<br />
the contact surfaces as the group of chemical disinfectants<br />
that oxidise, the surfaces in the plant rooms were classified<br />
as ‘easy to clean‘ and ‘hard to clean‘. Easy-to-clean<br />
surfaces included all flat stainless steel surfaces, such as<br />
filling machines, mixers, grinders, work benches etc., while<br />
equipment such as carving belts, carving boards and air<br />
cylinders were classified as hard-to-clean.<br />
Results<br />
The trial ended on 29 January 2012. With the exception<br />
of decomposition, zero values were recorded for<br />
enterobacteriaceae in all areas (Figures 2 and 3). This result<br />
underscores the necessity of using a foam cleaning agent<br />
with a brush at the cut-off point during the exposure period.<br />
Over the course of the second half of the trial, this result was<br />
also recorded.<br />
A further finding was the significant saving of drinking and/<br />
or hot water (Figure 4). A saving of 11.4% was recorded<br />
across all of the meat company’s departments. The most<br />
significant savings were found in the departments with the<br />
highest machine-to-space ratio, because more energy is<br />
used for rinsing disinfectant these areas than in corridors,<br />
for example.<br />
The results also showed a savings in working hours, with<br />
use of the technology resulting in an average reduction in<br />
personnel costs by more than 12.5% across the company<br />
(Figure 5).
Environmentally friendly water based surface disinfectants 63<br />
Figure 2. Hygiene monitoring from 04.10.2011 – Total germ count - Zero values were recorded for enterobacteriaceae in all areas<br />
Figure 3. Hygiene monitoring from 04.10.2011 – Enteric bacteria - Zero values were recorded for enterobacteriaceae in all areas.
64 Environmentally friendly water based surface disinfectants<br />
Figure 4. Comparison total water consumption/cost.<br />
Figure 5. Time required by cleaning personnel - Zero values were recorded for enterobacteriaceae in all areas
Environmentally friendly water based surface disinfectants 65<br />
Conclusion<br />
This project showed that the use of ECA technology enables<br />
a meat handling operation to improve the microbiological<br />
levels in the plant as compared to using the original<br />
chemical disinfectants. Measurable savings were made to<br />
the time required for cleaning, and the time saved using the<br />
new cleaning procedures can now be used for production.<br />
A significant decrease in water consumption was also<br />
experienced. An important side effect of using this technology<br />
is the automatic permanent disinfection of the drinking water<br />
supply network into which the application solution is fed. This<br />
improves safety, even in older supply networks. The annual<br />
thermal disinfection of the pipes that is frequently required,<br />
can be eliminated.<br />
Taking into consideration the results of the trial discussed<br />
here, the use of ECA technology as a replacement for<br />
chemical disinfection of plants in the meat handling<br />
industry can be recommended. These trials were run in a<br />
plant producing sausages. In plants that primarily produce<br />
other products and where there are other (more) germs<br />
on the surfaces from the outset (i.e., in an abattoir), a<br />
corresponding increase similar to the case study should be<br />
conducted before a recommendation about the suitability of<br />
the technology can be made.
European Hygienic Engineering & Design Group<br />
Flow behaviour of liquid jets impinging on vertical walls<br />
Surface cleaning devices such as spray balls and nozzles direct liquid onto walls and other<br />
surfaces in the form of jets. Knowledge of the area covered by the flow as it spreads out from the<br />
impingement point and drains down a wall or other surface is important for designing effective<br />
cleaning systems. Recent work on modelling the flow pattern and predicting the stability of wide<br />
draining films is summarised.<br />
Ian Wilson, Tao Wang and John F. Davidson, Department of Chemical Engineering and Biotechnology,<br />
Pembroke Street, Cambridge, CB2 3RA, UK, e-mail: diw11@cam.ac.uk<br />
Impinging water jets are widely used in cleaning walls,<br />
tanks and internals. The jets can be created by spray balls,<br />
fixed or moving nozzles. Soil removal occurs either by<br />
dissolution of the fouling layer into the liquid or by physical<br />
disruption of the soil by the shear forces generated by the<br />
flow. Improving the design of jet-based cleaning systems<br />
requires knowledge of the flow behaviour of the liquid<br />
after it strikes a wall. Figure 1 shows an example of a<br />
flow pattern generated by a horizontal impinging jet, seen<br />
looking through the transparent impact surface, along the<br />
axis of the jet.<br />
Figure 1. Photograph of flow pattern created by impinging water jet.<br />
The point of impingement is near the crossover of the ruler tapes.<br />
Figure 2 shows two of the possible flow patterns that can be<br />
generated by a horizontal jet impinging on a vertical wall.<br />
Both feature a zone around the point of impingement where<br />
the liquid moves at high velocity radially outwards until it<br />
forms a jump similar to the hydraulic jump seen with tap<br />
water in a sink. We term this a film jump to differentiate it<br />
from the hydraulic jump because gravity has less influence<br />
when the wall is vertical.<br />
The hydrodynamics of vertical liquid jets impinging on<br />
horizontal surfaces and the formation of hydraulic jumps is<br />
well understood. Jets impinging on vertical or inclined walls<br />
have received less attention.<br />
Figure 2. Schematics of two commonly observed flow patterns for<br />
a horizontal liquid jet impinging on a vertical wall. (a) gravity flow;<br />
(b) rivulet flow. O denotes the point of impingement.<br />
For cleaning applications, we want to know the size of the<br />
film jump, marked R in Figure 2, as the region within it<br />
involves higher velocities and larger shear forces. We also<br />
want to know the width of the falling film, which is marked W<br />
on Figure 2 (a). W is larger than 2R because of the liquid<br />
flowing around the film jump, and it gives an indication of<br />
the area below the point of impingement that will be wetted
Flow behaviour of liquid jets impinging on vertical walls 67<br />
by the falling film. Soil in this region will be removed by the<br />
action of detergent and lower shear stresses, as reported<br />
by Morison and Thorpe (2002). 1 Under some conditions<br />
the falling film will narrow below the impingent plane and<br />
give poor contact with the soil, as shown in Figure 2 (b). It is<br />
therefore important to be able to predict the transition from<br />
the wide, gravity, film flow behaviour to the narrow, rivulet<br />
regime.<br />
Predicting the film jump<br />
A model for the film jump has recently been developed. 2 This<br />
allows R to be predicted from<br />
¼<br />
⎡ m 3 ⎤<br />
R = 0.276 ⎢ ⎯⎯⎯⎯⎯⎯ ⎥<br />
⎣ μργ(1− cos b) ⎦<br />
(1)<br />
In this equation, m is the jet mass flow rate; μ is the viscosity<br />
of the liquid and ρ is its density; γ is the surface tension, and<br />
β is the contact angle of the liquid on the substrate.<br />
Figure 3 shows good agreement between experimental<br />
data and the model for water on Perspex. Nozzle sizes, d N<br />
,<br />
typical of those used in industrial practice have been tested.<br />
Comparison with other data sets, including those reported<br />
in Morison and Thorpe (2002), are reported in Wilson et al.<br />
(2011) and Wang et al. (<strong>2013</strong>). 1–3<br />
surfactant molecules had time to collect at the solid/liquid/air<br />
interface, gave poor agreement with the measured values.<br />
This indicates that dynamic surface tension effects are<br />
important in these flows.<br />
A second important finding reported in Wang et al. (<strong>2013</strong>)<br />
is that at higher flow rates and with larger nozzles, R was<br />
independent of the nature of the substrate. This indicates<br />
a change in the phenomena controlling the flow pattern at<br />
higher flow rates from one controlled mainly by interfacial<br />
forces to one where fluid inertia become important. Using<br />
a contact angle of 90° in Equation (1) gave reasonable<br />
predictions for R in these cases.<br />
Predicting the film width<br />
The relationship between W and R cannot be obtained using<br />
the simple models behind Equation (1). Measurements of<br />
W (= 2Rc in Figure 3) indicate that Rc ≈ 2R at lower flow<br />
rates and approaches Rc ≈ 4/3R at higher flow rates. These<br />
empirical results allow W to be estimated.<br />
Falling film flow patterns<br />
The tendency to exhibit gravity or rivulet flow in the region<br />
below the impingement plane has been found to follow the<br />
criterion given by Hartley and Murgatroyd (1964) for the<br />
stability of wide falling liquid films. 4 This says that film will be<br />
stable if the wetting rate, defined as m/W, is larger than the<br />
critical value given by<br />
m<br />
⁄ W<br />
≥ 1.69 (μρ/g) 0.2 [γ(1− cos b)] 0.6 (2)<br />
Here g is the acceleration due to gravity. Equation (2) holds<br />
for vertical surfaces; for inclined walls, g is modified to<br />
account for the angle of slope.<br />
We have found that Equation (2) gives reasonable predictions<br />
of the transition from the gravity to rivulet regimes for these<br />
falling films. Equation (2) has also been found to apply for<br />
solutions containing a surfactant, using the values of γ and<br />
b obtained from equilibrium contact angle measurements.<br />
Surfactants which promote wetting on the soil or substrate<br />
will give smaller values of b and therefore, from Equation<br />
(2), reduce the flow rate required to avoid rivulet formation<br />
(as W is less sensitive to surfactant content).<br />
Figure 3. Comparison of experimental measurements of R with<br />
values predicted from Equation (1) for water on Perspex for<br />
different nozzle sizes and temperatures. Reproduced from Wang et<br />
al. (<strong>2013</strong>) with permission.<br />
Equation (1) shows that R is larger for liquids with a small<br />
contact angle (i.e., ones that wet the surface) and for liquids<br />
with a lower surface tension. Surfactants are often added<br />
to promote wetting and change the contact angle. Recent<br />
work has demonstrated that the effect of surfactants on<br />
R comes mainly through their influence on the surface<br />
tension. 3 Predictions of R using Equation (1) using contact<br />
angles measured under equilibrium conditions, where the<br />
Figure 4 shows an example for water jets impinging on a<br />
vertical glass wall. Solid symbols indicate that the falling film<br />
exhibited gravity flow, while open symbols denote rivulet flow<br />
behaviour.<br />
The data are plotted in terms of the Eötvös number, a<br />
dimensionless width, and a dimensionless flow rate, F, given<br />
by<br />
and<br />
Eo = ρgW 2 ⁄ γ (3)<br />
F = ρgm 2 ⁄ γμ2 (4)
68 Flow behaviour of liquid jets impinging on vertical walls<br />
Application to cleaning<br />
Since R, and hence W, can now be estimated from Equation<br />
(1), we can obtain a reasonable estimate of the wall area<br />
contacted by the liquid in the jet and the stability of the falling<br />
film generated. The influence of surfactants or the effect of<br />
cleaning the surface, which will change the contact angle,<br />
can also be assessed. Ongoing work in our group includes<br />
investigations of inclined jets and non-vertical surfaces,<br />
detailed analysis of the shape of the falling films, and<br />
cleaning.<br />
Acknowledgment<br />
This work is not funded by a company or research council.<br />
A PhD scholarship for Tao Wang and input from project<br />
students is gratefully acknowledged.<br />
References<br />
Figure 4. Plot indicating stability of falling films generated by<br />
horizontal jets impinging on a vertical glass wall. The lines show the<br />
Hartley and Murgatroyd criterion, Equation (2), for water (in blue)<br />
and an aqueous 0.1 mM Tween 20 solution (in red). Data points:<br />
open symbols indicate that rivulet flow was observed, solid symbols<br />
indicate gravity flow. Rivulet flow is expected for points lying on or<br />
above the line. Test conditions: 1 mm nozzle, 20ºC.<br />
The two lines on Figure 4 show the conditions under which<br />
Equation (2) predicts a change in flow behaviour for water<br />
and for a surfactant solution. The theory says that points lying<br />
on or above the line should exhibit rivulet flow behaviour. For<br />
the flow rates tested here, water exhibits rivulet flow, which<br />
is consistent with Equation (2).<br />
1. Morison, K.R., and R.J. Thorpe. (2002). Liquid distribution from<br />
cleaning-in-place sprayballs. Food Bioproducts Proc., 80, 270-275.<br />
2. Wilson, D.I., B.L. Le, H.D.A. Dao, K.Y. Lai, K.R. Morison, and<br />
J.F. Davidson. (2011). Surface flow and drainage films created by<br />
horizontal impinging liquid jets. Chem. Eng. Sci., 68, 449–460.<br />
3. Wang, T., Davidson, J.F. and Wilson, D.I. (<strong>2013</strong>) 'Effect of<br />
surfactant on flow patterns and draining films created by a horizontal<br />
liquid jet impinging on a vertical surface', Chem. Eng. Sci., 88, 79-94.<br />
4. Hartley, D.E. and W. Murgatroyd. (1964). Criteria for the breakup<br />
of thin liquid layers flowing isothermally over solid surfaces. Intl<br />
J. Heat Mass Transfer, 7, 1003-1015.<br />
The presence of surfactant reduces the surface tension and<br />
gives a smaller contact angle, which causes the transition<br />
locus to move to larger Eötvös numbers. For similar flow<br />
rates to the water tests, the surfactant solutions give wide<br />
falling films, which is again consistent with Equation (2).
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All components made in Germany!
European Hygienic Engineering & Design Group<br />
Optimisation of tank cleaning<br />
Using hygienic sensors to monitor tank cleaning<br />
René Elgaard, Managing Director, Alfa Laval Tank Equipment A/S<br />
e-mail: rene.elgaard@alfalaval.com<br />
Tank cleaning is a time-honoured tradition essential<br />
for producing high-quality foodstuffs and beverages.<br />
Technological advances in tank cleaning have raised the<br />
standards for food and beverage processing dramatically;<br />
the most drastic changes have occurred within the last 50<br />
years. To ensure the highest standards of hygiene, more<br />
rigorous standards and tougher regulations are now in<br />
place, not only for the tank itself but also for tank cleaning<br />
equipment.<br />
The improvements in hygiene standards/guidelines are a<br />
direct result of equipment users’ demand, as well as support<br />
garnered through organisations such as the European<br />
Hygienic Engineering and Design Group (EHEDG), which<br />
share the common aim of promoting hygiene during<br />
food and beverage handling, processing and packaging.<br />
The guidelines put forth for hygienic design of food and<br />
beverage process equipment essentially put all equipment<br />
manufacturers on a level playing field by establishing<br />
minimum standards for equipment quality.<br />
With all equipment being equal, it stands to reason that<br />
proper control of the tank cleaning process is the primary way<br />
to differentiate equipment based upon the level of cleaning<br />
efficiency achieved. The objective: to get accurate, reliable<br />
and repeatable tank cleaning results after the completion of<br />
each production cycle, whether a continuous process or a<br />
batch process is used.<br />
There are several ways to achieve the desired tank cleaning<br />
results by controlling the tank cleaning process. However, it<br />
is important to understand the process of tank cleaning, the<br />
various tank cleaning methods and the product contained<br />
in the tank before determining the best method of control to<br />
achieve optimal cleaning efficiency.<br />
Traditional tank cleaning<br />
There are various parameters that contribute to effective<br />
tank cleaning. These are perhaps best described by the<br />
“Sinner Circle,” which was developed by the chemical<br />
engineer Herbert Sinner to illustrate how to obtain good<br />
cleaning results. 1 Sinner defined four critical parameters that<br />
may be combined in numerous ways and applied to virtually<br />
any cleaning task, whether in a pipe, on a floor or in a tank.<br />
The parameters are time, action (or flow of cleaning fluid),<br />
chemistry and temperature, or TACT for short (Fig. 1). All<br />
four parameters are important to secure optimal cleaning<br />
efficiency; however, how they are combined is decisive in<br />
achieving optimal cleaning efficiency.<br />
Figure 1. The Sinner Circle illustrating the cleaning parameters<br />
of TACT. Herbert Sinner defined four critical parameters – time,<br />
action (or flow of cleaning fluid), chemistry and temperature, or<br />
TACT for short – which are important to secure optimal cleaning<br />
efficiency.<br />
Applying effective chemicals or cleaning agents and optimum<br />
temperature to the surface to be cleaned weakens the<br />
bond between the soil and the surface to a point where the<br />
available force (or action) can remove the soil. 2 The unknown<br />
factor is the available force. Time, chemical concentration<br />
and temperature can be controlled.<br />
What is the available force, and how is it applied to the<br />
surface? This depends upon the method and technology<br />
used to distribute the cleaning media in the tank.<br />
One of the oldest methods of tank cleaning, the “fill, boil and<br />
dump” approach, is still used by many industries for various<br />
applications. This simple cleaning method involves filling the<br />
tank with water and chemicals and heating its contents to the<br />
required temperature. The mixture is kept in the tank for a<br />
sufficient amount of time in order to allow the chemicals and<br />
temperature to react with the soil. The tank is then emptied<br />
or its contents “dumped.” This is a very expensive and<br />
time-consuming cleaning method, and the amount of force<br />
applied is minimal.<br />
Tank cleaning<br />
Tank cleaning-in-place (tank CIP) is a commonly used<br />
cleaning method, which applies force to the tank surface<br />
for the removal of soil without having to open and enter the<br />
tank. There are three different types of technologies used for<br />
cleaning the tank interior:<br />
1. Static spray ball (static cleaning device)<br />
2. Rotary spray head (dynamic cleaning device)<br />
3. Rotary jet head (dynamic cleaning device)
Optimisation of tank cleaning 71<br />
Whilst these technologies are not new, they have been<br />
developed and improved over the past 50 years. The<br />
technological advances to dynamic cleaning devices in<br />
recent years are noteworthy. Some of the technologies have<br />
been tested and approved by the EHEDG; however, most of<br />
the equipment available today does not have approval from<br />
any standards organisation.<br />
All three technologies apply force to the tank surface in<br />
different ways and with different degrees of efficiency. The<br />
level of efficiency for the various technologies is determined<br />
by the impact force (mechanical force) and the shear stress,<br />
which significantly differ among the technologies.<br />
Static spray ball<br />
The static spray ball continuously disperses cleaning fluid<br />
through each perforated hole from a fixed location in the tank<br />
onto a fixed location on the tank surface (Fig. 2). As the jets<br />
hit the tank surface, they create an area, or footprint, where<br />
the impact force and shear stress are active. After impact,<br />
the jets change to cascades of cleaning fluid, which run<br />
down the sides of the tank, creating a free-falling film. This<br />
free-falling film generates shear stress on the interior walls<br />
of the tank in an uneven pattern. Here, time, chemistry and<br />
heat are the decisive factors that determine when the tank is<br />
clean. The wall shear stress of the free-falling film is fixed in<br />
the range of 1 to 5 Pa, which is comparable to that present in<br />
a pipe in which the liquid is pumped at a speed of 1.5 m/s. 3<br />
Optimize to<br />
economize<br />
So where is all your energy going? The surprising fact<br />
is that pumps account for as much as 50% of the<br />
power consumption in some processes. Pump optimization<br />
for maximum efficiency in each process is<br />
key, it could cut your bill considerably.<br />
Figure 2. Static spray ball. Static spray ball gently sprays cleaning<br />
fluid onto the tank walls, enabling the fluid to fall freely down the<br />
tank wall and provide uneven cleaning coverage.<br />
Rotary spray head<br />
Unlike the static spray ball, the rotary spray head is a dynamic<br />
cleaning device. The flow of the cleaning media released<br />
from the spray head causes the spray head to rotate (Fig. 3).<br />
This creates a swirling movement, which enables the fluid to<br />
hit the tank surface with an impact force that is higher than<br />
the impact force of the static spray ball. The pulsating force<br />
and impact created provide a combination of shear stress<br />
and variable falling film of cleaning fluid that covers all the<br />
internal surfaces of the tank. Compared to the static spray<br />
ball, the rotary spray head reduces the amount of cleaning<br />
time required to achieve the desired cleaning results.<br />
Watch our pump films:<br />
www.alfalaval.com
72 Optimisation of tank cleaning<br />
The impact force and subsequent coverage create a<br />
footprint that is much larger and wall shear stress that is<br />
much higher than that provided by a static spray ball or<br />
rotary spray head. The magnitude of the wall shear stress<br />
in a rotary jet head footprint is approximately 104 Pa and<br />
decreases to about 7.5 Pa at approximately 150 mm from<br />
the impact centre. 3 This is significantly higher than the wall<br />
shear stress of between 1 and 5 Pa in the free-falling film<br />
created by a static spray ball.<br />
Figure 3. EHEDG certified Rotary spray head. The rotary spray<br />
head has a higher impact force and higher wall shear stress<br />
compared to the static spray ball. This reduces cleaning time.<br />
Rotary jet head<br />
Of the three automated tank CIP technologies, the rotary<br />
jet head is by far the most effective because it creates the<br />
highest impact force and highest shear stress (Fig. 4). The<br />
rotary jet head has between one and four cleaning nozzles,<br />
each of which disperses cleaning fluid through a welldefined<br />
jet. The rotary jet head rotates at a predefined speed<br />
to provide a full 360-degree indexed cleaning pattern. This<br />
ensures that the tank surfaces are thoroughly covered after<br />
a specified interval of time, which is dictated by the actual<br />
configuration of the machine.<br />
Figure 5. The wall shear stress in the footprint of an impinging<br />
jet from a rotary jet head, with water temperature at 20°C and<br />
pressure at 5 bar, is shown.<br />
The water from each jet of the rotary jet head creates a<br />
moving footprint on the tank walls in the 360-degree indexed<br />
cleaning pattern (as mentioned above). Because of the<br />
significantly higher impact force of the rotary jet head and<br />
subsequent increase in wall shear stress, it is possible to<br />
predict the required cleaning time more accurately when<br />
using a rotary jet head (Fig. 5).<br />
Chemistry and temperature are therefore no longer the most<br />
important parameters for cleaning efficiency. Instead, impact<br />
force is the most important parameter. By increasing the<br />
impact force on the tank surface, it is possible to reduce the<br />
time, flow, chemistry and temperature.<br />
In other words, when using a rotary jet head in most tank<br />
CIP scenarios, it is possible to cut the cleaning time required,<br />
reduce the amount of cleaning fluids used and realise<br />
energy savings because the cleaning fluids do not need to<br />
be heated to high temperatures in order to achieve optimal<br />
tank cleaning efficiency.<br />
Figure 4. EHEDG certified Rotary jet head. The rotary jet head is<br />
by far the most effective tank cleaning technology available today.<br />
Reduction of cleaning time and fluids<br />
consumption<br />
Recent studies indicate how the impact force from a rotary jet<br />
head is distributed in the impact area on the tank wall (Figures<br />
6 and 7). 4 The highest impact force occurs at the centre of<br />
the impact area; it then decreases by approximately 50% at<br />
a distance of 40 mm from the centre of the impact area. It<br />
is also important to note that the rotary jet head effectively<br />
cleans high-viscosity products, such as sticky foodstuffs,<br />
using water at ambient temperature in just 15 seconds after<br />
the jets hit the tank wall.
Optimisation of tank cleaning 73<br />
In many applications, using a rotary jet head can reduce<br />
cleaning time by 50 to 70% and cut water and cleaning<br />
fluid consumption by up to 90% compared with using the<br />
conventional fill-boil-dump method or static spray ball<br />
technology. It is then easy to understand why so many<br />
companies are considering new ways to optimise tank<br />
cleaning performance yet maintain control over the tank CIP<br />
process.<br />
The Sinner Circle for tank cleaning with a static spray ball<br />
The Sinner Circle for tank cleaning with a rotary jet head<br />
Performance<br />
in good hands<br />
Validating the footprint<br />
Figures 6 and 7. Comparison of static spray ball and rotary jet<br />
head tank cleaning machines using the Sinner Circle. Adding the<br />
impact force of the rotary jet head results in savings in cleaning<br />
time, cleaning fluids and energy due to reduced pump running<br />
time and less heating time of the tank cleaning fluid.<br />
Ways to control the tank cleaning process<br />
Because uptime is key to production efficiency, optimising<br />
tank cleaning performance is critical. It is therefore important<br />
to optimise the tank cleaning process to ensure repeatable<br />
tank cleaning performance in the shortest possible amount<br />
of time.<br />
Although tank CIP systems are automated, these systems still<br />
require monitoring and control. Temperature, flow rate and<br />
chemical concentration are among the critical tank cleaning<br />
process control parameters. However, the performance of<br />
the CIP system itself also requires monitoring and control to<br />
ensure that it operates according to design parameters. Take<br />
the rotary jet head tank cleaning system, for instance; it is<br />
important that the rotary jet head cleaning fluids hit the tank<br />
surface with the right impact force in order to ensure optimal<br />
cleaning efficiency.<br />
The question remains: Is it possible to ensure validation of<br />
the rotation and impact?<br />
Alfa Laval launches the improved and innovative<br />
Rotacheck. Validating the cleaning process inside<br />
any hygienic tank, cleaned by a rotary jet head. The<br />
patented teach-in and monitoring system ensures:<br />
• Precise and reliable online monitoring<br />
of the cleaning head<br />
• Instant alarm output if error occurs<br />
during cleaning<br />
Minimizing down time, optimizing<br />
production time!<br />
More on tank equipment:<br />
www.alfalaval.com
74 Optimisation of tank cleaning<br />
Real-time tank cleaning process control<br />
Process control depends upon reliable real-time in-line<br />
measurements using electronic sensors, such as the<br />
Rotacheck sensor, to monitor and verify the performance of<br />
a rotary jet head and tank CIP. Various such devices are<br />
readily available today. However, it is important to consider<br />
the response time of the device, as well as its ability to<br />
register the actual pressure at which the jets hit the tank<br />
surface.<br />
Fast response time is critical in order to measure the impact<br />
force of the water jets accurately and reliably. A response<br />
time of less than 25 ms is considered necessary to register<br />
a jet hit against the tank wall; however, the response time for<br />
many sensors is too long, exceeding the 25 ms and therefore<br />
providing inaccurate measurements. Consequently, the<br />
sensors do not measure the entire actual impact and<br />
therefore do not properly validate the effect of the jet.<br />
Furthermore, the signal remains “high” on the sensor even<br />
after the jet has passed and is no longer hitting the sensor.<br />
Registering the actual pressure at which the jet hits the tank<br />
surface is equally important. This pressure is the actual<br />
impact force that the jet exerts upon the tank surface. If the<br />
amount of pressure applied to the tank surface decreases,<br />
then the impact force decreases as well (Fig. 8). As the<br />
pressure decreases so too does cleaning efficiency, which<br />
consequently causes the cleaning time to increase.<br />
Advanced sensors, such as the Rotacheck+ version that<br />
carries the 3-A symbol and has been EHEDG-certified, offer<br />
the same advantages as basic sensors but include built-in<br />
intelligence. This consists of a teach-in function where the<br />
sensor records and stores the unique and actual cleaning<br />
pattern for any individual tank cleaning machine based upon<br />
its initial cleaning cycle, which has the design parameters<br />
(set point) intact.<br />
Every time a CIP process is initiated thereafter, the sensor will<br />
compare the actual measurements to the recorded pattern<br />
(set point). Operators are immediately alerted during tank<br />
CIP if there is any deviation from the initially recorded time,<br />
pressure or registration of jet hits. This enables operators to<br />
act immediately to remedy the situation, thereby reducing<br />
the risk of losing valuable production time. With the right CIP<br />
sensor in place, the process is under control.<br />
Figure 9. EHEDG certified Electronic verification tools, such as the<br />
Rotacheck and Rotacheck+ sensors, validate the proper function of<br />
rotary jet heads during tank cleaning.<br />
Figure 8. Jet impact profile of a rotary jet head when passing a<br />
Rotacheck sensor. Typical pressure characteristics of a water jet<br />
from a rotary jet heat at 3 bar and at 5 bar shown.<br />
Selection of the right CIP process control<br />
system<br />
Choosing the right system to monitor and control tank CIP<br />
processes can be challenging. It is important to define your<br />
objectives for monitoring and control and to understand the<br />
available options and advantages.<br />
Basic sensors transmit a simple logic signal to the plant’s<br />
control system, which indicates all jet hits and verifies<br />
the operation of the rotary jet head. In addition to signal<br />
transmission, some sensors also have a clear visual light<br />
signal that is visible to operators on the plant floor. Most are<br />
easy to install anywhere on the tank, even on a pressurised<br />
tank.<br />
Tank CIP process control optimises plant<br />
hygiene and efficiency<br />
There are several ways to achieve optimal tank cleaning<br />
efficiency. To determine the right tank cleaning method for<br />
a particular process, it is important to define the cleaning<br />
criteria, understand the options available and consider the<br />
level of cleaning efficiency and process control required.<br />
Selecting the right tank cleaning method puts the food<br />
manufacturer in control of the tank cleaning process and<br />
ensures that the best cleaning results can be achieved in<br />
terms of accuracy, reliability and repeatability.<br />
Whilst manual tank cleaning may seem sufficient for<br />
some processes, there are advantages to switching to an<br />
automated system, including cleaning consistency, reduced<br />
labour costs and increased production time. Enhancing<br />
automated tank cleaning processes also has its advantages<br />
in terms of less downtime, higher energy savings and<br />
reduced water and cleaning fluid consumption.
Optimisation of tank cleaning 75<br />
The addition of CIP process control systems, whether using<br />
basic or advanced sensors, can further enhance cleaning<br />
efficiency. The only way to validate that an automated tank<br />
cleaning system is working effectively is to monitor and verify<br />
its performance.<br />
With so much invested in hygienic food and beverage<br />
production, the additional expense of hygienic sensors to<br />
validate the tank cleaning process seems a small price to<br />
pay to ensure the optimal cleaning efficiency.<br />
References<br />
1. Sinner, H. 1959. The Sinner Circle “TACT.” Sinner’s Cleaning<br />
Philosophy. Henkel.<br />
2. Jensen, B.B.B. 2009. May the force (and flow) be with you:<br />
importance of flow in CIP. Food Safety Magazine, 14:28-31, 51.<br />
3. Jensen, B.B.B. et al. 2011-2012. Tank cleaning technology:<br />
Innovative application to improve clean-in-place (CIP). EHEDG<br />
<strong>Yearbook</strong> 2011-2012, pp. 26-30.<br />
4. Therkelsen, Niels Vegger. 2012. Methods to determine the efficiency<br />
of nozzles for cleaning process equipment. Master’s thesis.<br />
BioCentrum-DTU, Technical University of Denmark.<br />
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European Hygienic Engineering & Design Group<br />
Effective tank and vessel cleaning:<br />
How different systems can help meet today’s demands<br />
Continuously developing tank cleaning technology with the aim of improving effectiveness and<br />
efficiency will help to reduce the required amount of energy and media.<br />
Falko Fliessbach, GEA Breconcherry, e-mail: falko.fliessbach@gea.com, www.gea.com<br />
Ever higher demands for process hygiene, combined with<br />
significantly increased costs for the energy required to<br />
heat up and convey cleaning media and long downtimes,<br />
are typical challenges for many production plants. It is<br />
therefore logical to critically analyse the cleaning processes<br />
in production plants to determine and exploit the potential<br />
for optimisation. Developing tank cleaning technology to<br />
improve effectiveness and efficiency will help to reduce<br />
the required amount of energy and media, and increase<br />
hygiene in the plant environment.<br />
Cleaning components are used for cleaning in various<br />
production plants in the food, beverage, pharmaceutical<br />
and chemical industries. They allow the cleaning of tank<br />
vessel and reactor surfaces – irrespective of whether they<br />
are in contact with product or not – to be integrated into<br />
the process. Cleaning media such as water, detergents<br />
or disinfectant solutions are applied to soiled surfaces.<br />
Depending on the application (i.e. whether vertical or<br />
horizontal tanks with or without internal fittings are to be<br />
cleaned and what type of residues are to be removed),<br />
various types of cleaning devices lend themselves to be<br />
used more effectively in some situations than others.<br />
Users typically want answers to the following questions:<br />
• What is the difference between the systems on the<br />
market?<br />
• Which system is the most effective and the most<br />
economical for my type of application?<br />
• Who has the expertise to advise me and develop the<br />
best solution?<br />
The most popular systems on the market and details<br />
about their technical characteristics and performance<br />
capabilities are introduced below. Special processes also<br />
are described.<br />
Three groups of cleaner types are distinguished:<br />
• Static cleaners<br />
• Rotating cleaners<br />
• Orbital cleaners<br />
Static cleaners<br />
Static cleaners, also known as spray balls, are available with<br />
various spray patterns: up only, down only or 360°, in various<br />
sizes and with different capacities (Figures 1 and 2). Spray<br />
patterns that direct liquid “up” are ideally suited for tanks<br />
without internal fittings, because the full amount of cleaning<br />
solution can be applied directly to the tank cover and the<br />
tank wall. “Down” spray pattern cleaners are best utilised for<br />
tanks that are open at the top, and “360°” spray patterns are<br />
designed for tanks with internal fittings. Depending on the<br />
application, the spray ball requires flow rates in the range<br />
of 30-50 litres per minute per metre of tank circumference<br />
to work efficiently. Spray balls are usually available with a<br />
threaded connection or pipe clip. Using spray balls for the<br />
cleaning of tanks with internal fittings is recommended<br />
only if large parts of the tank can be cleaned by wetting<br />
all surfaces. If this is not the case, other cleaning devices<br />
should be selected.<br />
Figure 1. Different types of spray balls.<br />
Figure 2. (a) Spray pattern “Down”; (b) Spray pattern “Up”; (c)<br />
Spray pattern “360°.”
Efficient conveying of liquids<br />
GEA Tuchenhagen offers a complete range of normal-priming and self-priming<br />
centrifugal pumps, finely tuned to the task at hand.<br />
• Reduced energy consumption<br />
• Gentle product handling<br />
• Hygienic design<br />
• Capacity range of 1 m³/h up to 210 m³/h<br />
• Optimal SIP/CIP characteristics<br />
• EHEDG approved and certified<br />
Whatever your process, GEA Tuchenhagen has a clever solution for you.<br />
GEA Tuchenhagen GmbH<br />
Am Industriepark 2 – 10, 21514 Büchen, Germany<br />
Phone +49 4155 49-0, Fax +49 4155 49-2423<br />
sales.geatuchenhagen@gea.com<br />
www.gea.com<br />
engineering for a better world<br />
GEA Mechanical Equipment
78 Effective tank and vessel cleaning: How different systems can help meet today’s demands<br />
Rotating cleaners<br />
Rotating cleaners rotate around an axis, and they can be<br />
found as fast or slowly rotating types (Figures 3 and 4).<br />
Slowly rotating cleaners use flat or round jet nozzles to spray<br />
the cleaning solution on the tank wall. Unlike spray balls,<br />
the cleaner does not wet all inner tank surfaces at the same<br />
time, but rather, applies a concentrated liquid jet to one<br />
segment of the tank wall at a time. This means that the full<br />
impact energy of the jet can act on this particular segment<br />
and that a thicker liquid film forms on the tank wall, which,<br />
due to its higher energy, achieves better cleaning results as<br />
it runs down to the tank outlet. Without switching the supply<br />
pump on/off, this produces a pulse/pause type of operation<br />
for each segment of the tank that allows the product residues<br />
to be softened and rinsed off. This effect cannot be achieved<br />
by a spray ball.<br />
As a result, the mechanical cleaning effect of the slowly<br />
rotating cleaner is much greater than that of a spray ball.<br />
This even applies if the cleaning solution flow rate is relatively<br />
low. Under normal operating conditions the cleaning medium<br />
consumption is about 30-50% less compared to a spray<br />
ball.<br />
Figure 4. Rotating cleaner in the head of a mixing tank.<br />
Figure 3. Various types of rotating cleaners.<br />
Orbital cleaners<br />
The special characterristics of this type of cleaner are the<br />
round-jet nozzles that rotate in two planes and produce<br />
highly focused high impact jets for intensive cleaning of the<br />
inside surfaces of tanks or vessels (Figure 5). Depending on<br />
the type, the cleaners have two or four nozzles. The nozzles<br />
have an inside diameter of up to 12 mm in accordance with<br />
application requirements. The horizontal and vertical rotary<br />
movement is produced by a turbine gear unit, driven by the<br />
cleaning medium, or by a separate drive such as an electric<br />
or pneumatic motor. The continuous rotation in two planes<br />
produces a finely meshed, net-like pattern of cleaning jets<br />
on the inside wall of the tank. At the end of a full cycle, each<br />
and every point of the tank has been directly subjected<br />
to mechanical impact from a strong jet. A complete cycle<br />
typically takes between 3 and 9 minutes. In practice, orbital<br />
cleaners generally operate at pressures of 4 to 8 bar and<br />
can easily cover an effective horizontal cleaning diameter
Fine-tuned UHT-plants<br />
The basis for aseptic product treatment<br />
The decisive factors in the selection of the appropriate UHT (Ultra High Temperature)<br />
process for thermal product treatment are product quality, production safety and<br />
efficiency. GEA TDS markets three different types of UHT-plants – with a capacity<br />
range from 50 to 40,000 l/h for the treatment of low and medium viscosity products,<br />
but also allowing thermal and aseptic treatment of products with portions of fibres<br />
and particles.<br />
GEA TDS now offers an addition for a very smooth and gentle product handling:<br />
the new infusion technology for milk and juice. Applying this new direct heating<br />
technology makes the product taste remain very fresh, especially when producing<br />
ESL milk.<br />
GEA TDS GmbH<br />
Am Industriepark 2 – 10, 21514 Büchen, Germany<br />
Phone +49 4155 49-0, Fax +49 4155 49-2724<br />
geatds@gea.com<br />
www.gea.com<br />
engineering for a better world<br />
GEA Process Engineering
80 Effective tank and vessel cleaning: How different systems can help meet today’s demands<br />
of up to 33 metres, depending on the nozzle diameter used.<br />
This type of cleaner is especially recommended for large<br />
tanks, tanks and vessels with complex internal fittings, and<br />
for products that are difficult to clean (Figure 6).<br />
Compared with a spray ball, the cleaning medium<br />
consumption is up to 70% less.<br />
Figure 6. Mixing tank for toothpaste, (a) before and (b) after<br />
cleaning using orbital cleaners.<br />
Figure 5. Various types of orbital cleaners.<br />
Monitoring the function<br />
Static cleaners do not have any wearing parts so that they<br />
are mistakenly regarded as operationally reliable. But like<br />
rotating and orbital cleaners, this type of cleaner also must<br />
be protected from particles that could block the roughly 200<br />
holes with a diameter of 1-3 mm each (e.g., by installing line<br />
filters). Regular inspection is required for all devices, even if<br />
the cleaning process has been validated.<br />
For devices that rotate around one or two axes there are<br />
various ways to monitor around the operation. On devices<br />
where the turbine is fitted outside of the tank, direct<br />
monitoring by proximity switches is easily possible. For the<br />
other cleaner types, various measuring devices, working<br />
according to the principles of noise/vibration analysis,<br />
pressure pulse measurement and flow rate changes in<br />
combination with microwave measurement, are available on<br />
the market. Depending on the manufacturer and the type of<br />
sensor, installation is achieved quickly and easily or is rather<br />
complex, depending on whether, for example, separate<br />
evaluation electronics are required for the control system in<br />
the control cabinet or not (Figure 7a/b).
Figure 7 a/b. (a) Monitoring sensor and (b) monitoring sensor<br />
installed.<br />
Tanks with internal fittings<br />
For cleaning tanks with internal fittings such as agitators,<br />
deflectors, scrapers, and so on, it is essential that at least<br />
two cleaning devices should be installed in the tank top,<br />
so that no spray shadows (i.e., areas left uncleaned) are<br />
produced. The decisive factor is that the spray pattern<br />
should be 360°. For products that are difficult to clean, slowly<br />
rotating cleaners or orbital cleaners are the best option.<br />
If agitators with several agitator blades are fitted, it is also<br />
possible to use so-called “in-line sprayers,” which can<br />
be moved into the tank after the process by a pneumatic<br />
extended in order to clean the underside of the agitator<br />
blades (Figure 8a/b). While tanks with agitators are being<br />
cleaned, these should generally turn slowly to ensure<br />
complete cleaning coverage. Accumulating a certain amount<br />
of clean-in-place (CIP) medium in the tank can support the<br />
cleaning of the lower tank sections.<br />
The Solution Finder.<br />
There is only one thing we will not separate:<br />
your process and our customized solution.<br />
We adapt machines to needs, not needs to machines.<br />
GEA Westfalia Separator Group GmbH<br />
Werner-Habig-Straße 1, 59302 Oelde, Germany<br />
Phone: +49 2522 77-0, Fax: +49 2522 77-2488<br />
ws.info@gea.com, www.gea.com<br />
engineering for a better world<br />
GE-90-01-011
82 Effective tank and vessel cleaning: How different systems can help meet today’s demands<br />
Figure 8a/b. In-line sprayer (a) “closed” and (b) “open”.<br />
Conclusion<br />
There is a large variety of tank cleaning devices available on<br />
the market. However, this does not make selecting the right<br />
one any easier. The most efficient and economic solution<br />
can only be chosen from the broad portfolio offered on the<br />
market today if the cleaning problem is clearly analysed and<br />
all process criteria are assessed beforehand.
European Hygienic Engineering & Design Group<br />
Practical considerations for cleaning validation<br />
Hein Timmerman, Diversey, part of Sealed Air, Amsterdam, the Netherlands,<br />
e-mail: hein.timmerman@sealedair.com, www.diversey.com<br />
The European Hygienic Engineering & Design Group<br />
(EHEDG) subgroup Cleaning Validation, chaired by<br />
Professor Rudolf Schmitt of HES-SO in Switzerland, is<br />
working on a new guideline pertaining to cleaning validation<br />
expected to be published in <strong>2014</strong>. Cleaning and/or<br />
disinfection validation is defined as ‘obtaining documented<br />
evidence that cleaning and/or disinfection processes<br />
are consistently effective at reaching a predefined level<br />
of hygiene, if properly implemented on equipment and<br />
production environment and used as intended.’ In contrast,<br />
cleaning verification is defined as ‘the application of<br />
methods, procedures, tests and other evaluations, in<br />
addition to monitoring, to determine whether a control<br />
measure is or has been operating as intended.’ Verification<br />
is sometimes described as the documented evidence<br />
showing that an assigned entity continues to meet the<br />
required (hygiene) specifications. According to International<br />
Standards Organisation (ISO) 22000, verification is the<br />
‘confirmation through the provision of objective evidence<br />
that specified requirements have been fulfilled.’<br />
The goal of developing the new EHEDG guideline is<br />
to provide a complete validation approach suitable for<br />
equipment manufacturers, cleaning product and equipment<br />
manufacturers and all industrial food producers, from smalland<br />
medium-sized enterprises (SME) to multinational<br />
companies. Cleaning validation is a documented process<br />
that shows evidence demonstrating that the cleaning<br />
methods that have been found applicable and acceptable<br />
for a process/product, achieve consistently the required<br />
levels of cleanliness.<br />
The objective of the cleaning validation is to demonstrate<br />
the effectiveness of the cleaning procedures in the<br />
removal of product residues, degraded products,<br />
preservatives, allergens, and/or cleaning, disinfecting,<br />
cross- contamination and enzymatic agents that can post<br />
a risk to the consumer of manufactured food products.<br />
Together, validating cleaning, assuring a validation<br />
standard and achieving consistent results is a topic of high<br />
priority in the food processing industry. Cleaning validation<br />
is used to show proof that the cleaning system consistently<br />
performs as expected and provides scientific data that the<br />
system consistently meets predetermined specifications<br />
for the residuals. However, when starting a new Greenfield<br />
plant, the integration of a validation approach from the<br />
design phase is a good base from which to achieve the<br />
required result. When an existing plant or line requires an<br />
effective and validated cleaning program, a huge amount<br />
of effort will be needed. More than 80 percent of cleaning<br />
procedures and methods executed on a daily basis in the<br />
food industry are not validated and are poorly documented.<br />
Lack of cleaning validation can be one of the root causes<br />
of food safety incidents as it relates to underperforming<br />
cleaning routines.<br />
The validation of process lines is more than the lineup of<br />
single equipment. Implementation of a new validation plan<br />
will require a holistic approach. Validation can absorb a<br />
huge amount of a dedicated team’s time and will have an<br />
economic impact on the manufacturing operation. Finding<br />
the balance between a theoretical and academic-proven<br />
method and the practical realisation of the validation plan<br />
will require good insights in current available technologies<br />
and their practicality on the plant floor. In addition, a simple<br />
engineered line modification, such as the changing of a<br />
pump type or the addition of a valve or new instrument, can<br />
necessitate a new validation of the entire process line.<br />
Validation requires a deep understanding of all elements<br />
involved in the cleaning result, such as the importance<br />
of design and development for an effective program; the<br />
principles and calculations of residue limits for a wide variety<br />
of residue types; routes of administration; and dosage<br />
types the selection of available analytical methods, along<br />
with appropriate levels of analytical method validation.<br />
It also requires a knowledge base about the selection of<br />
sampling methods and sampling sites, along with proper<br />
selection of blanks and controls using the appropriate<br />
strategies and documentation for sampling recovery<br />
studies; the presence of a cleaning validation master plan<br />
and/or policy components; the appropriate documentation<br />
for cleaning validation protocols and reports; the tools used<br />
for monitoring, verification and revalidation; and validation<br />
maintenance for validated cleaning processes.
84 Practical considerations for cleaning validation<br />
The new EHEDG guideline will demonstrate a practical<br />
approach that takes into account all of the needed steps<br />
to come to a validated cleaning. The partnership between<br />
the food operator and cleaning chemicals suppliers and<br />
optimisation of related services is essential to assure a<br />
focused and professional validation approach. However,<br />
it will be a crucial task to define a balanced strategy in<br />
grouping cleaning activities and simplifying the validation<br />
work to keep the validation implementation a task that will<br />
not disrupt the company’s efficiency.<br />
SMART SAFETY<br />
Thanks to smart automation, the new<br />
Tetra Alcip CIP unit uses exactly the<br />
right temperature, amount of water,<br />
detergent concentration and cleaning<br />
time to achieve uncompromising food<br />
safety. While cutting the consumption<br />
of water by 21% and chemicals by 6%.<br />
And delivering unique flexibility to meet<br />
every CIP need. All at the lowest operational<br />
cost.<br />
Certified equipment conforming to the guidelines<br />
of EHEDG, of which Tetra Pak is an active member.<br />
www.tetrapak.com<br />
Tetra Pak, , ProTeCTs WhAT’s<br />
good and Tetra Alcip are trademarks<br />
belonging to the Tetra Pak group.
European Hygienic Engineering & Design Group<br />
Integrated hygienic tamper-free production<br />
The challenge for producers is to secure food safety in their production line, profitably. It is<br />
important to secure against operator mistakes, inconsistent product quality, and even against<br />
manipulation of the product. Adopting a holistic view on the entire production is the answer.<br />
Stefan Åkesson, Tetra Pak, Lund, Sweden, e-mail: stefan.akesson@tetrapak.com<br />
Today, production is integrated: The product flows continuously<br />
through the plant, from raw material intake to distribution,<br />
without stopping. This means that producers must control<br />
every step, both individually and as part of the whole.<br />
However, recurring problems with hygienic issues are<br />
reported from all over the world. Inconsistent food quality,<br />
manipulation of product, wilful tampering, human error – all<br />
of these reports have a huge impact on brands, profitability,<br />
and consumer confidence in the food industry as a whole.<br />
Securing tamper-free production is essential.<br />
Hygienic design<br />
It all starts with hygienic design. Hygienic design ensures that<br />
every material that will ever come in contact with food – from<br />
components right down to connections and welds – is designed<br />
and constructed for cleanability. Using and following the<br />
European Hygienic Engineering and Design Group (EHEDG)<br />
guidelines ensures state-of-the-art hygienic design. It is also<br />
important to conduct a hygienic risk assessment during the<br />
development and engineering phases of a project to analyse<br />
and evaluate hazards in order to eliminate or reduce hygienic<br />
risks. Following hygienic design principles means that the<br />
production process is designed with quality control functions<br />
that ensure food safety from start to finish.<br />
With quality assurance operations in place, substandard<br />
products can be handled at an early stage, which minimises<br />
product losses and increases product quality. One way<br />
to secure food safety is to use guidelines – structured<br />
procedures – as an important aid in the daily work of a food<br />
processing plant. Furthermore, the control system not only<br />
should monitor the procedures, but it should also actively<br />
provide hygienic functionalities that help the producer avoid<br />
operator mistakes, ensure quality control and secure a<br />
tamper-free production environment.<br />
To assist the producer’s food safety management system,<br />
it is important that the quality control system monitors the<br />
implementation and attainment of good manufacturing<br />
practices (GMP) and identifies measures to correct any<br />
failure to achieve GMP.<br />
Integration of hygienic, aseptic and control systems is shown<br />
in EHEDG Guideline 24.<br />
Tamper-free production solution<br />
Advanced control systems with recipe handling, production<br />
monitoring and production analysis access information<br />
about the ongoing process. To secure consistent product<br />
quality and avoid intentional tampering, the optimal tamperfree<br />
solution should involve all phases of production, with<br />
multiple levels of security (e.g., automated material handling<br />
that secures the mixing accuracy, even of manual ingredient<br />
additions or monitoring of the cleaning sequence through<br />
clean-in-place [CIP] sensors, and automatic adaption of<br />
the cleaning procedure, depending on the information<br />
received and analysed). The control system also ensures<br />
that the product and cleaning agents are not mixed. In<br />
the warehouse, recipe handling functions should ensure<br />
that the right material and amounts are stored, and stock<br />
management should show continuous inventory information.<br />
The recipe handling also helps the operator to create the<br />
batches according to the recipe and production schedule,<br />
and a unique batch identification (ID) number is generated<br />
when ingredients are being prepared for different batches to<br />
ensure that the right ingredients and amounts are added into<br />
the right tanks (Figure 1).<br />
Figure 1. Cabinets containing the different ingredients have<br />
automatic locking system integrated with the recipe handling<br />
system. The operator is prompted by the system to add ingredients<br />
in a preset order, and through the cabinet locking system, the<br />
operator can pick only the correct mixture, securing product quality.<br />
Another security function is in the mixing area. A stock-inand-out<br />
solution is integrated with the weighing system and<br />
a scanner device that the operator uses to keep track of<br />
all additions. In the process area next to the mixing tanks<br />
the operator scans the generated batch ID barcode on the<br />
prepared bin and the barcode on the tank. If the codes<br />
match the automatic tank locking system the tank will open.<br />
The interlocking function makes sure that the right mix<br />
goes into the right tank. Locks on both tanks and ingredient<br />
containers secure the integrity of the system and this ensures<br />
consistent product quality while reducing waste and product<br />
loss. Another feature of an automated control system is the<br />
availability of reports: Batch reports, stock reports, journals
86 Integrated hygienic tamper-free production<br />
and audit reports are key performance indicators used to<br />
optimise production through improved production planning,<br />
logistics and production analysis.<br />
The tamper-free production solution supports the food<br />
safety management system for food producers, by avoiding<br />
operator mistakes, keeping track of all raw materials and<br />
ingredients, and preventing intentional tampering and other<br />
food safety issues.<br />
HigH-pressure safety<br />
Super-efficient UHT treatment of highviscous<br />
soups, sauces, tomato pastes, you<br />
name it. Based on a coil tubular heat exchanger<br />
– Tetra Vertico – that handles up<br />
to 350 bar pressure, giving less sticking<br />
and fouling, and up to 50% less product<br />
loss. Faster product changes. Easier<br />
cleaning. Safer for food. Safer for the environment.<br />
Safer for your business.<br />
Traceability is about trust<br />
A well-developed method that ensures traceability can<br />
prove invaluable to food safety while significantly reducing<br />
the cost of recalls and bad will. A sophisticated automated<br />
control system enables traceability quickly and efficiently<br />
throughout the entire production chain, from raw material<br />
intake to packaged product. Effective traceability is the result<br />
of structured data acquisition, where the acquired data are<br />
accessible and searchable. Traceability is essential if a<br />
product needs to be recalled, and it limits the size of the<br />
recall. With a traceability tree, the entire production flow can<br />
be viewed and analysed, and performance can be improved.<br />
Advanced control systems with traceability technologies<br />
improve the speed and reliability of the entire production<br />
process through real-time monitoring. In addition, complete<br />
automation control secures traceability of the final product.<br />
The system compares the product samples to the production<br />
parameters. If the values are out of range, the system can<br />
give alerts.<br />
Traceability can make production transparent and allows<br />
anyone along the supply chain (including the consumer) to<br />
discover the origin and route of any given food via an Internet<br />
portal. By tracking the origin of foods and their routes through<br />
the food supply chain, the risk of unexpected incidents can<br />
be reduced and consumers’ trust in food production can be<br />
maintained.<br />
Certified equipment conforming to the guidelines<br />
of EHEDG, of which Tetra Pak is an active member.<br />
www.tetrapak.com<br />
Tetra Pak, , ProTEcTS wHaT’S<br />
good and Tetra Vertico are trademarks<br />
belonging to the Tetra Pak group.
European Hygienic Engineering & Design Group<br />
Damage scenarios for valves:<br />
Identifying the potential for optimisation<br />
Willi Wiedenmann, Krones AG, D- Neutraubling, e-mail: willi.wiedenmann@krones.com, www.krones.com<br />
Ideally, valves used in the production process would go<br />
unnoticed and remain problem-free throughout a line’s<br />
entire functional lifetime. But valve integration cannot be<br />
ignored quite so easily; after all, these components are<br />
indispensable for automated production processes to ensure<br />
the appropriate routing paths and to shut off product flows.<br />
They are required to exhibit maximum reliability in terms of<br />
design and function, and to be sturdy enough to effortlessly<br />
cope with any events occurring in the production process.<br />
Where exactly are the potential problems associated with<br />
valves? Moving parts for opening and closing the shut-off<br />
components, duty limits of seal materials as well as product<br />
characteristics, and the temperatures encountered in the<br />
production and cleaning processes all demand a lot from<br />
the components involved and influence their useful lifetimes.<br />
Then there are the imponderables, such as water hammers<br />
or human error in handling the individual components<br />
when removing and installing wear parts. By designing a<br />
radically new series of valves, Krones has taken on board<br />
the empirical feedback from operating aseptic and nonaseptic<br />
production lines, and has created a family of valves<br />
that exhibit salient improvements for many of the problems<br />
encountered in valve design. This involves valve design that<br />
contributes to safe and contamination-free product routing,<br />
and incorporates features that simplify the operator’s work<br />
and enhance personnel safety.<br />
Seal design for butterfly valves<br />
Numerous cases of damage when using valves are<br />
associated with the seal. In the case of a butterfly valve,<br />
for instance, volume changes will occur, caused by rises<br />
in temperature. These swellings on the seals protrude into<br />
the product compartment, so that during the opening and<br />
closing operations for the valve disc, the increased level<br />
of friction causes small particles to be abraded, which<br />
are then entrained in the product or the cleaning agent<br />
(Figure 1).<br />
The result is that the valve no longer closes properly, which<br />
means that the liquids are no longer dependably separated,<br />
resulting in product contamination. For example, if the flap<br />
is no longer being positioned in a 90° configuration, the<br />
feedback signal from the proximity sensor is not being sent,<br />
and the system goes into fault mode, which entails substantial<br />
costs in terms of lost production output (Figure 2).<br />
Figure 2. Swelling of the seal, with tear, in conjunction with<br />
imprecise closing of the butterfly valve.<br />
With a seal design that incorporates two expansion grooves<br />
the expansion caused by a change in temperature can be<br />
purposefully confined to the seal’s installation space in the<br />
housing, and the abrasion or damage in areas coming into<br />
contact with the product can thus be avoided (Figure 3).<br />
Figure 3. Cross-sectional view of a butterfly valve with optimum<br />
installation situation for the seal.<br />
Figure 1. Seal abrasion at the disc.<br />
And in order to prevent wear phenomena due to valve<br />
flap movements, a smooth surface has been provided in<br />
the product compartment, thus relocating the dividing line<br />
to outside the product area. A lead-in chamfer on the seal
88 Damage scenarios for valves: Identifying the potential for optimisation<br />
supports the switching mechanisms of the disc, so that all<br />
switching operations are performed with minimum stress on<br />
the material.<br />
Extensive tests on the capability of the valve design to<br />
withstand pressure chock (or water hammer) also provide<br />
precise data on the production conditions under which the<br />
valves can be operated. Thus, in the event of unexpected<br />
water hammers (which cannot be entirely ruled out in any<br />
production operation), a clear statement can be made on the<br />
state of the seal. (Figure 4).<br />
Figure 6. Sealing configuration at the valve plate.<br />
In the event of damage to the valve disc, safe and<br />
contamination-free operation of the production line can only<br />
be restored by a time-consuming and expensive replacement<br />
of the valve plate.<br />
The frequently observed phenomenon of the seat seal’s<br />
tearing out at the opening and closing movements of the<br />
valve discs is manifested with one-piece valve discs, where<br />
installation of the seal is, in most cases, not easy, and in<br />
actual practice is also accompanied by a bit of “helping out”<br />
with the use of grease or washing up liquid.<br />
Figure 4. Seal torn out after a water hammer.<br />
The design of a two-part screwed-together valve disc with a<br />
defined installation space for the seal ensures significantly<br />
more precise installation conditions, and concomitantly,<br />
reliable positioning of the seal. This provides concomitant<br />
gains in terms of reliability against pull out and fluid behind<br />
the seal. Leakage detection according EHEDG is warranted<br />
between the parts of the valve disc. (Figure 7).<br />
Weak point: Valve stem and seat seal<br />
In the case of seat valves, it is not uncommon for traces of<br />
wear at the valve disc and the valve shaft to be responsible for<br />
entraining dirt into the product area and for leaks (Figure 5).<br />
Figure 7. Sealing configuration at the seat.<br />
Similar phenomena can be observed with mix proof valves.<br />
Damage to the radial seal and traces of wear at the valve<br />
disc can be prevented by providing a defined installation<br />
space for the seal, and by designing the seal with a support<br />
ring (Figure 8).<br />
Figure 5. Traces of wear on the valve disc.<br />
This is prevented by integrating a second shaft seal, which<br />
strips off any dirt, and avoids any damage to the valve shaft<br />
from wear traces. Leakage detection according EHEDG is<br />
warranted between housing and seat ring. (Figure 6)
Figure 8. Traces of wear on the valve disc.<br />
Moreover, since the seals are identical, there is no possibility<br />
that the product paths will be shut off incorrectly due to<br />
confusion between the axial and radial seals (Figure 9).<br />
Figure 9. Identical seals for radial and axial sealing of the valve<br />
disc at a mix proof valve.<br />
Compounds for high operating temperatures<br />
It holds true for all valve designs that newly developed highperformance<br />
compounds have led to higher temperature<br />
resistance. Whereas 10 years ago temperatures of up to<br />
160°C were customary for the steam involved, in systems<br />
designed today the temperature spectrum has to be<br />
extended up to 210°C, which means the seal has to possess<br />
significantly enhanced performance capabilities. By utilising<br />
the finite element method (FEM), the framework conditions<br />
were simulated by Krones during the design phase, and<br />
the stress limits and expansion reproduced under defined<br />
temperature conditions and with specified installation<br />
spaces. A comparison with a seal of conventional design<br />
revealed definite advantages for the newly chosen seal<br />
construction.<br />
Uncompromising safety<br />
At Tetra Pak, exceptional efficiency goes<br />
hand in hand with uncompromising food<br />
safety. For example, our unique OneStep<br />
technology, which combines heat treatment,<br />
separation and standardization in a<br />
single step, cutting the production time of<br />
UHT or ESL milk by up to 90%, and cutting<br />
operational costs by up to 50%. Complete<br />
with aseptic buffering, it gives you an unbroken<br />
chain of safety.<br />
Certified equipment conforming to the guidelines<br />
of EHEDG, of which Tetra Pak is an active member.<br />
www.tetrapak.com<br />
Tetra Pak, , and PrOTECTS<br />
wHAT’S gOOd are trademarks<br />
belonging to the Tetra Pak group.
90 Damage scenarios for valves: Identifying the potential for optimisation<br />
Aseptic – strong bellows essential<br />
The requirements involved are even more stringent in<br />
aseptic operations. Dependable separation of the product<br />
from its surroundings has been the strategy pursued<br />
for many years now. Integrating the bellows elements<br />
as a seal at the valve disc can indeed create the desired<br />
separation; however, this introduces a not-inconsiderable<br />
source of possible malfunctions. Defective bellows and the<br />
concomitant possibility of rear infiltration may be responsible<br />
for contamination phenomena not amenable to easy<br />
detection, causing substantial losses of productivity in actual<br />
operation quite apart from a contamination of the product<br />
involved (Figure 10).<br />
The conditions for operators and<br />
maintenance staff<br />
Besides replacing any worn seals, staff are also involved<br />
in maintenance work on the valves and the actuators. So<br />
maximised safety has to be assured. The foundations for<br />
this are in place: clients, and thus the valve manufacturers<br />
too, have to ensure that the design of their systems and<br />
components is such as to fundamentally rule out any risk of<br />
injury during operation, and conforms to the requirements<br />
of the EU’s Machinery Directive (2006/42/EC) and the EU’s<br />
Pressure Equipment Directive (97/23/EC).<br />
With a welded version of the actuator (designed for one<br />
million switching cycles), the amount of maintenance work<br />
required is minimised, while the accident risk from opening<br />
up an actuator is eliminated as well. In this context, special<br />
attention has been paid to easy handling of the actuators, as<br />
evidenced by the weight of < 25 kg in the case of nominal<br />
diameters of up to ND 100. In addition, accident prevention<br />
in production mode is enhanced by covers for moving parts<br />
(valve yoke, feedback system) (Figure 12).<br />
Figure 10. Damage to the bellows means that contamination is<br />
inevitable.<br />
A study of the stresses acting on the stainless-steel bellows<br />
under a flow of p = 7 bar shows unequivocally (with different<br />
process parameters and stroke positions) what vibrations<br />
occur in the bellows construction. This quickly reveals why<br />
a bellows breaks after only a very brief period of operation.<br />
In the newly designed valve series, this is remedied by an<br />
integrated support body (Figure 11), which ensures that the<br />
bellows is properly guided and dampens the vibrations at the<br />
individual pleats. Moreover, this also avoids damage to the<br />
bellows due to overstressing at removal.<br />
Figure 12. Personnel safety – protective feature at the valve yoke<br />
and feedback system<br />
Figure 11. Support body for guiding the bellows.<br />
With a component inspection conducted by the TÜV Süd<br />
technical control board, comprising a pressure test, a safety<br />
test and a strength test, the new series of valves has been<br />
subjected to all tests designed to document operational<br />
safety down to the tiniest detail.
Besides safety considerations, of course, features designed<br />
to facilitate care and maintenance work have also been<br />
integrated, such as quick and easy seal replacement in the<br />
product compartment without needing any special tools, and<br />
(as already mentioned) eliminating any risk of confusion<br />
when replacing seals.<br />
Advertisement<br />
Summary<br />
New methods for determining the performance capabilities<br />
of components, plus a rigorous scrutiny of damage<br />
occurrences, are indispensable as a basis for design<br />
enhancements. State-of-the-art components offer possible<br />
approaches for optimising the useful lifetime and for reducing<br />
cases of damage in actual production conditions.<br />
This new designs also score in terms of financial aspects,<br />
since with lower compressed-air consumption, fast lifting<br />
time and free cross-sectional areas in the product flow<br />
energy costs can be meaningfully reduced.<br />
Of the utmost importance are improvements in terms of<br />
hygienic design of valves. It is an excellent idea to confirm<br />
the cleanability of valves in the process through certification<br />
by the European Hygienic Engineering & Design Group.<br />
Lödige supplies high-grade subsystems,<br />
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LÖDIGE - ALWAYS THE RIGHT MIX
European Hygienic Engineering & Design Group<br />
Infection-free preparation of bacterial cultures<br />
The preparation and compounding of freeze-dried bacterial cultures available in powder form<br />
requires extremely high standards of hygiene. If the material is also deep frozen the mixing<br />
equipment must have very good insulation and meet increased strength requirements.<br />
Dipl.-Ing. Ludger Hilleke, amixon GmbH, D-33106 Paderborn, Phone: +49 5251 68 88 88-0, info@amixon.de,<br />
www.amixon.de<br />
Today, fermented specialities enhance nearly all of the most<br />
commonly produced dairy products. Whether in cheese,<br />
curd and yoghurt, or when used for improving meat, they<br />
can be found everywhere. However, the production of these<br />
powdery granular materials is a real challenge, especially in<br />
further processing environments, which demand a high level<br />
of cleanliness, quality of handling, and a granular dust-free<br />
structure.<br />
A determinant of the quality in this process is operation<br />
with the minimum of interruptions; in other words, as nearly<br />
continuously as possible. High-purity bacterial cultures form<br />
by cell division, and for industrial production, the aqueous<br />
suspension of bacteria is continuously diluted with nutrient<br />
solution. After a constant dwell time, the matured suspension<br />
is removed and washing processes follow. The cell division<br />
process does not stop until the extracted cultures are frozen.<br />
To facilitate handling, the cultures also are sometimes freeze<br />
dried, which produces a loose powder or granulate with bulk<br />
densities around 0.1 to 0.4 kg/dm 3 .<br />
In subsequent automated processing of bacterial cultures<br />
there is often a mixing process. Naturally, a quick result is<br />
desirable, with the mixing done in a way that avoids causing<br />
damage and that work efficiently under difficult conditions<br />
(i.e., differing filling degrees, bulk densities, particle sizes,<br />
rotational speeds, etc.). In addition, as a result of the<br />
alternating stresses that result from very high temperature<br />
changes in these processes, mixers must be specially<br />
designed to avoid fatigue cracks.<br />
Meeting all of these challenges of producing powderform<br />
freeze-dried bacterial cultures in a hygienic manner<br />
requires mixers that are designed with hygiene in mind.<br />
A good example is a single-shaft mixer whose mixing<br />
principle is based on a three-dimensional rearrangement,<br />
such as those produced by amixon GmbH (Figure 1). In<br />
such a mixer, the material in the periphery of the mixing<br />
chamber is screwed upwards and then flows downwards<br />
in the centre. The helical mixing tool performs mixing<br />
very gently at circumferential speeds of 0.2 to 0.9 m/s. A<br />
particularly useful feature is that the mixing process takes<br />
place independently of the filling level. In this respect the<br />
emptying process also takes place without segregation,<br />
even when it takes a long time or occurs while pulsating.<br />
The high degree of residue emptying assists in keeping the<br />
mixer highly sanitary.<br />
Figure 1. Example of a single-shaft mixer that can be used in the<br />
manufacture of powder-form freeze-dried bacterial cultures.<br />
Thorough cleaning of a processing plant in which mixing<br />
of powders occurs is also clearly essential. Avoiding<br />
contamination is both a determinant of quality and an<br />
absolute ‘must’ in producing foods free of allergens. One<br />
solution to this challenge is the automation of wet cleaning<br />
and drying of powder mixers. In one patented process, a<br />
clean-in-place (CIP) device is firmly installed on the mixing<br />
chamber and remains there permanently. For wet cleaning,<br />
the sealing plug in the mixing chamber opens and makes<br />
the space available for the motion of a rotating wash lance.<br />
The latter moves into the mixing chamber with translatory<br />
motion. With an applied water pressure of about 3.5 bar,<br />
the head rotates and three nozzles spray the entire mixing<br />
chamber interior. Depending on the size and execution of<br />
the mixer, three, four, or in some cases five, washing heads<br />
are necessary for wetting the entire mixing chamber and all<br />
parts of the mixing tool.<br />
After completion of the wet cleaning, drying is essential.<br />
Bearing in mind that the specific heat capacity of water is<br />
about nine times as great as that of stainless steel, the wet<br />
cleaning with hot water spontaneously heats up the mixer.<br />
This heat assists the steam stripping of the mixer. Additional<br />
hot air entering via an inlet through the main connection of<br />
the CIP device accelerates the drying process.<br />
The entire mixer and the CIP system are dried. Only then<br />
does the rotating lance move out of the mixing chamber and<br />
the sealing plug closes the container, gas-tight and liquidtight.
From the operator’s viewpoint, it is worth noting that the<br />
sequence of movements of the patented device requires only<br />
a single electro-pneumatic drive, making it easy to control.<br />
It is employed with success in mixers, dryers, reactors and<br />
other systems. In specific cases the rotating washing nozzle<br />
is replaced by high-pressure aiming nozzles, particularly if<br />
the cleaning is to be done with a small amount of water but<br />
utilises high pressures.<br />
Ultimately, any mixer used in the preparation and<br />
compounding of freeze-dried bacterial cultures must<br />
be built to sanitary standards in compliance with US<br />
Food and Drug Administration (FDA) requirements, 3-A<br />
Sanitary Standards, and the requirements of the European<br />
Hygienic Engineering Design Group (EHEDG).<br />
Individual and<br />
future-oriented<br />
plants for your<br />
process.<br />
Tailor-made solutions for process systems<br />
for the food, beverage and pharmaceutical<br />
industries. Consulting, planning, construction<br />
and service - all from a single source.<br />
Plant design at its best.<br />
Ruland Engineering & Consulting GmbH<br />
Im altenschemel 55<br />
67435 neustadt, Germany<br />
Phone: +49 6327 382 400<br />
Fax: +49 6327 382 499<br />
info@rulandec.de, www.rulandec.de
European Hygienic Engineering & Design Group<br />
Modern level detection and measurement technologies<br />
Sticky media, foam, changing media and hygienic installation present challenges for fill level<br />
detection and measurement. In order to improve reliability and reduce the downtime of machinery<br />
it is crucial that a level sensor switches off when the tank, vessel or tube is empty, even if the tip<br />
is still covered with the medium. Any medium that produces foam is especially tricky because<br />
an overflow protection has to detect it, whereas a level measurement and an empty detection<br />
should mask the foam. A modern level measurement and detection should also work even if the<br />
medium changes. This article gives a guideline of technologies to solve these challenges, as<br />
well as some information on hygienic mounting.<br />
Daniel Walldorf, Baumer GmbH, Friedberg, Germany, dwalldorf@baumer.com, www.baumer.com<br />
Frequency sweep technology<br />
for level switches<br />
Frequency sweep technology for level switches detects fill<br />
level of a tank, vessel or tube on the basis of the DK value.<br />
As opposed to a classical capacitive sensor, this technology<br />
opens the possibility to distinguish different media (e.g.,<br />
liquid and its foam) and adhesions from sticky media to a<br />
full tank (Figure 1). Clever set-up strategies make it possible<br />
to use the same sensor with the same set up for a large<br />
variety of media. Advanced sensor versions usually make it<br />
possible to do visual set up and to get a measurement output<br />
from the sensor (e.g., for condition monitoring of a tank).<br />
Figure 2. Setup of a sensor for sticky media (chocolate).<br />
Figure 1. The frequency sweep technology opens the possibility to<br />
distinguish different media and adhesions from sticky media.<br />
The working principle involves analysing an inductorcapacitor<br />
(LC) circuit for its resonance frequency where the<br />
medium to detect influences the capacitor. Therefore, the<br />
resonance frequency depends on the medium in front of the<br />
sensor tip. At the resonance frequency, power consumption<br />
is at its minimum.<br />
Hydrostatic level measurement<br />
One might think that measuring level by hydrostatic pressure<br />
is not very modern. Nevertheless, it is with reason that<br />
this measurement approach remains the most popular<br />
technology. The food, beverage and pharmaceutical industry<br />
facilities typically operate machinery using a wide temperature<br />
range from 0°C to 140°C. Therefore, it is critical to use a<br />
pressure sensor with good temperature compensation.<br />
This is typically reached by sensor manufacturers with an<br />
internal temperature measurement and an identification of<br />
temperature compensation for each individual sensor during<br />
the production process. In most data sheets, the temperature<br />
error is indicated either as temperature coefficient or as a<br />
value for a total error band available in the compensated<br />
temperature range.
Modern level detection and measurement technologies 95<br />
Hygienic connection of pressure sensors are inside the<br />
recommended tubings. For the mounting in tanks there<br />
are fewer possibilities with standard connections. Most<br />
manufactures offer special cavity-free process connections<br />
for tanks together with the fitting welding parts. The user and<br />
planner should look at the European Hygienic Engineering<br />
& Design Group (EHEDG)-certified connections to be on the<br />
safe side.<br />
Altogether, hydrostatic level measurement offers a very<br />
good and cost-effective method for tanks from about 1 m<br />
in height and up, which corresponds to a pressure range of<br />
about 100 mbar. For tanks under 1 m high, the use of other<br />
technologies should be investigated.<br />
Capacitive contact-less level switching<br />
Standard capacitive switches can be used to detect a<br />
medium in a tank through the tank wall. This is especially<br />
interesting because no hygienic process connection is<br />
needed and the set up can be extremely compact and easy<br />
to add to an existing tank.<br />
Potentiometric level measurement<br />
For tanks heights lower than about 1 m, potentiometric level<br />
measurement technology offers a very good alternative.<br />
This technology uses a metallic rod inside the tank and<br />
measures the level by detecting the length of the rod, which<br />
is connected to the tank wall by a liquid.<br />
The technology masks foam as well as adhesions by sticky<br />
media. It is very interesting that sensors based on this<br />
principle do not have to be set up to the used medium.<br />
Hygienic applications are matched by taking care of special<br />
process connections that are typically together with fitting<br />
welding parts for tanks. A short response time of a few<br />
milliseconds is typical, so that even for fast filling processes,<br />
this technology offers a great alternative.<br />
However, the technology is limited in that the medium should<br />
be liquid, homogeneous, and must have at least a small<br />
conductivity. In most applications in the food, beverage and<br />
pharmaceutical industries, the parameters are inside these<br />
limits.<br />
Conclusion<br />
There are several options that enable accurate measurement<br />
of the level in tanks with liquids, even if the product is sticky<br />
or has a layer of foam. Moreover, available technologies can<br />
be applied in a hygienic way.<br />
Figure 3. Capacitive sensor setup at a glass tube.<br />
As a limitation this only works through plastic tanks or glass<br />
windows.
European Hygienic Engineering & Design Group<br />
An example of the development process of hygienic<br />
process sensors: A hygienic level switch<br />
The development of new technologies usually follows predefined pathways. The development<br />
of sensors for use in hygienic processes has additional requirements. This article shows the<br />
impact of hygienic design in the product development process.<br />
Holger Schmidt, Grad. Brewmaster, Endress+Hauser, Weil am Rhein, Germany,<br />
e-mail: holger.schmidt@de.endress.com,<br />
Some developments start with a good idea that seems to<br />
come out of the blue and the result is a useful technology.<br />
More often, the market has a specific need and the new<br />
development is based on changing an existing instrument,<br />
automation technology or process. It could also be based<br />
on an economic need to improve the process. But usually,<br />
customers want to improve safety, quality and performance<br />
of their plant, so that their operations and facilities remain<br />
state-of-the-art.<br />
The Liquipoint FTW33 point level switch was born out of the<br />
latter desire. The need for a reliable high- or low-level signal<br />
and pump protection in point level switch technology was<br />
previously achieved successfully over a number of years<br />
by using tuning fork technology for nearly all applications<br />
in hygienic processing. However, the successful use of this<br />
technology was limited in highly viscous media in which small<br />
“voids” are created around the vibrating forks that can cause<br />
uncertainty in level detection. Another challenge with tuning<br />
fork and capacitance level technologies is related to their<br />
ingressing parts, which makes cleaning more demanding,<br />
time-consuming and costly than necessary. This is especially<br />
true if mechanical support is required such as the use of a<br />
cleaning ball in pipes.<br />
Driven by these needs, the goal was clear: Design a<br />
sensor that works in highly viscous media without buildup<br />
issues. The design would need to be flush-mounted to<br />
allow sufficient cleaning such as is outlined in the European<br />
Hygienic Engineering & Design Group (EHEDG) Guidelines<br />
8 and 10.1<br />
well as global customers who require additional process<br />
connections. For this sensor, an adapter concept was<br />
chosen to ensure necessary flexibility without compromising<br />
any of the hygienic requirements set forth in the original<br />
goals. It was important to focus on a smart design of the<br />
connecting parts and gaskets. The design needed to ensure<br />
exposure of the seal at the right place, and also protect it<br />
against mechanical stress.<br />
Document 10 of the EHEDG Guidelines backs up these<br />
design criteria with a focus on corners, dead ends, edges,<br />
gaskets, seals, and the connection of different materials. The<br />
parts that are in contact with product, but also the housing,<br />
only show even surfaces.<br />
The definition phase<br />
The engineering phase begins with determining which<br />
technology best meets the specified goals. In this case, there<br />
was already good know-how in capacitance and conductivity<br />
measurement available within the engineering team. The<br />
sensor design approach focused on a combination of both<br />
tuning fork and capacitance technologies. The design started<br />
with understanding the guidelines in which hygienic design<br />
is described. For the food and beverage Industry, these are<br />
primarily the EHEDG and 3A Sanitary Standards guidelines.<br />
It includes EHEDG Document 8, which describes how to<br />
define the choice of material, cleanability, tightness against<br />
intruding microorganisms, geometry, surface treatment,<br />
installation and self-draining requirements.<br />
The choice of appropriate process connections was another<br />
important decision to take in the sensor development<br />
process. Standards like DIN 11864 were considered, as<br />
Figure 1. Polished surfaces and crevice-free welding at wetted parts<br />
and housing.<br />
The sensor must also be protected against the cleaning<br />
processes of the food and beverage industry. Even if<br />
a high pressure jet cleaner typically spreads dirt and<br />
microorganisms more so than manual mechanical cleaning<br />
methods do in a given plant, the deisgn of the sensor should<br />
ensure its reliability and ruggedness on a daily basis.<br />
To meet the development objectives, EHEDG Document 37,<br />
which details function and design of sensors for hygiene and<br />
safety, also was taken into consideration. For the Liquipoint,
98 An example of the development process of hygienic process sensors: A hygienic level switch<br />
the fulfillment of these requirements led to a design that<br />
works with very smooth angles on a nearly flat plate. The<br />
slight warp is needed to ensure the support of a self-cleaning<br />
process and ensures, together with the active build-up<br />
compensation, high reliability in nearly all media. The<br />
precondition for reliable level detection is the requirement<br />
for a conductivity of more than 1µS.<br />
The materials of the Liquipoint — 316L stainless steel and<br />
virgin PEEK as an isolator — are combined in a specific<br />
process that ensures long-term, crevice-free tightness of<br />
the sensor (Figures 1 and 2). All materials follow FDA and<br />
European requirements (EN 1935/2004) as described in<br />
EHEDG guidelines. The surfaces of wetted parts have a<br />
surface finish better than 0.76 µm. The sensor is compact<br />
enough to fit in small process connections, but also supports<br />
an adapter concept. It is self-draining, and has no gaps or<br />
crevices.<br />
Production considerations<br />
Following the design and testing process, there are several<br />
significant production considerations that must be taken<br />
into account in producing the sensor. First, production of<br />
equipment to be used in hygienic installation must meet<br />
all specific regulatory requirements. In ISO 9001 and<br />
attached norms, the specific considerations are described<br />
and equipment and component manufacturers are charged<br />
to follow good manufacturing practices. It starts with the<br />
purchasing of raw material, internal handling and traceability,<br />
and continues through to a clean working environment. The<br />
wetted parts, including all materials that are in contact with<br />
the product, such as cleaning media or lubricants, must follow<br />
the international regulations for food-contact materials. If<br />
after cleaning the product prior to completion there remains<br />
any cleaning solution or lubricant residues, there must be<br />
validation that they cannot cause any harm. Periodic review<br />
of procedures and the resulting products ensure that the<br />
packaged sensor is of the expected quality.<br />
Figure 2. Liquipoint point level switch, flush mounted, even surface.<br />
The resulting design results in less shear forces on the<br />
sensor, especially in agitated vessels, and offers the ability<br />
to install the sensor in areas with very little space. The final<br />
design fulfills the basic technical requirement: a reliable<br />
switch signal under all conditions.<br />
Conclusion<br />
On the one hand, the development of a specific technology<br />
for the hygienic industry is demanding. On the other, it is<br />
easy, because there are clear guidelines and customer<br />
expectations to meet. EHEDG supports efforts to join the two<br />
market participants’ recommendations and expectations.<br />
The supplier can be confident that by following the EHEDG<br />
guidelines the sensor will be market-ready. And the user<br />
is sure that he receives a hygienically designed process<br />
component that will have a positive impact on the safety,<br />
quality and performance of the manufacturing plant .<br />
In this case, the technical requirements dictated the basic<br />
design definitions, which led to the development of an<br />
improved, safe and reliable switch that works with different<br />
media—specifically with high- or low-viscosity media—is<br />
unaffected by build-up, is easy to handle, and is safe to<br />
install and operate. But even if measuring technology drives<br />
the development, it is possible to use hygienic guidelines<br />
to ensure proper design. The Liquipoint FTW33 is a good<br />
example of how the product development process and result<br />
of such a process can look.<br />
The field testing phase<br />
The definition of applications for testing the new device<br />
was easy in this case, because market recommendations<br />
led to this product development. Targeted installations were<br />
“sticky” and demanding processes, including products such<br />
as yogurt, jam, cream cheese, smoothies, dough or ketchup.<br />
In these applications, the sensor must show how it can cope<br />
with build-up, cleaning cycles, and sterilisation, and must<br />
show its flexibility in dealing with changing products. The<br />
installation and set-up must be easy. In-house tests with<br />
specific treatments were added to the field test. In a short<br />
time, a high number of cycles could be simulated through<br />
these in-house tests. Finally, a mandatory step in product<br />
development in the food and beverage industry is to show<br />
how the sensor behaves in a defined cleaning cycle. In this<br />
case, the sensor was tested using the EHEDG cleanability<br />
test rig as a reference.
European Hygienic Engineering & Design Group<br />
Storage in silos and pneumatic conveying of milk powder<br />
with up to 60% fat content<br />
Hermann Josef Linder, Solids Solutions Group, S.S.T.-Schüttguttechnik Maschinenbau GmbH, Landsberg, Germany,<br />
Phone: +49-8191-3359-0, e-mail: H.Linder@solids.de, www.solids.de<br />
The storage and flow of fine food-based powders with high<br />
fat content is a challenge. An investigation conducted by<br />
Hausner-Zahl in 1996 showed that for these types of powders<br />
a very high degree of compaction occurs during conveying<br />
and storage. This results in the categorisation of the product<br />
in its deposited state as “non-flowing,” which presents<br />
further quality and food safety control issues associated with<br />
storage capacity in silos. 1 In addition, according to Geldart<br />
(1973) in his assessment of pneumatic conveying, when a<br />
classification in Group C (i.e., fine powders) was carried out,<br />
flowability of these products was cohesive, difficult or not<br />
able to fluidise. 2<br />
Solid Solutions Group (S.S.T.) has conducted complex<br />
investigations of materials used for storage and<br />
transportability, partially under simulation of the operating<br />
conditions, that have led to fine powder processing and<br />
apparatus technical solutions. The primary goal was to<br />
design pneumatic conveying apparatus and storage silos<br />
that comply with the European Union’s (EU) Machinery<br />
Directive 2006/42/EC, Annex 1, Clause 2.1, including food<br />
processing equipment, as well as with the DIN EN1672/2<br />
hygiene requirements. In addition, equipment had to<br />
follow the European Hygienic Engineering and Design<br />
Group (EHEDG) guidelines and the U.S. Food and Drug<br />
Administration (FDA) good manufacturing practices (GMP)<br />
and related rules and recommendations. Goals for the<br />
development of hygienically designed equipment systems<br />
used in the production and storage of fine powders included:<br />
• The entire system should be free of dead spaces,<br />
should be capable of being completely emptied and<br />
should be easily cleanable.<br />
• Where possible, dry cleaning by air flushing is<br />
preferable, but wet cleaning is also possible when an<br />
unavoidable greasy film is present in the process or<br />
system.<br />
• During storage, particularly during the pneumatic<br />
conveying, the primary grain size, bulk density and<br />
appearance of the product should be maintained and<br />
loss of product quality should be avoided.<br />
To ensure the flowability of fine milk powder with up to 60%<br />
fat content, and thus the product’s storage capacity, S.S.T.<br />
conducted investigations as outlined by Jenike (1964).<br />
Due to the influence of the fat content, these investigations<br />
were extended to include various storage temperatures and<br />
storage periods.<br />
Avoiding flowability and storage problems<br />
through hygienic design<br />
Higher fat content in fine powders leads to significant<br />
deterioration of the flowability of the product. Reducing<br />
temperatures in the product during storage results in<br />
an increase of the bulk resistance, which leads to the<br />
deterioration of both flowability and storability. In just a few<br />
hours of storage time, very high levels of fat in a product<br />
typically result in high consolidation stress, which means that<br />
achieving flow without discharge aids is no longer possible.<br />
Higher temperatures worsen the wall friction values, which<br />
leads to distinctive adhesion affinity.<br />
To make the process storage and pneumatic conveying<br />
controllable, a distinction was made in terms of fat content:<br />
• Milk powder with a fat content of
100 Storage in silos and pneumatic conveying of milk powder with up to 60% fat content<br />
Storage in mass flow silo<br />
Figure 1. Solids mass flow silo in hygienic design.<br />
The resulting mass flow silo designed in compliance with<br />
hygienic design goals is characterised by a horizontal drop<br />
of the product level. The product in the entire silo crosssection<br />
is in motion during the discharge. There are no dead<br />
zones, and thus no product residue. The total mass has a<br />
uniform residence time. The premise of “first-in first-out” is<br />
upheld. During the discharge over the entire cross-section<br />
there is a backmixing of the material, which was probably<br />
segregated before when filling in.<br />
Figure 3. Solids Vibration bin discharger provided in mass flow silo.<br />
For the support and assurance of the mass flow at a<br />
reasonable outlet diameter, vibration bin dischargers were<br />
provided (Figure 3). All surfaces that are in contact with the<br />
product have an average surface roughness of Ra
solids_Anz_EHEDG_<strong>Yearbook</strong>_2012_DR.indd 1 21.08.12 15:21<br />
solids<br />
components and<br />
complete plants<br />
The solids solutions group is specialised in the development and manufacturing of components<br />
as well as in the engineering and realisation of complete, automatic bulk handling systems.<br />
The group members are offering individual solutions acc. to the EHEDG-guidelines.<br />
HYGIENIC DESIGN<br />
for powder handling<br />
Minimal cleaning costs at<br />
maximum production hygiene<br />
solids Vibration bin discharger<br />
solids Pneumatic conveyor<br />
solids Rotary valve<br />
Bulk solids installation: storage, discharge, conveying,<br />
feeding, weighing/metering, process automation<br />
solids Dosing screw<br />
system-technik GmbH<br />
Lechwiesenstr. 21<br />
86899 Landsberg / Germany<br />
Phone: +49 8191 / 3359-0<br />
Email: info@solids-systems.de<br />
solids system-technik s.l.<br />
Iñurritza Torrea, Extepare 6<br />
20800 Zarautz / España<br />
Phone: +34 943 / 830 600<br />
Email: systems@solids.es<br />
S.S.T.-Schüttguttechnik GmbH<br />
Lechwiesenstr. 21<br />
86899 Landsberg / Germany<br />
Phone: +49 8191 / 3359-50<br />
Email: info@solids-service.de<br />
solids components MIGSA s.l.<br />
Erribera Kalea 1<br />
20749 Aizarnazabal / España<br />
Phone: +34 943 / 147 083<br />
Email: comercial@migsa.es<br />
www.solids.eu
102 Storage in silos and pneumatic conveying of milk powder with up to 60% fat content<br />
The connection of the pneumatic conveyor occurs with<br />
centred connecting components with gap-free sleeves. The<br />
material inlet valve is a disc valve in hygienic design, easily<br />
disassembled and cleaned by a divided housing and gapfree<br />
connection by centring flanges and a seal that conforms<br />
with FDA requirements as published in the U.S. Code of<br />
Federal Regulations (Figure 4).<br />
The pneumatic conveyor is free of dead zones, has gapfree<br />
centred mounting connections with FDA-conforming<br />
gaskets. Mass flow during emptying with vibration support<br />
and air flood cleaning minimise the need for cleaning. For wet<br />
cleaning, the pneumatic conveyor with the entire conveying<br />
line system is CIP-able and piggable.<br />
Summary<br />
The flowability of a product is influenced significantly<br />
by moderate fat content. Longer periods of storage or<br />
temperature variations, even when fat content is
European Hygienic Engineering & Design Group<br />
Material and design optimisation calculated by EHEDG:<br />
Tubing systems<br />
The development and manufacturing of tubing for EHEDG-compliant production are demanding<br />
tasks that require careful engineering. They depend not only on detailed hygienic design,<br />
but also targeted optimisation with an emphasis on flow resistance, maintenance costs and<br />
ergonomic criteria.<br />
Dr. Torsten Köcher, Sales Manager, Dockweiler AG, D – Neustadt-Glewe,<br />
e-mail: t.koecher@dockweiler.com, www.dockweiler.com<br />
Products manufactured according to European Hygienic<br />
Engineering & Design Group (EHEDG) hygienic<br />
requirements generally follow a series of steps that apply<br />
to a variety of machines and system stations. Accordingly,<br />
they must be transported as intermediate products from one<br />
process step to the next. Provided production quantities<br />
exceed a certain amount, engineers use tubing designed<br />
and constructed in compliance with EHEDG requirements<br />
for liquid and semi-liquid products. In addition to product<br />
lines, the design of the gassing lines mounted onto the<br />
corresponding vessels also have to meet these strict<br />
guidelines.<br />
EHEDG compliant tubing: strict<br />
requirements<br />
These requirements are significant. They are about<br />
achieving the level of purity and avoiding the dead space<br />
required by EHEDG, as well as ensuring that the unhindered<br />
flow of material through the tubing system is accounted for<br />
in dimensioning and planning. The potential dead space<br />
geometry must also account for flow rates. A permissible<br />
n x D ratio (e.g. 2xD, distance of valve – main tube) at a low<br />
flow rate can cause problematic dead space (Figure 1). The<br />
engineering expense is worth it, because the user profits<br />
from lower operating costs and minimised maintenance<br />
expenses, among other things. However, comprehensive<br />
know-how and production capabilities custom-tailored to<br />
this challenging task are an absolute must. This point is<br />
elaborated in this article using case studies from Dockweiler<br />
AG’s development and production portfolio.<br />
Figure 1. A permissible n x D ratio (e.g. 2xD, distance of valve - main<br />
tube) at a low flow rate can cause problematic dead space.<br />
Source material: Stainless steel tubing<br />
There are three essential methods for producing tubing:<br />
1. In the production of seamless tubing, a thick-walled<br />
tube, a so-called blank or hollow, is stretched using a<br />
plug drawing. In doing so, the wall becomes thinner.<br />
There can be many steps to the process. In general,<br />
tubing up to approximately DN 25 is manufactured in<br />
this way. The drawing process causes displacement of<br />
the crystalline areas along the crystallographic planes.<br />
The metal ‘flows’ through the tool and is smoothed.<br />
Grid tension causes the metal to harden and deformation<br />
martensite occurs. A final heat treatment is<br />
necessary for maintaining homogeneous austenitic<br />
structures.<br />
2. In the manufacture of welded tubing, cold-rolled steel<br />
from a coil with the best surface qualities available is<br />
used as the primary material for producing tubing of<br />
excellent quality. The steel sheet from the coil runs<br />
through a series of shaping rollers, on the ends of<br />
which the welding of the longitudinal seam occurs.
104 Material and design optimisation calculated by EHEDG: Tubing systems<br />
After additional production steps, such as grinding,<br />
annealing and leveling, the tubing must undergo eddy<br />
current testing in order to ensure the quality of the longitudinal<br />
weld seam.<br />
3. The third method plays a role in refinery and power<br />
plant technologies, which use tubing with wall thicknesses<br />
exceeding 16 mm. Hot rolled steel is typically the<br />
primary material. It is formed into tubing with the aid of<br />
presses that exert hundreds of tons of pressure onto<br />
the material and then longitudinally seam welded.<br />
The mastery and exploitation of such manufacturing<br />
processes means achieving optimal material properties. The<br />
suitability of the material for further processing is equally<br />
important. Analysis is made possible by the countless material<br />
and surface testing procedures currently available. The most<br />
well-known method is the measurement of Ra values. The<br />
results of surface profile measurements, however, are limited<br />
in validity because they do not provide information about<br />
the microstructure. Additional inspections are necessary for<br />
proving suitability of the tubing, for example, welding tests,<br />
electrolytic polishing tests and microscopy.<br />
Important: Materials selection<br />
The right selection of suitable materials determines, among<br />
other things, cleaning qualities and system life. Today, there<br />
are a multitude of alloys on the market that possess the<br />
necessary stable properties to stand up against different<br />
types of corrosion. In order to fully utilise their properties,<br />
however, they must be properly processed. The application<br />
and its particular influencing factors, such as medium,<br />
concentration, time and temperature determine the selection<br />
of materials and surfaces.<br />
Figure 2. Beyond standards: Example of a customised branch<br />
solution.<br />
Manifolds: Dead space minimisation is the<br />
objective<br />
Figure 3 shows a manifold with attached valve, for example,<br />
for dosing an additive into a base fluid. Conspicuous here is<br />
the short distance between the central tubing and the valve<br />
base plate. As a result, a tiny dead space occurs when the<br />
valve is closed. In comparison to conventional construction<br />
with T-pieces, the potential dead space volumes are reduced<br />
by approximately 38%; at the same time, the component is<br />
clearly more compact (Figure 4).<br />
Branch conduits: Know-how is in the details<br />
The production of geometrically simple and frequently<br />
used components, such as branches, demonstrates the<br />
complexity of implementing EHEDG guidelines. This<br />
begins with the selection of materials. This is the only<br />
way that optimal welding can be ensured. Furthermore,<br />
the processing methods must be adjusted to the future<br />
application.<br />
Different techniques (boring, saddle, and collaring<br />
methods) are available for the processing of T-pieces, each<br />
of which have their merits, but also their application limits.<br />
Dockweiler uses the collaring method for branch conduits<br />
with a diameter of 19.05 to 168.30 mm and also produces<br />
special T-pieces, for example, with inclined or eccentric<br />
outlets (Figure 2). The advantages are exact geometry and<br />
complete drainability of the production system. Dockweiler<br />
solely uses the Wolfram Inert Gas Process (WIG) orbital<br />
welding method for producing components. Validated<br />
documentation is available for all welding seams and<br />
surfaces; depending on requirements, components are<br />
electropolished after production. If desired by the customer,<br />
pressure calculations or X-ray testing can be conducted for<br />
critical components.<br />
Figure 3. The minimisation of dead space is an important design<br />
objective for many EHEDG-compliant tubing components.<br />
Figure 4. Compact and hygienic: Short branch with valve base plate.
Material and design optimisation calculated by EHEDG: Tubing systems 105<br />
The orbital welding method enables tubing to be connected<br />
with a continuous 360º welding seam (Figure 5). To<br />
accomplish this task, Dockweiler AG uses orbital welding<br />
equipment, among other tools, with welding electrodes<br />
positioned on the inside of the tubing. The result is a<br />
continuous, high-quality welding seam that prevents dead<br />
space, ridges, etc., and thus fulfils hygiene requirements.<br />
At the same time, narrow dimensional tolerances are<br />
maintained and the branches from manifolds and special<br />
parts can be designed to be extremely short. This method is<br />
used to engineer a variety of manifold designs for food and<br />
pharmaceutical production.<br />
Figure 6. Thermowell: Tube section with immersion rod for ‘inline’<br />
measurement in product flow.<br />
Example: Optimising design during<br />
engineering phase<br />
Another example: A manufacturer with a complex system<br />
desires two individual valves for the material feed and two<br />
valve blocks, each with three hand-operated shut-off valves,<br />
which need to be mounted directly onto the respective entry<br />
and outlet openings on the backside of the system. Dockweiler<br />
AG’s engineering team determined that the valves, which<br />
must be regularly controlled during system operation, would<br />
be too inaccessible. An alternative was developed that<br />
allows an operator to control all eight fittings from one central<br />
station that is also at an easily accessible height (Figure 7).<br />
Additional functions can be included with this basic concept,<br />
for example, a sequence for each of the eight lines.<br />
Figure 5. Orbital welding enables the optimal design of hygienic<br />
tubing components.<br />
Special components for sensors under<br />
EHEDG conditions<br />
Dockweiler AG also develops and produces customised<br />
tubing components for EHEDG-compliant sensors, for<br />
example, for detecting the temperature of media in tubing<br />
systems. This includes, among other things, a tube section<br />
with an dip tube where the sensor is housed (‘thermowell’).<br />
The medium flows past the dip tube and is subject to the<br />
strictest hygiene requirements. The entire construction<br />
should be designed so that disruption of flow and turbulence<br />
are avoided (Figure 6). Measurement results that are actually<br />
reproducible are obtained in this way.<br />
Figure 7. Clearly better results can be achieved through optimisation<br />
of design during the engineering phase.<br />
Strict requirements for documentation<br />
The ‘correct’ production methods and engineering<br />
competency are important when it comes to putting EHEDGcompliant<br />
special constructions into practise. These examples<br />
demonstrate the importance of designing and producing<br />
tubing that meets the highest standards of hygiene. This<br />
applies not only to basic processes like drawing, boring,<br />
expanding and welding, but also surface treatments that<br />
employ processes like grinding, honing, pickling and electropolishing.<br />
All production steps are documented in detail so<br />
that the traceability of each individual component as well as<br />
the reproducibility of the processes is possible. Using this<br />
holistic approach means that manufacturers and operators of<br />
EHEDG-compliant systems can ensure and credibly document<br />
that their tubing meets the highest quality standards.
European Hygienic Engineering & Design Group<br />
Improved hygienic design and performance of food<br />
conveyor belts<br />
Olaf Heide, Habasit AG (Headquarters), CH - 4153 REINACH-BASEL, e-mail: olaf.heide@habasit.com<br />
Food conveyor belts can be found in nearly all industrial food<br />
processing and packaging lines. They are integral to ensuring<br />
a smooth and trouble-free process flow on the production<br />
line. For example, unexpected failures or breakdowns<br />
can be costly and cause severe problems in a continuous<br />
production. Hence, conveyor belts that are designed to<br />
be reliable and rugged in the production environment can<br />
contribute significantly to process efficiencies and profitability.<br />
Furthermore, they typically come into direct contact with food<br />
as an integral part of a process line, and therefore play an<br />
important role in terms of safe and hygienic food processing.<br />
The European Hygienic Engineering & Design Group<br />
(EHEDG) and all of its member companies aim to support<br />
and improve safe food production through hygienic design<br />
of equipment and components. Several leading conveyor<br />
belt manufacturers are members of EHEDG and actively<br />
contribute to various subgroups. As part of the equipment<br />
design process, EHEDG assesses hygienic design of<br />
dedicated belting solutions for direct food contact. An<br />
example is the Habasit HyCLEAN CIP system, Following<br />
thorough evaluation and implementation of improvements,<br />
EHEDG recently assigned for the first time a certificate of<br />
compliance to Habasit’s plastic modular belt types M5060<br />
and M5065 with sprocket and clean-in-place (CIP) system.<br />
All three components comply with hygienic design principles<br />
but utilise their full potential when incorporated as a package<br />
into food conveyors and equipment.<br />
Challenges related to food conveyor belts<br />
The vast variety of food products, processes, manufacturing<br />
methods and equipment requires belts that are able to cope<br />
with mechanical, chemical and environmental conditions.<br />
Each single aspect of production, from size, weight and<br />
shape, to consistency or temperature of conveyed goods,<br />
can have an impact on the performance and lifetime of<br />
a food conveyor belt. Needless to say, there is not one<br />
universal solution that can address all of these aspects. Belts<br />
have to be designed and selected for the intended use and<br />
associated requirements of the manufacturing operation.<br />
This article focuses on improving the hygienic design and<br />
performance of synthetic conveyor belts using plastic<br />
materials as a main design element, since steel belts<br />
follow a different design pathway and thus require separate<br />
considerations.<br />
If this is not done correctly it can cause process problems<br />
such as unexpected breakdowns, yield reduction, product<br />
and allergen contamination by foreign objects and/or<br />
microbial contamination and improper hygiene conditions.<br />
All of these aspects have an impact on the food processor’s<br />
costs and profitability.<br />
Scratched / damaged Plastic Surface damages on coated<br />
Modular Belt (Meat cutting line) fabric belt (Fish processing)<br />
Waste and soiled belt surface<br />
(dough processing)<br />
Fraying belt edges<br />
(Pizza processing)<br />
Figures 1. Things you do not want to see in a food process.<br />
Problems, as shown above, can be avoided by dedicated<br />
selection of belts for their specific application. There are<br />
many solutions on the market to improve durability, chemical<br />
resistance, good release of sticky goods and cleaning<br />
efficacy. But there is more to consider, including the three<br />
pillars of conveyor belt hygiene:<br />
• Food contact material legislation<br />
• Hygiene and food safety requirements<br />
• Impact of equipment hygienic design and cleaning<br />
Pillars of conveyor belt hygiene<br />
Food conveyor belt manufacturers not only must care for the<br />
design of their products, but also ensure that all materials<br />
used in belt construction comply with food contact legislation.<br />
It is especially important to understand and follow the<br />
requirements of regional legislation where food processes<br />
are located and/or where the equipment is put into operation.<br />
Many equipment and component manufacturers also maintain<br />
compliance with the US Food and Drug Administration (FDA)<br />
regulations pertaining to food-contact materials; however,<br />
these rules are not sufficient for operations in the European<br />
Union (EU). In Europe, the most important regulation is the<br />
framework directive EC 1935/2004 and its amendments,<br />
which cover materials and articles intended to come into<br />
contact with food. EU regulation 10/2011 (also known as<br />
Plastics Implementation Measure [PIM]) is a dedicated<br />
regulation governing the use of plastic materials, such as
Improved hygienic design and performance of food conveyor belts 107<br />
plastic conveyor belts. Conformity with these rules must be<br />
ensured and declared by the belt supplier with a document<br />
of compliance that must be provided for each belt type sold<br />
to a food processor or equipment manufacturer.<br />
In addition to consideration of hygienic design principles<br />
and use of safe materials and articles that are allowed to<br />
come into contact with food, all equipment and component<br />
manufacturers also should understand the challenges and<br />
requirements involved in cleaning and sanitation. Cleaning<br />
can be a nightmare if this important activity is not considered<br />
thoroughly during the design phase of food processing<br />
equipment and components.<br />
Design<br />
Food safety<br />
Process hygiene<br />
Cleaning<br />
Regulations<br />
Experience / Innovation / Training<br />
How to identify the ideal belting solution<br />
Know the<br />
Industry,<br />
process and<br />
applications<br />
Analyze<br />
conveyed<br />
goods<br />
Evaluate<br />
problems and<br />
needs for<br />
optimization<br />
5 Tips to upgrade hygiene of food<br />
conveyor belts<br />
Select and<br />
install proper<br />
equipment &<br />
components<br />
Evaluate your currently installed equipment and<br />
components. Check if they are up-to-date and comply<br />
with advanced hygiene requirements, standards and<br />
legislation.<br />
Work with experienced partners who understand your<br />
industry, processes, applications and challenges.<br />
Aim for upgrades and/or improvements.<br />
Check the ability of your belting supplier to deliver them.<br />
In addition to selecting equipment and components that<br />
provide ideal solutions for the target applications, make<br />
sure to consider the cleaning and maintenance as part<br />
of the total costs of ownership.<br />
Figure 2. Design, cleaning and regulations compose the three<br />
pillars of conveyor belt hygiene.<br />
No pillar can stand without a good foundation. To achieve good<br />
design that takes into account regulatory and cleanability<br />
requirements, the food conveyor belt manufacturer will need<br />
a solid foundation of experienced people, the willingness to<br />
strive for innovative solutions, and commitment to ongoing<br />
education and learning (Figure 2). Establishing these<br />
foundational elements are vitally important for food conveyor<br />
belt manufacturers who aim to achieve the ultimate goals of<br />
the EHEDG: To ensure food safety and process hygiene for<br />
all food manufacturing operations.
European Hygienic Engineering & Design Group<br />
Smart hygienic solutions for the food industry<br />
Despite a stagnant economy, food and beverage companies intend to increase investments<br />
into developing new products and technologies to fuel business growth and improve revenues,<br />
according to a recent survey by the global audit company KPMG. While investing in growth,<br />
many companies remain focused on keeping costs low and efficiencies high, while at the same<br />
time emphasising compliance with food safety standards and global regulatory mandates. This<br />
article describes continuing food safety threats and the food industry’s motivation to incorporate<br />
smart hygienic solutions to overcome these challenges.<br />
Peter Uttrup, Interroll España S.A., Barcelona, Spain, phone +34 677 462 788, e-mail: p.uttrup@interroll.com<br />
and Lorenz G. Koehler, Interroll (Schweiz) AG, Sant’Antonino, Switzerland, phone: +41 91 850 25 21,<br />
e-mail: l.koehler@interroll.com, www.interroll.com<br />
Proactive risk management is the key to success in today’s<br />
economically challenging global market. For businesses<br />
in the food supply chain, this means keeping abreast of<br />
changes in the global regulatory environment, especially new<br />
food safety and hygiene standards and laws, and investing<br />
in business strategies and technologies that reduce risk to<br />
the company’s brand reputation and financial health. Some<br />
of the risks that remain high on the list of concern for the food<br />
sector are foodborne illness outbreaks, food product recalls,<br />
and quality control gaps in manufacturing facilities and other<br />
points along the supply chain.<br />
Foodborne illnesses – a constant threat<br />
A foodborne disease is any illness resulting from the<br />
consumption of food that is contaminated by pathogenic<br />
bacteria, viruses, parasites or chemical agents. Foodborne<br />
diseases pose a growing threat to public health worldwide.<br />
The most common effect of foodborne diseases takes the<br />
form of gastrointestinal symptoms, but such diseases can<br />
also lead to chronic, life-threatening conditions including<br />
neurological or immunological disorders, multi-organ<br />
failure, cancer and death. Recent global developments are<br />
increasingly challenging international health security. These<br />
developments include the growing industrialisation and trade<br />
of food production and the emergence of new or antibioticresistant<br />
pathogens.<br />
Although we do not currently have an exact figure of the global<br />
economic impact of foodborne diseases on societies, businesses<br />
and trade, the latest estimations project the costs in hundreds<br />
of billions of U.S dollars. Some of the most significant estimates<br />
include:<br />
• The U.S. Center for Disease Control and Prevention<br />
(CDC) estimates that there are roughly 48 million<br />
cases, 3,000 deaths, and 128,000 hospitalisations from<br />
foodborne pathogens each year in the United States<br />
alone. Children, the elderly, pregnant and post-partum<br />
women and individuals with compromised immune<br />
systems are at highest risk of developing complications<br />
from foodborne illness.<br />
• A new study by a former U.S. Food and Drug<br />
Administration (FDA) economist estimates the total<br />
economic impact of foodborne illness across the U.S.<br />
to be a combined $152 billion annually.<br />
• According to the CDC, in industrialised countries, the<br />
percentage of the population suffering from foodborne<br />
diseases each year has been reported to be up to 30%.<br />
• Thirty-one (31) known pathogens are responsible<br />
for 9.4 million illnesses (20% of the total), 55,961<br />
annual hospitalisations (44% of the total) and 1,351<br />
deaths (44% of the total), according to CDC data.<br />
The remaining unknown/unspecified pathogens are<br />
responsible for 38.4 million illnesses (80% of the total),<br />
71,878 annual hospitalisations (56% of the total) and<br />
1,686 deaths (56% of the total).<br />
These statistics illustrate why companies throughout the<br />
food sector continue to invest in food safety and hygiene<br />
technologies and systems that will effectively mitigate<br />
potential risks of foodborne illness associated with their<br />
products.<br />
Food recall risks<br />
Food sector companies also are increasing their vigilance<br />
in monitoring the quality and safety of foods they place on<br />
market shelves to avoid costly product recalls. A food recall<br />
occurs when there is reason to believe that a food may<br />
cause consumers to become ill. A food manufacturer or<br />
distributor initiates the recall to take foods off the market. In<br />
some situations, food recalls are requested by government<br />
agencies. A food recall can cost millions and is potentially<br />
fatal to a business. Public perception and attitudes toward a<br />
company’s products can be negatively affected by bacteriarelated<br />
recalls that make the headlines.<br />
Risk reduction technologies<br />
As a consequence of these challenges, one can expect<br />
further pressure on food manufacturers to improve quality<br />
control in the coming years. Risk management and reduction<br />
is the foundation of better food safety practices. To help<br />
food manufacturers all over the world comply with the strict<br />
national and international regulations in terms of hygiene<br />
in their material handling processes, many equipment<br />
manufacturers and component makers are investing their<br />
expertise into creating innovative hygienically designed<br />
products to assist industry with improving quality control<br />
measures to reduce contamination risks.
Smart hygienic solutions for the food industry 109<br />
Advances in hygienic conveyor drives provide a good<br />
example of how hygienic design is helping the food sector<br />
control food safety risks on the production line. Conventional<br />
gear motors are bulky, complex to install, require expensive<br />
cabinets and guarding, and most importantly, are not tested<br />
and verified as cleanable by the independent Danish<br />
Technological Institute. In comparison, today’s drum motors<br />
are designed to be regularly cleaned and disinfected to a<br />
great degree of hygiene, even in environments where high<br />
pressure water, steam and chemicals are used (Figure 1).<br />
This helps food manufacturers achieve the highest possible<br />
hygiene standards.<br />
Drum motors that meet the European Hygienic Engineering<br />
& Design Group (EHEDG) Guidelines, and that use<br />
materials in compliance with EU Regulation 1935/2004<br />
raise the user’s confidence that the drum motor utilised<br />
offers optimum cleanability, providing for the lowest possible<br />
levels of Salmonella, Listeria, E. coli and other harmful<br />
microorganisms in the food processing environment.<br />
Further, drum motors with standard IP66 and IP69k sealing<br />
systems are well-suited for wet and high pressure washdown<br />
applications (Figure 2).<br />
Interroll drum motors meet all of these hygienic requirements<br />
and are therefore suited for application in environments<br />
in which high and constant exposure to great amounts of<br />
sanitation chemicals and/or water is the norm.<br />
Figure 2.Hygienically designed drum motors are well-suited for wet<br />
and high pressure wash-down applications.<br />
Figure 1.Drum motors should be designed to withstand regular<br />
high-pressure washdown procedures at food processing plants.
European Hygienic Engineering & Design Group<br />
Examination of food allergen removal from two flat<br />
conveyor belts<br />
Food allergens are an increasing public health concern. Allergen contamination can occur through<br />
cross-contact with equipment surfaces. Designing hygienic, sanitary equipment is essential for<br />
reducing allergen contamination risks and its consequent food recalls. The need for effective<br />
allergen removal calls for improved dry-cleaning technologies. The results of the study illustrated<br />
in this article demonstrate that solid, homogeneous, smooth-surface plastic flat belts can be used<br />
in combination with a dry-cleaning tool as an alternative to fabric-reinforced flat belting in order<br />
to reduce allergen carryover risk during dry food processing.<br />
Dr. Zhinong Yan, Gary Larsen, Roger Scheffler, and Karin Blacow. Intralox, L.L.C., Amsterdam,<br />
Netherlands, e-mails: zhinong.yan@intralox.com; gary.larsen@intralox.com; roger.scheffler@intralox.com;<br />
karin.blacow@intralox.com<br />
Food allergens are a growing public health concern. In the<br />
United States, an estimated 9 million adults and 6 million<br />
children are affected by food allergies. 1,2 The prevalence of<br />
food allergies and associated anaphylaxis appears to be on<br />
the rise. According to a study released in 2008 by the US<br />
Centers for Disease Control and Prevention, an increase of<br />
approximately 18% in incidences of food allergies occurred<br />
between 1997 and 2007. 3 Undeclared allergens are the<br />
leading cause of food recalls. A summary of US Food and<br />
Drug Administration (FDA) recall data from 2010 noted that<br />
more than 60 recalls were due to undeclared allergens,<br />
making it the second most prevalent reason for declaring a<br />
recall, behind only Salmonella contamination. 4 In addition,<br />
the second annual report of the US FDA’s Reportable Food<br />
Registry showed that undeclared food allergens accounted<br />
for 30.1% and 33.3% of food hazard adulterations in 2009<br />
and 2010, respectively. 3<br />
There is no cure for food allergies, so strict avoidance<br />
of allergen-containing foods and early recognition and<br />
management of allergic reaction are the only viable<br />
measures for preventing severe health consequences. The<br />
US Food Allergen Labeling and Consumer Protection Act<br />
(2004) requires clear food allergen labeling in order to avoid<br />
potential consumption of foods that contain one of eight<br />
major allergens (milk, eggs, fish, crustacean shellfish, tree<br />
nuts, peanuts, wheat, and soybeans).<br />
Allergen contamination can occur during any stage of food<br />
processing. Cross-contact during food manufacturing is<br />
an increasing concern, especially when different types<br />
of food are processed along the same production lines or<br />
equipment. Removal of allergens from shared equipment or<br />
processing lines has been identified as an important aspect<br />
of an allergen-management program. 5 Poorly designed or<br />
maintained equipment can make allergen removal more<br />
difficult. A set of 10 principles of equipment design for<br />
low-moisture foods has been developed by the Grocery<br />
Manufacturers Association’s (GMA) Sanitary Design Working<br />
Group in the United States. This group also has developed<br />
an equipment checklist. More detailed information can be<br />
found in the European Hygienic Engineering and Design<br />
Group (EHEDG) Guidelines.<br />
Conveyor belts —<br />
critical food-contact surfaces<br />
Of all the types of equipment used for food processing,<br />
conveyor belts are the most likely food-contact surfaces<br />
to become allergen cross-contact points if not cleaned<br />
thoroughly. There are three major conveyor belt types<br />
employed in dry-food processing: fabric-reinforced flat<br />
belting; continuous, homogenous positively driven flat belts<br />
(e.g., ThermoDrive ® belting from Intralox); and modular<br />
plastic belts. These belts’ materials (plastics, fabric), surface<br />
properties (roughness, crevices), and manufacturing<br />
methods (extrusion, fabric reinforcement) need to be<br />
considered in relation to belt designs and uses in order to<br />
fully follow the 10 principles of sanitary equipment design.<br />
However, few studies regarding these conveyor belts’<br />
ease of cleaning and sanitation have been carried out. Yan<br />
(2011) investigated the potential bacterial-contamination<br />
risks of fabric-reinforced belts during normal processing,<br />
finding that bacteria could penetrate the surface of the<br />
fabric and migrate to foods during conveyance, especially<br />
when driven by friction between the belt and motor. 6 This<br />
same migration process also might occur with allergens. Al-<br />
Taher and Jackson (2011) tested dry-steam vacuuming for<br />
removing allergenic food from a urethane-faced conveyor<br />
belt. 7 This study demonstrated that a recent commercialised<br />
dry-steam cleaning unit may not effectively remove various<br />
allergens from the fabric flat belt, though the efficacy of this<br />
cleaning device may depend upon which different allergens<br />
are applied to the belt surface. The recent development of<br />
solid, homogeneous, positively driven smooth-plastic flat<br />
belting might reduce the problems of cleaning and sanitation<br />
occurring on fabric materials. However, no comparative<br />
testing has been conducted to date.<br />
Cleaning is considered the most fundamental method for<br />
preventing allergens due to cross-contamination from shared<br />
equipment or processing lines. Therefore, developing and<br />
applying effective cleaning methods is critical for removing<br />
allergens. The most powerful tool for removing allergens from<br />
surfaces or interior equipment is water. For environments<br />
that process wet mixes with floor drains, water is the best<br />
choice. However, for the manufacturing of low-moisture<br />
foods, introducing water into the equipment or environment
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112 Examination of food allergen removal from two flat conveyor belts<br />
may lead to microbial growth, especially of pathogens like<br />
Salmonella that are resistant to dry conditions and that grow<br />
with minimal moisture. Hence, dry cleaning methods for<br />
low-moisture food production have been a focus in recent<br />
years, especially with the frequent incidence of Salmonella<br />
contamination in various dry foods.<br />
Currently, methods for dry cleaning are limited to brushing,<br />
vacuuming, sweeping, scraping, use of compressed air, and<br />
pushing through, or wiping with cloths. However, allergencleaning<br />
protocol using these tools remains challenging for<br />
effective and acceptable allergen removal. For instance,<br />
compressed air can blow food debris from hard-to-reach<br />
areas where brushing is difficult, but it also poses risks of<br />
future allergen contamination to food-contact surfaces from<br />
the floor or hidden areas. Recently, several companies have<br />
developed dry-steaming (< 5% moisture) and vacuuming<br />
systems that demonstrate great potential to clean equipment<br />
and environments for dry food processing.<br />
Figure 2. Polyurethane ThermoDrive flat belt.<br />
As common food-contact surfaces, conveyor belts may<br />
be the most critical points for food allergen contamination.<br />
However, allergen removal on the fabric-reinforced and<br />
homogenous flat plastic belts that are used in some dry-food<br />
processing has not been much investigated. The objective<br />
of this study was to assess the cleanability of allergens on<br />
the above two types of flat conveyor belts using a new drysteam<br />
cleaning system. 6<br />
Cleanability of two flat conveyor belts:<br />
A study<br />
A vinyl fabric-reinforced belt (Figure 1) and a polyurethane<br />
solid-homogenous-plastic flat belt (Figure 2) were installed<br />
onto two different conveyors with friction drive and positive<br />
drive, respectively. Three allergen-containing foods —<br />
creamy peanut butter, soy protein, and egg whites — were<br />
spread onto the belts to form a set of thin soils (ca. 1 mm)<br />
within marked areas (10 x 10 cm), then air dried until the<br />
soils were stuck onto belt surfaces (Figures 3 and 4).<br />
Figure 3. Peanut butter on fabric flat belt.<br />
Figure 4. Peanut butter on ThermoDrive belt.<br />
Figure 1. Vinyl fabric flat belt.<br />
A steam vacuum-cleaning device was then placed on<br />
the belt surface (Figure 5). The temperature in the steam<br />
generator was set to 180°C, which passed steam to the<br />
chamber with 5% moisture and reached 77-82°C and 90<br />
psi. The chamber was designed to clean and vacuum the<br />
debris into a container connected to the chamber while the<br />
belt runs at the speed of 10 meters/min. for eight revolutions<br />
until visibly clean.
Examination of food allergen removal from two flat conveyor belts 113<br />
Figure 5. Steam vacuum chamber installed on the conveyor.<br />
(Photo provided courtesy of AmeriVap.)<br />
Reveal 3-D peanut, soy, and egg test kits (Neogen) were<br />
used to validate the effect of allergen cleaning. Each kit<br />
contains a sterile cotton swab, buffer solution, a sample<br />
tube, and a Reveal 3-D test device. The standard testing<br />
protocol provided by Neogen was followed. The device<br />
was read five minutes after reaction. The allergen<br />
acceptable limit was determined by the testing kits’ supplier<br />
to be < 5 ppm.<br />
The effect of allergen cleaning was tested on each belt.<br />
Each allergen-belt combination was tested three times with<br />
six swab samples each time for a total of 18 samples.<br />
Table 1. Allergen testing results on fabric-reinforced flat belt.<br />
Replication Allergen<br />
Peanut Soy Egg white<br />
1 4/6 0/6 0/6<br />
2 5/6 0/6 1/6<br />
3 5/6 1/6 0/6<br />
Total 14/18 (78%) 1/18 (6%) 1/18 (6%)<br />
As shown in Table 1, after dry-steam vacuum cleaning<br />
on the fabric reinforced flat belt, 78% of the samples<br />
tested positive for peanut, 6% tested positive for soy, and<br />
6% tested positive for egg whites. Allergens were not<br />
satisfactorily cleaned, especially for peanut butter, using<br />
this steam-cleaning system.<br />
Table 2. Allergen testing results on homogenous smooth urethane<br />
flat belt.<br />
Replication Allergen<br />
Peanut Soy Egg white<br />
1 0/6 0/6 0/6<br />
2 0/6 0/6 0/6<br />
3 0/6 0/6 0/6<br />
Total 0/18 0/18 0/18<br />
As indicated in Table 2, the three allergens were effectively<br />
removed from the solid smooth surface of the urethane flat<br />
belt using the steam vacuum cleaning device.<br />
Discussion<br />
The results of the allergen cleaning tests using the steamvacuum<br />
system clearly demonstrate that allergens cannot<br />
be removed from fabric-reinforced flat belts to a level<br />
where it cannot be detected with the applied test method<br />
with its specific detection limits, using the system. This<br />
was consistent with the testing carried out by Al-Taher et<br />
al. (2011) on urethane-faced fabric belts using a dry-steam<br />
cleaning device to clean peanuts, non-fat milk, and whole<br />
eggs. The results showed that no egg soils were detected –<br />
with the method applied – for all the cleaning times tested,<br />
while peanut and milk soils were still detected after cleaning<br />
the belt for 10 minutes using the same test kits as used in<br />
this study. The results also demonstrated that the efficacy of<br />
the dry-steam-cleaning unit on fabric flat belts depends on<br />
the type of food soil applied to the belt surface, which was<br />
also in agreement with the results obtained in this study –<br />
that peanut butter was more difficult to clean than soy and<br />
egg whites.<br />
On the other hand, the smooth, solid homogeneous<br />
urethane belt employed in this study showed effective<br />
removal of all allergens using the same cleaning system as<br />
the fabric flat belt. The difference with respect to allergen<br />
cleaning could be due to the belt’s homogenous surface<br />
properties, which fully meet the requirements for hygienic<br />
design of equipment developed by GMA. The fabricreinforced<br />
flat belt’s thin, laminated surface may not be<br />
fully enclosed, which could entrap allergen molecules. In<br />
addition, the fabric materials on the belt’s back side can<br />
absorb moisture accumulated from steam. The belt’s<br />
friction-driving mechanism allows that moisture to squeeze<br />
between the drum and the belt itself, which can result in<br />
allergens and other soils migrating to the top layer of the<br />
belt.<br />
In conclusion, the results from this study demonstrated<br />
that the newly developed solid-plastic flat belt can be used<br />
to reduce the potential allergen contamination during dry<br />
food processing in combination with the dry-steam vacuum<br />
system.<br />
Acknowledgement<br />
The authors are grateful to AmeriVap Company for allowing<br />
the use of their dry-steam cleaning unit to carry out this<br />
study.<br />
References<br />
1. The Food Allergy & Anaphylaxis Network (FAAN). Food Allergy<br />
Facts and Statistics for the U.S. www.foodallergy.org/files/Food<br />
AllergyFacts andStatistics.pdf. Accessed August 10, 2012.<br />
4. US Food and Drug Administration (FDA). 2011. The reportable<br />
food registration second annual report: Targeting inspection<br />
resources and identifying patterns of adulteration. www.fda.gov/<br />
Food/FoodSafety/FoodSafetyPrograms/RFR/ucm200958.htm.<br />
Accessed August 10, 2012.<br />
3. Branum, A., M.S.P.H. and Susan L. Lukacs, D.O., M.S.P.H. 2008.<br />
Food allergy among U.S. children: Trends in prevalence and<br />
hospitalizations. http://www.cdc.gov/nchs/data/databriefs/db10.pdf.<br />
Accessed August 10, 2012.
114 Examination of food allergen removal from two flat conveyor belts<br />
4. US Food and Drug Administration (FDA). 2010. FDA 2010 recalls,<br />
market withdraws and safety alerts. www.fda.gov/Safety/Recalls/<br />
ArchiveRecalls/2010/default.htm. Accessed August 10, 2012.<br />
5. Jackson, L., F.M., Al-Taher, M. Moorman, J. DeVries, R. Tippett,<br />
K. Swanson, T.-J. Fu, R. Salter, G. Dunaif, S. Estets, S. Albillos,<br />
and S. M. Gendel. 2008. Cleaning and other control and validation<br />
strategies to prevent allergen cross-contact in food-processing<br />
operations. J. Food Prot. 71: 445-458.<br />
6. Yan, Zhinong. 2011. Examining the microbial contamination<br />
potential of fabric-reinforced flat conveyor belts. Technical presentation<br />
at International Association for Food Protection Annual Meeting.<br />
July 31 – August 3, 2011. Milwaukee, WI.<br />
7. Al-Taher, F., C. Pardo, and L. Jackson. 2011. Use of a dry steam<br />
belt washer for removal of allergenic food residue. P1-43. Abstract.<br />
International Association for Food Protection Annual Meeting. July<br />
31 – August 3, 2011. Milwaukee, WI.<br />
8. Yan, Z. 2011. Examining the microbial contamination potential of<br />
fabric flat belts. EHEDG <strong>Yearbook</strong> 2011/2012: 49-52.<br />
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European Hygienic Engineering & Design Group<br />
The future of food grade lubrication<br />
Food safety is and will remain the most important issue in the food production industry. Issues<br />
such as 100% machine availability and cost-cutting and efficiency programs also are important<br />
to a processing plant’s performance. As food processors aim to meet the objectives of both<br />
food protection and production efficiencies in a slow economy, it is important to consider how<br />
food grade lubricants can play a positive role in many operations.<br />
Taco Mets, Van Meeuwen Groep B.V., NL-1382 LV Weesp, e-mail: tm@vanmeeuwen.nl<br />
Fortunately, the going concern of the food industry is not at<br />
stake: Everybody will continue to consume food. Despite<br />
the economic crisis resulting in a global manufacturing<br />
slowdown, the food industry continues to run strong.<br />
However, margins are always under pressure and many<br />
people do not realise what is essential to keep production<br />
plants operating efficiently. Today, not only are food safety<br />
rules and regulations becoming increasingly strict but<br />
company budgets are getting tighter and more limited for<br />
technical departments driven by mandatory cost-efficiency<br />
programs. These realities make it more important than ever<br />
for food manufacturing operations to find ways to achieve<br />
both objectives simultaneously.<br />
Differences in lubricants for food processing<br />
applications<br />
Creating a mindset for preventive maintenance is the<br />
most important factor in establishing an environment in<br />
which significant advantages can be achieved with quality<br />
lubricants. Food manufacturers should make sure to use H1<br />
registered lubricants, which are allowed for incidental food<br />
contact (Figure 2). Many experts in the lubrication sector<br />
believe products that are H2 registered (products for the<br />
food industry that are absolutely not allowed to come into<br />
contact with food) will disappear from the market. Either the<br />
processor uses a food grade lubricant, or not, that is the key<br />
choice. Today’s technology makes it possible to formulate a<br />
H1 registered lubricant for (almost) every application.<br />
Figure 1. Lubrication maintenance is key to sustainable and<br />
hygienic performance of production lines.<br />
Food processors can maximise their current machinery<br />
performance by focusing on maintenance of all equipment<br />
and components along the production line. There is little<br />
to be gained by a costly revision of a whole production line<br />
and not optimising every aspect of maintenance of this line<br />
to guarantee a long sustainable performance after revision<br />
(Figure 1). Lubrication is key in this process. A focus on<br />
the lubrication aspect of maintenance means investing in<br />
quality lubricants, combined with performing a structural<br />
trend analysis. Together, these will result in both hygienic<br />
production and significant cost savings.<br />
Figure 2. Food manufacturers should select the right type of<br />
lubricant for the right application.<br />
Processors may also have heard about 3H lubricants.<br />
These 3H registered lubricants (to be differentiated from H3<br />
lubricants that represents soluble and edible oils that prevent<br />
rust) are allowed to come in direct food contact. There are<br />
certain applications and situations in which contact with<br />
the food product is inevitable, and in these situations, a 3H<br />
registered lubricant is a good choice.<br />
It is important to note that sometimes the status of NSF<br />
International (US) and/or InS Services (UK) non-food<br />
compound certification is unclear. Both registration institutes<br />
use the similar U.S. Department of Agriculture/U.S. Food<br />
and Drug Administration (USDA/FDA) guidelines. Therefore,<br />
a lubricant needs to have an H1 or other registration<br />
regardless of whether certification is from NSF or InS.
116 The future of food grade lubrication<br />
Monitoring machines and lubricants offer<br />
other benefits<br />
By monitoring the machine conditions and lubricants by oil<br />
analysis, thermography and/or ultrasonic measurements,<br />
both the machine availability and lubricant lifetime can and<br />
probably will increase. In addition, energy saving is definitely<br />
possible without compromising on food safety, especially if<br />
the right lubricant is chosen for the right machinery. Most<br />
importantly, processors should monitor machines before<br />
switching the lubricant, shortly after the switch and then<br />
continue measuring both energy and wear patterns for a<br />
few months. Why is wear key? Because although some<br />
lubricants can create energy savings, they also can damage<br />
machines.<br />
To make sure the lubrication maintenance is secured, a<br />
lubrication inspection can be conducted by the lubricant<br />
manufacturer or supplier. Such an inspection should include<br />
questions like:<br />
• Are all critical control points lubricated with H1<br />
lubricants?<br />
• How is the lubrication organised and is it efficient?<br />
• Are there any unsafe food processing or handling<br />
situations in the production area? (Figure 3)<br />
Figure 3. These are all situations found in food production facilities<br />
that can clearly be improved.<br />
A summary of the findings can be shared with individuals in<br />
upper management to effectively show the key importance<br />
of investing in lubrication-related matters to guarantee both<br />
efficient production and safe food products for consumers.<br />
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NSF4646 EHEDG Ad.indd 1 10/10/2012 16:20
European Hygienic Engineering & Design Group<br />
Hygienic automation technology in food production<br />
How clean design automation products support food safety<br />
Alexander Wagner, Festo AG & Co. KG, Esslingen, Germany, e-mail: awn@de.festo.com, www.festo.com<br />
Protecting the consumer and the manufacturer’s brand are<br />
the key benefits of hygienic and efficient automation in food<br />
production. The aims are two-fold: high productivity and<br />
perfect tasting food.<br />
The key questions for food safety in the automation<br />
technology are:<br />
• What are the potential hazards in food production and<br />
processing?<br />
• What are the valid standards and directives for<br />
hygienic automation technology?<br />
• What standards are to be respected in the material<br />
selection and design for hygienic machinery<br />
components?<br />
• How are machinery parts in the food sector to be<br />
cleaned?<br />
• How is a hygienic food production system to be<br />
implemented?<br />
Recognising and preventing risks<br />
Salmonella in sausages, Listeria in cheese – the list of<br />
foodborne illness outbreaks and scandals is endless.<br />
Significant hazards in the food sector are caused by:<br />
• Biological factors: illness caused by microorganisms or<br />
their toxins<br />
• Chemical factors: cleaning and disinfecting agents and<br />
lubricants<br />
• Foreign particles: from machines, often caused by<br />
corrosion or abrasion, or from other sources<br />
When ensuring that a machine‘s design is hygienic, all<br />
known and potential hazards must be taken into account,<br />
and action must be taken to reduce these risks.<br />
Figure 1: Resistant surfaces and a high IP protection class, such<br />
as those of the pneumatic valve terminal CDVI, are component<br />
features that meet requirements for hygiene regulations.<br />
Machinery Directive 2006/42/EC<br />
This directive focuses on health and safety requirements<br />
put in place to protect machinery operators. Possible risks<br />
should be eliminated. Special hygiene requirements apply to<br />
machinery intended for the preparation and handling of food.<br />
The machinery must be designed and constructed in such a<br />
way as to avoid any risk of infection, sickness or contagion.<br />
This directive forms the basis for the EC conformity mark.<br />
The basics – standards and directives<br />
Standards and directives form the basis that allows people<br />
to enjoy food with reduced risk of adverse health effects from<br />
consuming contaminated products (Table 1). Implementing<br />
these regulations during production reduces the risks for the<br />
manufacturer and the consumer. The aim of the European<br />
Commission (EC) Machinery Directive 2006/42/EC is the<br />
protection and safety of consumers and operators wherever<br />
food comes into direct contact with machine parts and<br />
components. The application of standards and directives<br />
for design (EN 1672-2 and European Hygienic Engineering<br />
& Design Group [EHEDG] Documents 8 and 13) and<br />
materials (US Food and Drug Administration [FDA] Code of<br />
Regulations Title 21, International Standards Organisation<br />
[ISO] 21469, and EC Regulation1935/2004/EC) provide<br />
additional support for food safety.<br />
Figure 2: The threadless design for the bearing cap as it is used<br />
in the stainless steel round cylinder CRDSNU reduces the risk<br />
of contamination. In addition, the self-adjusting end position<br />
cushioning system is designed without adjusting screws, which are<br />
susceptible to contamination.
118 Hygienic automation technology in food production<br />
The three production zones<br />
The European standard EN 1672-2, Food processing<br />
machinery - Basic concepts, defines three production zones:<br />
• The food zone<br />
This zone encompasses all system parts and<br />
components that are mounted directly in the food<br />
flow and come into contact with foodstuffs. Food may<br />
become contaminated and end up back in the product<br />
flow. System parts and components that come into<br />
contact with foodstuffs must be easy to clean and<br />
disinfect. They should be corrosion-resistant, non-toxic<br />
and non-absorbent (Figure 2). A smooth, continuous<br />
or sealed surface reduces the chance of food getting<br />
caught and leaving residue that is difficult to remove,<br />
making it a contamination risk. In addition, only special<br />
food-compatible lubricants may be used.<br />
• The splash zone<br />
In the splash zone, machine parts and components<br />
come into direct contact with foodstuffs, but the<br />
food does not end up back in the product flow.<br />
Nevertheless, these parts must be designed and built<br />
according to the same criteria as those in the food<br />
zone.<br />
• The non-food zone<br />
In this zone, the machine components do not come<br />
into contact with the product. However, the system<br />
parts used in this zone should be manufactured from<br />
corrosion-resistant materials and be easy to clean and<br />
disinfect, as sources of infection can develop over time.<br />
Selecting the material<br />
In order to protect food, the machine components must<br />
not deposit any substances during the production process<br />
that are harmful to health or that impair the taste or aroma,<br />
through either direct or indirect contact with the food. To<br />
make certain that the work carried out during the cleaning<br />
phase is safe, the materials used for the machine parts<br />
must not react with the cleaning agents or the antimicrobial<br />
chemicals (disinfectants). They must be corrosion-resistant<br />
and mechanically stable to prevent the surface from being<br />
adversely affected.<br />
Figure 3: Quick and easy cleaning can be accomplished with large<br />
radii, such as those of the standard cylinder Clean Design DSBF.<br />
Common materials<br />
• Austenitic stainless steel<br />
High-alloy stainless steel is usually the logical choice<br />
of material for the construction of a production<br />
system in the food industry. Typical materials include<br />
AISI-304, AISI-316 and AISI-316L (DIN material no.<br />
1.4301/1.4401/1.4404).<br />
• Aluminium<br />
Aluminium is frequently used for construction. It is<br />
affordable and easy to work with and process. Typical<br />
aluminium grades include AlMg2Mn0.8, AlMgSi1 and<br />
AlMgSi0.5. Aluminium components can be rendered<br />
resistant to cleaning agents through the application of<br />
an additional coating or anodised oxide layer.<br />
• Plastics<br />
Plastic components permitted to come into direct<br />
contact with food must comply with Regulation<br />
1935/2004/EC and the Plastics Directive 10/2011<br />
(which replaces Regulation 2002/72/EU) or the<br />
approvals of the FDA (CFR 21, Sections 170-199).<br />
In addition to resistance to strain, ease of cleaning<br />
also is an important factor in the selection of suitable<br />
plastic materials. They must not give off or absorb any<br />
hazardous substances.<br />
• Lubricants<br />
Lubricating greases and oils must comply with FDA<br />
regulations (especially Section 21 CFR 178.3570) or<br />
ISO 21469. For parts that will unavoidably come into<br />
sporadic contact with foods, approved lubricants as per<br />
NSF-H1 must be used.<br />
Hygienic component design<br />
The application of EN 1672-2, ISO 14159 and DOC 8+13<br />
of the EHEDG forms the basis for the hygienic design of<br />
machines and components. These standards take into<br />
account the fundamental design elements that can be used<br />
in the construction of components and systems.<br />
• Surfaces<br />
A high surface finish is absolutely essential on<br />
components that come into contact with the product<br />
in order to reduce microbial contamination. This can<br />
be achieved by using a mean peak-to-valley height of<br />
0.4 to 0.8 µm within the food zone. Components with a<br />
peak-to-valley height of ≤ 3.2 µm are often used in the<br />
splash zone.<br />
• Connecting pieces, threads<br />
Connecting components, such as screws, bolts,<br />
rivets and so on, may cause hygiene problems. Open<br />
threads are difficult to clean and provide the perfect<br />
breeding ground for bacteria. Any threads that cannot<br />
be avoided should therefore be closed off with suitable<br />
covers and seals.<br />
• Inner angles, corners and radii<br />
Very small radii and corners are always a hygiene risk<br />
as they are difficult to clean. The prescribed minimum<br />
radius is 3 mm (Figure 3).
Hygienic automation technology in food production 119<br />
The fundamental challenge of cleaning<br />
All manufacturers are liable for their products. In the food and<br />
beverage industry, complete product safety, especially from<br />
a microbiological standpoint, must be ensured to protect the<br />
consumer. As such, one important aspect involves designing<br />
components and systems with hygiene and ease of cleaning<br />
in mind in order to guarantee exemplary cleanliness, shortest<br />
possible cleaning times and minimal expense.<br />
To avoid drives failing in aggressive environments, for<br />
example, the component materials must have certain<br />
qualities that make them suitable for reliably withstanding<br />
the prevailing ambient conditions, as well as guaranteeing<br />
full functionality and a long service life. This applies to both<br />
the materials used for the drive unit and those used for<br />
interface components, such as connections and seals.<br />
Seals and lubricants that comply with FDA regulations<br />
must be used for system components that come into<br />
contact with food. Depending on the requirements of the<br />
specific application, there is a choice of valve types either<br />
for normal cleaning or for applications using intensive foam<br />
cleaning. Intensive cleaning of machine parts also can<br />
wash out the lubricating grease and impair the operation<br />
of the components. Using dry-running seals ensures that<br />
the washed out machine components still function reliably<br />
(Figure 4).<br />
Figure 4: Dry-running seals are indispensable for a reliable<br />
functionality, even when the lubricant has been washed out.<br />
Clean and safe!<br />
Many potential sources of contamination in food and<br />
packaging systems such as bacteria, chemical influences<br />
or corrosion particles in the factory can be eliminated with<br />
just a few design tweaks. Easy-to-clean, corrosion-resistant<br />
system components make food production safer.<br />
When buying food, the consumer expects high-quality<br />
products that have been hygienically produced, dispensed<br />
and packaged by the food industry. That is why customerspecific<br />
process and factory automation solutions are an<br />
important part of any hygienic value-added chain.<br />
Table 1. Important European standards and legislation pertaining<br />
to hygienic design of equipment and components used in food<br />
production environments.<br />
2006/42/EC<br />
ISO 21469<br />
EN 1672-2<br />
ISO14159<br />
EHEDG Doc 8<br />
EHEDG Doc 10<br />
EHEDG Doc 13<br />
1935/2004/EC<br />
Plastics Directive<br />
10/2011<br />
FDA CFR 21<br />
Festo<br />
Directive 2006/42/EC of the European<br />
Parliament and of the Council of 17<br />
May 2006 on machinery, and amending<br />
Directive 95/16/EC (recast)<br />
Safety of machinery – Lubricants with<br />
incidental product contact – Hygiene<br />
requirements<br />
Food processing machinery – Basic<br />
concepts – Part 2: Hygiene requirements<br />
Safety of machinery - Hygiene requirements<br />
for the design of machinery (IS=<br />
141:2002)<br />
Hygienic equipment design criteria<br />
Hygienic design of closed equipment<br />
for processing of liquid food<br />
Hygienic design of open equipment for<br />
processing of food<br />
Regulation (EC) NO 1935/2004 of the<br />
European Parliament and of the Council<br />
of 27 October 2004 on materials<br />
and articles intended to come into contact<br />
with food and repealing Directives<br />
80/590/EEC and 89/109/EEC<br />
Commission regulation (EU) No<br />
10/2011 of 14 January 2011 on plastic<br />
materials and articles intended to come<br />
into contact with food<br />
Food & Drugs, Part 11 “Electronic<br />
Records, Electronic Signatures”<br />
Product overview for the food and<br />
beverage industry, 7 th edition
European Hygienic Engineering & Design Group<br />
Cleanability test of a hygienic design-compatible washer<br />
Process Seals has developed a hygienic washer with elastomeric sealing ring for use in the<br />
food and beverage, pharmaceutical and biotechnology industries. The rings are made for static<br />
sealing that is free of dead-spaces between bolts and dome nuts. This article illustrates how an<br />
EHEDG testing method confirms the cleanability of such hard-to-reach equipment components.<br />
Julia Eckstein, Application Consultant, Freudenberg Process Seals GmbH & Co. KG, Weinheim, Germany,<br />
e-mail: julia.eckstein@fst.com, http://www.freudenberg-process-seals.com<br />
When it comes to protecting bolt heads and nuts from being<br />
contaminated with products from the food and beverage,<br />
pharmaceutical or biotech industries, many plant and<br />
machinery manufacturers that supply the process industries<br />
use complicated (and often “home-made”) solutions. This is<br />
problematic because the complete cleaning of these points<br />
is the only safeguard for the producers of perishable foods<br />
and beverages and high-purity medications. Threaded<br />
connectors generally come into contact with the product, and<br />
after use, only the residues can be removed via disassembly.<br />
But today’s facilities are predominantly cleaned without<br />
disassembly, using clean-in-place (CIP), wash-in-place<br />
(WIP) and sterilisation-in-place (SIP) methods.<br />
With this problem in mind, a hygienic seal has been<br />
developed. It is based on a standard design of rings for<br />
non-food applications to simply and affordably protect<br />
non-moving machine parts from fluid and gaseous media.<br />
The ring consists of a combination of metallic flat seal and<br />
elastomeric sealing ring for static sealing. The resilient,<br />
trapezoidal sealing ring can be vulcanised on either the inner<br />
or outer diameter of the metal disk to match applicationspecific<br />
requirements. However, their “hard-to-clean<br />
design” makes these sealing elements used in mechanical<br />
engineering poorly suited to (and/or not approved for) food<br />
processing applications.<br />
In response, the design has ben reworked completely.<br />
Together with hexagon bolts with flange and dome nuts<br />
designed according to DIN EN 1665, the revised design<br />
forms an easy-to-clean combination, which has been tested<br />
and approved by the Weihenstephan Research Center for<br />
Brewing and Food Quality using the European Hygienic<br />
Engineering and Design Group (EHEDG) Cleanability<br />
Method (Fig. 1).<br />
Elastomeric sealing ring<br />
made of high-performance compound<br />
In traditional threaded connectors, fluids are able to collect<br />
under the bolt head or in the threading. This is by no means<br />
EHEDG-compliant and is highly unhygienic. In contrast,<br />
the improved design ensures the clean sealing of DIN EN<br />
1665 bolt heads with flanges in aseptic isolators and in<br />
areas where they could come into contact with the product.<br />
This optimal sealing prevents the medium from penetrating<br />
under the bolt head, which can lead to the multiplication of<br />
microbes. The washer’s design, which is tailor-made for<br />
hexagon bolts with flanges, ensures that the sealing ring<br />
is cleanly seated on the flange, precluding the formation of<br />
spaces where microorganisms can accumulate (Fig. 2).<br />
The black 70 EPDM 291, a premium compound for static<br />
sealing in the food and beverage and pharmaceutical<br />
industries, is used as the elastomer for the sealing ring.<br />
Critical process conditions and aggressive media in the<br />
food, beverage and pharmaceutical production demand<br />
the usage of highly stable seals. The 70 EPDM 291 with<br />
a temperature range of up to +180°C offers considerably<br />
higher stability in water vapour, can stand up to +210°C<br />
for a short time, and is ideally resistant to CIP-, WIPand<br />
SIP-methods. It is accepted by the US Food and<br />
Drug Administration (FDA) and also satisfies the criteria<br />
of the European regulation EU (VO) 1935/2004. Its<br />
biocompatibility has also been tested and approved for use<br />
in pharmaceutical components and facilities in keeping with<br />
USP Class VI requirements 1 .<br />
EHEDG – Test and results<br />
The EHEDG has developed a testing method in which<br />
microorganisms are allowed to collect in hygienically<br />
problematic areas, in so-called dead spaces. A subsequent<br />
cleanability test identifies those critical points that cannot<br />
be adequately reached by the cleaning medium. 2 The same<br />
method was used to test the cleanability of the redesigned<br />
bolt/dome nut combination using a standard size M6 bolt. In<br />
this test, the cleanability of the hygienic seal was compared<br />
with that of a reference pipe with a known low inner surface<br />
roughness (Ra = 0.5 µm).<br />
However, before this test could be started, the elastomer<br />
used had to be tested for antibacterial components, so as<br />
to rule out a potential skewing of the test results. As the test<br />
could not find any evidence of antibacterial properties in the<br />
EPDM material, the hygienic seal then was ready for the<br />
cleanability test.<br />
In order to test their cleanability, components are<br />
intentionally soiled with a suspension that contains spores<br />
of a thermophilic bacterium. These spores not only remain<br />
stable at high cleaning temperatures; they also are resistant<br />
to the cleaning media. Following the soiling, components are<br />
CIP cleaned using a 1.0-percent concentration detergent<br />
at a temperature of +63°C for 10 minutes, followed by a<br />
rinsing with water. The test area is then coated with an agar<br />
growth medium, which is allowed to incubate for 18 hours<br />
at a temperature of +58°C. In the last step, the colour of the<br />
MSHA agar medium, which changes from violet to yellow in<br />
response to microbial growth, is assessed. 3
Cleanability test of a hygienic design-compatible washer 121<br />
To ensure that the results are representative, the cleanability<br />
test is conducted a total of four times. In the case of the new<br />
seal, none of the four tests showed a yellow discolouration<br />
following the incubation of the agar coating covering the bolt<br />
and dome nut. The yellow discolouration in the reference<br />
pipe was present in an average of 13 percent of its inner<br />
surface, which is within the tolerance range of +5 to +30<br />
percent stated in EHEDG Guideline Doc 2 and corresponds<br />
to an acceptable level of contamination after the very mild<br />
(test method) cleaning cycle. As such, the new design clearly<br />
demonstrated better cleanability than the reference pipe.<br />
In June 2012, the TUM (Forschungszentrum für Brauund<br />
Lebensmittelqualität) at Weihenstephan (Germany)<br />
declared officially that the new design, which Process Seals<br />
has named “Hygienic Usit,” meets the Hygienic Equipment<br />
Design Criteria of the EHEDG.<br />
Fig. 2. The Hygienic Usit combines metallic flat seal and<br />
elastomeric ring in one component.<br />
References<br />
1. U.S. Pharmacopeia, USP 29, General Chapter Biological<br />
reactivity tests, in vivo, USP 29 – NF24, page 2526.<br />
2. European Hygienic Engineering and Design Group (EHEDG).<br />
EHEDG Guideline Nr. 2, Method for Assessing the In-place<br />
Cleanability of Food Processing Equipment, 3rd Ed, July 2004,<br />
(Revised June 2007).<br />
3. European Hygienic Engineering and Design Group (EHEDG).<br />
EHEDG Report 01: Cleanability Test, Hygienic Usit with Bolt.<br />
Weihenstephan Research Center for Brewing and Food Quality,<br />
TU Munich. December 5, 2011.<br />
Fig. 1. The Hygienic Usit provides simple and FDA-compliant<br />
sealing for threaded connectors with flanges, while also fulfilling<br />
the criteria of hygienic design.
European Hygienic Engineering & Design Group<br />
Aspects of compounding rubber materials for contact<br />
with food and pharmaceuticals<br />
Equipment and equipment components made with rubber materials that come into contact<br />
with food in processing lines must comply with regulatory requirements such as FDA’s Code<br />
of Federal Regulations (CFR), 3-A Sanitary Standards, and US Pharmacoepia (USP) Class VI<br />
standards. It is also necessary to consider the working conditions in which the gasket will be<br />
used, including what products are produced, the cleaning and sterilization agents utilized in<br />
those processes, and temperatures or other factors that may impact the efficiencies of equipment<br />
and components throughout the process line. In order to maintain a high hygienic standard, a<br />
very good cleanability of any equipment component with a rubber surface must be achieved and<br />
thorough documentation provided.<br />
Anders G. Christensen, Sales and R&D Director, AVK GUMMI A/S, Mosegaardsvej 1, DK-8670 Laasby, Denmark,<br />
email: avk@avkgummi.dk, www.avkgummi.dk<br />
For many years the food processing industry has referred<br />
to regulatory guidelines and standards that cover the use<br />
and compliance of rubber materials that come into contact<br />
with food. Among these are rules outlined in the U.S. Food<br />
and Drug Administration (FDA) 21 CFR 177.2600 (Rubber<br />
articles intended for repeat use) and the recommendations<br />
of the German BfR XXI (Commodities based on natural<br />
and synthetic rubber) or XV (silicone oil, resins and rubber<br />
requirements). Recently, 3-A Sanitary Standard 18-03 also<br />
has become a de facto standard for many food processing<br />
sectors beyond the dairy industry from which it originates.<br />
This standard not only regulates rubber materials that come<br />
into contact with food, but also the manufacturing conditions,<br />
taking hygienic standards and traceability into consideration.<br />
EN 1935/2004 is an attempt to have a common set of rules<br />
within the European Union (EU). While this regulation is<br />
fully operational with regard to metals and plastics, it is still<br />
a work-in-progress with regard to rubber materials. Until<br />
positive lists of approved ingredients that can be used in<br />
food-contact rubbers and associated testing methods are in<br />
place, the FDA and BfR lists, together with extraction tests,<br />
appear to be the most relevant regulations for food-contact<br />
rubber materials. The member states have now begun to turn<br />
this framework into statutory instruments; however, this may<br />
be at the cost of uniformity and transparency.<br />
Other standards-related developments are affecting require<br />
ments as well. For example, the Danish Ministry<br />
of Food is enforcing the rules of traceability and good<br />
manufacturing practices (GMPs) by means of third-party<br />
inspection of manufacturers’ facilities and process lines. For<br />
pharmaceuticals, normally Class VI under the USP Monograph<br />
88, testing is required. Alternatively, the customer can ask for<br />
in vitro testing, either according to USP Monograph 87 or<br />
International Standards Organisation (ISO) 10993-5.<br />
In addition, end users require documentation for cleanability<br />
of equipment surfaces. Most often this is provided by means<br />
of an European Hygienic Equipment Design Group (EHEDG)<br />
cleanability test of the component in which the rubber part<br />
is present. Except for the geometry and the corresponding<br />
flow profile, the rubber surface is typically the most critical<br />
material when conducting any hygienic test.<br />
For this reason, it is important to consider the affinity between<br />
rubber compounds, products and cleaning agents. Long-term<br />
field studies, such as those conducted by AVK GUMMI, have<br />
been conducted and have led to easy-to-clean formulation of<br />
compounds within the families of ethylene proplene rubber<br />
(EPDM), hydrogenated nitrile (HNBR), fluorocarbon (FPM)<br />
and silicone.<br />
Material performance<br />
In addition to ensuring that food-contact rubber materials<br />
have the relevant approvals, meet appropriate compliance<br />
requirements and have traceability documentation, it<br />
is important to consider material performance. No two<br />
formulations are equal. Even if two manufacturers develop<br />
a compound for the same application, the end user will<br />
experience different performances with each due to<br />
variabilities ranging from the food being produced, the<br />
production line systems, and the level of hygienic operations<br />
in the processing plant and performed on equipment, among<br />
others. The reason for this is shown in Figure 1:<br />
Figure 1. Example comparison of good quality compounds versus<br />
low-cost compounds as recipes for an EPDM 70 Sh A material.
Aspects of compounding rubber materials for contact with food and pharmaceuticals 123<br />
Figure 1 assumes two different compound recipes of an<br />
EPDM 70 Sh A material, both of which aim for FDA Aqueous<br />
Food compliance. The “good” compound is of a very good<br />
quality, while the other “cheap” compound is made from<br />
low-cost materials. Several factors can be used to compare<br />
the two recipes in order to determine the differences, and<br />
ultimately, judge the material performance parameters.<br />
For example. in looking at the EPDM polymer, one can see<br />
that this could either be a very pure material with no residues<br />
from the catalysts and no residual monomers (Good) or low<br />
molecular weight oligomers (Cheap). The polymerisation is<br />
very well controlled, giving a uniform molecular architecture<br />
and molecular weight distribution. Also, the batch-to-batch<br />
variation is kept at a minimum. Or it could be the opposite,<br />
which clearly would reduce the cost. Both compounds can<br />
be formulated to meet the same standards, ie. FDA or<br />
BfRFrom an end user point of view, this relates to durability,<br />
compression set, taste and smell, uniformity of the product<br />
and extraction of residues to the product.<br />
The next functional group is carbon black, which acts as a<br />
reinforcing agent. Basically, this is soot, which is produced<br />
by combusting a hydrocarbon source in a controlled<br />
atmosphere. The type and amount is regulated to some<br />
extent. For the good compound as shown in Figure 1,<br />
a carbon black is used for which the hydrocarbon source<br />
is clean and well defined. For the cheap compound, the<br />
hydrocarbon source has a higher content of sulphur and<br />
consists of many different molecules, preventing a uniform<br />
end product. The end user will see a difference in taste and<br />
smell and extraction of residues.<br />
When aiming for a cheap compound, it is common practice<br />
to “dilute” the compound by using chalk. This will increase<br />
the hardness of the material and so it is necessary to add<br />
more plasticiser in order to reach the same hardness. The<br />
usage of chalk will increase swelling in aqueous solutions,<br />
and the chemical resistance will suffer.<br />
Plasticiser is added to these compounds to ensure<br />
homogeneity and to adjust the hardness. For EPDM mineral<br />
oil is used. This can be either a medical grade oil, which<br />
is also used as edible oil and in healthcare products, or a<br />
technical grade oil, which will have a higher content of<br />
naphthenics and aromatics. Again, the user will notice the<br />
difference in the taste and smell, as well as extractables.<br />
Finally, a curing system must be decided upon. This is what<br />
makes the final product elastic. While a thermoplast, which<br />
is uncured, will deform permanently upon load, rubber will<br />
regain the original shape due to the cross-linking of the<br />
polymer chains. For EPDM, two curing systems are normally<br />
used. Peroxide curing gives excellent thermal stability,<br />
compression set, taste and smell and chemical resistance,<br />
but the manufacturing process is more expensive. As<br />
an alternative, a sulphur system may be used. The<br />
manufacturing cost goes down, but so does the performance<br />
as described for the peroxide system.<br />
The example illustrates the complexity of choosing<br />
materials and suppliers. As the figure illustrates, end users<br />
of food-contact rubber materials in food or pharmaceutical<br />
manufacturing lines should specify functional requirements<br />
rather than material, ask for documentation, and choose<br />
a rubber supplier who can successfully translate specific<br />
needs into rubber solutions.
European Hygienic Engineering & Design Group<br />
New developments for upgrading stainless steel to<br />
improve corrosion resistance and increase equipment<br />
hygiene<br />
Siegfried Piesslinger-Schweiger, POLIGRAT GmbH, 81805 Munich, Germany, e-mail: petra.ressmann@poligrat.de,<br />
www.poligrat.de<br />
New developments enable the upgrading of stainless steel to<br />
improve the corrosion resistance of manufacturing equipment<br />
and components. Unlike the state-of-art techniques that use<br />
higher alloyed steel to produce corrosion-resistant equipment<br />
and components, new methods have been developed<br />
that can be applied as final treatments after production<br />
and elevate the passive layers independently from the<br />
underlying metallic base. One of these methods is based<br />
on a significant increase of the chrome/iron ratio within the<br />
passive layers by extraction of iron and iron oxides, leaving<br />
primarily chrome oxide. The second is a heat treatment that<br />
changes the structure and thickness of the passive layer.<br />
The latter application can be utilised on all types of finishes<br />
and in nearly all commonly used alloys.<br />
These new methods result in a substantial increase of the<br />
resistance against any type of corrosion. They also allow an<br />
effective restoration of corroded surfaces, and with regular<br />
application, can maintain corrosion resistance even in<br />
cases in which stainless steel is not long-term resistant. The<br />
treatments also can be applied to scale and heat discoloration<br />
without pre-treatment, which could widely replace pickling or<br />
mechanical descaling.<br />
Since these methods are based on a treatment with a waterbased<br />
solution of special organic compounds, they are<br />
biodegradable, environmentally friendly, and produce no<br />
fumes or nasty smells. The new methods also allow selection<br />
of the best alloy and structure in terms of hardness, strength<br />
and weight. They open a wide and commercially important<br />
potential for additional applications of stainless steel.<br />
Basics of corrosion-resistant stainless steel<br />
According to the state of the art, the corrosion resistance<br />
of stainless steel is considered a secondary property<br />
of alloy and structure. To increase corrosion resistance<br />
it is necessary to select a higher alloy quality. To meet<br />
the objectives of development a fundamentally different<br />
approach to stainless steel and its functional behaviour is<br />
necessary.<br />
Stainless steel is a composite consisting of a metallic base<br />
and an oxidic cover layer, and the passive layer is similar to<br />
aluminium and titanium. The metallic base determines the<br />
material’s mechanical, electric and magnetic properties and<br />
provides the metals for the formation of the passive layer.<br />
The passive layer determines most of its other properties,<br />
including corrosion resistance. As soon as passive layers<br />
are locally damaged, local corrosion of the metallic base<br />
occurs, such as pitting corrosion, crevice corrosion, Ironinduced<br />
corrosion, stress corrosion cracking (SCC), and<br />
more.<br />
Passive layers completely and densely cover the surface<br />
of stainless steel as long as it does not corrode. Passive<br />
layers are 10 to 15 nm thick and are formed by the reaction<br />
of the metallic base with oxygen from the environment.<br />
They primarily consist of chrome oxides and iron oxides.<br />
Additionally, they contain metallic chrome and iron, and<br />
eventually, other metals like nickel and molybdenum.<br />
Passive layers on stainless steel are not insulators like<br />
the oxides on aluminium and titanium. They are crystalline<br />
semiconductors with all the special properties of these<br />
materials. Thus, the approach to understanding corrosion on<br />
stainless steel should include semiconductor physics.<br />
The ratio of chrome oxides to iron oxides (chrome/iron<br />
ratio) typically is within the range of 0.8 to 2.0. The higher<br />
this ratio, the better the corrosion resistance. That means,<br />
that chrome oxides increase and iron oxides reduce the<br />
corrosion resistance.<br />
Methods to increase corrosion resistance<br />
To improve the corrosion resistance of stainless steel two<br />
methods are promising success. The first is to improve the<br />
chrome/iron ratio within the passive layer and the second is<br />
to improve the crystalline structure.<br />
Conventional state-of-art method. According to the current<br />
state-of-the-art approach, the method for raising the chrometo-iron<br />
ratio within passive layers consists of reducing the<br />
concentration of iron in the metallic base and increasing the<br />
concentration of chrome, and eventually nickel, in the alloy.<br />
This secondary effect leads to a higher chrome/iron ratio<br />
in the passive layers. The structure of passive layers is not<br />
influenced. The concentration of alloying elements besides<br />
iron is only needed within a surface layer of less than 10-<br />
nm thickness to provide the metal for the formation of the<br />
passive layer.<br />
There are a few downsides to the conventional method of<br />
producing corrosion-resistant stainless steel. The adaption<br />
of total alloy and structure to form the passive layer<br />
substantially determines the other properties of the alloy.<br />
A potential consequence of this is that expensive details<br />
of construction like wall thickness and weldability must be<br />
adapted. The adaption of alloy and structure to achieve<br />
gains in the level of corrosion resistance can only occur in<br />
the production of steel. This means that a great number of<br />
qualities of stainless steel must be produced and be available<br />
as semi-finished product, which reduces the flexibility in the<br />
material’s application and increases costs.
New developments for upgrading stainless steel to improve corrosion resistance and increase equipment hygiene 125<br />
New methods. Unlike the conventional method, new<br />
methods have been developed to produce the desired<br />
level of corrosion resistance by changing the consistency<br />
and structure of existing passive layers on stainless steel,<br />
independently from the alloy and structure of the metallic<br />
base. These methods—one chemical and one thermal—are<br />
applied as final treatments after fabrication and substantially<br />
increase corrosion resistance.<br />
Chemical treatment. A precondition for the application of<br />
the new chemical treatment method is that the stainless<br />
steel to which it is applied must have an existing passive<br />
layer. Therefore, its application immediately following a<br />
pickling process is not effective.<br />
The chemical treatment selectively breaks the iron oxides<br />
within passive layers and extracts the iron without affecting<br />
or removing the passive layer. In this way, the concentration<br />
of iron in passive layers is strongly reduced and the chrome/<br />
iron ratio is substantially increased up to values of 6 to 8 (Fig.<br />
1). This treatment of stainless steel substantially increases<br />
the resistance to all types of corrosion (Figures 2 and 3). The<br />
resistance to thermal discolouration is raised to 100-150°C.<br />
Fig. 2. Structure of passive layer on stainless steel AISI 316 Ti -<br />
original condition.<br />
Fig. 3. Structure of passive layer on stainless steel AISI 316 Ti –<br />
chemically treated.<br />
Fig. 1. The chemical treatment significantly reduces the<br />
concentration of iron in passive layers and the chrome/iron ratio is<br />
substantially increased up to values of 6 to 8.<br />
The applied chemicals are water-based solutions of organic<br />
and biologically degradable substances, mainly comprised<br />
of a special combination of chelating and complexing<br />
agents. They do not contain mineral acids or their salts and<br />
have a pH value of about 4.0. Application does not produce<br />
harmful fumes or foul odours. Since no dissolution of metal<br />
or passive layers takes place, the liquid does not contain<br />
heavy metals in noticeable concentrations.<br />
Application can be done by dipping, spraying or wiping during<br />
a three- to four-hour period. The temperature in dipping tanks<br />
should be kept above a minimum of 50°C to avoid biological<br />
degradation. Higher temperatures increase the effect of the<br />
treatment, while longer treatment times do not. All types of<br />
finishes and nearly all types of stainless steel can be treated.<br />
However, when the chrome content in the alloy is less than<br />
15% the required temperature, concentration and time of<br />
treatment must be modified.<br />
Thermal treatment. The effect of chemical treatment can<br />
strongly be increased by a subsequent controlled-heat<br />
treatment. The heat treatment optimises the structure and<br />
distribution of elements in the passive layer and increases<br />
its thickness. The thermal treatment leads to the formation of<br />
a second layer containing iron oxides on top of the existing<br />
passive layer mainly formed by chrome oxides. These layers<br />
are semiconductors forming a n/p-transition and immediately<br />
provide a further substantial increase in corrosion resistance<br />
(Fig. 4).<br />
The heat treatment takes place under atmospheric conditions<br />
at temperatures in the range of 120-220°C, dependant on<br />
the alloy, and for a time of 5 to 10 minutes.
126 New developments for upgrading stainless steel to improve corrosion resistance and increase equipment hygiene<br />
Fig. 4. Structure of passive layer on stainless steel AISI 316 Titreated<br />
with combined chemical and thermal process.<br />
Fig. 7. Comparison of pitting corrosion potential on different<br />
materials before and after treatment with the chemical and with the<br />
combined chemical/thermal treatment.<br />
Applications<br />
Corrosion resistance. The chemical treatment and<br />
especially the combined chemical and thermal treatment of<br />
stainless steel each substantially improve the resistance to<br />
most types of corrosion, except in the cases in which high<br />
temperature and wear are factors. Test results and practical<br />
experience have shown that local mechanical damage,<br />
such as scratches, do not result in corrosion when the<br />
new treatments are used. For example, in one study (two<br />
years test study by BMW), the chemical treatment was<br />
applied to car parts made of stainless steel (AISI 304 with<br />
brushed finish). After more than five years no corrosion was<br />
observed due to mechanical impact or by de-icing salt or<br />
crevice corrosion (Figures 5 and 6). Fig. 7 shows the results<br />
of a comparison of pitting corrosion potential on different<br />
materials before and after treatment with the chemical and<br />
with the combined chemical/thermal treatment.<br />
Organic pickling and passivating. In addition to the<br />
increase in corrosion resistance, the chemical treatment<br />
removes iron and iron oxides from scale and heat tint. It<br />
converts the thermal oxides into effective passive layers.<br />
Therefore, it is not necessary to remove heat tint and<br />
local scale by pickling or mechanical cleaning prior to the<br />
treatment (Figure 9).<br />
Fig. 9. Use of the chemical treatment makes it unnecessary to<br />
remove heat tint and local scale by pickling or mechanical cleaning<br />
prior to the treatment.<br />
Figures 5 and 6. The stainless steel chemical treatment protected<br />
car finishes from corrosion over a give-year period.<br />
The treatment also removes iron and rust contamination. It<br />
does not change the finish and can be applied to construction<br />
consisting of various qualities of stainless steel. There is no<br />
danger of crevice corrosion initiated by residual pickling<br />
acid. Consequently, in numerous cases the treatment can<br />
replace pickling and passivating with mineral acids and<br />
avoid associated environmental risks and health hazards, as<br />
well as problems with wastewater and fumes.<br />
Cleaning and maintenance. For application outside of<br />
dipping tanks and to existing structures on site, a cleaner also<br />
has been developed that can be applied at environmental<br />
temperatures. Regular and repeated application of the<br />
cleaner can maintain corrosion resistance under conditions<br />
in which the stainless steel otherwise would not be resistant<br />
long-term. Finally, the chemicals do not attack or degrade
New developments for upgrading stainless steel to improve corrosion resistance and increase equipment hygiene 127<br />
other materials such as glass, plastic, lower alloyed stainless<br />
steel and seals. The cleaner can be applied to complete<br />
installations and assembled components without prior<br />
dismantling.<br />
Restoration. After corroded surfaces on stainless steel are<br />
cleaned, the corrosion resistance will be restored at a higher<br />
level. Corrosion marks remain visible, but are passivated on<br />
their surface. Even chloride-induced pitting corrosion has<br />
been removed and the corrosion resistance successfully<br />
restored without prior pickling. This new technique has been<br />
shown to have successfully repaired a considerable number<br />
of damaged equipment and components made of stainless<br />
steel in production plants for chemical and pharmaceutical<br />
products, on railway coaches and handrails on seashores,<br />
and on components for ships and offshore components.<br />
Conclusion<br />
To a substantial degree, the corrosion resistance of stainless<br />
steel can be upgraded independently from alloy and structure,<br />
as well as independently from the mechanical and other<br />
properties of the base metal. The new methods described<br />
here enable the selection of materials with higher strengths<br />
and lower weights, which eventually should result in reduced<br />
costs. The new methods also extend the lifetime of stainless<br />
steel with upgraded corrosion resistance, maintenance and<br />
restoration.<br />
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European Hygienic Engineering & Design Group<br />
International Hygienic Study Award 2012<br />
Happy awardees in Valencia<br />
Dr. Peter Golz, VDMA, Frankfurt, Germany, phone: +49 69 6693-1656, e-mail: peter.golz@vdma.org<br />
Prof. Dr. Jens-Peter Majschak, Technische Universität Dresden, Dresden, Germany,<br />
phone: +49 (351) 463 3 4746, e-mail: jens-peter.majschak@tu-dresden.de<br />
Since 2009, the communication and information platform<br />
www.hygienic-processing.com and its partners have held a<br />
competition for the annual Hygienic Study Award to honour<br />
outstanding, innovative, high-quality diploma, bachelor and<br />
master degree theses of studies in the field of hygienic<br />
design. In 2012, the Hygienic Study Award expanded its<br />
global reach to recognise and strengthen the network of<br />
international institutions engaged in academic education and<br />
research in the field of hygienic design. Fifteen renowned<br />
research institutes and universities from eleven countries<br />
were invited to partake in the competition. Seven abstracts<br />
from five countries were submitted.<br />
The European Hygienic Engineering & Design Group<br />
(EHEDG) World Congress 2012 in Valencia, Spain, hosted<br />
this year’s award ceremony where two first prizes and one<br />
second prize were awarded to young research fellows from<br />
Cambridge and Dresden. Hygienic Study Award 2012 was<br />
sponsored jointly by EHEDG and VDMA.<br />
Winner of 1st prize:<br />
Hannes Stoye, University of Dresden<br />
Development of a test set-up for pulsed spray cleaning<br />
examinations<br />
Abstract: As part of this work, one of the test rigs existing<br />
at the Fraunhofer AVV was modified in such a way that<br />
cleaning investigations could be carried out with pulsating<br />
fluid jets on vertical plates of stainless steel. The control<br />
unit enables it to vary two factors, pulsation frequency and<br />
duty cycle. The detection of the cleaning process could be<br />
ensured by use of a phosphorescent food model soil.<br />
For the evaluation of the tests regarding cleaning time<br />
and cleaned surface, a program was created that allows<br />
comparison of different forms of falling liquid film and the<br />
distinction between cleaning due to ‘direct impingement’<br />
and cleaning due to falling liquid films. The verification of<br />
the complex of experimental set-up, including experimental<br />
evaluation, was based on measurements of coherent<br />
distilled water jets from distilled water. Here, in case of<br />
cleaning due to falling liquid films, the potential savings of<br />
cleaning medium was 50% and in the case of cleaning due<br />
to ‘direct impingement’ cost savings of up to 60% could be<br />
realised. In addition, variation of the volume of flow was<br />
performed with the aim of advancing a first user-friendly<br />
approach to the establishment of the pulsating jet cleaning<br />
supply.<br />
(From left) Prof. Dr. Majschak of TU Dresden congratulates the<br />
winners of the Hygienic Study Award 2012 first prizes: Dr. Patrick<br />
Gordon, University of Cambridge, and Hannes Stoye, University of<br />
Dresden, at the award ceremony on occasion of the EHEDG World<br />
Congress 2012 in Valencia, Spain (Source: H.-W. Bellin).<br />
Winner of 1st prize:<br />
Dr. Patrick Gordon, University of Cambridge<br />
Development of a scanning fluid dynamic gauge for<br />
cleaning studies<br />
Abstract: This thesis describes the development of a<br />
scanning version of a fluid dynamic gauge (sFDG) to<br />
study the cleaning of soft layers from rigid substrates,<br />
such as the food soils encountered within an automatic<br />
dishwasher. The sFDG measures the thickness of such
International Hygienic Study Award 2012 129<br />
layers within a liquid environment, in real time, as they are<br />
removed, enabling the influence of solution temperature,<br />
composition and shear stress to be quantified between<br />
or within experiments. It is shown to offer significant<br />
improvements over previous fluid dynamic gauge<br />
(FDG) variants, including improved resolution (±5 µm),<br />
reproducibility, automation, data quantity and the ability to<br />
generate topographical images.<br />
The sFDG is used to study the stages of swelling and<br />
removal during the cleaning of gelatine, egg yolk, starchbased<br />
and oil/albumin layers. The FDG technique could<br />
also be applied to several novel applications, including<br />
the study of crossflow microfiltration and fragile biofilms. A<br />
second-generation sFDG, optimised for cleaning studies<br />
within an industrial research laboratory, has been designed,<br />
constructed and commissioned. This technology transfer will<br />
allow the technique to contribute toward future developments<br />
in commercial dishwasher formulations.<br />
Winner of 2nd prize:<br />
Dr. Ing. Martin Schöler, University of Dresden<br />
Analysis of cleaning procedures for complex geometries<br />
in immerged systems<br />
Abstract: Industrial cleaning processes are of great<br />
importance for ensuring hygienic production conditions.<br />
Furthermore, they represent a target for economic<br />
optimisation due to their high consumption of energy and<br />
natural resources. To improve the efficiency of cleanin-place<br />
systems (CIP) it is essential to understand the<br />
mechanisms controlling complex cleaning processes. The<br />
investigation of cleaning phenomena shows two major<br />
difficulties. First, there is a need for parameters that can<br />
provide comparability between investigations that are<br />
currently isolated because they have used different material<br />
combinations or different experimental setups. Second,<br />
the availability of monitoring methods to investigate<br />
these phenomena is limited. In this work the novel local<br />
phosphorescence detection (LPD) method is presented to<br />
investigate the cleaning performance. It combines the use<br />
of complex cohesive food soil, complex pipe geometries<br />
and continuous observation of the cleaning progress to<br />
investigate the mechanisms of cleaning in immersed CIP<br />
systems. Cleaning tests on a sudden expansion were<br />
compared to soil and swelling investigations, as well as CFD<br />
results conducted by other scientists. It was shown that the<br />
tested cleaning configuration was controlled by the mass<br />
transfer of the detached parts of the soil. The mathematical<br />
parameters provided can help to determine the apparent<br />
cleaning mechanisms based on soil characteristics and the<br />
conditions of fluid flow.<br />
Interested in taking part in the Hygienic<br />
Study Award <strong>2013</strong>?<br />
Next year, drinktec in Munich will host the award ceremony.<br />
Interested research and university institutes are requested<br />
to contact Prof. Dr. Jens-Peter Majschak, TU Dresden<br />
(jens-peter.majschak@tu-dresden.de). drinktec <strong>2013</strong> –<br />
the world‘s leading trade fair for the beverage and liquid<br />
food industry – will take place from September 16 through<br />
September 20 at Munich Trade Fair Centre. Deadline for<br />
submitting abstracts is June 30, <strong>2013</strong>.<br />
Consult www.hygienic-processing.com to get full abstracts of<br />
the studies awarded.
European Hygienic Engineering & Design Group<br />
EHEDG Regional Sections<br />
Chairmen and contacts<br />
The Regional Sections are the local extensions of the EHEDG and are created to promote hygienic<br />
manufacturing of food through regional activities. EHEDG has established Regional Sections in<br />
various countries in Europe and overseas. These groups organise local meetings, courses and<br />
workshops.<br />
ARMENIA<br />
• Professor Dr. Karina Badalyan<br />
Armenian Society of Food Science and Technology<br />
(ASFoST)<br />
Phone: (+374 10) 55 05 26 / e-mail: foodlab@inbox.ru<br />
• Dr. Suren Martirosyan<br />
Armenian Society of Food Science and Technology<br />
(ASFoST)<br />
Phone: (+374 10) 56 40 29<br />
E-mail: surmar.3137@gmail.com<br />
BELGIUM<br />
• Hein Timmerman<br />
Diversey Europe BV<br />
Phone: (+32 495) 59 17 81<br />
E-mail: hein.timmerman@diversey.com<br />
• Frank Moerman<br />
Phone: (+32 9) 3 86 65 44<br />
E-mail: fmoerman@telenet.be<br />
CZECH REPUBLIC<br />
• MV Dr. Ivan Chadima<br />
MQA s.r.o.<br />
State Veterinary Authority of the Czech Republic<br />
Phone (+420 607) 90 99 47<br />
E-mail: ivan.chadima@mqa.cz<br />
• Petr Otáhal<br />
MQA s.r.o.<br />
Phone (+420 724) 13 81 68<br />
E-mail: petr.otahal@mqa.cz<br />
DENMARK<br />
• Bjarne Darré<br />
GEA Liquid Processing<br />
Phone: (+45 87) 94 11 38<br />
E-mail: bjarne.darre@gea.com<br />
• Jon Kold<br />
Stålcentrum<br />
Phone: (+45 88) 70 75 15<br />
E-mail: jon.kold@staalcentrum.dk<br />
FRANCE<br />
• Erwan Billet<br />
Hydiac<br />
Phone: (+33 61) 2 49 85 84<br />
E-mail: erw.billet@infonie.fr<br />
• Nicolas Chomel<br />
Laval Mayenne Technopole<br />
Phone: (+33 243) 49 75 24<br />
E-mail: chomel@laval-technopole.fr<br />
GERMANY<br />
• Dr. Jürgen Hofmann<br />
TU München / Wissenschaftszentrum Weihenstephan<br />
Phone: (+49 8161) 8 76 87 99<br />
E-mail: jh@hd-experte.de<br />
• Hans-Werner Bellin<br />
BELLIN.Consult<br />
Phone: (+49 6120) 97 99 62 0<br />
hans-werner.bellin@bellinconsult.de<br />
ITALY<br />
• Dr. Giampaolo Betta<br />
University of Parma<br />
Phone: (+39 05) 21 90 62 34<br />
e-mail: giampaolo.betta@unipr.it<br />
JAPAN<br />
• Takashi Hayashi<br />
Kanto Kongoki Industrial Ltd.<br />
Phone: (+81 3) 39 66-86 51<br />
E-mail: hayashi@kanto-mixer.co.jp<br />
• Hiroyuki Ohmura<br />
JFMA – The Japan Food Machinery Manufacturers’<br />
Association<br />
Phone: (+81 3) 54 84-09 81<br />
E-mail: ohmura@fooma.or.jp<br />
LITHUANIA<br />
• Dr. Raimondas Narkevicius<br />
Kaunas University of Technology<br />
Phone (+370 68) 4 32 26<br />
E-mail: r.narkevicius@lmai.lt<br />
• Prof. Dr. Rimantas Venskutonis<br />
Kaunas University of Technology<br />
Phone: (+370 37) 30 01 88<br />
E-mail: rimas.venskutonis@ktu.lt<br />
MACEDONIA<br />
• Professor Dr. Vladimir Kakurinov<br />
Consulting and Training Center KEY<br />
Phone: (+389 070) 688-652<br />
E-mail: vladimir.kakurinov@key.com.mk
EHEDG Regional Sections 131<br />
MEXICO<br />
• Professor Marco Antonio León Félix<br />
Mexican Society for Food Safety and Quality<br />
for Food Consumers (SOMEICCA)<br />
Phone: (+52 55) 56 77 86 57<br />
E-mail: cuccalmexico@yahoo.com.mx<br />
NETHERLANDS<br />
• Jacques Kastelein<br />
TNO Kwaliteit van Leven<br />
Phone: (+31 30) 6 94 46 85<br />
E-mail: jacques.kastelein@tno.nl<br />
• Ernst Paardekooper<br />
Foundation Food Micro & Innovation<br />
Phone: (+31 73) 5 51 34 70<br />
E-mail: e.paardekooper@planet.nl<br />
NORDIC (FI, N, S)<br />
• Dr. Gun Wirtanen<br />
VTT Technical Research Centre of Finland<br />
Phone: (+358 20) 7 22-1 11<br />
e-mail: gun.wirtanen@vtt.fi<br />
• Stefan Akesson<br />
Tetra Pak Processing Systems AB<br />
Research & Technology<br />
Phone: (+46 46) 36 58 69<br />
E-mail: stefan.akesson@tetrapak.com<br />
POLAND<br />
• Dr. Matuszek, Tadeusz<br />
Gdansk University<br />
Phone: (+48 58) 3 47 16 74<br />
E-mail: tmatusze@pg.gda.pl<br />
RUSSIA<br />
• Professor Dr. Mark Shamtsyan<br />
St. Petersburg State Institute of Technology<br />
Phone: (+7 960) 2 72 81 68<br />
E-mail: shamtsyan@yahoo.com<br />
SERBIA<br />
• Professor Dr. Miomir Nikšić<br />
University of Belgrade, Faculty of Agriculture<br />
Phone: (+381 63) 7 79 85 76<br />
E-mail: miomir.niksic@gmail.com<br />
• Professor Dr. Victor Nedović<br />
University of Belgrade, Faculty of Agriculture<br />
Phone: (+381 11) 2 61 53 15<br />
E-mail: vnedovic@agrif.bg.ac.rs<br />
SPAIN<br />
• Andrès Pascual<br />
AINIA Centro Tecnológico<br />
Phone: (+34 96) 13 66 09 0<br />
E-mail: apascual@ainia.es<br />
• Irene Llorca / Rafael Soro<br />
AINIA Centro Tecnológico<br />
E-mail: illorca@ainia.es, rsoro@ainia.es<br />
SWITZERLAND<br />
• Professor Rudolf Schmitt<br />
University of Applied Sciences Western Switzerland<br />
Phone.: (+41 27) 6 06 86 52<br />
E-mail: rudolf.schmitt@hevs.ch<br />
• Matthias Schäfer<br />
GEA Tuchenhagen GmbH<br />
Phone: (+41 61) 9 36 37 40<br />
E-mail: matthias.schaefer@gea.com<br />
TAIWAN<br />
• Dr. Binghuei Barry Yang*<br />
FIRDI Food Industry Research and Development.<br />
Phone: (+886 6) 3 84 73 01<br />
E-mail: bby@firdi.org.tw<br />
THAILAND<br />
• Dr. Navaphattra Nunak<br />
King Mongkut’s Institute of Technology, Bangkok<br />
Phone: (+66 2) 7 39 23 48<br />
E-mail: kbnavaph2@yahoo.com<br />
TURKEY<br />
• Samim Saner<br />
TFSA - Turkish Food Safety Association, Istanbul<br />
Phone: (+90 216) 5 50 02 23<br />
E-mail:: samim.saner@ggd.org.tr<br />
UKRAINE<br />
• Professor Yaroslav Zasyadko<br />
National University of Food Technologies, Kyiv<br />
Phone: (+38 44) 2 87 96 40<br />
E-mail: yaroslav@nuft.edu.ua<br />
• Professor Ivanov Sergiy<br />
National University of Food Technologies, Kyiv<br />
Phone: (+38 44) 2 89 95 55<br />
E-mail: yaroslav@nuft.edu.ua<br />
USA<br />
• Professor Mark Morgan<br />
Purdue University<br />
Department of Food Science<br />
Phone: (+1 765 ) 4 94 11 80<br />
E-mail: mmorgan@purdue.edu<br />
More EHEDG Regional Sections are in the process of<br />
being formed. These are:<br />
• Bulgaria<br />
• Croatia<br />
• Romania<br />
• Slovakia<br />
• South Africa<br />
• United Kingdom<br />
List status as of spring <strong>2013</strong>
132 EHEDG Regional Sections<br />
EHEDG Armenia<br />
Karina Grigoryan, Laboratory of Biological Control of Food Products, Yerevan State University, Faculty of Biology,<br />
A.Manoogyan1, Yerevan Armenia, 0025 (phone: 37410550526; e-mail: asofst@gmail.com)<br />
and Suren Martirosyan, Chair of electrochemistry, Department of Chemical Technologies and Environmental<br />
Protection, State Engineering University of Armenia, Teryan 105, Yerevan 25009 Armenia, (phone: 3741054742;<br />
Fax: 37410587284; e-mail: surmar.3137@gmail.com)<br />
Late in 2010, the Armenian Regional Section of the EHEDG<br />
participated in the PRODEXPO 2010 exhibition. Huub<br />
Lelieveld and Piet Steenaard, were invited to participate in<br />
this event. A number of meetings in UNIDO were carried out<br />
in American University of Armenia and in food processing<br />
companies. More than a hundred people visited the EHEDG<br />
exhibition pavilion.<br />
Figure 1. EHEDG exhibition pavilion in PRODEXPO 2010<br />
In 2012, the EHEDG Armenian Regional Section focused its<br />
efforts in Guideline translation.<br />
EHEDG Armenia has the following Guidelines ready for<br />
publication:<br />
• Doc. 21 Challenge tests for the evaluation of the<br />
hygienic characteristics of packing machines for liquid<br />
and semi-liquid products;<br />
• Doc. 38 Hygienic engineering of rotary valves in<br />
process lines for dry particulate materials;<br />
• Doc. 12 The continuous or semi-continuous flow<br />
thermal treatment of particulate foods;<br />
• Doc. 10 Hygienic design of closed equipment for the<br />
processing of liquid food;<br />
• Doc. 29 Hygienic design of packing systems for solid<br />
foodstuffs.<br />
The following Guidelines are in the process of being<br />
translated:<br />
• Doc. 31 Hygienic engineering of fluid bed and spray<br />
dryer plants;<br />
• Doc. 35 Welding of stainless steel tubing in the food<br />
industry;<br />
• Doc. 37 Hygienic design and application of sensor;<br />
The Guidelines presented below, are currently being<br />
adapted to the Armenian Standards on hygienic design of<br />
food processing factories:<br />
• Doc 11 Hygienic packing of food products<br />
• Doc 8 Hygienic equipment design criteria<br />
• Doc 13 Hygienic design of equipment for open<br />
processing<br />
In 2012, the Armenian Society of Food Science and<br />
Technology started the creation of their own web page.<br />
A course of lectures “Hygienic design” will be introduced<br />
for the departments of Food Processing Technologies and<br />
Hygiene in Engineering and Agricultural State Universities<br />
during the master study courses in 2012/<strong>2013</strong>.<br />
In 2012, the Armenian Regional Section carried out several<br />
activities to spread the requirements of EHEDG hygienic<br />
design among Armenian companies. Seminars have been<br />
organized at EHEDG company members and for other<br />
companies as well.<br />
The Armenian Regional Section also published several<br />
newsletters about the EHEDG and hygienic design, which<br />
have been distributed among the food industry, some food<br />
equipment manufactures and universities.<br />
UNIDO partnership has been established with the EHEDG<br />
to strengthen national capacities and producers in meeting<br />
international standards and quality management for<br />
development of hygienic conditions in the food industry. A<br />
series of Round Tables and Seminars were conducted to<br />
introduce EHEDG Guidelines and principles.
EHEDG Regional Sections 133<br />
In October 2012, a seminar with representatives from<br />
state organizations was carried out in UNIDO and Food<br />
Safety Agency. During this seminar our Regional Section<br />
presented possibilities of cooperation with EHEDG, e.g.<br />
the organization of trainings and providing certification<br />
of the equipment in food factories. Using the materials of<br />
EHEDG presentations, joint seminars were organized with<br />
agricultural and engineering universities.<br />
Figure 2. Meetings and seminars in UNIDO<br />
Company-members of EHEDG have been successful,<br />
due to our collaboration, i.e. the introduction of EHEDG<br />
Guidelines and the organization of meetings and seminars<br />
at the manufacturers’ locations.<br />
The food companies of Armenia which co-operate with the<br />
following subgroups are presented below:<br />
• “Bari Samaratsi” LTD – “Meat Processing” subgroup.<br />
• “Akvatechavtomatika”LTD – “Fish Processing”<br />
subgroup.<br />
In these enterprises interesting research work is carried out,<br />
the results of which are the basis for determining the material<br />
for the corresponding subgroups, for example:<br />
• Influence of technology of processing surfaces<br />
and equipment by biocides, on survival rate of<br />
the microorganisms, causing safety and quality of<br />
foodstuff;<br />
• Use of modern methods of packing and storage of<br />
fresh fish.<br />
In 2012, mass media were actively used for the advancement<br />
of EHEDG in Armenia; these are transfers on Armenian TV<br />
and radio.<br />
Figure 3. Meeting at Yerevan Sate Agrarian University, Department<br />
of Food Technologies<br />
Contact<br />
Professor Dr. Karina Badalyan<br />
Armenian Society of Food Science and Technology<br />
(ASFoST)<br />
Phone (+374 10) 55 05 26<br />
E-mail: foodlab@inbox.ru<br />
Dr. Suren Martirosyan ASFoST<br />
Phone (+374 10) 56 40 29<br />
E-mail: surmar.3137@gmail.com<br />
EHEDG Belgium<br />
Hein Timmerman, Diversey Belgium, a Sealed Air Company, E-mail: hein.timmerman@telenet.be<br />
A Regional Section on the rise<br />
For EHEDG Belgium, 2012 was a busy year. A number of<br />
people from Belgium have been active in EHEDG work for<br />
quite some time. Finally, after many years of involvement,<br />
the team has taken up the task of founding the Belgium<br />
section. EHEDG Belgian Regional Section has created a<br />
legal identity as non-profit organisation (vzw or “stichting”<br />
in Dutch, and “Vereinigung ohne Gewinnerzielungsabsicht”<br />
in German). This legal identity is required to legally protect<br />
the individuals and to be able to receive and send out<br />
accountable invoices.
134 EHEDG Regional Sections<br />
The following positions have been confirmed:<br />
Chairman:<br />
Hein Timmerman<br />
Vice-chairman: Laurent Paul, and looking after<br />
Walloon and German region<br />
Vice-chairman: Johan Roels, and looking after<br />
Flemish region<br />
Secretary:<br />
Frank Moerman<br />
Treasurer:<br />
Noel Hutsebaut<br />
3. Preparation of a three day EHEDG Advance Course on<br />
Hygienic Design training course in the Walloon region<br />
by exploring the possible cooperation with EHEGD<br />
France<br />
4. Organisation of an EHEDG seminar as instigator of<br />
the initiative, with possible cooperation of Agoria and<br />
Flanders Food<br />
5. Establishing links to different Flemish and Walloon universities<br />
and technical colleges in order to promote our<br />
advisory function to legislators and standards groups<br />
6. Expanding the network to all major food producers in<br />
the Flemish and Walloon regions<br />
7. Expanding a networking platform for local experts in<br />
hygienic design.<br />
The legal papers were officialised during the Food & Feed<br />
Value Added Services Event on Wednesday September 19,<br />
2012 at Fortress Singelberg, Antwerp.<br />
The bylaws were signed at the EHEDG annual meeting in<br />
Valencia in November 2012.<br />
He main objectives for 2012-<strong>2013</strong> are:<br />
1. Creation and publication of the bylaws of EHEDG<br />
Belgium vzw in the “Belgisch staatsblad”. From the day<br />
of publication the organisation will be officialised.<br />
2. Organisation of a three day EHEDG Advance Course<br />
on Hygienic Design training course in the Flemish<br />
region<br />
Contact<br />
For more information and if interested in the activities of<br />
EHEDG Belgium, please contact<br />
Hein Timmerman<br />
E-mail: hein.timmerman@telenet.be<br />
Phone: +32 495 591781<br />
EHEDG Czech Republic<br />
New Regional Section<br />
Ivan Chadima, MQA s.r.o., phone: (+420 607) 90 99 47, e-mail: ivan.chadima@mqa.cz<br />
With help of the general secretary of EHEDG Susanne<br />
Flenner, a small group of EHEDG members organised an<br />
“EHEDG Day” in the Czech Republic on 11th September<br />
2012. The aim was to promote ideas of hygienic design<br />
between participants from Czech and Slovak food and food<br />
machinery industry and teachers from universities. President<br />
Knuth Lorenzen and general secretary Susanne Flenner<br />
participated in this event, too.<br />
Three presentations showing hygienic design from different<br />
viewpoints were presented (Knuth Lorenzen from EHEDG,<br />
Ivan Chadima from MQA s.r.o. and Jiří Loníček from ACO<br />
Industries k.s.). There was also a fruitful informal discussion<br />
about the founding of a Czech Regional Section.<br />
Potential members of the Regional Committee were invited<br />
to a separate meeting in November 2012 where Regional<br />
committee members was confirmed and the future of<br />
EHEDG in the Czech Republic discussed.<br />
Contact:<br />
MQA s.r.o.<br />
Dr. Ivan Chadima<br />
Jevineves 58<br />
27705 SPOMYSL<br />
CZECH REPUBLIC<br />
Phone: (+420 607) 90 99 47<br />
E-mail: ivan.chadima@mqa.cz
EHEDG Regional Sections 135<br />
EHEDG Denmark<br />
Jon J. Kold, regional chairman EHEDG, general manager Staalcentrum, e-mail: jk_innovation@yahoo.com<br />
EHEDG Denmark can boast an increase of both company<br />
and individual members that joined the EHEDG. New<br />
members have also joined relevant subgroups to share the<br />
work of determining the future trend for hygienically designed<br />
equipment.<br />
Figure 3. Display at international conference<br />
EHEDG Denmark have been actively in contact with<br />
the Danish technical magazines in order to promote the<br />
awareness of hygienic design of processing equipment.<br />
Very good connections have been made with several editors<br />
and journalists from these magazines.<br />
Figure 1. Display at the international conference<br />
In November 2011, EHEDG Denmark and Staalcentrum<br />
held an international conference “Food Processing Hygiene<br />
– Future demands from markets and Authorities” at Hotel<br />
Comwell in Kolding. Included in the program were more than<br />
60 B2B meetings. Furthermore four workshops covering the<br />
following topics were held: Robots in Production, Alternative<br />
Materials to Stainless Steel, Testing and Certification and<br />
Microbiology.<br />
Since the Danish Technological Institute stopped their<br />
testing and certification, EHEDG Danmark have been<br />
cooperating with the Danish Technical University (DTU)<br />
in Lyngby, north of Copenhagen, in order to transfer the<br />
testing and certification experience to them. The chairman<br />
for the Subgroup for Testing Methods has visited the site<br />
and advised the management at DTU how to proceed. It is<br />
expected that a new test rig will be in operation before the<br />
end of 2012.<br />
In November 2012, a seminar was held in connection with<br />
the FoodTech exhibition in Herning, the subject was new<br />
developments in open equipment design as open and<br />
accessible construction and the importance of integrating<br />
all EHEDG Guidelines when designing processing lines.<br />
The use of certified equipment has to go hand in hand with<br />
hygienic design guidelines for construction. Testing and<br />
certification at DTU was part of the seminar.<br />
Figure 2. Lecture at the international conference<br />
The focus of the programme was to look into the future and<br />
see how demands from the market could be implemented in<br />
the future design of equipment as well as the documentation<br />
for hygienic design. More than 70 persons participated in the<br />
2 day programme.<br />
The Danish EHEDG Committee<br />
Chairman<br />
Jon J. Kold, Staalcentrum<br />
Secretary:<br />
Ulla Stadil, Novozymes A/S<br />
Treasurer<br />
Bjarne Darré, GEA Liquid A/S<br />
Members:<br />
Mogens Roy Olesen, Grundfos A/S<br />
Peter Uttrup, Interroll A/S<br />
Kjeld Bagger, AVS Denmark ApS<br />
Bo Boje Busk Jensen, Alfa Laval A/S<br />
Per Væggemose Nielsen, IPU / DTU
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M E M B E R<br />
EHEDG France:<br />
Seven years of existence<br />
Nicolas Chomel, Secretary of EHEDG France,<br />
e-mail: nchomel@<strong>ehedg</strong>.fr<br />
Created in the end of 2005, the French Regional Section<br />
is now well established in the national 110 x landscape 303 mm of the<br />
food industry. EHEDG France has 76 members, including<br />
57 industrial companies, Farbe: and is directed 4c by an administration<br />
committee of 15 people.<br />
The new president, Erwan Billet, elected in 2010, wished for<br />
a closer collaboration with the EHEDG, and 2011 has been<br />
a key year from this point<br />
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After his first visit to Laval in September, Knuth Lorenzen<br />
returned in November to EHEDG give a presentation Secretariat at the “Autumn<br />
Conferences” of EHEDG France.<br />
The collection of 41 guidelines has been translated into<br />
French, and 59 documents were sold in 2011.<br />
French members are involved in nine international Subgroups<br />
and their contribution Fax is growing, +49 especially 69 6603-2249 through the<br />
creation of “mirror groups“ connected to international groups.<br />
The first “mirror groups“ have already taken up their jobs<br />
for “Cleaning validation“, “Air handling“, and “Education &<br />
training“. EHEDG France will also initiate a new international<br />
subgroup on “CIP“ and probably another one regarding the<br />
hygienic design of brushes.<br />
In the framework of the last international conference Food<br />
Factory in July of 2012, EHEDG France was involved in<br />
tel: 069-6603-1232<br />
the organization of the “SME day“, gathering technical<br />
presentations on hygienic design.<br />
Food Factory 2012, Laval, July 5.<br />
Contact<br />
Erwan Billet*<br />
Hydiac<br />
Phone: (+33 61) 2 49 85 84<br />
E-mail: e.billet@hydiac.com<br />
Nicolas Chomel<br />
Laval Mayenne Technopole<br />
Phone: (+33 243) 49 75 24<br />
E-mail: chomel@laval-technopole.fr<br />
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EHEDG Regional Sections 137<br />
EHEDG Germany<br />
Dr. Jürgen Hofmann, Hygienic Design Weihenstephan, Postfach 1311, D-85313 Freising, Germany;<br />
Phone +49(0)8161-8768799, e-mail: jh@hd-experte.de<br />
Hans-Werner Bellin, BELLINconsult, Heidestr. 3, D-65326 Aarbergen, Phone: +49/(0)6120/9799620,<br />
mobile phone: +49(0)151/42415256 , e-mail: Hans-Werner.Bellin@BELLINconsult.de.<br />
EHEDG Germany/Austria has a total of 283 members and<br />
about 90 member companies (2 from Austria) which is an<br />
increase of more than 50% within the last two years. These<br />
companies generate more than 40 % of the total income of<br />
EHEDG.<br />
The experience made during these tests has been used for<br />
further training courses and seminars.<br />
The idea of hygienic design has a long tradition in Germany<br />
and goes back right to the beginnings of the EHEDG and its<br />
history. Hygienic design research continues at the “Lehrstuhl<br />
für Verfahrenstechnik disperser Systeme” (formally<br />
“Lehrstuhl für Maschinen- und Apparatekunde”, Technical<br />
University of Munich) whilest the University of Dresden<br />
(Professur Verarbeitungsmaschinen / Verarbei-tungstechnik<br />
with Prof. Dr. Majschak) does research on topics such as the<br />
cleaning effect on open surfaces and is now involved in the<br />
Subgroup Training & Education to develop training material.<br />
The German Section is very active in Training and today has<br />
six EHEDG authorized trainers: Dipl.-Ing. Martin Barnickel<br />
(Technikerschule in Kempten), Dipl.-Ing. Hans-Werner Bellin<br />
(BELLIN.consult), Knuth Lorenzen (EHEDG President,<br />
Chairman of the Training & Education Subgroup), Dr. Jürgen<br />
Hofmann (Hygienic Design Weihenstephan), Prof. Dr. Jens<br />
Majschak (TU Dresden) Dr. Marc Mauermann (Fraunhofer<br />
AVV), and Ferdinand Schwabe (HD-Consultant).<br />
The “Forschungszentrum Weihenstephan für Brau- und<br />
Lebensmittelqualität” is an authorised EHEDG Test Institute.<br />
With approximately 50 EHEDG components assessed to<br />
provide of optimization guidance about design and with<br />
more than 30 EHEDG certificates in 2012, it is one of the<br />
most active test labs for the EHEDG. The highlight last year<br />
was the cleanability testing of a self-priming centrifugal<br />
pump. This kind of pump is able to transport air in the liquid<br />
phase and has different chambers and tends to be difficult<br />
to clean. The important requirement of self-draining also has<br />
to be considered.<br />
Another highlight was the first certificates of Type EL Aseptic<br />
Class I to be issued. The item tested was a pressure sensor<br />
for mounting in pipe lines, sealed with an O-ring. This<br />
certificate was followed by an air-operated pinch valve.<br />
Figure 2. left to right: Dr. J. Hofmann, K. Lorenzen, Dr. Fischer,<br />
H-W.Bellin, D. Nikoleiski<br />
The German Section has an annual meeting which is part of<br />
the HygieniCon in Karlsruhe (www.hygienicon.com).<br />
At this meeting, the members receive the latest news about<br />
what has been happening during the last year within the<br />
EHEDG and new strategies are discussed. This year, the<br />
Region Germany was made public by the signature of the<br />
By-Laws through Dr. Jürgen Hofmann, Chairman, Hans-<br />
Werner Bellin, Secretary, Dr. Sven Fischer, Treasurer and<br />
Dirk Nikoleiski, Member of the EHEDG Executive Board.<br />
Figure 3. Presentation of the EHEDG test during the HygieniCon<br />
2012<br />
Figure 1. Speech of the EHEDG President Knuth Lorenzen at the<br />
meeting of the German Group during the HygieniCon, Karlsruhe<br />
At the 2012 Anuga FoodTec (March 12) in Cologne EHEDG<br />
organized a Symposium with international speakers and<br />
around 70 participants. The EHEDG had their own booth<br />
which helped to establish contact with many people from all<br />
over the world.
138 EHEDG Regional Sections<br />
Currently, there are at least three Hygienic Design courses<br />
per year held by members of the German Section. The<br />
“Hygienic Design Weihenstephan Akademie” will start<br />
the additional training which will communicate the idea of<br />
EHEDG mainly to non-EHEDG-members.<br />
The training courses are scheduled for each February,<br />
July and October in Munich, Cologne and Stuttgart. More<br />
details are available under http://www.hygienic-designakademie.de/.<br />
Contact<br />
Figure 4. The EHEDG both on the Anuga FoodTec with Susanne<br />
Flenner and Knuth Lorenzen<br />
Chairman:<br />
Dr. Jürgen Hofmann<br />
Ingenieurbüro Hofmann<br />
Fichtenweg 8 a<br />
85604 Zorneding<br />
E-mail: juergen.hofmann@<strong>ehedg</strong>.org<br />
Secretary:<br />
Hans-Werner Bellin<br />
BELLIN.consult<br />
Heidestr. 3<br />
65326 Aarbergen<br />
E-mail: hans-werner.bellin@bellinconsult.de<br />
Figure 5. The EHEDG Symposium at the Anuga FoodTec in<br />
Cologne, March 12<br />
EHEDG Italy<br />
Giampaolo Betta, Università degli Studi di Parma, e-mail: giampaolo.betta@unipr.it<br />
News from the Italian Regional Section<br />
The Italian food industry, along with agriculture, related<br />
activities and distribution, is the foremost economic sector<br />
in the country. It buys and processes about 70% of domestic<br />
raw materials. It is also the ambassador of “Made in Italy” in<br />
the world, since 76% of the food exports consist of industrial<br />
branded products.<br />
The Italian food industry has a turnover of € 120 billion,<br />
with 6,400 companies (with more than nine employees)<br />
comprising a total of 386,000 employees. Exports amounted<br />
to € 19.84 billion (Data 2008).<br />
61% of the total turnover is achieved in the Lombardy, Emilia<br />
Romagna, Veneto and Piedmont regions, making this area<br />
the most important “food valley” of Europe.<br />
Within this area, the Province of Parma distinguishes itself<br />
as 23% of all employees of the food industry of the entire<br />
region Emilia Romagna work in that province.<br />
The province of Parma is home to historically consolidated<br />
food products, such as “Prosciutto di Parma” PDO,<br />
“Formaggio Parmigiano Reggiano” PDO and tomato<br />
products. Currently, Parma is the location of many well-known<br />
food manufacturing and food-equipment manufacturing<br />
groups.<br />
In addition, Parma is the headquarters of the Stazione<br />
Sperimentale Industria Conserve Alimentari (SSICA), an<br />
institute of research and experimentation founded in 1922.<br />
Finally, Parma is home to the European Agency for Food<br />
Safety Authority (EFSA) and, as such, is often the privileged<br />
meeting place for working groups, seminars and conferences<br />
involving top European experts.<br />
Since 2007, Parma has also been the location of the Italian<br />
Section of the European Hygienic Engineering and Design<br />
Group.
EHEDG Regional Sections 139<br />
Members and Subgroups<br />
The Italian Section officially started on 17 October 2007,<br />
the date of the “Hygiene Requirements and Standards for<br />
Foodstuffs Machinery” Conference, which took place at<br />
Parma at the time of the CIBUSTEC2007 Exhibition.<br />
Italy supports EHEDG with 10 company members (Table 1),<br />
10 individuals and Italian members actively work in 8<br />
Subgroups (Table 2).<br />
Italian Company Members (2012)<br />
Ammeraal Beltech S.r.l.<br />
AROL S.p.A.<br />
CFT S.p.A.<br />
CSF Inox S.p.A.<br />
Ilinox S.r.l.<br />
PNR Italia S.p.A.<br />
RattiInox S.r.l.<br />
Seital Separatori S.r.l.<br />
S.K.F Industrie S.p.A.<br />
Vincas S.r.l.<br />
Table 1: EHEDG Italian Company Members in 2012<br />
Subgroup with Italian members<br />
Seals and Valves<br />
Pumps, Homogenizers, Dampening Devices<br />
Chemical treatment of stainless steel<br />
Materials of Construction<br />
Separators<br />
Test Methods<br />
Training and Education<br />
Table 2: Subgroups with Italian members<br />
Company / Institute<br />
Documents<br />
Bardiani valvole S.p.A. 14,20,<br />
Centro Inox Milano 32<br />
CFT S.p.A. 2,8,10<br />
Csf Inox S.p.A. 14,17,20,25<br />
GEA-Niro Soavi S.p.A. 17<br />
GEA-Procomac 8<br />
CFT S.p.A. 13, 34<br />
IVG Colbachini S.p.A. 32<br />
Omac Pompe S.r.l. 17<br />
Parmalat S.p.A. 8,34<br />
Sidel S.p.A 2,8,10,34<br />
Stazione Sperimentale per l’Industria delle 8<br />
Conserve Alimentari<br />
University of Parma 2,8,10,13,<br />
14,17,20,<br />
25,32,34<br />
Table 3: translation working groups<br />
EHEDG Italy Events<br />
The Italian Regional Section frequently participates in Italian<br />
congresses, seminars and conferences with speeches on<br />
Hygienic Design and Engineering. Some examples are<br />
shown in Table 4.<br />
The Italian Regional Section is also a candidate for hosting<br />
and organizing the <strong>2014</strong> EHEDG World Congress.<br />
Participation in events<br />
Date<br />
McT Alimentare - Bologna 19-06-2012<br />
R2B - Bologna 11-06-2011<br />
Gruppo CMS Updating - Modena 20–05-2011<br />
51° AITB - Bari 23-09-2010<br />
Table 4: participation in events<br />
Translations<br />
By now (September 2012) the Documents 2, 8, 10, 13, 14,<br />
17, 20, 32, 34 have been translated and are hence available<br />
in the Italian language; Documents 25, 1, 3 and 6 are under<br />
revision.<br />
A frequently updated list of the translated documents is<br />
available in the web-page www.<strong>ehedg</strong>.unipr.it → Guidelines.<br />
Many companies and institutes joined the translation<br />
working groups of the Italian Section. The list is shown in<br />
Table 3.<br />
Training<br />
The Italian Regional Section participates in the Training and<br />
Education Subgroup.<br />
Training on basic and advanced hygienic design and<br />
engineering is offered in English and in Italian language. For<br />
further information please contact giampaolo.betta@unipr.it<br />
Contact<br />
For more information and also if you are interested in the<br />
activities of EHEDG Italy, please contact Dr. Giampaolo Betta,<br />
e-mail: giampaolo.betta@unipr.it Phone: +39 0521 90 62 34<br />
or the EHEDG Secretariat.
140 EHEDG Regional Sections<br />
EHEDG Japan<br />
Hiroyuki Ohmura, JFMA The Japan Food Machinery Manufacturers’, ohmura@fooma.or.jp<br />
With the full support from the Japan Food Machinery<br />
Manufacturers‘ Association (FOOMA), EHEDG JAPAN<br />
mainly pursues the following activities: Translation of<br />
EHEDG guidelines, holding seminars on EHEDG guidelines,<br />
and EHEDG PR activities.<br />
Translation of EHEDG guidelines<br />
EHEDG JAPAN considers the translation of EHEDG<br />
guidelines to be its foremost task.<br />
In Japan, there is a strong need for translations of the<br />
following guidelines: Doc. 9, Doc. 18, Doc. 20, Doc. 23, Doc.<br />
32, and Doc. 37. EHEDG JAPAN set up a special translation<br />
working group for each of these documents.<br />
The translations of Doc. 20 and Doc. 23-2 have already<br />
been completed.<br />
Seminars on EHEDG guidelines, and EHEDG<br />
PR activities<br />
Every year in June, FOOMA organises the “FOOMA<br />
JAPAN“, a comprehensive exhibition on food machinery and<br />
technology industry. About 650 companies from all over the<br />
world participate in this exhibition. The number of visitors<br />
runs up to about 100,000. This year, FOOMA JAPAN was<br />
held for four days from June 5 through 8 at Tokyo Big Sight.<br />
Throughout the exhibition period, EHEDG JAPAN performed<br />
PR activities at a booth provided by FOOMA and held a free<br />
seminar to make EHEDG guidelines known.<br />
EHEDG seminar<br />
To spread the knowledge about EHEDG guidelines, EHEDG<br />
JAPAN held a free seminar intended for food machinery<br />
manufacturers and food manufacturing engineers in Japan.<br />
EHEDG President Mr. Lorenzen was invited as a lecturer<br />
(Fig 3/4).<br />
• Topic: Materials of Construction for Equipment Coming<br />
into Contact with Food (Doc. 32)<br />
• Date and time: June 6, 10:00–12:30<br />
• Attendants: 230 people<br />
With the first FOOMA JAPAN having been held in 2009,<br />
EHEDG JAPAN this year already held its fourth EHEDG<br />
seminar. The audience has increased every year. This year,<br />
with an audience of 232 people, the venue was almost bookedout.<br />
(The number was 180 last year.) All these activities have<br />
boosted publicity for EHEDG in Japan considerably.<br />
Figure 2. EHEDG seminar in FOOMA JAPAN 2012<br />
PR booth of EHEDG<br />
At the EHEDG booth (Fig. 1), EHEDG pamphlets and<br />
yearbooks were distributed to visitors. In addition, panel<br />
displays were set up to explain the hygienic structure of food<br />
processing machines as defined in the Codex Alimentarius<br />
Commission’s “Food Hygiene – Basic Texts” and ISO/JIS, as<br />
well as the relationship between these documents.<br />
Figure 3. President Lorenzen acted as the speaker<br />
Contact<br />
Figure 1. EHEDG PR booth<br />
Hiroyuki Ohmura<br />
JFMA - The Japan Food Machinery Manufacturers’ Association<br />
Fooma Bldg., 3-19-20 Shibaura<br />
Minato-ku<br />
108-0023 TOKYO<br />
JAPAN<br />
E-mail: ohmura@fooma.or.jp
EHEDG Regional Sections 141<br />
EHEDG Lithuania<br />
Dr.Raimondas Narkevicius, regional chairman EHEDG, Food Institute of Kaunas University of Technology,<br />
e-mail: r.narkevicius@lmai.lt<br />
In May 2012, a workshop on topical issues of food safety<br />
and innovations was held in Kaunas. At this workshop<br />
representatives of food manufacturing companies, food<br />
research and safety control organisations participated. It<br />
was there that the decision was reached to establish the<br />
EHEDG Lithuanian Section.<br />
An agreement between Kaunas University of Technology<br />
and EHEDG was duly signed and the Food institute of<br />
Kaunas University of Technology was appointed as the<br />
regional representative of EHEDG in Lithuania.<br />
In the first year of existence, the main tasks of the Lithuanian<br />
EHEDG section were:<br />
• translation of EHEDG Guidelines into Lithuanian and<br />
spreading the Guidelines among food processing<br />
companies<br />
• organisation of and participation in events aimed at<br />
promoting the hygienic manufacturing of food<br />
• presentation of EHEDG activities and spreading the<br />
knowledge about EHEDG amongst Lithuanian food<br />
manufacturers.<br />
In November 2012 at the annual conference of Food<br />
Institute of Kaunas University of Technology, the EHEDG<br />
will be widely presented and we expect to persuade food<br />
manufactures and other professionals to join the EHEDG.<br />
Mr. Huub Lelieveld giving a presentation at the Workshop in<br />
Lithuania<br />
For more information please contact<br />
Raimondas Narkevicius<br />
Kaunas University of Technology<br />
Department of Food Technology<br />
Taikos pr. 92<br />
50254 KAUNAS<br />
LITHUANIA<br />
Phone: +370 68 4 32 26<br />
E-mail: r.narkevicius@lmai.lt<br />
EHEDG Macedonia<br />
Prof. Dr. Vladimir Kakurinov, Consulting and Training Centre KEY, Macedonian Regional Section Chairman,<br />
Phone/Fax: +389 2 3211-422; e-mail: vladimir.kakurinov@key.com.mk<br />
Consulting and Training Centre Key, the headquarters of<br />
the Macedonian EHEDG Regional Section, has organized<br />
the First EHEDG World Congress in Hygienic Engineering<br />
and Design. This event was a Summit of Hygienic Design<br />
expertise, where over 230 participants from 31 countries<br />
worldwide came for an experience exchange, and discussed<br />
new developments and innovations.<br />
The EHEDG World Congress took place in Hotel Granit in<br />
Ohrid, Macedonia, 22 - 25 September, 2011.<br />
EHEDG World Congress in Hygienic<br />
Engineering and Design 2011 – Macedonia<br />
During the Conference organized by RUSFoST (4 –<br />
5 October, 2010 in St. Petersburg, Russia), EHEDG<br />
Macedonian Regional Section was chosen to host the First<br />
World Congress for Hygienic Engineering and Design.<br />
Figure 1. World Congress opening
142 EHEDG Regional Sections<br />
This event was a Summit of Hygienic Design expertise:<br />
more than 230 participants from 31 countries worldwide<br />
exchanged their experience, new developments and<br />
innovations in this area.<br />
The Congress had full media coverage. Its content,<br />
participants, new developments and ideas were covered not<br />
only by media in Macedonia, but in the region and worldwide.<br />
42 presentations in two parallel sessions:<br />
1. Hygienic Design<br />
and<br />
2. Food Quality & Safety and Food Production & Processing<br />
gave an insight into the various fields of expertise of the<br />
high-class EHEDG lecturers and academia representatives<br />
who offered the delegates two highly informative days.<br />
All participants were more than satisfied with the successful<br />
outcome as is documented in the 1st Journal of Hygienic<br />
Engineering and Design. The journal consists of 75 highquality<br />
practical and science based papers, peer to peer<br />
reviewed, by 32 Congress Scientific Committee members.<br />
Figure 4. World Congress media coverage<br />
This great event was organized by Consulting and<br />
Training Center KEY, the headquarters of the EHEDG<br />
Macedonian Regional Section.<br />
Beside the working part of the Congress, there was a special<br />
social programme, where all participants had an opportunity<br />
to get familiar with our beautiful country, its traditions,<br />
heritage and Macedonian hospitality.<br />
You can find more information about the EHEDG World<br />
Congress in Hygienic Engineering and Design at:<br />
Figure 2. World Congress session<br />
http://www.<strong>ehedg</strong>.mk/categories/view/430<br />
The sponsor companies of the event: Van Meeuwen, Tensid<br />
Chemie Cmbh, Swisslion, Tetra Pak, Danfoss, Kozuvcanka,<br />
Scanjet, GEA, Serendipity, SKF, Skovin, and Makprogres<br />
were able to present their latest products and services in the<br />
exhibition space. It was an excellent and unique opportunity<br />
for them to attract new customers, reaffirm long-term<br />
customer relationships and present their most innovative<br />
products, equipment, materials and services in the area of<br />
safe food production.<br />
The Congress turned out to be an excellent platform for<br />
networking and meetings, especially on its final ‘Brokerage<br />
Event’ day, where business deals were concluded reaching<br />
a total of more than € 10 million.<br />
Figure 3. World Congress Brokerage event<br />
Journal of Hygienic Engineering and Design<br />
The Journal of Hygienic Engineering and Design is<br />
a platform for publication of evidence-based studies,<br />
investigations, research and experience on all scientific and<br />
expert aspects for: equipment and components, hygienic<br />
principles, processing, utilities, services, food production<br />
and processing, food quality and safety, and education. It<br />
is a peer-reviewed and open access journal intended to<br />
reveal new approaches, innovations, expert opinions and<br />
the highest possible global scientific standards.<br />
The first JHED volume was issued in 2011 for the first World<br />
Congress in Hygienic Engineering and Design. This first<br />
issue included 75 papers from 19 countries worldwide: The<br />
Netherlands, Germany, France, Great Britain, Denmark,<br />
Finland, Belgium, Spain, Poland, Bulgaria, Ireland, Sweden,<br />
Macedonia, Serbia, Croatia, Montenegro, Russia, Armenia<br />
and USA. This issue was published as a print copy. By now<br />
each paper is available in electronic form and downloadable<br />
from<br />
http://www.<strong>ehedg</strong>.mk/categories/view/413.<br />
The publisher of the Journal for Hygienic Engineering and<br />
Design, Consulting and Training Center KEY, will continue<br />
preparing the second and other following web based issues<br />
of this Journal. Authors all over the world are invited to<br />
submit their articles for the second issue.
EHEDG Regional Sections 143<br />
Beside the manuscripts, JHED content is extended to meet<br />
industry and consumer needs. On a regular basis, at the<br />
JHED web page, all new developments, technologies and<br />
innovations within the food and beverage industry worldwide<br />
will be updated. In this way, JHED aims to be a source of<br />
information and a networking platform for all key decision<br />
makers throughout the world and will be an essential read<br />
for anyone involved in this sector.<br />
Guidelines translation into Macedonian<br />
The translation of EHEDG Guidelines is an important part of<br />
the EHEDG Macedonian Regional Section’s regular activities.<br />
Seeing that all activities were focused on the organization of<br />
the EHEDG World Congress in 2011, for that year EHEDG<br />
Macedonia translated five Guidelines into the Macedonian<br />
language. Macedonian titles are shown in Table 1.<br />
More information about the Journal of Hygienic Engineering<br />
and Design can be found at:<br />
http://www.<strong>ehedg</strong>.mk/categories/naslovna/<br />
Doc.<br />
2<br />
Title<br />
Метод за проценка на чистливоста во место на<br />
опремата за прехранбена индустрија<br />
Info Days<br />
In order to promote the EHEDG Congress in September,<br />
2011, the Macedonian EHEDG Regional Section had<br />
organized 4 informative days:<br />
1. South-eastern region Strumica<br />
2. Region Pelagonia Bitola<br />
3. Macedonian Chambers of Commerce State level<br />
4. Economic Chamber of Macedonia State level<br />
In 2012, two more Info Days were held. The first EHEDG Info<br />
Day took place in February 2012, with a main topic:<br />
• Hygienic engineering and design of buildings for the<br />
pharmaceutical and food industry.<br />
The second Info Day was organized in April, 2012, with an<br />
accent on<br />
• Hygienic engineering and design of equipment and<br />
its components and machinery intended for food<br />
production and processing.<br />
Both Info Days were attended by more than 80<br />
representatives from civil engineering and architectural<br />
companies engaged in food industry design and building<br />
(construction), equipment producers, producers and<br />
distributors of materials and components intended for food<br />
and pharmaceutical companies, food and pharmaceutical<br />
companies. Both events inspired huge interest among the<br />
participants and broader public and it was covered by all<br />
media. Also, National Television Telma prepared special<br />
shows broadcasts solely dedicated to these events.<br />
Figure 5. EHEDG Info Day special broadcast<br />
12<br />
15<br />
26<br />
Континуиран или полу-континуиран проток при<br />
термички третман на храна со парченца<br />
Метод за проценка на чистливоста во место на<br />
опрема за производство со умерена големина<br />
Хигиенски инженеринг на фабрики за<br />
производство на суви материи<br />
37 Хигиенски дизајн и апликација на сензори<br />
Table 1: EHEDG Guidelines translated in 2011<br />
In 2012, the EHEDG Macedonian Regional Section translated<br />
twelve EHEDG Guidelines into Macedonian (one per month,<br />
as planned in the activity plan for 2012). Macedonian titles<br />
are shown in Table 2.<br />
Doc. Title<br />
Метод за проценка на стерилизација на<br />
5<br />
опремата на производната линија<br />
Микробиолошки безбеден континуиран проток<br />
6<br />
при термичка стерилизација на течна храна<br />
Заварување на не’рѓосувачкиот челик според<br />
9<br />
хигиенски барања<br />
Хигиенски дизајн на вентили наменети за<br />
14<br />
производство на храна<br />
16 Хигиенски спојници за цевки<br />
Хигиенски дизајн и безбедна употреба на<br />
20<br />
вентили што оневозможуваат мешање<br />
Tест за евалуација на хигиенските<br />
21 карактеристики на машините за пакување на<br />
течни и полу-течни производи<br />
Водич за управување со воздух во<br />
30<br />
прехранбената индустрија<br />
Хигиенски дизајн на пумпи, хомогенизатори и<br />
17<br />
направи за навлажнување<br />
Хигиенски дизајн на системите за пакување на<br />
29<br />
цврста храна<br />
Хигиенски инженеринг на системи за пренос на<br />
36<br />
суви материјали<br />
Хигиенско инженерство на вентили во<br />
40 производни линии за суви материјали со<br />
парченца<br />
Table 2: EHEDG Guidelines translated in 2012<br />
(more on http://www.<strong>ehedg</strong>.mk/categories/view/429)
144 EHEDG Regional Sections<br />
Hygienic Engineering and Design Conference<br />
The First Conference for Hygienic Engineering and Design in<br />
the Republic of Macedonia will take place on 9th of October,<br />
2012, at the Municipality Karpos Conference Hall in Skopje.<br />
Invited speakers at this Conference are:<br />
Mr. Huub Lelieveld who will speak on the topics of Hygienic<br />
engineering and design requirements for buildings and<br />
EU legislation, standards and codes regarding hygienic<br />
engineering and design, while Prof. Dr. Vladimir Kakurinov,<br />
Chairman of the Macedonian EHEDG Regional Section will<br />
speak about hygienic engineering and design requirements<br />
regarding machinery and equipment.<br />
EHEDG Macedonian Regional Section members will also<br />
speak at the Conference and share their experience.<br />
This event will be attended by representatives from the food,<br />
pharmaceutical and cosmetics industry, food machinery,<br />
equipment and components manufacturing companies,<br />
companies supplying engineering services, the Food and<br />
Veterinary Agency and inspection bodies.<br />
Contact<br />
You can find more detailed information about EHEDG<br />
Macedonia and Journal of Hygienic Engineering and Design<br />
at: http://www.<strong>ehedg</strong>.mk/categories/naslovna/<br />
EHEDG Mexico<br />
In 2011, the very first year of the EHEDG Regional Section Mexico, SOMEICCA A.C. as the<br />
representative has organised the 4th International CUCCAL Congress on Food Safety, Quality<br />
and Functionality with EHEDG support and an informative breakfast about the aims and tasks of<br />
EHEDG. Sponsors of SOMEICCA, such as Lefix and Dantek, promoted EHEDG.<br />
León Félix Marco Antonio. Sociedad Mexicana de Inocuidad y Calidad para Consumidores de Alimentos,<br />
SOMEICCA, A.C. 28 de diciembre # 87 Col. Emiliano Zapata. Coyoacán, D.F.C.P.04815 México.<br />
www.someicca.com.mx ;marcoelp@lefix.com.mx<br />
4th International Congress CUCCAL on Food<br />
Safety, Quality and Functionality in the Food<br />
Industry and in Foodservice.<br />
In October 2011, 400 attendees from México, Cuba, Chile,<br />
Brazil, Venezuela and the United States of America enjoyed<br />
the sessions, workshops and roundtables during the<br />
Congress. The EHEDG was represented by Huub Lelieveld<br />
who was the trainer of the “hygienic design in food facilities”<br />
workshop and speaker at the conference. 16 delegates<br />
attended the workshop and the entire conference was<br />
attended by 50 persons, including students’ participation.<br />
It was very interesting to note that having Cancun as the<br />
hosting city, the attendees were from Foodservice rather<br />
than the Food Industry, but they were very pleased by the<br />
course. Of course, the congress also had academia and<br />
industry representatives.<br />
Figure 1. Closing Award session during the 4th International<br />
CUCCAL Congress at Cancún México.<br />
Figure 2. Attendees during the EHEDG session.
EHEDG Regional Sections 145<br />
To promote EHEDG and to let the Mexican Chambers and<br />
Universities know about the Congress results, SOMEICCA<br />
organised an informative breakfast in December 2011.<br />
The twelve attending guests were from the Industrial Food<br />
Chambers (Seafood, Bakery and Dairy) as well as from<br />
Universities that teach Food Science and Nutrition careers.<br />
Before the Congress, SOMEICCA offered an informative<br />
session about what the EHEDG is, for the most important<br />
facilities processing seafood in México and Latin America.<br />
Professor León Félix was present and explained the<br />
EHEDG goals and invited Seafood enterprises to attend<br />
the EHEDG workshop during the 5th International CUCCAL<br />
Congress.<br />
Figure 3. EHEDG´s Breakfast for Mexican Food Chambers and<br />
Universities<br />
5th International CUCCAL Congress on<br />
Food Safety, Quality and Functionality for<br />
Food service and Industry<br />
In October 2012, SOMEICCA held the 5th International<br />
CUCCAL Congress at Mazatlán, Sinaloa,México with two<br />
EHEDG speakers, both for a short course on Hygienic<br />
Design in Food Facilities and for conferences and round<br />
table sessions on the importance of hygienic design.<br />
SOMEICCA also held an informative session with the most<br />
important facilities for Seafood Processors in Latin America<br />
at Mazatlán, Sinaloa.<br />
The EHEDG was represented by Huub Lelieveld and Piet<br />
Steenaard as speakers both for a workshop on Hygienic<br />
Design in Food Facilties and for a conference and round<br />
table sessions about the importance and impact of hygienic<br />
design on food safety and quality. The Congress gathered<br />
Mexican and International experts on Food Safety, Quality<br />
and Functionality from México, Brasil, Venezuela, United<br />
States of America and the Netherlands.<br />
Figure 4. CUCCAL Congress poster with EHEDG logo<br />
Contact<br />
Professor Marco Antonio León Félix<br />
Sociedad Mexicana de Inocuidad y Calidad<br />
para Consumidores de Alimentos AC<br />
(SOMEICCAAC)<br />
Phone: (+52 55) 56 77 86 57<br />
E-Mail: lefix04@yahoo.com.mx<br />
EHEDG Netherlands<br />
E.J.C. Paardekooper, info@<strong>ehedg</strong>.nle-mail, info@<strong>ehedg</strong>.nl<br />
Translation of Guidelines<br />
At this moment, 32 guidelines have been translated into<br />
Dutch, 22 of which are available as print-versions. Eight of<br />
the 32 versions are still waiting for final approval. The plan<br />
is to translate the remaining guidelines into Dutch and to<br />
finalize all translations in <strong>2013</strong>.<br />
The Dutch Society for Food Entrepreneurs<br />
(OSV) & Dutch Food Business Events (VMT):<br />
EHEDG Netherlands was present at the SVO EVENT<br />
October 27th, 2011 in Velp about Hygienic Design of<br />
Conveyor Belts<br />
EHEDG Netherlands Seminar “Hygienic Design & Allergens”<br />
with the Dutch Food Magazine VMT was held December 4th,<br />
2012 in Utrecht.
146 EHEDG Regional Sections<br />
Training<br />
Training and education materials remain the main topic to<br />
promote hygiene awareness and understanding among<br />
staff/personnel involved in the food chain, ‘from farm to fork’.<br />
Knowledge dissemination<br />
Other channels of spreading knowledge are magazines<br />
and online publications. Targeted were Dutch media such<br />
as Voedingsmiddelentechnologie (VMT), WEKA and Eisma<br />
Voedingsmiddelenindustrie (EVMI) with 12 articles published<br />
in total.<br />
Several in-house training sessions were organised for<br />
food companies as well as for equipment suppliers and<br />
engineering firms. Most food equipment suppliers and a<br />
large number of food companies in the Netherlands are<br />
familiar with the EHEDG.<br />
A significant number of seminars was held introducing<br />
developments fulfilling EHEDG requirements and some<br />
lectures were held at fairs, p.e. Industrial Processing, Solids<br />
Fairs, Technivent and Stainless Steel World; in total about 30<br />
lectures with a total exposure of more than 700 participants<br />
were presented.<br />
Board members of EHEDG Netherlands are active in the<br />
Subgroups Building Design, Tank Cleaning and Testing &<br />
Certification.<br />
Joint activities with other associations<br />
Interest has arisen from the metal industry to enter into a<br />
cooperation introducing EHEDG requirements in the metal<br />
industry.<br />
Contact<br />
Ernst Paardekooper<br />
Foundation Food Micro & Innovation<br />
Phone (+31 73) 5 51 34 70<br />
E-mail: e.paardekooper@planet.nl<br />
Jacques Kastelein*<br />
TNO Kwaliteit van Leven<br />
Phone (+31 30) 6 94 46 85<br />
E-mail: jacques.kastelein@tno.nl<br />
High Technology Solutions<br />
in the dairy and fruit processing industries.<br />
bawaco ag · Stauffacherstrasse 77 · CH-3014 Bern / Switzerland · www.bawaco.ch<br />
bawaco gmbh · Poststrasse 15/1 · D-71384 Weinstadt / Germany · www.bawaco.de
EHEDG Regional Sections 147<br />
EHEDG Russia<br />
Prof. Dr. Mark Shamtsyan, St. Petersburg State Institute of Technology (RUSFoST),<br />
e-mail: shamtsyan@yahoo.com<br />
In 2012, the Russian Section of EHEDG made good progress<br />
in translating EHEDG Guidelines and started translating<br />
presentations for training courses.<br />
On April 22-24, the First North and East European Congress<br />
on Food was held in Saint Petersburg. The congress was<br />
organised by RUSFoST and the St. Petersburg State<br />
Institute of Technology (Technical University) in cooperation<br />
with EHEDG, GHI, IUFoST and EFFoST.<br />
The congress programme focused on recent developments<br />
in the fields of innovative technology, food safety,<br />
manufacturing and design of food equipment, functional<br />
and bioactive food, new trends in food safety, and impact<br />
of food on human health. More than 120 delegates from 28<br />
countries participated in the congress.<br />
During the congress, EHEDG and its activities were<br />
specifically introduced.<br />
Figure 2. Mr. Huub Lelieveld<br />
Further contributions in the development of food science<br />
and technology in Eastern Europe were given by Professor<br />
Sergiy Ivanov, Chair of the Ukrainian Section of EHEDG,<br />
Rector of National University of Food Technology of Ukraine<br />
and also by Professor Kostadin Fikiin, specialist for food<br />
refrigeration (Technical University of Sofia, Bulgaria). It was<br />
decided to hold the second NEEFood Congress in May <strong>2013</strong><br />
in Kiev, and after that every second year.<br />
Contact<br />
Figure 1. First North and East European Congress on Food<br />
One of the founders of the EHEDG, Mr. Huub Lelieveld,<br />
was awarded a special prize of NEEFood Congress for<br />
his lifetime achievements and great contribution in Food<br />
Science and Technology.<br />
St. Petersburg State Institute of<br />
Technology (RUSFoST)<br />
Technical University<br />
Moskovsky prospect 26<br />
ST. PETERSBURG 198013<br />
RUSSIAN FEDERATION<br />
E-mail: shamtsyan@yahoo.com<br />
Phone: (+7 960) 2 72 81 68
148 EHEDG Regional Sections<br />
EHEDG Serbia<br />
A new EHEDG regional section was established in Serbia<br />
Prof. Dr. Miomir Niksic, University of Belgrade, Faculty of Agriculture, Dep. of Industrial Microbiology,<br />
E-mail: miomir.niksic@gmail.com<br />
On the 24th of May 2012, at the meeting organised in<br />
conjugation with CEFood2012 in Novi Sad, EHEDG Serbia<br />
was founded as a formal organization according to the<br />
Serbian Civil Code, with the election of Chairman, Secretary,<br />
Treasurer and Members at Large. The regional section is<br />
strongly supported by Serbian Microbiological Society and<br />
the Society for Nutrition and Society for Food Technology.<br />
On the 25th September 2012 regional section were officially<br />
established on the first Info day-mini Symposium on Hygienic<br />
engineering and Design for Food Machinery, organized<br />
in Belgrade in conjunction with Chamber of Commerce of<br />
Serbia. At the meeting EHEDG Treasurer Piet Steenaard<br />
and Huub Lelieveld and Regional Section Chairman, Prof Dr.<br />
Miomir Niksic signed off the Regional Section By-Laws.<br />
Figure 2. Participants at the constitutional meeting EHEDG-<br />
Regional Section Serbia<br />
The Serbian EHEDG Committee will schedule meetings<br />
and training courses to be held quarterly in different regions/<br />
cities, probably in conjunction with other regional events.<br />
A number of actions at the end of 2012 and in <strong>2013</strong> are<br />
planned, including translation of guidelines, flyers, the<br />
Serbian version of the EHEDG web-site and we hope to gain<br />
ever more attention from local companies to disseminate<br />
hygienic design issues.<br />
Contact<br />
Figure 1. Signing the foundation of EHEDG regional section Serbia<br />
At the symposium several topics were presented by Huub<br />
Lelieveld and Piet Steenaard including: Hygienic design of<br />
food factories, Safe use of lubricants in the food industry,<br />
Hygienic design of equipment and Management of hygiene<br />
in food factories. Approximately 50 attendees from different<br />
companies, from both food processors and academia<br />
participated in this meeting.<br />
Professor Miomir Niksic<br />
University of Belgrade<br />
Faculty of Agriculture<br />
Department of Industrial Microbiology<br />
Phone: (+381 63) 7 79 85 76<br />
E-mail: mniksic@agrif.bg.ac.rs<br />
EHEDG Spain<br />
Rafael Soro, AINIA Technological Centre, Valencia – Spain, e-mail: rsoro@ainia.es<br />
The Spanish Regional Section continues to<br />
promote EHEDG activities and to increase<br />
the awareness of hygienic design among<br />
the Spanish food industry and equipment<br />
manufacturers.<br />
The first EHEDG event in Spain was in 2001, when the 11th<br />
International Conference was, for the first time, combined<br />
with a Training Workshop on hygienic engineering that was<br />
held in Valencia. The 3-day conference “Food in Europe:<br />
Building in Safety” was organised by AINIA, and attracted<br />
more than 200 attendees from European food companies<br />
and food equipment manufacturers.<br />
Four years later, in 2005, the Spanish Regional Section was<br />
created under the initiative of AINIA Technological Centre.<br />
In the following years, the Spanish Regional section carried<br />
out several activities to spread the requirements of hygienic<br />
design and EHEDG among Spanish companies. Seminars
EHEDG Regional Sections 149<br />
and advanced courses have been organised and held<br />
in Valencia and Barcelona. In 2006, the translation of the<br />
EHEDG published guidelines was initiated.<br />
A relationship was established with AMEC (Spanish Food<br />
Equipment Manufacturers Association) aiming to disseminate<br />
EHEDG activities in Spain. A Spanish EHEDG website was<br />
created. Ainia has also published several newsletters about<br />
EHEDG and hygienic design that have been distributed<br />
among most of the Spanish food industries and many food<br />
equipment manufacturers.<br />
Recent activities<br />
Dissemination activities have been organized to spread<br />
relevant information on the EHEDG among Spanish speaking<br />
professionals. Different communication channels have been<br />
used for this purpose (ainia webpage, Tecnoalimentalia<br />
electronic bulletin, etc.).<br />
Representatives of the Regional Section participated as<br />
speakers with lectures related to the EHEDG and hygienic<br />
design in 6 events during 2011:<br />
• CED Annual Meeting. Detergency and Cosmetics.<br />
Barcelona. Rafael Soro<br />
• Meeting at FIAB (Association of food and beverages<br />
companies). Madrid. Andrés Pascual<br />
• Jornadas Técnicas sobre el mantenimiento en la<br />
Industria Alimentaria. AEM. Burgos. Irene Llorca<br />
• Seminar on clean rooms. AICE (Spanish Association of<br />
the Meat Industry). Madrid. Rafael Soro<br />
• Food Safety Master. Veterinary Faculty. Madrid. Irene<br />
Llorca<br />
• AMEC. Hygienic Design and Food Safety. Barcelona.<br />
Rafael Soro<br />
The fourth edition of the Advanced Course on Hygienic Design<br />
was held at Ainia in June 2012. As in previous occasions,<br />
both food industries and equipment manufacturers were<br />
represented among delegates. The 3-day course was<br />
presented from a very practical viewpoint, relating the<br />
theoretical fundamentals of the different subjects to practice<br />
by means of examples on video, pictures, samples and the<br />
EHEDG Toolbox. The course included some case studies<br />
that were developed in a pilot plant and was held by experts<br />
from the EHEDG Training & Education Subgroup. The<br />
course was given in English and Spanish, with simultaneous<br />
translation.<br />
The process of guideline translation has continued since<br />
its beginning in 2006. Currently, forty guidelines have been<br />
translated into Spanish, some of which them are already<br />
available from the EHEDG website. For some, review is still<br />
pending or the original guideline is being updated.<br />
Hygienic design course 2012 at Ainia<br />
Since the EHEDG webpage had been translated into<br />
Spanish in previous years, the activity now has turned into<br />
a continuous translation of updated contents. In November<br />
2011 a representative of the Regional Section was trained<br />
in webpage management to be able to keep the Spanish<br />
language contents updated and contribute with other<br />
national contents. These translation activities are considered<br />
crucial for the Regional Section since it is a very effective<br />
way of spreading EHEDG and hygienic design issues not<br />
only in Spain but also in other Spanish speaking countries.<br />
EHEDG World Congress on Hygienic<br />
Engineering and Design 2012 Spain<br />
The EHEDG World Congress 2012 will be held in<br />
Valencia-Spain, co-organized by EHEDG and ainia Centro<br />
Tecnológico. More than 20 experts coming from all over the<br />
world will offer lectures on topics related to hygienic design<br />
and other hygiene issues.<br />
Parallel activities are organised to complement and enrich<br />
the Congress programme. Among others, 1:1 business<br />
meetings have been arranged to encourage interaction and<br />
future business relations of the participants, as well as an<br />
exhibition area for companies and a posters sessions<br />
area.<br />
The Plenary Meeting of all EHEDG ExCo Members,<br />
Regional and Subgroup Chairpersons will take place on the<br />
pre-congress day at ainia’s facilities.<br />
More information on the Congress is available at www.<br />
<strong>ehedg</strong>-congress.org.<br />
Contact<br />
Rafael Soro Martorell<br />
ainia centro tecnológico<br />
c/ Benjanmin Franklin, 5-11<br />
Parque Tecnologico de Valencia<br />
46980 PATERNA (VALENCIA)<br />
SPAIN<br />
E-mail: rsoro@ainia.es
150 EHEDG Regional Sections<br />
EHEDG Switzerland<br />
Matthias Schäfer, e-mail: matthias.schaefer@gea.com<br />
It is one of the objectives of the EHEDG Regional Section<br />
Switzerland to promulgate the knowledge on “Hygienic<br />
Design” in Switzerland. Shortly after the foundation of<br />
the Regional Section, the Regional Committee agreed on<br />
following this objective by organising at least one seminar on<br />
“Hygienic Design” every year.<br />
One seminar was organised in 2010 at the biggest Swiss<br />
brewery “Feldschlösschen” belonging to the Carlsberg<br />
Group. More than 100 participants from three different<br />
countries came to enjoy six presentations on different topics<br />
related to “Hygienic Design” and of course also to participate<br />
in the brewery tour offered by “Feldschlösschen”.<br />
The 2011 seminar was hosted by “Bühler AG” in Switzerland.<br />
Our host is the biggest food machinery manufacturer in<br />
Switzerland and also a company member of EHEDG. About<br />
90 people joined this seminar to listen to six speakers coming<br />
from different food business related fields.<br />
It has to be mentioned that the EHEDG received great support<br />
from “Feldschlössen” and “Bühler” when they were hosting<br />
our seminars. Nevertheless it also has to be mentioned that<br />
the organisation of each seminar was a big effort for our<br />
small Regional Committee. People have worked hard to put<br />
the programs together and to find the right speakers and<br />
topics ensuring interesting and attractive lectures.<br />
The financial success of these seminars made it possible<br />
to give a direct financial support to the work of the EHEDG<br />
Subgroup “Cleaning Validation” which is headed by<br />
Dr. Rudolf Schmitt from the “University of Applied Sciences<br />
Western Switzerland” who also acts as the Chairman of the<br />
Regional Section.<br />
The next milestone of the development of this Regional<br />
Section was the completion and enhancement of the<br />
Regional Committee during the general assembly in 2012. A<br />
total of nine persons from different industries are now going<br />
to ensure that the successful work will continue. Thank you<br />
very much to all companies and people who have supported<br />
the work of the Regional Section Switzerland during the past<br />
two years. We can be proud that this “just” 4 year old section<br />
is already such a success story!<br />
Contact:<br />
Matthias Schäfer<br />
GEA Tuchenhagen GmbH<br />
Phone +41 61 936 37 40, Fax +41 61 936 37 49<br />
Mobile +41 79 304 80 43<br />
matthias.schaefer@gea.com<br />
Seminar at Bühler AG in Uzwil, Switzerland.<br />
EHEDG Taiwan<br />
A growing regional section outreaching in Far East<br />
B. Barry Yang, Ph.D., Director, Southern Taiwan Service Center, Food Industry R&D Institute,<br />
e-mail: bby@firdi.org.tw<br />
Seminar<br />
EHEDG Taiwan was present at a Hygienic Design Seminar held<br />
by the Bürkert Fluid Control Systems and Food Industry R&D Institute<br />
(FIRDI) in October of 2011. At this seminar, Dr. B. Barry Yang,<br />
Regional Section Chairman, gave his presentation introducing the<br />
EHEDG Guidelines and theirs relative applications. Moreover, an<br />
expert from Bürkert, Mr. Mike Rodd also talked about the importance<br />
of EHEDG and the industrial application of different types of<br />
connections. Besides, Ms Andrea Borowsky, manager of media &<br />
communications of the German Trade Office in Taipei also attended<br />
this seminar to give support to Bürkert as a company of German<br />
origin. Approximately 120 attendees from more than 40 companies,<br />
both from food processors and the machinery manufacturing industry,<br />
participated in this seminar.
EHEDG Regional Sections 151<br />
Translation of Guidelines<br />
At the present time, a total of 27 guidelines have been<br />
translated into Traditional Chinese. 12 of these are being<br />
corrected and proofread by experts in their special areas as<br />
required by these document subjects. These guidelines are<br />
scheduled to be submitted for publication by the end of 2012.<br />
The translation of the remaining Guidelines is under way.<br />
Training<br />
Dr. Yang gave an introduction of EHEDG guidelines at the Hygienic<br />
Design Seminar<br />
In order to facilitate training and practice for the hygienic<br />
design of food process equipment, FIRDI has set up a<br />
team to build a test laboratory for the EHEDG equipment<br />
assessing methods including Doc. 2, Doc. 4, Doc. 5, Doc.<br />
7, Doc. 15, Doc. 19, and Doc. 21. The major tasks of this<br />
team are to demonstrate the hygienic design concept of<br />
food equipment and its related validation methods to food<br />
equipment manufacturers and food processing companies.<br />
Contact<br />
For more information and if interested in the activities of<br />
EHEDG Taiwan, please contact Dr. B. Barry Yang, Phone:<br />
+886-6-3847301, e-mail: bby@firdi.org.tw.<br />
EHEDG Thailand<br />
Thai Regional Section<br />
Navaphattra Nunak, Taweepol Suesut, King Mongkut’s Institute of Technology Ladkrabang, Faculty of Engineering,<br />
Thailand, e-mail: kbnavaph@kmitl.ac.th<br />
EHEDG Thailand was established in 2009. The Thai Section<br />
was initiated between EHEDG centre and King Mongkut’s<br />
Institute of Technology Ladkrabang (KMITL). The Thai<br />
Section officially started on April 20, 2009. At present, just<br />
one Institute member from KMITL is member of EHEDG.<br />
However, several industrial companies are interested and<br />
attended the activities of the Thai Section.<br />
Translation<br />
• Guideline no. 8 has already been published on EHEDG<br />
website.<br />
• Guidelines no. 1, 11, 27, 28 and 37 have already been<br />
translated into Thai.<br />
• Guidelines no. 2, 4, 6, 10, 13, 14, 15, 17, 20, 23,<br />
24, 30, 32, 34 and 38 is now in the process of being<br />
translated.<br />
• Website Translation is also now in the process of being<br />
translated.<br />
EHEDG Thailand Seminar 2012<br />
There were two seminars on EHEDG guidelines in 2012. The<br />
first seminar was organised by EHEDG Thailand (KMITL),<br />
Kasetsart University and HABLA-Chemie GmbH and CPC-<br />
Holding Ltd, at KU, Bangkok on 25th June, 2012 under the<br />
topic of “Update on Environmental-friendly Cleaning and<br />
Sanitizing in the Food and Beverage Industry and Rapid<br />
Methods of Assessing Cleaning Efficiency” (Fig. 1). A<br />
second seminar was organized by EHEDG Thailand under<br />
the topic of “Hygienic application of Instruments for Food<br />
Industry” on July 27, 2012 at KMITL, Bangkok (Fig. 2). About<br />
50, 120 participants respectively attended the seminars. The<br />
participants could be divided into 4 groups as follows:<br />
• Government officers<br />
• Technical and engineering consultants<br />
• Owner and staffs from food factories<br />
• Students
152 EHEDG Regional Sections<br />
Figure 1. Update on Environmental-friendly Cleaning and<br />
Sanitizing in the Food and Beverage Industry and Rapid Methods<br />
of assess Cleaning Efficiency” (25th June 2012)<br />
Figure 2. “Hygienic application of Instruments for Food Industry” on<br />
27th, July 2012<br />
Contact Person<br />
For more information and if you are interested in the activities<br />
of EHEDG Thailand, please contact<br />
Dr. Navaphattra Nunak<br />
Email: kbnavaph@kmitl.ac.th<br />
Dr.Taweepol Suesut<br />
Email:kstaweep@kmitl.ac.th<br />
Phone: +66 2 3298356-8<br />
EHEDG Turkey<br />
Dr. Samim Saner, Turkish Food Safety Association (TFSA), Turkey, e-mail: samim.saner@ggd.com.tr<br />
News from a new Regional Section<br />
EHEDG Turkey was officially established at the 3rd Food<br />
Safety Congress which was held on May 3-4, 2012, in<br />
Istanbul. The event was hosted and organized by the Turkish<br />
Food Safety Association (TFSA) with about 700 delegates<br />
from Turkey and abroad. Dr. Patrick Wouters (Unilever,<br />
EHEDG Vice President) and Dirk Nikoleiski (Kraft Foods,<br />
EHEDG Executive Committee Member) were invited to<br />
lecture during the Hygienic Design Session of the Congress<br />
and experienced a lot of interest in their topics.<br />
On the second congress day, the EHEDG ‘By-Laws’ (Regional<br />
Section agreement) were officially signed by TFSA President<br />
Dr. Samim Saner, the Turkish Committee members and the<br />
above mentioned representatives of EHEDG International.<br />
Recent Activities<br />
EHEDG Turkey has formed its Regional Committee and<br />
immediately started its activities. The translation of the<br />
EHEDG website has already been completed. Starting in<br />
the 4th quarter of 2012, EHEDG Turkey is already busily<br />
translating EHEDG guidelines.<br />
An article about the EHEDG and its activities was published in<br />
Turkish Food Safety Magazine’s latest issue. This magazine<br />
is distributed to 5000 people consisting of food producers,<br />
food engineers, managers, equipment manufacturers and<br />
health authorities and will help to spread the news about<br />
EHEDG in Turkey.<br />
Contact<br />
For more information and if interested in the activities of<br />
EHEDG Turkey, please contact:<br />
Dr. Samim Saner<br />
Gida Güvenligi Dernegi<br />
TFSA - Turkish Food Safety Association<br />
Hasan Amir Sok. Dursoy Is Merkezi No.4<br />
KIZILTOPRAK ISTANBUL 34724<br />
TURKEY<br />
Phone: +90 0216 550 02 23 - 550 02 73<br />
E-mail: samim.saner@ggd.org.tr
EHEDG Regional Sections 153<br />
EHEDG Ukraine<br />
Prof. Yaroslav Zasyadko, National University of Food Technologies, Kyiv, e-mail: yaroslav@nuft.edu.ua<br />
In the years 2011 to 2012, the Ukrainian Regional EHEDG<br />
Section was engaged in a number of projects. As it has<br />
become our usual routine, the main effort has been assigned<br />
to the translation and adaptations of the EHEDG Guidelines<br />
to the Ukrainian State Standards where applicable. On top<br />
of the listed in the previous issue of EHEDG <strong>Yearbook</strong>, the<br />
following Guidelines are ready for publication:<br />
• Doc. 9 Welding stainless steel to meet hygienic<br />
requirements.<br />
• Doc. 10 Hygienic design of closed equipment for the<br />
processing of liquid food.<br />
Guidelines Doc. 11 through to Doc. 17 are currently in the<br />
process of being adaptated to the Ukrainian Standards.<br />
We have finalized translation of the EHEDG webpage into<br />
Ukrainian and also developed a website of the Ukrainian<br />
Regional EHEDG Section linked to the main EHEDG web<br />
site.<br />
The Ukrainian Regional EHEDG Section has developed<br />
a program of teaching materials including a syllabus of<br />
the MS lecture course “Food Safety and Hygienic Design<br />
and Operation of Food Manufacturing Equipment”. The 18<br />
hours course contains a brief account of food contamination<br />
sources, case studies, and practical examples. The course<br />
also contains the EHEDG cleanability testing procedure<br />
film subtitled in Ukrainian and Russian. The course will be<br />
introduced at the National University of Food Technologies<br />
(Kyiv) for MS students majoring in Mechanical Engineering<br />
in <strong>2013</strong> year.<br />
During this period we have held three EHEDG-UkrUFoST<br />
Conferences aimed at strengthening our relations with<br />
the industry, engagement of new members, and the<br />
popularisation of EHEDG practices.<br />
At the Conference held on April 4, we presented the<br />
Guidelines that had been properly prepared for publication<br />
and explained the procedure of EHEDG Certification to the<br />
representatives of the industry.<br />
In September 2012, the Ukrainian Regional EHEDG Section<br />
became a co-organizer of the Round Table which was<br />
conducted within a framework of the National Exhibition<br />
INTERPRODMASH. The issues of the EHEDG activities in<br />
the EU and in Ukraine were among the topics discussed at<br />
the Round Table. The representatives of Dutch companies<br />
active in Ukraine with their presentations paid special<br />
attention to the necessity to comply with the EHEDG<br />
Guidelines on every stage of the technological process.<br />
Huub Lilieveld, honorary representative of the EHEDG,<br />
co-chaired the event together with Professor Yaroslav<br />
Zasyadko, Ukrainian Regional EHEDG Section Executive<br />
Director, and gave comprehensive presentations describing<br />
the EHEDG activities.<br />
Recently, we have established a number of useful contacts<br />
with the industry and with the National Certification Bodies.<br />
UkrEHEDG were invited to give a presentation depicting<br />
the EU Food Safety Regulations and Legal Practices and<br />
the EHEGD activities by the Ukrainian State Enterprise<br />
UKRMETROTESTSTANDARD which is the main Ukrainian<br />
Body responsible for all aspects of certification, testing and<br />
standardisation of food products in Ukraine. As a result of<br />
the meeting we have jointly marked some steps that may<br />
lead to common projects in the future.<br />
Figure 1. The Round Table event. Co-chairs Huub Lelieveld and<br />
Yaroslav Zasyadko<br />
Figure 2. Yaroslav Zasyadko giving presentation about the EHEDG<br />
activities at the SE UkrMETRTESTSTANDARD<br />
Contact<br />
Prof. Yaroslav Zasyadko<br />
National University of Food Technologies Kyiv<br />
68, Volodymyrska Str.<br />
01033 KYIV<br />
UKRAINE<br />
E-mail: yaroslav@nuft.edu.ua
European Hygienic Engineering & Design Group<br />
EHEDG Guidelines<br />
EHEDG Guidelines can be ordered from the Webshop<br />
by non-members and individual members. They are<br />
free for EHEDG Company and Institute Members while<br />
Individual EHEDG Members receive a 50 % discount.<br />
Doc. 1. Microbiologically safe continuous<br />
pasteurisation of liquid foods<br />
First edition, November 1992 (17 pages)<br />
There are many reasons why, in practice pasteurised products<br />
sometimes present a microbiological health hazard. Due to<br />
distribution in residence time, not all products may reach the<br />
temperature required for pasteurisation or may do so for too<br />
short a time. Further there may be a risk of contamination<br />
with a non-pasteurised product, or the cooling medium. This<br />
document describes the requirements particularly for liquid<br />
foods without particulates.<br />
Languages available:<br />
Dutch, English, French, Spanish, Ukrainian<br />
Doc. 2. A method for assessing the in-place<br />
cleanability of food processing equipment<br />
Third edition, June 2007 (16 pages)<br />
The method is intended as a screening test for hygienic<br />
equipment design and is not indicative of the performance<br />
of industrial cleaning processes (which depend on the<br />
type of soil). See Doc 15 for a test procedure designed for<br />
moderately-sized equipment.<br />
Training DVD available.<br />
Languages available: Armenian, Dutch, English,<br />
French, German, Italian, Macedonian, Russian,<br />
Spanish<br />
Doc. 3. Microbiologically safe aseptic<br />
packing of food products<br />
First edition, January 1993 (15 pages)<br />
This guideline stresses the need to identify the sources of<br />
This guideline stresses the need to identify the sources of<br />
micro-organisms that may contaminate food in the packaging<br />
process, and to determine which contamination rates are<br />
acceptably low. It clarifies the difference in risk of infection<br />
between aseptic processing and aseptic packing and<br />
recommends that aseptic packing machines be equipped with<br />
fillers that are easily cleanable, suitable for decontamination<br />
and bacteria-tight. Requirements for the machine interior<br />
include monitoring of critical decontamination parameters.<br />
See also Doc. 21 on challenge tests.<br />
Languages available:<br />
Armenian, Dutch, English, French, Spanish,<br />
Ukrainian<br />
Doc. 4. A method for the assessment of<br />
in-line pasteurisation of food processing<br />
equipment<br />
First edition, February 1993 (12 pages)<br />
Food processing equipment that cannot be or does not need<br />
to be sterilised may need to be pasteurised to inactivate<br />
relevant vegetative micro-organisms and fungal spores.<br />
It is important to test the hygienic characteristics of such<br />
equipment to ensure that it can be pasteurised effectively.<br />
This document describes a test procedure to determine<br />
whether equipment can be pasteurised by circulation with<br />
hot water.<br />
Training DVD available.<br />
Languages available: Armenian, Dutch, English,<br />
French, Spanish, Ukrainian<br />
Doc. 5. A method for the assessment of<br />
in-line sterilisability of food processing<br />
equipment<br />
Second edition, July 2004 (9 pages)<br />
Food processing equipment may need to be sterilised before<br />
use, and it is important to ensure that the sterilisation method<br />
applied is effective. Thus, it is necessary to determine under<br />
which conditions equipment can be sterilised. This paper<br />
details the recommended procedure for assessing the<br />
suitability of an item of food processing equipment for in-line<br />
sterilisation. It is advisable to conduct in-place cleanability<br />
trials (ref. Doc.2) prior to this test in order to verify the<br />
hygienic design of the equipment.<br />
Training DVD available.<br />
Languages available: Armenian, Dutch, English,<br />
French, German, Macedonian, Spanish,<br />
Ukrainian<br />
Doc. 6. The microbiologically safe continuous<br />
flow thermal sterilisation of liquid foods<br />
First edition, April 1993 (26 pages)<br />
Thermal sterilisation is aimed at eliminating the risk of food<br />
poisoning and, when used in conjunction with aseptic filling,<br />
at achieving extended product storage life under ambient<br />
conditions. Whereas pasteurisation destroys vegetative<br />
micro-organisms, sterilisation destroys both vegetative<br />
micro-organisms and relevant bacterial spores. This<br />
document presents guidelines on the microbiologically safe<br />
continuous sterilisation of liquid products. The technique of<br />
Ohmic heating was not considered in this paper but may<br />
be included in an update being prepared. See Doc. 1 for<br />
guidelines on continuous pasteurisation of liquid foods.<br />
Training DVD available.<br />
Languages available: Armenian, Dutch, English,<br />
French, Macedonian, Spanish, Ukrainian
EHEDG Guidelines 155<br />
Doc. 7. A method for the assessment<br />
of bacteria tightness of food processing<br />
equipment<br />
Second edition, July 2004 (10 pages)<br />
This document details the test procedure for assessing<br />
whether an item of food processing equipment, intended<br />
for aseptic operation, is impermeable to micro-organisms.<br />
Small motile bacteria penetrate far more easily through<br />
microscopic passages than (non-motile) moulds and yeasts.<br />
The facultative anaerobic bacterium Serratia marcescens<br />
(CBS 291.93) is therefore used to test bacteria-tightness or<br />
the impermeability of equipment to micro-organisms. The<br />
method is suitable for equipment that is already known to be<br />
in-line steam sterilisable (see also Doc. 5).<br />
Training DVD available.<br />
Languages available: Armenian, Dutch, English,<br />
French, Spanish, Ukrainian<br />
Doc. 8. Hygienic equipment design<br />
criteria<br />
Second edition, April 2004 (16 pages)<br />
This guideline describes the criteria for the hygienic design<br />
of equipment intended for the processing of foods. Its<br />
fundamental objective is the prevention of the microbial<br />
contamination of food products. It is intended to appraise<br />
qualified engineers who design equipment for food processing<br />
with the additional demands of hygienic engineering in order<br />
to ensure the microbiological safety of the end product.<br />
Upgrading an existing design to meet hygiene requirements<br />
can be prohibitively expensive and may be unsuccessful<br />
and so these are most effectively incorporated into the initial<br />
design stage. The long term benefits of doing so are not<br />
only product safety but also increased life expectancy of<br />
equipment, reduced maintenance and consequently lower<br />
operating costs.<br />
This document, first published in 1993, describes in<br />
more detail the hygienic requirements of the Machinery<br />
Directive (98/37/EC ref.1). Parts of it have subsequently<br />
been incorporated in the standards EN1672-2 and EN ISO<br />
14159.<br />
Training DVD available<br />
Languages available: Armenian, Dutch, English,<br />
French, German, Italian, Japanese, Macedonian,<br />
Russian, Spanish, Thai, Ukrainian<br />
Doc. 9. Welding stainless steel to meet<br />
hygienic requirements<br />
First edition, July 1993 (21 pages) – update in progress<br />
since 2010 in conjunction with Doc. 35<br />
This document describes the techniques required to<br />
produce hygienically acceptable welds in thin walled (< 3<br />
mm) stainless steel applications. The main objective was<br />
to convey the reasons and requirements for hygienic<br />
welding and to provide information on how this may best<br />
be achieved. This document is superseded by Doc 35,<br />
recently published. The subgroup will continue with a<br />
guideline on inspection of the quality of welds in food<br />
processing machinery.<br />
Training DVD available<br />
Languages available: Dutch, English, French,<br />
Japanese, Macedonian, Spanish, Ukrainian<br />
Doc. 10. Hygienic design of closed<br />
equipment for the processing of liquid food<br />
Second edition, May 2007 (22 pages)<br />
Using the general criteria for the hygienic design of equipment<br />
identified in Doc 8, this paper illustrates the application of<br />
these criteria in the construction and fabrication of closed<br />
process equipment. Examples, with drawings, show how<br />
to avoid crevices, shadow zones and areas with stagnating<br />
product, and how to connect and position equipment in a<br />
process line to ensure unhampered draining and cleaning<br />
in-place. Attention is drawn to ways of preventing problems<br />
with joints, which might otherwise cause leakage or<br />
contamination of product.<br />
Training DVD available<br />
Languages available: Dutch, English, French,<br />
German, Italian, Macedonian, Russian,<br />
Ukrainian<br />
Doc. 11. Hygienic packing of food products<br />
First edition, December 1993 (15 pages)<br />
Products with a short shelf-life, or whose shelf life is<br />
extended by cold storage or in-pack heat treatments, do not<br />
have to conform to such strict microbiological requirements<br />
as aseptically packaged foods (Doc 3 discusses aseptic<br />
packing). This paper discusses the packing of food products<br />
that do not need aseptic packing but which nevertheless<br />
need to be protected against unacceptable microbial<br />
contamination. It describes guidelines for the hygienic<br />
design of packing machines, the handling of packing<br />
materials and the environment of the packing machines.<br />
See also Doc. 21.<br />
Languages available:<br />
Dutch, English, French, Spanish, Thai, Ukrainian<br />
Doc. 12. The continuous or semi-continuous<br />
flow thermal treatment of particulate foods<br />
First edition, March 1994 (28 pages)<br />
Thermal sterilisation is a process aimed at eliminating the<br />
risk of food poisoning and, when used in conjunction with<br />
aseptic filling, it aims to extend product storage life under<br />
ambient conditions. This is achieved by the destruction of<br />
vegetative micro-organisms and relevant bacterial spores.<br />
Liquid foods containing particulates are inherently more<br />
difficult to process than homogenous liquids due to heat<br />
transfer limitations in particulate-liquid mixtures and the<br />
additional problems of transport and handling. This paper<br />
presents guidelines on the design of continuous and semi-
156 EHEDG Guidelines<br />
continuous plants for the heat treatment of particulate foods.<br />
Ohmic heating techniques are not covered. See also Doc. 1<br />
on continuous pasteurisation and Doc. 6 on sterilisation of<br />
liquid products without particles.<br />
Languages available:<br />
Dutch, English, French, Spanish, Ukrainian<br />
Doc. 13. Hygienic design of equipment<br />
for open processing<br />
Second edition, May 2004 (24 pages) –<br />
update to be published in <strong>2013</strong><br />
It is important that the plant design takes into account<br />
factors affecting the hygienic operation and cleanability of<br />
the plant. The risk of contamination of food products during<br />
open processing increases with the with the concentration<br />
of micro-organisms in the environment and their opportunity<br />
to grow in poorly designed equipment. This means that<br />
in open plants, environmental conditions, in addition to<br />
appropriate equipment design, have an important influence<br />
on hygienic operation. The type of product and the stage<br />
of the manufacturing process must also be taken into<br />
consideration.<br />
This paper deals with the principal hygienic requirements for<br />
equipment for open processing and applies to many different<br />
types, including machines for the preparation of dairy<br />
products, alcoholic and non-alcoholic drinks, sweet oils,<br />
coffee products, cereals, vegetables, fruit, bakery products,<br />
meat and fish. It describes methods of construction and<br />
fabrication, giving examples as to how the principal criteria<br />
can be met. See also guidelines on hygienic design criteria<br />
Doc 8, hygienic welding Doc 9, and the hygienic design of<br />
equipment for closed processing Doc 10.)<br />
Languages available:<br />
Dutch, English, French, German, Italian,<br />
Japanese, Macedonian, Ukrainian<br />
Doc. 14. Hygienic design of valves for<br />
food processing<br />
Second edition, July 2004 (17 pages) –<br />
update in progress since 2009<br />
Valves are essential components of all food processing plants<br />
and the quality used strongly influences the microbiological<br />
safety of the food production process. These valves must<br />
therefore comply with strict hygienic requirements<br />
The guidelines apply to all valves used in contact with food<br />
or food constituents that are to be processed hygienically<br />
or aseptically. Aside from general requirements with regard<br />
to materials, drainability, microbial impermeability and other<br />
aspects, additional requirements for specific valve types are<br />
also described. See also Doc. 20 on double-seat mixproof<br />
valves.<br />
Training DVD available.<br />
Languages available: Dutch, English, French,<br />
Italian, Macedonian, Spanish<br />
Doc. 15. A method for the assessment of<br />
in-place cleanability of moderately-sized food<br />
processing equipment<br />
First edition, February 1997 (12 pages)<br />
This document describes a test procedure for assessing<br />
the in-place cleanability of moderately sized equipment,<br />
such as homogenisers. The degree of cleanliness is based<br />
on the removal of a fat spread soil, and is assessed by<br />
evaluating the amount of soil remaining after cleaning by<br />
visual inspection and swabbing of the surface. This method<br />
is not as sensitive as the microbiological method described<br />
in Doc. 2.<br />
Languages available:<br />
Armenian, Dutch, English, German, Macedonian,<br />
Spanish, Ukrainian<br />
Doc. 16. Hygienic pipe couplings<br />
First edition, September 1997 (21 pages)<br />
This paper identifies and defines critical design parameters<br />
for welded pipe couplings: easily cleanable in-place; easily<br />
sterilisable in place; impervious to micro-organisms, reliable<br />
and easy to install.<br />
Gaskets of various types were tested for reliability and<br />
hygienic aspects using EHEDG cleanability test methods<br />
and repeated sterilisation. The objective was to provide a<br />
reliable dismountable joint which is bacteria-tight at the<br />
product side under the conditions of processing, cleaning<br />
and sanitation.<br />
Training DVD available.<br />
Languages available: English, French, German,<br />
Ukrainian<br />
Doc. 17. Hygienic design of pumps,<br />
homogenisers and dampening devices<br />
Second edition, September 2004 (16 pages) -<br />
update to be published in <strong>2013</strong><br />
This paper sets the minimum requirements for pumps,<br />
homogenisers and dampening devices for hygienic<br />
and aseptic applications. The scope includes all pumps<br />
intended for use in food processing, including centrifugal,<br />
piston, lobe rotor, diaphragm, screw and gear pumps. The<br />
requirements also apply to valves integral to the pump<br />
head and the complete homogeniser head. Design aspects<br />
and the characteristics of materials, surfaces and seals<br />
are discussed and additional requirements for aseptic<br />
equipment are identified. This document is currently being<br />
updated.<br />
Training DVD available.<br />
Languages available: English, French, German,<br />
Italian, Macedonian
EHEDG Guidelines 157<br />
Doc. 18. Passivation of stainless steel<br />
First edition, August 1998 (13 pages) –<br />
update to be published in <strong>2013</strong><br />
Passivation is an important surface treatment that helps<br />
assure the successful corrosion resistant performance of<br />
stainless steel used for product contact surfaces (eg. tubing/<br />
piping, tanks and machined parts used in pumps, valves,<br />
homogenisers, de-aerators, process monitoring instruments,<br />
blenders, dryers, conveyors, etc).<br />
The purpose of this document is to provide manufacturers,<br />
users and regulatory personnel with basic information and<br />
guidelines relative to equipment passivation. The complete<br />
passivation process is described and environmental, as well<br />
as safety, concerns are discussed.<br />
Training DVD available.<br />
Languages available: Armenian, Dutch, English,<br />
French, German, Macedonian, Russian,<br />
Spanish,<br />
Doc. 19. A method for assessing<br />
the bacterial impermeability of hydrophobic<br />
membrane filters<br />
First edition, June 2000 (9 pages)<br />
Research has shown that hydrophobic membrane filters,<br />
with a pore size of 0.22µm, do not retain micro-organisms<br />
under all process conditions. Investigations were conducted<br />
into risk assessment of sterilising hydrophobic membrane<br />
filters, evaluating the performance of the filters under a<br />
range of operating conditions.<br />
To validate the bacterial retention ability of sterilising grade<br />
hydrophobic membrane filters, a bacterial aerosol challenge<br />
test methodology was developed.<br />
Languages available:<br />
Dutch, English, Spanish<br />
Doc. 20. Hygienic design and safe use of<br />
double-seat mixproof valves<br />
First edition, July 2000 (20 pages) –<br />
update in progress since 2009<br />
This document describes the basic hygienic design and<br />
safe use of single-body double-seat mixproof valves. Today,<br />
food process plants incorporate various multifunctional flow<br />
paths. Often one piping system is cleaned while another<br />
still contains product. This simultaneous cleaning can<br />
potentially result in the dangerous situation where product<br />
and cleaning liquid are separated by just one single valve<br />
seat. Any cleaning liquid that leaks across such a seat will<br />
contaminate the product. Therefore, often two or three<br />
single seat valves in a “block-and-bleed” arrangement are<br />
applied.<br />
Training DVD available.<br />
Languages available: Dutch, English, French,<br />
Japanese, Macedonian, Russian<br />
Doc. 21. Challenge tests for the<br />
evaluation of the hygienic<br />
characteristics of packing machines<br />
for liquid and semi-liquid products<br />
First edition, July 2000 (32 pages)<br />
After documents 3 and 11, this is the third test method<br />
in the series. It discusses how packing machines should<br />
be designed to comply with hygiene design criteria and<br />
thereby with the requirements specified in Annex 1 of the<br />
Machinery Directive1. To determine whether those criteria<br />
are met requires validation of the design and measurement<br />
of essential parameters. Proven methods for testing the<br />
performance of the various functions of packing machines<br />
are described.<br />
These methods may also be used by the manufacturer to<br />
optimise or redesign a packing machine and by the food<br />
processor who may want to compare different packing<br />
machines.<br />
Upon delivery, a packing machine needs to be checked by a<br />
commissioning procedure to be agreed in advance between<br />
the food processor and the supplier. Commissioning may<br />
include physical as well as microbiological tests. Additional<br />
tests are specified for commissioning of machines for<br />
aseptic packing.<br />
1 Machinery Directive 98/37/EC – Annex 1, point 2.1, Agrifoodstuffs<br />
machinery<br />
Languages available:<br />
Armenian, English, French, Macedonian,<br />
Russian, Spanish<br />
Doc. 22. General hygienic design criteria<br />
for the safe processing of dry particulate<br />
materials<br />
First edition, March 2001 (23 pages) –<br />
update in progress since 2012<br />
Dry food processing and handling requires equipment that<br />
are different from those typically associated with wet and<br />
liquid products. This is the first in a series of documents<br />
that go beyond equipment design and covers installation<br />
and associated practices. In the case of dry materials, other<br />
considerations include material lump formation, creation of<br />
dust explosion conditions, high moisture deposit, formation<br />
in the presence of hot air, and material remaining in the<br />
equipment after shutdown. Appropriate cleaning procedures<br />
are described, dry cleaning being favoured to reduce risks<br />
of contamination.<br />
Languages available:<br />
Dutch, English, French, Macedonian, Russian,<br />
Spanish
158 EHEDG Guidelines<br />
Doc. 23. Production and use of food-grade<br />
lubricants, Part 1 and 2<br />
Second edition, May 2009 (Part 1: Use of H1<br />
Registered Lubricants - 23 Pages / Part 2: Production<br />
of H1 Registered Lubricants - 10 Pages)<br />
Lubricants, grease and oil are necessary components<br />
for the lubrication, heat transfer, power transmission<br />
and corrosion protection of machinery, machine parts,<br />
instruments and equipment. Incidental contact between<br />
lubricants and food cannot always be fully excluded and<br />
may result in contamination of the food product. This risk<br />
applies to all lubricants equally. PART 1 of this guideline<br />
covers the hazards that may occur when using food grade<br />
lubricants and describes the actions and activities required<br />
to eliminate them or to reduce their impact or occurrence<br />
to an acceptable level. PART 2 of this guideline lays<br />
down the general requirements and recommendations<br />
for the hygienic manufacturing and supply of food-safe<br />
lubricants.<br />
Training DVD available.<br />
Languages available: Dutch, English, French,<br />
German, Japanese, Macedonian, Spanish<br />
Doc. 24. The prevention and control of<br />
legionella spp (incl. legionnaires’ disease)<br />
in food factories<br />
First edition, August 2002 (21 pages)<br />
There are many locations in food industry sites where the<br />
potential for the proliferation of Legionella spp in water<br />
systems exists. These bacteria can give rise to a potentially<br />
fatal disease in humans, which is identified as legionellosis<br />
or legionnaires’ disease.<br />
This document applies to the control of Legionella spp. in<br />
any undertaking involving a work activity and to premises<br />
controlled in connection with a trade, business or other<br />
undertaking where water is used or stored and where there<br />
is a means of transmitting water droplets which may be<br />
inhaled, thereby causing a reasonably foreseeable risk of<br />
exposure to Legionella spp.<br />
The guidelines summarises the best practice for controlling<br />
Legionella in water systems. It consists of two parts; namely,<br />
Management Practices and Guidance on the Control of<br />
Legionella spp. in Water Systems.<br />
The first section describes a management programme:<br />
risk identification and assessment; risk management (incl<br />
personnel responsibilities); preventing or controlling risk of<br />
exposure to the bacteria; and record keeping.<br />
The second part provides guidance on the design and<br />
construction of hot and cold water systems as well as the<br />
management and monitoring of these systems. Water<br />
treatment programmes, with attention to cleaning and<br />
disinfection, are also discussed.<br />
Languages available:<br />
Dutch, English, Macedonian<br />
Doc. 25. Design of mechanical seals for<br />
hygienic and aseptic applications<br />
First edition, August 2002 (15 pages) –<br />
update in progress since 2012<br />
This guideline compares the design aspects of different<br />
mechanical seals with respect to ease of cleaning, microbial<br />
impermeability, sterilisability or pasteurisability. It can<br />
serve as a guide for suppliers and users of this important<br />
component. Using EHEDG definitions, mechanical seals<br />
are classified according to use in the food industry into<br />
three categories: Aseptic, Hygienic equipment Class I,<br />
and Hygienic Equipment Class II. Both single and dual<br />
mechanical seals fall under the first two categories, which by<br />
definition, are subject to more stringent hygienic demands.<br />
General design criteria and basic material requirements for<br />
food applications are explained. Materials covered include<br />
carbon-graphite, ceramics, elastomers and metals. Hygienic<br />
implications of seal elements and components are also<br />
discussed. Finally, installation requirements are described<br />
and illustrated, taking into account the product environment<br />
side, the flushing side and the cartridge design.<br />
Languages available:<br />
Armenian, English, German<br />
Doc. 26. Hygienic engineering of plants for<br />
the processing of dry particulate materials<br />
First edition, November 2003 (30 pages)<br />
This document describes general engineering guidelines<br />
to be applied to ensure that buildings, individual equipment<br />
items and accessibility of equipment when integrated within<br />
the plant layout are designed so that aspects of the process<br />
operation, cleaning and maintenance comply with hygienic<br />
design standards. It details requirements related to plant<br />
enclosure, including hygienic zoning, building structures<br />
and ele¬ments (from floor to ceiling) as well as process line<br />
installation. Attention is also given to air stream and water<br />
related aspects within the plant as well as cleaning and<br />
contamination aspects. See also Doc. 22.<br />
Languages available:<br />
Dutch, English, French, Macedonian, Spanish<br />
Doc. 27. Safe storage and distribution of<br />
water in food factories<br />
First edition, April 2004 (16 pages)<br />
Water is a vital medium used for many different purposes in<br />
the food industry. Systems for storing and distributing water<br />
can involve hazards, which could cause water quality to fall<br />
below acceptable standards. It is therefore critical to ensure<br />
that water storage and distribution in a food manufacturing<br />
operation takes place in a controlled, safe way. This Guideline<br />
summarizes the best practice for three water categories<br />
used in the food industry: product water, domestic water and<br />
utility water. See also Doc. 24.<br />
Languages available:<br />
Armenian, Dutch, English, French, Macedonian,<br />
Spanish
EHEDG Guidelines 159<br />
Doc. 28. Safe and Hygienic Water Treatment<br />
in Food Factories<br />
First edition, December 2004 (21 pages)<br />
Water is a vital medium used for many different purposes<br />
in the food industry. Systems for storing and distributing<br />
water can involve hazards, which could cause water quality<br />
to fall below acceptable standards. It is therefore critical<br />
to ensure that water storage and distribution in a food<br />
manufacturing operation takes place in a controlled, safe<br />
way. This Guideline summarizes the best practice for three<br />
water categories used in the food industry: product water,<br />
domestic water and utility water. See also Doc. 24.<br />
Languages available:<br />
Armenian, English, French, Spanish<br />
Doc. 29. Hygienic design of packing systems<br />
for solid foodstuffs<br />
First edition, December 2004 (24 pages)<br />
This document addresses packing systems of solid food<br />
products and supplements earlier guidelines. Solid food<br />
is characterised as having a water activity of >0.97, low<br />
acid, not pasteurised or sterilised after packaging, and<br />
distributed through the cool chain. Examples include fresh<br />
meat and some meat products, cheeses, ready meals, cut<br />
vegetables, etc. Hygiene requirements of the packaging<br />
operations, machinery as well as personnel, are described<br />
and reference is made to the American Meat Institute’s<br />
principles of sanitary design. See also Docs. 3 and 11.<br />
Languages available:<br />
Armenian, Dutch, English, Macedonian<br />
Doc. 30. Guidelines on air handling<br />
in the food industry<br />
First edition, March 2005 (43 pages) –<br />
update in progress since 2012<br />
The controlled properties of air, especially temperature and<br />
humidity, may be used to prevent or reduce the growth rate<br />
of some micro-organisms in manufacturing and storage<br />
areas. The particle content - dust and micro-organisms -<br />
can also be controlled to limit the risk of product<br />
contamination and hence contribute to safe food<br />
manufacture. Airborne contaminants are commonly<br />
removed by filtration. The extent and rate of their removal<br />
can be adjusted according to acceptable risks of product<br />
contamination and also in response to any need for dust<br />
control.<br />
These guidelines are intended to assist food producers<br />
in the design, selection, installation, and operation of air<br />
handling systems. Information is provided on the role of<br />
air systems in maintaining and achieving microbiological<br />
standards in food products. The guidelines cover the<br />
choice of systems, filtration types, system concepts,<br />
construction, maintenance, sanitation, testing,<br />
commissioning, validation and system monitoring. They<br />
are not intended to be a specification for construction of<br />
any item of equipment installed as part of an air handling<br />
system. Each installation needs to take account of local<br />
requirements and specialist air quality engineers should<br />
be consulted, to assist in the design and operation of the<br />
equipment.<br />
Languages available:<br />
Armenian, English, Macedonian<br />
Doc. 31. Hygienic engineering of fluid bed<br />
and spray dryer plants<br />
First edition, May 2005 (19 pages)<br />
Because these plants handle moist products in an airborne<br />
state, they are susceptible to hygiene risks, including<br />
a possible transfer of allergens between products. It is<br />
therefore critical to apply hygienic design considerations to<br />
both the process and machinery to prevent occurrence of<br />
such risks.<br />
Starting from the basics with regard to design, construction<br />
materials, layout, and zone classification of the drying<br />
systems to meet hygienic requirements, this paper outlines<br />
component design aspects of the processing chamber, with<br />
particular attention to the atomization assembly and the<br />
distribution grids for fluidization. Systems for both supply<br />
and exhaust air should operate in a hygienic manner and<br />
recommendations for the use and installation of various<br />
types of filters are listed. Finally, operational aspects,<br />
including sampling, control and general housekeeping are<br />
briefly discussed.<br />
Languages available:<br />
Dutch, English, Spanish<br />
Doc. 32. Materials of construction for<br />
equipment in contact with food<br />
First edition, August 2005 (48 pages) –<br />
update in progress since 2012<br />
This guideline aims to offer a practical ‘handbook’ for those<br />
responsible for the specification, design and manufacture of<br />
food processing equipment. It offers guidance on the ways in<br />
which materials may behave such that they can be selected<br />
and used as effectively as possible. The properties and<br />
selection procedures with regard to metals, elastomers and<br />
plastics are covered in detail. Potential failure mechanisms<br />
and influenced of manufacturing processes are also<br />
discussed. A more general overview of composites, ceramics<br />
and glass and materials is provided.<br />
The guideline can serve as an aide-memoir during the design<br />
process, so that equipment manufacturers and end-users<br />
can together ensure that all aspects of materials behaviour<br />
are taken into account in designing safe, hygienic, reliable<br />
and efficient equipment which can be operated, maintained<br />
and managed economically.<br />
Training DVD available.<br />
Languages available: Armenian, English, French,<br />
Italian, Macedonian
160 EHEDG Guidelines<br />
Doc. 33. Hygienic engineering of<br />
discharging systems for dry particulate<br />
materials<br />
First edition, September 2005 (16 pages)<br />
The introduction of the product into the processing system<br />
is a key step in maintaining the sanitation and integrity of<br />
the entire process. Discharging systems are designed to<br />
transfer, in this case dry solids, from one system into another<br />
without powder spillage, contamination or environmental<br />
pollution. Many dry systems do not have any additional<br />
protective heating steps, as they are merely specialty<br />
blending processes. Therefore, any contamination that<br />
enters the system will appear in the finished product.<br />
Guidelines for the design of bag, big bag, container and<br />
truck discharging systems are presented. They are intended<br />
for use by persons involved in the design, sizing, and<br />
installation of bag, big bag and truck discharging systems<br />
operating under hygienic conditions.<br />
Languages available:<br />
Dutch, English, Spanish<br />
Doc. 34. Integration of hygienic and<br />
aseptic systems<br />
First edition, March 2006 (45 pages)<br />
Hygienic and/or aseptic systems comprise inter alia<br />
individual components, machinery, measurement systems,<br />
management systems and automation that are used to<br />
produce for example food products, medicines, cosmetics,<br />
home & personal products and even water products.<br />
This horizontal guideline is about the hygienically safe<br />
integration of hygienic (including aseptic) systems in a food<br />
production/ processing facility.<br />
Systems and components are frequently put together in a<br />
way that creates new hazards, especially microbiological<br />
ones. Deficiencies during the sequence of design,<br />
contract, design-change, fabrication, installation and<br />
commissioning are often the cause of these failures,<br />
even when specific design guidelines are available and<br />
are thought to be well understood. Errors in sequencing<br />
and content can also result in major penalties in terms<br />
of delays and in costs of components and construction.<br />
This document examines integration aspects that can<br />
affect hygienic design, installation, operation, automation,<br />
cleaning and maintenance and uses system flow charts<br />
and case studies describing the integration processes and<br />
decision steps. It does not provide detailed guidance on<br />
specific manufacturing processes, products, buildings or<br />
equipment.<br />
Training DVD available.<br />
Languages available: Armenian, English, Italian,<br />
Macedonian<br />
Doc. 35 Welding of stainless steel tubing<br />
in the food industry<br />
First edition, July 2006 (29 pages) - update in progress<br />
since 2010 in conjunction with Doc. 9<br />
Abundantly illustrated, this paper provides guidelines for<br />
the correct execution of on-axis hygienic (sanitary) welding<br />
between pipe segments, or between a tube and a control<br />
component (e.g. valve, flow meter, instrument tee, etc.) It<br />
deals with tube and pipe systems with less than 3.5 mm wall<br />
thickness, built in AISI 304(L) (1.4301, 1.4306 or 1.4307),<br />
316(L) (1.4401, 1.4404 or 1.4435), 316Ti (1.4571) or 904L<br />
(1.4539) and their equivalents. The requirements for a<br />
weld destined for hygienic uses are first described, then<br />
the possible defects which can affect the weld are listed,<br />
and at the end the procedure for a state-of-the-art welding<br />
execution is illustrated, including preparation of pipe ends,<br />
final inspection and a trouble shooting guide.<br />
It mainly refers to the part of the weld in contact with the<br />
finished or intermediate product and the only welding method<br />
considered is the GTAW (Gas Tungsten Arc Welding,<br />
commonly known as TIG) without filler material (autogenous<br />
weld), since this technique is capable of assuring the best<br />
performance in the execution of welds for the fabrication of<br />
thin wall stainless steel tubing. Inspection of welds will be<br />
covered in more detail in the next project.<br />
Training DVD available.<br />
Languages available: Dutch, English, French,<br />
German, Macedonian, Spanish<br />
Doc. 36. Hygienic engineering of transfer<br />
systems for dry particulate materials<br />
First edition, June 2007 (21 pages)<br />
Transfer (also known as transport or conveying) of dry<br />
particulate materials (products) between or within plant<br />
components in a process line is well practiced in the food<br />
industry. The transfer operation must be carried out in<br />
a hygienic and safe manner and the physical powder<br />
properties must not be affected during this operation. In this<br />
document, hygienic transfer systems for transport of bulk<br />
materials within a food processing plant are described. This<br />
document also covers situations where transfer systems are<br />
used as a dosing procedure.<br />
In principle, the less the need for product transfer within<br />
a food processing plant, the easier it is to make a factory<br />
hygienically safe. Furthermore, with a minimum of product<br />
transfer between equipment, there are the added advantages<br />
of a more compact plant, lower energy consumption and<br />
reduced cleaning time. Less product handling results in less<br />
adverse effects on product properties.<br />
This guideline is intended for use by persons involved in<br />
the design, technical specification, installation and use of<br />
transfer systems for dry bulk particulate materials operating<br />
under hygienic conditions.<br />
Languages available:<br />
Dutch, English, French, Macedonian
EHEDG Guidelines 161<br />
Doc. 37. Hygienic design and application<br />
of sensors<br />
First edition, November 2007 (35 pages)<br />
According to their working principles, all sensors rely on an<br />
interaction with the material to be processed. Therefore, the<br />
use of sensors is commonly associated with hygiene risks.<br />
In many cases, the basic measuring aspect of a sensor and<br />
the optimum hygienic design may conflict.<br />
This guideline is intended to advise both, sensor designers<br />
and manufacturers as well as those in charge of production<br />
machinery, plants and processes about the appropriate<br />
choice of sensors and the most suitable way for application<br />
in dry and wet processes.<br />
Sensors are crucial in the monitoring of the critical process<br />
steps as well as the CCP´s as established by the HACCP<br />
study of the process. Therefore validation and calibration of<br />
sensors in time sequences are essential.<br />
This guideline applies to all sensors coming into contact<br />
with liquids and other products to be processed hygienically.<br />
However, it focuses upon sensors for the most common<br />
process parameters, particularly temperature, pressure,<br />
conductivity, flow, level, pH value, dissolved oxygen<br />
concentration and optical systems like turbidity or colour<br />
measurements.<br />
Languages available:<br />
English, French, German, Macedonian<br />
Doc. 38. Hygienic engineering of rotary<br />
valves in process lines for dry particulate<br />
materials<br />
First edition, September 2007 (13 pages)<br />
Rotary valve selection and operation has a considerable<br />
influence on the hygiene standard of a process line and<br />
thus, the end-product quality of the dry material handled.<br />
Incorrect selection of valve type and size must be regarded<br />
as a serious hygienic risk in the food industry. Hence, only<br />
valves strictly conforming to hygienic design standards<br />
and suited for hygienic operations must be used.<br />
This guideline applies to rotary valves that are in contact<br />
with dry particulate food and/or food related materials<br />
being processed hygienically in designated dry particulate<br />
material processing areas. The objective of this guideline<br />
is to provide guidance on the essential requirements for<br />
hygienic rotary valve design and operation. The guideline<br />
is intended for persons involved in the design, selection,<br />
sizing, installation and maintenance of rotary valves<br />
required to operate under hygienic conditions.<br />
Languages available:<br />
Armenian, English, French, Spanish<br />
Doc. 39. Design principles for<br />
equipment and process areas for<br />
aseptic food manufacturing<br />
First edition, June 2009 (14 pages)<br />
In many areas there is an increasing demand for self stable<br />
products. However, microbial product contamination limits<br />
the shelf life of sensitive products which are not protected by<br />
any preservatives or stabilised by their formulation. Products<br />
which fail this inherent protection have to be sterilised<br />
and in consequence, the equipment must be cleanable<br />
and sterilisable. Micro-organisms which are protected by<br />
product residues or biofilms are very difficult or impossible<br />
to inactivate and the same applies to process areas if<br />
resulting in a recontamination risk. This guideline is intended<br />
to describe the basic demands for equipment and process<br />
areas for aseptic food manufacturing.<br />
Languages available:<br />
English, French, Spanish<br />
Doc. 40. Hygienic engineering of valves<br />
in process lines for dry particulate materials<br />
First edition, October 2010 (26 pages)<br />
Every process plant is equipped with valves. In dry<br />
particulate materials processing, valves fulfil numerous<br />
functions: shut-off and opening of flow lines, direction and<br />
flow control, protection against excessive or insufficient<br />
pressure and against intermixing of incompatible media<br />
at intersection points in the process. The quality of the<br />
valve has a considerable influence on the quality of the<br />
production process and hence, the product itself. Hygienic<br />
deficiencies resulting from poor valve design must be<br />
regarded as a production risk in the food industry which<br />
must ensure that only valves strictly conforming to hygienic<br />
requirements are used. This Guideline describes in detail<br />
the hygienic requirements of butterfly valves, slide gate<br />
valves and ball segment valves. It also briefly mentions<br />
pinch-off valves, ball and plug valves as well as cone<br />
valves. The hygienic design requirements of rotary and<br />
diverter valves are subject of separate EHEDG Documents<br />
(Doc. 38 and 41).<br />
Languages available:<br />
English, French, Spanish<br />
Doc. 41. Hygienic engineering of diverter<br />
valves in process lines for dry particulate<br />
materials<br />
First edition, February 2011 (23 pages)<br />
Every process plant is equipped with valves, which fulfil<br />
numerous functions. These include line shut-off, opening,<br />
change-over and control of product flow, while also giving<br />
protection against both excessive or insufficient pressure<br />
and intermixing of incompatible media at intersection points<br />
in the process line.
162 EHEDG Guidelines<br />
When dry particulate material (product) flow has to be<br />
diverted into several directions during processing or product<br />
coming from different lines converges into one line, diverter<br />
valves are applied. In the area of dry product handling, these<br />
valves need a dedicated design.<br />
This Guideline deals with the hygienic aspects of diverter<br />
valve design.<br />
Valve construction, however, has a considerable influence on<br />
the quality of the production process and hence, the product<br />
itself. Hygienic deficiencies resulting from poor valve design<br />
must be regarded as a production risk in the food industry<br />
which must ensure that only valves strictly conforming to<br />
hygienic requirements are used.<br />
Languages available:<br />
English<br />
This guideline covers the hygienic aspects of disc stack<br />
centrifuges used to separate fractions of liquid food products<br />
or to remove dense solid matter from products. The hygienic<br />
operation of a disc stack centrifuge, which is a complex<br />
machine with the purpose of collecting non-milk-solids<br />
(NMS) or other solid matter from liquid products, relies on<br />
proper cleaning by CIP/COP. Therefore, this guideline deals<br />
with cleaning as well as design.<br />
The guideline does not cover cyclonic types of separators,<br />
decanters, basket centrifuges or other types of devices.<br />
Languages available:<br />
English<br />
Doc. 42. Disc stack centrifuges<br />
First edition, April <strong>2013</strong> (24 pages)<br />
Special demands are made with regard to CIP-capability<br />
of disc stack centrifuges used in the food processing<br />
and pharmaceutical industry. These requirements, their<br />
implementation and related design principles are handled in<br />
detail in this guideline.<br />
Webshop:<br />
http://www.world-of-engineering.eu/EHEDG:::390.html
European Hygienic Engineering & Design Group<br />
EHEDG Congresses<br />
Share our know-how and enhance your hygienic design network!<br />
The EHEDG World Congress on Hygienic Engineering<br />
& Design from 7 – 8 November 2012 in Valencia / Spain<br />
was a gathering of more than 260 delegates from 24<br />
countries world-wide who are decision makers, food<br />
safety and quality specialists, engineers and designers<br />
as well as other high level representatives of food-related<br />
industries and academia. During 25 lectures various<br />
topics were discussed including the role that EHEDG<br />
plays to help ensuring food safety, e. g. the principles<br />
and latest developments in hygienic equipment and<br />
factory design, the layout of a hygienic process<br />
environment and the adequate use of construction<br />
materials, advanced welding technology, EHEDG test<br />
methods and certification as well as new trends in<br />
cleaning and disinfection.<br />
Sponsoring companies found excellent opportunities<br />
for presenting themselves at the congress venue of the<br />
Chamber of Commerce Valencia and the programme<br />
was enriched by scientific poster presentations, One to<br />
One business meetings, face-to-face expert talks and<br />
many opportunities for experience exchange.<br />
The next opportunity for sharing in this high-level expert platform will be the<br />
EHEDG World Congress<br />
on Hygienic Engineering & Design<br />
from 30-31 October <strong>2014</strong> in Parma/Italy<br />
in conjunction with Cibus Tec.<br />
We kindly invite you to participate and details are available from www.<strong>ehedg</strong>-congress.org.
European Hygienic Engineering & Design Group<br />
EHEDG Subgroups<br />
Within the EHEDG a number of international experts gathered in Subgroups are responsible for<br />
the development of Guidelines. Each Subgroup is responsible for an area of expertise, and within<br />
each area certain specific scopes are defined.<br />
The EHEDG Subgroup specialists meet regularly to update<br />
existing and draw up new Guidelines. They originate from<br />
many different countries ensuring the international validity of<br />
the work. Participants with the relevant expertise are always<br />
welcome to join these Subgroups and share in the work and<br />
contribute their expertise and point of view.<br />
EHEDG is grateful for the participation of these volunteers<br />
who share their expertise and invest their time for the<br />
advancement of EHEDG – for the good of all. Without these<br />
excellent specialists the good work of EHEDG would not be<br />
possible as it is.<br />
New guidelines still in the process of being<br />
drawn up are<br />
• Building design<br />
• Cleaning validation<br />
• Conveyor systems<br />
• Hygienic design requirements for the processing of<br />
fresh fish<br />
• Meat processing between slaughtering and packaging<br />
• Seals<br />
• Test methods /Test institutes<br />
• Dry Materials Handling<br />
• Bakery Equipment<br />
• Tank cleaning systems<br />
Currently under revision:<br />
• Hygienic design of equipment for open processing<br />
(Doc. 13)<br />
• Hygienic design of valves for food processing (Doc. 14<br />
and 20)<br />
• Design of mechanical seals for hygienic and aseptic<br />
applications (Doc 25)<br />
• Chemical treatment of stainless steel (to substitute<br />
Doc 18: Passivation of stainless steel)<br />
• Materials of construction for equipment in contact with<br />
food (Doc 32)<br />
• Hygienic welding of stainless steel tubing in the food<br />
processing industry (Doc 9 and 35)<br />
• Guidelines on air handling in the food industry<br />
(Doc 30)<br />
The following guideline topics are currently<br />
being planned:<br />
• CIP / Hygienic brushes<br />
• Food refrigeration<br />
• Pasteurization of liquid food”, Doc. 6 “The<br />
microbiologically safe continuous flow thermal<br />
sterilisation of liquid foods”, Doc. 12 “The continuous<br />
or semi-continuous flow thermal treatment of<br />
particulate foods”<br />
• Update of EHEDG Guidelines on “Packaging”<br />
(Doc. 3, 11, 21, 29)<br />
• Update of EHEDG Guidelines on “Water treatment”<br />
(Doc. 27 and 28)<br />
EHEDG Subgroup “Air handling”<br />
Dr. Thomas Caesar, e-mail: Thomas.Caesar@Freudenberg-Filter.com<br />
The Subgroup Air Handling is currently editing and revising<br />
the Guideline<br />
• Doc 30 Guidelines on Air Handling in the Food Industry<br />
to bring it up to date. The last issue dates back to 2005 and<br />
is in need of revision.<br />
A wide range of food products must be protected against<br />
airborne contamination during the manufacture and primary<br />
packing stages. Subject to a product risk assessment air<br />
hygiene and quality control is one of a number of factors<br />
necessary that promote good manufacturing practice to<br />
ensure that safe, wholesome food is produced. These<br />
Guidelines are intended to assist food producers in the
EHEDG Subgroups 165<br />
design, selection, installation, and operation of air handling<br />
systems with regard to hygienic requirements. Information<br />
is provided on the role of air systems in maintaining and<br />
achieving microbiological standards in food products. The<br />
guidelines cover the choice of systems, filtration types,<br />
system concepts, construction, maintenance, sanitation,<br />
testing, commissioning, validation and system monitoring.<br />
Compared to the previous version, the scope in the ongoing<br />
revision, has been narrowed and focused on air handling<br />
systems used for building ventilation and to make up<br />
atmospheric pressure process supply air. Supply systems for<br />
pressurized air and exhaust air systems such as grease filter<br />
systems or dust removal units are excluded from the scope<br />
of the document. These systems are significantly different<br />
from the air handling systems dealt with in this document<br />
and require their own Guidelines.<br />
Chairman:<br />
Dr. Thomas Caesar<br />
Freudenberg Filtration Technologies SE & Co. KG<br />
69465 Weinheim<br />
Germany<br />
Phone: +49 (6201) 80-2596<br />
Fax: +49 (6201) 88-2596<br />
E-mail: thomas.caesar@freudenberg-filter.com<br />
EHEDG Subgroup “Hygienic Building Design”<br />
Dr. John Holah, e-mail: j.holah@campden.co.uk<br />
With its inaugural meeting on 4th October 2011, the Building<br />
Design Subgroup is tasked with providing guidelines on<br />
all aspects of construction detail relating to the hygienic<br />
design of food factories – a significant challenge given<br />
the complexity and diversity of operations in a global field.<br />
Some 18 participants attended the first meeting – a healthy<br />
cross section of producers, consultants, contractors and<br />
building product manufacturers ensured productive debate.<br />
Whilst comprehensive design guidelines exist at an<br />
individual food manufacturer or organisation level there are<br />
no public documents. This situation may give rise to different<br />
specifications from food producers with the potential to<br />
cause conflict for building suppliers in their ability to meet<br />
all requirements. It was accepted that a common reference<br />
would be extremely valuable to the industry.<br />
A focus was decided on food processing operations with<br />
the remit covering detailed hygienic design in wet and dry<br />
factories. Furthermore the guidance should acknowledge<br />
EU legislation and the Global Food Safety Initiative. It was<br />
envisaged that the document would consist of text but be<br />
rich in illustrations, ideally showing both ‘good’ and ‘bad’<br />
examples.<br />
Given the complex nature of building design and construction<br />
the group decided to define what should be included in terms<br />
of hygienic requirements. Agreement was made on the<br />
following aspects:<br />
• Defence against external hazards<br />
• Defence against internal hazards –<br />
• Internal flows to prevent cross-contamination<br />
• Security against deliberate contamination<br />
• Maintaining hygienic conditions via structure rigidity<br />
• Maintaining hygienic conditions via material<br />
durability<br />
• Compliance with customer/GFSI best practice<br />
A separate working group was set up for floors, drains,<br />
kerbs and doors – coordinated by Martin Fairley of ACO.<br />
Work groups like this present a fantastic opportunity to<br />
pull together experience and expertise from a variety<br />
of perspectives to the benefit of the industry as a<br />
whole; however there can clearly be cases for conflict<br />
between competing technologies or between competing
166 EHEDG Subgroups<br />
manufacturers within the same technology field. A number<br />
of mechanisms have allowed successful conclusion to the<br />
work groups’ tasks, including:<br />
• The breadth of the groups experiences - the flooring<br />
team consisted of manufacturers, academics, and a<br />
national agency, the drainage team had more than one<br />
representative from each company.<br />
• Where competition is direct, then work toward common<br />
agreement before wider group presentation.<br />
• The interrelationships between building components –<br />
for example floors and drains.<br />
• Intermediate stage presentation of intended structure<br />
of the proposal at the central Building Design Group<br />
meetings.<br />
Taking part in the extra meeting the flooring group had<br />
representation from ANSES - Brigitte Carpentier; Argelith<br />
– Volker Aufderhaar; BASF Ucrete – Phillip Ansell; with<br />
further input from Prof Vladimir Kakurinov. Key themes<br />
of the flooring group included a hygienic floors checklist;<br />
challenges in flooring; gradients; joints, materials; installation<br />
and waterproofing.<br />
The Drainage group from ACO – Martin Fairley, Vaclav<br />
Kralicek and Jiri Lonicek; and Blucher Metal A/S – Martin<br />
Frølund and Palle Madsbjerg. Key themes from the drainage<br />
group included flow and capacity, layout, application areas<br />
and examples, materials, installation considerations and<br />
floor interface details, maintenance and cleaning. Input from<br />
the door industry was supplied solely by manufacturer coolit<br />
– Kristian Kissing. Many others have made contribution to<br />
these teams as they progressed.<br />
As might be expected such an extensive overall work<br />
programme from the Building Design Group has potential<br />
to raise issues worthy of debate; one such issue related to<br />
the definition of segregation and zoning – critical elements<br />
of overall hygienic design principles in modern production<br />
facilities. A separate work group comprising of 5 participants<br />
(Kraft Foods, Unilever, Cargill, Heinz and Campden BRI), is<br />
to further the discussion on this central topic. Zone definitions<br />
could include:<br />
• Factory site – between the perimeter fence and the<br />
building envelope<br />
• Non food production area, e.g. locker rooms, canteens/<br />
restaurants, smoking areas, boiler rooms, workshops,<br />
machinery rooms, laboratories, offices, meeting rooms,<br />
living accommodation<br />
• Enclosed product areas, e.g. warehouses, despatch<br />
areas, cleaning stores<br />
• Raw material processing zone, e.g. slaughter house,<br />
vegetable washing, waste disposal<br />
• General processing zone, e.g. ingredients suitable for<br />
further processing, exposed packaging and processed<br />
products often termed Low risk, Low care or GMP<br />
areas<br />
• Controlled zones for decontaminated products,<br />
microbiologically driven and often termed High Care<br />
or High Risk areas for chilled RTE products or the<br />
Primary Salmonella Control Area for dry RTE products<br />
• Controlled equipment, e.g. clean to aseptic handling<br />
and filling<br />
It is anticipated that the Group will have its draft proposals<br />
in place by the end of 2012 or the beginning of <strong>2013</strong>. If it is<br />
met then a substantial piece of work has been produced in a<br />
relatively short timescale of just a little over a year – a great<br />
achievement.<br />
Chairman:<br />
Dr. John Holah<br />
Campden BRI<br />
Food Hygiene Department<br />
Chipping Campden<br />
GLOUCHESTERSHIRE GL55 6LD<br />
GREAT BRITAIN<br />
e-mail: j.holah@campden.co.uk<br />
phone: (+44 1386) 84 20 41<br />
EHEDG Subgroup<br />
“Chemical Treatment of Stainless Steel”<br />
Dr. Gerhard Hauser, e-mail: gerhardwrhauser@yahoo.de<br />
The task of the group was to review EHEDG Doc.18<br />
“Passivation of Stainless Steel” published in 1998 which<br />
gives essential recommendations to one of the most<br />
important properties of stainless steels for product contact<br />
surfaces in the food and beverage industry.<br />
Food equipment manufacturers and users choose stainless<br />
steels as the predominant material of construction because<br />
of their excellent mechanical properties combined with a<br />
high level of corrosion resistance and cleanability. The latter<br />
two attributes are the primary determinants of the material’s<br />
hygienic behaviour. They rely upon the ‘passive surface<br />
layer’, a chromium-rich oxide film which naturally forms on<br />
all stainless steels. This layer is adequately protective for the<br />
vast majority of food and beverage applications.
EHEDG Subgroups 167<br />
Given a clean surface and sufficient oxygen from the air<br />
or from water, stainless steels will naturally and rapidly<br />
establish a tenacious passive layer on all exposed surfaces.<br />
If the passive layer is physically damaged during or after<br />
the fabrication of the equipment, it must be afforded the<br />
opportunity to repair itself, which it will do rapidly as soon as<br />
the surface is clean and exposed to oxygen again.<br />
Nevertheless, for particularly demanding applications,<br />
the strength of the passive layer can be improved by a<br />
treatment known as chemical passivation. For highly-critical<br />
applications, the hygienic quality of the surface can be even<br />
further enhanced by electro-polishing. However, the need for<br />
the enhancement of the passive layer should be regarded as<br />
the exception rather than the rule.<br />
The heat of welding can destroy the passive layer local to<br />
the weld and leave a distinctive, coloured ‘heat-tint’ which<br />
will exhibit reduced resistance to corrosion. In this case<br />
welding must be followed by a pickling procedure specifically<br />
designed to remove heat-tint and allow the passive layer to<br />
reform naturally.<br />
Pickling, chemical passivation and electro-polishing should<br />
be seen as separate treatments and not as alternatives. Each<br />
treatment should only be carried out with care. It also must<br />
be remembered that the chemical used for those treatments<br />
in an integrated system may adversely affect elastomeric,<br />
plastic and glass materials. It is therefore important to apply<br />
to assembled equipment only surface treatments which are<br />
appropriate to all the materials with which they might come<br />
into contact.<br />
Because of the described different influences to ensure<br />
and improve the hygienic performance of the product<br />
contact surface, the group decided to integrate pickling,<br />
and electro-polishing in addition to passivation into the new<br />
draft “Chemical Treatment of Stainless Steel”. It was finished<br />
during the last meeting in August 2012 and has been<br />
submitted to the EHEDG Guideline approval procedure.<br />
Chairman:<br />
Dr. Gerhard Hauser<br />
Goethestr 43<br />
85386 Eching<br />
E-mail: gerhardwrhauser@yahoo.de<br />
Fax (+49 81 61) 71 42 42<br />
EHEDG Subgroup “Cleaning Validation”<br />
Dr. Rudolf Schmitt, rudolf.schmitt@hevs.ch<br />
In June 2011 the Subgroup “Cleaning Validation” became<br />
active. More than 30 participating experts in this group<br />
are ample proof for the strong interest in this particular<br />
subject.<br />
The purpose of this Subgroup is to prepare a new EHEDG<br />
guideline on the basics and principles of “Cleaning<br />
Validation” in the food sector. An inadequate cleaning<br />
process may result in residue being carried forward.<br />
This residue may then contaminate the next batch to be<br />
manufactured in the same equipment.<br />
The most significant contaminants in the food sector<br />
are product from the previous batch, microorganisms,<br />
allergens, cleaning agents and lubricants.<br />
Cleaning validation is necessary to prove the consistency<br />
and effectiveness of established procedures that have<br />
been found acceptable. This document shall describe<br />
how design principles and the qualification of equipment<br />
are employed in a validation scheme that gives<br />
documentary evidence of the effectiveness of the cleaning<br />
procedure.<br />
The guideline shall cover validation in the food sector in<br />
a general way and can be applied for different purposes.<br />
However, the development of further specific guidelines<br />
for particular applications i.e. the validation of CIP, the<br />
validation of manual cleaning, the validation of dry<br />
cleaning, and the validation of disinfection, is strongly<br />
recommended.<br />
Chairman:<br />
Dr. Rudolf Schmitt<br />
HES-SO Valais<br />
Institute of Life Technologies<br />
Rue du Rawyl 64<br />
1950 Sion<br />
Switzerland<br />
Phone +41 27 6068611<br />
Fax +41 27 606 86 15<br />
E-mail rudolf.schmitt@hevs.ch
168 EHEDG Subgroups<br />
EHEDG Subgroup “Conveyor Systems”<br />
Jon J. Kold, e-mail: jk_innovation@yahoo.com<br />
In January 2011 the EHEDG Subgroup “Conveyor Systems”<br />
became active.<br />
The group has collected a huge amount of material and is in<br />
the process of editing the content.<br />
The purpose of the Subgroup is to prepare a new EHEDG<br />
Guideline on the hygienic design of conveyor systems to be<br />
used in food manufacturing or processing. The Subgroup<br />
consists of approximately 15 professionals from companies<br />
and institutions. This underlines the industry’s broad interest<br />
in the subject.<br />
Conveyor systems are widely used in food manufacturing<br />
for moving raw materials, processed food and packaged<br />
products. The upcoming guideline is primarily aimed at<br />
conveyors used in high risk areas, i.e. the processing of<br />
non-packaged foods in direct contact with the conveyor or<br />
transported in open boxes.<br />
There are several reasons to reduce the hygiene risk by<br />
applying hygienic design to conveyor systems.<br />
The guideline may be used as a communication tool<br />
between purchasing companies and suppliers making sure<br />
that new conveyors comply with hygienic requirements<br />
specification.<br />
The Subgroup “Conveyor Systems” is chaired by EHEDG<br />
Denmark who have previously elaborated a guideline for<br />
hygienic deign of conveyers for the food industry.<br />
Hygienic design of conveyor systems<br />
The hygienic design of conveyor systems is complex and<br />
demanding. Many solutions with regard to function, design,<br />
cleanability and service of the equipment must be considered<br />
thoroughly.<br />
The equipment should be as open as possible for easy<br />
accessibility and cleaning. The number of guards should<br />
be minimised to what is necessary for reasons of safety<br />
and should not prevent efficient cleaning. Guards should<br />
be removable during cleaning/disinfection, either through<br />
opening or by unhinging.<br />
Topics which are being dealt with during the working period:<br />
• Different types of belts<br />
• Lateral guides for belts<br />
• Lateral guides for product<br />
• Drive stations<br />
• Drum motors<br />
• Gear motors<br />
• CIP cleaning systems<br />
Time schedule<br />
The new guideline is intended to be finalized within the next<br />
12 – 18 months.<br />
If you are interested in joining this Subgroup please contact<br />
the chairman, Mr. Jon J. Kold, jon.kold@staalcentrum.dk, or<br />
the EHEDG Secretariat jana.huth@<strong>ehedg</strong>.org.<br />
Chairman<br />
Jon Kold<br />
Fredensvang 38<br />
7600 STRUER<br />
DENMARK<br />
Phone:(+45 40) 57 13 46<br />
E-mail: jk_innovation@yahoo.com<br />
EHEDG Subgroup “Dry Materials Handling”<br />
Karel Mager, e-mail: karel.mager@givaudan.com<br />
When the EHEDG started in 1989 most of the available<br />
knowledge on hygienic design was about liquid handling and<br />
liquid processing equipment.<br />
In the following years a couple of documents about test<br />
methods and design principles concerning this topic were<br />
published.<br />
In the area of dry particulate materials (powders) there was a<br />
need for similar documents: design principles and guidance<br />
for hygienic engineering for the safe processing of dry<br />
particulate materials.<br />
The subgroup started in 1998 and since then has published<br />
eight documents.<br />
Published guidelines<br />
• Doc. 22 General hygienic design criteria for the safe<br />
processing of dry particulate materials (2001)
EHEDG Subgroups 169<br />
• Doc. 26 Hygienic engineering of plants for the<br />
processing of dry particulate materials (2003)<br />
• Doc. 31 Hygienic engineering of fluid bed and spray<br />
dryer plants (2005)<br />
• Doc. 33 Hygienic engineering of discharging systems<br />
for dry particulate materials (2005)<br />
• Doc. 36 Hygienic engineering of transfer systems for<br />
dry particulate materials (2007)<br />
• Doc. 38 Hygienic engineering of rotary valves in<br />
process lines for dry particulate materials (2008)<br />
• Doc. 40 Hygienic engineering of valves in process lines<br />
for dry particulate materials (2010)<br />
• Doc. 41 Hygienic Engineering of Diverter Valves in the<br />
Dry Materials Handling Area (2011)<br />
Currently the subgroup is working on a document one<br />
powder pack-off systems.<br />
Furthermore, members of the subgroup have been active in<br />
the organization of conferences, seminars and workshops.<br />
Participants have also contributed by giving several lectures<br />
in the area of Dry Materials Handling.<br />
The work of this Subgroup attracts a great deal of interest.<br />
Many requests to join this Subgroup and share the workload<br />
have led to the decision to start a second group which will<br />
deal with other aspects of similar topics. This Subgroup has<br />
yet to get started.<br />
Chairman:<br />
Karel Mager<br />
Givaudan Nederland B.V.<br />
Huizerstraatweg 28<br />
1411 GP Naarden<br />
Netherlands<br />
Phone: +31 35 6 99 21 86<br />
Fax: +31 35 6 94 37 19<br />
E-mail: karel.mager@givaudan.com<br />
EHEDG Subgroup “Fish Processing”<br />
Dr. Sanya Vidacek, e-mail: svidacek@pbf.hr<br />
The future EHEDG document “Hygienic Design<br />
Requirements for the Processing of Fresh Fish” will<br />
describe and illustrate how the design principles of the<br />
EHEDG Guidelines<br />
• Doc. 8 Hygienic Equipment Design Criteria<br />
and<br />
• Doc. 13 Hygienic Design of Equipment for Open<br />
Processing<br />
can be applied to the mechanised and/or automated<br />
processing of fish.<br />
This document will cover the processing of fresh fish<br />
from grading, gutting, de-heading, deboning, pin-boning,<br />
trimming, filleting, skinning and portioning (including<br />
its ice producing system) until packaging. Its scope will<br />
not, however, cover further fish processing including the<br />
smoking, cooking, frying, marinating etc. or the manual<br />
processing of fish.<br />
Specific hygienic risks related to the fish and the processing<br />
conditions will be defined. The document will describe the<br />
specific hygienic requirements of the processing lines and<br />
the processing environment as well as the requirements for<br />
water and ice and hygienic fish packaging. Cleaning and<br />
disinfection practices and environmental issues associated<br />
with fish processing will be discussed.<br />
So far, the Subgroup has identified the risks and is putting<br />
together the requirements for the hygienic processing of<br />
such a sensitive product. The guideline is due to be finished<br />
in the course of <strong>2013</strong>.<br />
Chairman:<br />
Dr. Sanya Vidacek<br />
University of Zagreb.<br />
Faculty of Food Technology&Biotechnology<br />
Pierottijeva 6<br />
10000 Zagreb<br />
Croatia<br />
Phone: +385 1 4 60 51 26<br />
Fax: +385 1 4 60 50 72<br />
E-mail: svidacek@pbf.hr
170 EHEDG Subgroups<br />
EHEDG Subgroup “Materials of Construction<br />
for Equipment in Contact with Food”<br />
Eric Partington, e-mail: eric@effex.co.uk<br />
EHEDG Doc. 32 “Materials of Construction for Equipment<br />
in Contact with Food” offers practical guidance about the<br />
ways in which materials may behave such that they can be<br />
selected and used as effectively as possible. The Guideline<br />
is intended to serve as an aide-memoir during the design<br />
process, so that equipment manufacturers and end-users<br />
can together ensure that all aspects of materials behaviour<br />
can be taken into account in designing safe, hygienic, reliable<br />
and efficient equipment which can be operated, maintained<br />
and managed economically.<br />
The Guideline was first published in 2005. Its 54 pages<br />
addressed legislation, materials behaviour, hygienic design<br />
and cleanability. The materials covered included metallics,<br />
elastomers, plastics, composites, ceramics and glasses,<br />
and the characteristic ways in which each group of materials<br />
behaves were discussed. Potential failure mechanisms were<br />
identified, together with the conditions under which there is<br />
the greatest risk of them occurring.<br />
But since that first issue was written, much has changed in<br />
the world of Food Contact Materials including revisions of<br />
the Framework Directive and the Machinery Directive, new<br />
constraints on the selection and application of some nonmetallic<br />
materials, advances in composites, glasses and<br />
anti-microbial materials and the advent of nano-materials. It<br />
is now time for Doc. 32 to be reviewed and updated.<br />
A successful first meeting of the re-formed SG Materials of<br />
Construction was held on 27 June 2012. It established a<br />
base for the revision of Doc 32 ― the structure of the new<br />
Guideline would generally follow the format of the original,<br />
each group of materials (e.g: metallics, plastics, elastomers,<br />
ceramics) being discussed in its own separate section<br />
prepared by a small team of experts in those materials.<br />
The SG Materials of Construction currently comprises<br />
experts in legislation, metals, cleanability and some areas<br />
of plastics and elastomers but would welcome offers of<br />
assistance in the fields of ceramics, glasses, composites,<br />
anti-microbial surface treatments and biocidal materials,<br />
metallic surface coatings and intelligent materials where<br />
they apply to Materials of Construction. If you would like to<br />
participate in the updating of Doc. 32, the secretariat and the<br />
Chairman would be very pleased to hear from you.<br />
Chairman:<br />
Eric Partington<br />
Nickel Institute<br />
Well Croft<br />
Ampney St. Mary<br />
Gloucestershire GL7 5SN<br />
United Kingdom<br />
Phone: +44 1285 610 014<br />
E-mail: eric@effex.co.uk<br />
EHEDG Subgroup<br />
“Hygienic Design of Meat Processing Equipment”<br />
Dr. Aleksandra Martinovic, e-mail: aleksmartinovic@t-com.me<br />
In March 2011, the new EHEDG Subgroup “Hygienic design<br />
of meat processing equipment” again became active after a<br />
long period since the first kick off meeting held in Belgrade<br />
in 2009.<br />
The purpose of the subgroup is to develop a guideline to<br />
specify and illustrate the hygienic design of machinery<br />
and equipment used in the meat processing industry. The<br />
document will provide guidance by highlighting good and<br />
bad design examples as well as by describing installations,<br />
operations and maintenance of such equipment according<br />
to the state-of-the-art achievements in the field. The scope<br />
of the new EHEDG guideline in progress will focus on ‘Meat<br />
processing between slaughtering and packaging’.<br />
The subgroup consists of some 15 professionals from<br />
companies and institutions. This underlines the industry’s<br />
broad interest in the subject.<br />
Poorly designed equipment may increase the risk of<br />
contamination of food products such as meat and meat<br />
products with micro-organisms, and different stages of<br />
processing and manufacturing may demand different levels<br />
of hygienic design. The fundamental principle, however, is<br />
that the design of any piece of equipment must not allow any<br />
increase in the concentration of relevant contaminants.<br />
The guideline will cover the hygienic aspects of equipment<br />
design, engineering unit processes, transportation systems,<br />
production procedures, cleaning and disinfection procedures<br />
and specific environmental requirements.
EHEDG Subgroups 171<br />
It will address different types of equipment in connection<br />
with the various operations during meat processing, such<br />
as: deboning and trimming, freezing, cutting and slicing,<br />
marinating, tumbling, mixing and grinding, forming and<br />
coating as well as other types of handling devices.<br />
Time schedule<br />
The new guideline is intended to be finalized within the next<br />
24–30 months. It is planned to have three meetings per year<br />
to evaluate progress.<br />
New participants from manufacturers of meat<br />
processing equipment and machinery welcome<br />
Additional experts in this field who wish to contribute to the<br />
workare welcome.<br />
If you are interested in joining this Subgroup please contact<br />
the chairman, Dr. Aleksandra Martinovic or the EHEDG<br />
Secretariat.<br />
Chairman:<br />
Dr. Aleksandra Martinovic<br />
University of Montenegro<br />
Biotechnical Faculty<br />
Mihaila Lalica 1<br />
81 000 Podgorica<br />
Montenegro<br />
Phone: +382 69 737 403<br />
E-mail: aleksmartinovic@t-com.me<br />
EHEDG Subgroup “Open Equipment”<br />
Guideline on Essential Hygienic Design Requirements for Equipment used In Open Processes<br />
Dr. Gerhard Hauser, e-mail: gerhardwrhauser@yahoo.de; Dr. Jürgen Hofmann, e-mail: jh@hd-experte.de<br />
The objective is to cover all equipment in food and beverage<br />
processing plants between the ceiling, floor, and walls<br />
which are not intended to be in direct contact with food. In<br />
this context the term equipment comprises all items which<br />
are supposed to have a potential impact on product safety<br />
when integrated into open equipment machinery or open<br />
processes (axillaries items, integration items).<br />
The decision as to whether an item has an adverse influence<br />
or not must be based on a risk assessment. It must decide<br />
what kind of equipment design is essential and how<br />
equipment must be cleaned (CIP, automatically with foam,<br />
or manually) to avoid cross-contamination.<br />
The basic strategy for selecting hygiene measures for the<br />
design shall include:<br />
• identification of the process for which the equipment is<br />
intended;<br />
• identification of hazards associated with the product(s)<br />
produced;<br />
• risk assessment associated with each hazard<br />
identified;<br />
• hygienic design methods/measures which can<br />
eliminate hazards or reduce risks associated with<br />
these hazards;<br />
• means of verification of the effectiveness of the hazard<br />
elimination - or the risk reduction method;<br />
• description of residual risks and any additional<br />
precautions necessary in the information for use<br />
where applicable.<br />
The subgroup is divided into 3 working groups to achieve<br />
more effectiveness.<br />
• The topics of Group 1 contain the design of (e.g.)<br />
cables and their connections, field busses, wiring,<br />
cable trays, sensor installation, HMI, signal devices,<br />
lamps and pneumatics.<br />
• Group 2 deals mainly with motors and gear boxes,<br />
pumps, process connections, covers, and thermal<br />
insulation.<br />
• Group 3 is involved in (e.g.) climate units, control<br />
boxes, enclosures and mountings, movable equipment<br />
with wheels, steel structures, frameworks and<br />
supporting feet.<br />
At the last Subgourp meeting (January 2012) the input of<br />
the groups has been discussed and partly integrated into<br />
the final draft.<br />
Chairmen:<br />
Dr.-Ing. Gerhard Hauser<br />
Goethestr. 43<br />
85386 Eching<br />
gerhardwrhauser@yahoo.de<br />
Dr. Jürgen Hofmann<br />
Fichtenweg 8 a<br />
85604 Zorneding<br />
(+49 8161) 8 76 87 99<br />
jh@hd-experte.de
172 EHEDG Subgroups<br />
EHEDG Subgroup<br />
“Pumps, Homogenisers and Dampening Devices”<br />
Ralf Stahlkopf, e-mail:ralf.stahlkopf@gea.com<br />
For the last four years the Subgroup has worked on the 3rd<br />
revised edition of the EHEDG Guideline and will be finished<br />
in spring <strong>2013</strong>.<br />
• Doc. 17 “Hygienic Design of Pumps, Homogenisers<br />
and Dampening Devices”<br />
The revised edition is scheduled to be published in 2012.<br />
The objective of this Guideline is to provide a set of minimum<br />
requirements for pumps, homogenisers and dampening<br />
devices for hygienic and aseptic applications, to ensure that<br />
food products are processed hygienically and safely.<br />
These requirements will apply to all pumps intended for<br />
use in food processing, including centrifugal pumps, piston<br />
pumps, lobe rotor pumps, peristaltic pumps, diaphragm<br />
pumps, water ring pumps, progressive cavity pumps, screw<br />
pumps, and gear pumps and also to homogenisers and<br />
dampening devices. It will include any valves integral with<br />
the pump head and the complete homogeniser head.<br />
A classification of the pumps discussed is provided together<br />
with illustrations and pictures to explain graphically the<br />
issues, problems (such as gabs and dead-ends) and their<br />
solutions.<br />
Chairman:<br />
Ralf Stahlkopf<br />
GEA Tuchenhagen GmbH<br />
Am Industriepark 2-10<br />
21514 Büchen<br />
Germany<br />
Phone +49 4155 49 25 78<br />
Fax +49 4155 48 27 76<br />
E-mail: ralf.stahlkopf@geagroup.com<br />
EHEDG Subgroup “Seals”<br />
Dr. Till Riehm, e-mail: till.riehm@fst.com<br />
The Guideline “Seals” covers all aspects of seals and<br />
seal design relevant to the construction of hygienic<br />
equipment for food processing and packaging. It details<br />
both the European and international regulations currently<br />
applicable to elastomeric seals used in the food and<br />
beverage industry. It then discusses the general design<br />
principles which have to be taken into consideration when<br />
designing a sealing point and it includes a practical guide<br />
on failure analysis.<br />
In conjunction with the Sub-Group “Materials of<br />
Construction” (Doc. 32) it was decided that “Materials of<br />
Construction” should describe the properties of elastomers,<br />
leaving the Guideline Seals to recommend basic seal<br />
design principles and to discuss which parameters have to<br />
be taken into consideration according to the surrounding<br />
conditions.<br />
The Guideline “Seals” therefore identifies both the relevant<br />
legislation and the most critical design parameters and then<br />
gives hands-on advice for the construction and design of<br />
such components.<br />
Chairman:<br />
Dr. Till Riehm<br />
Freudenberg Process Seals GmbH & Co. KG<br />
Lorscher Str. 13<br />
69469 Weinheim<br />
Germany<br />
Phone: +49 6201 80 89 19 00<br />
Fax: +49 6201 88 89 19 69<br />
E-mail: till.riehm@freudenberg-ds.com
EHEDG Subgroups 173<br />
EHEDG Subgroup “Separators”<br />
Reinhard Moss, e-mail: reinhard.moss@gea.com<br />
The Subgroup Separators is working on a new EHEDG<br />
document dealing with the hygienic aspects of disc stack<br />
centrifuges. These machines are used to separate fractions<br />
with different densities of liquid food products or to remove<br />
dense solid matter from products. Doc. 42 “Disc Stack<br />
Centrifuges” will be finished in spring <strong>2013</strong>.<br />
Many of the design principles applicable to this kind of<br />
equipment are already shown in the EHEDG Guidelines<br />
Doc. 8 Hygienic equipment design criteria; Doc. 9 Welding<br />
stainless steel to meet hygienic requirements; Doc. 10<br />
Hygienic design of closed equipment for the processing of<br />
liquid food; Doc. 16 Hygienic pipe couplings<br />
• Doc. 9 Welding stainless steel to meet hygienic<br />
requirements<br />
• Doc. 10 Hygienic design of closed equipment for the<br />
processing of liquid food<br />
• Doc. 16 Hygienic pipe couplings<br />
• Doc. 17 Hygienic design of pumps, homogenizers and<br />
dampening devices<br />
• Doc. 32 Materials of construction for equipment in<br />
contact with food<br />
• Doc. 35 Welding of stainless steel tubing in the food<br />
Industry<br />
The document was revised several times and descriptions<br />
for the hygienic design of special areas were added. Also<br />
illustrations, drawings and pictures were added to get<br />
the sanitary problem zones across to the users of the<br />
guideline.<br />
The Subgroup has defined specific rules applicable to the<br />
CIP-cleaning capability of separators which are not yet<br />
covered by existing EHEDG documents. Also other special<br />
hygienic design features necessary for this kind of machinery<br />
are also described.<br />
A final draft of the Guideline is currently going through the<br />
EHEDG Guideline approval process.<br />
Chairman:<br />
Reinhard Moß<br />
GEA Mechanical Equipment<br />
GEA Westfalia Separator Group GmbH<br />
Operative Technical Services<br />
Phone: +49 2522 77-2571<br />
Fax: +49 2522 77-32571<br />
Mobile: +49 172 536 8803<br />
E-mail: reinhard.moss@gea.com<br />
EHEDG Subgroup “Tank Cleaning”<br />
Design of tanks for cleanability and using cleaning devices<br />
Bo Boye Busk Jensen, e-mail: bobb.jensen@alfalaval.com<br />
The workgroup started at the beginning of 2012. The<br />
objective of the guideline has been discussed and is currently<br />
described as:<br />
“This guideline is intended to provide recommendations on<br />
cleaning aspects and hygienic design of vessels. It is limited<br />
to product contact surfaces of tanks for liquid processing,<br />
both vertical, horizontal and of any arbitrary shape. Excluded<br />
are the selection of chemistry and temperature for cleaning<br />
specific products.”<br />
The guideline will cover many different aspects related to the<br />
hygienic design of tanks, their appurtenances, the installation<br />
of such in tanks and the cleaning technology chosen for CIP<br />
cleaning. The focus of the guideline is on how the differences<br />
in the choice of tank cleaning technology influence the<br />
hygienic design criteria for appurtenances used in and on<br />
tanks. The available tank cleaning technology and its design<br />
will be presented from the point of view of its functionality in<br />
order to allow users to make the most sensible choice of tank<br />
cleaning equipment for their tank, tank design and product.<br />
The cleaning mechanisms during tank cleaning somewhat<br />
differ from those encountered in a closed pipe system. The<br />
tanks and appurtenances are rarely cleaned by a pressurized<br />
liquid flowing through the tank, but rather by a film or local<br />
high impact cleaning. Also, the category of soil may influence<br />
the best value for money choice when selecting tank cleaning<br />
technology and cleaning strategy.<br />
Finally, validation of tank cleaning is also included as this is<br />
a prerequisite for a satisfactory and consistent cleaning of a<br />
Chairman:<br />
Bo Boye Busk Jensen<br />
Alfa Laval Tank Equipment A/S<br />
Baldershoej 19<br />
2635 ISHOEJ<br />
DENMARK<br />
Phone: (+45 43) 55 86 88<br />
Fax: (+45 43) 55 86 03<br />
E-mail: bobb.jensen@alfalaval.com
174 EHEDG Subgroups<br />
EHEDG Subgroup “Test Methods”<br />
The EHEDG Test Methods Subgroup was one of the first Subgroups established by EHEDG and is<br />
responsible for publishing test methods, defining validation criteria and providing assessments<br />
of equipment according to the hygienic design criteria of EHEDG in conjunction with the EHEDG<br />
Certification Scheme<br />
Andrew Timperley, e-mail: andy.timperley@tesco.net<br />
At the beginning of 2011 the Test Methods Subgroup work<br />
was sub-divided into two divisions under the common<br />
direction of the Authorised EHEDG Test Institutes. One<br />
division has since been concentrating its efforts on the<br />
development of a new test method for evaluating ‘open’<br />
processing equipment. This division met in April 2011 and<br />
defined various work items to develop this method. The<br />
primary task was to construct a ‘reference piece’ in order<br />
to conduct trials on various soiling, cleaning and detection<br />
techniques. Results of these initial trials have shown that<br />
it is very difficult to obtain repeatable results due to the<br />
many variables associated with the uniformity of the<br />
application of soil and controlling the cleaning procedure.<br />
However, work is ongoing in this division to investigate<br />
other techniques.<br />
Member Companies. The website will continue to be<br />
updated with this additional information and provide more<br />
benefits for EHEDG Member companies to showcase their<br />
certified equipment.<br />
The Test Institutes efforts have been concentrated on the<br />
updates of the test methods used to evaluate equipment in<br />
conjunction with the Certification Scheme and these will be<br />
reviewed by the EHEDG Executive Committee for com-ments<br />
before publishing. Additionally, the Certification Scheme has<br />
been expanded to include a new certification class, Type EL-<br />
Class II Aseptic, to enable equipment to be certified for use<br />
in Aseptic applications where CIP cleaning is not practical<br />
and the equipment must be dismantled for cleaning. The flow<br />
chart and testing matrix of the Scheme has been updated on<br />
the EHEDG website and manufacturers are encouraged to<br />
liaise with their local Test Institutes in order to co-ordinate<br />
certification activities.<br />
In September 2011 the Annual Test Institutes meeting was<br />
held at ADRIA Normandie in France to review progress<br />
on becoming an Authorised Test Institute. During the<br />
same Year EHEDG received notification that the Danish<br />
Technological Institute would resign as the Authorised<br />
Institute in Denmark and this role is now being taken up<br />
by the Danish Technical University. These new Institutes<br />
will provide accessibility to manufacturers for testing and<br />
certification of equipment in these regions and the Group<br />
will continue to work with these new Institutes to satisfy the<br />
criteria for authorisation.<br />
In September 2012, all the Test Institute representatives<br />
held their main Annual meeting at TNO in the Netherlands to<br />
review any specific issues associated with repeatability and<br />
reproducibility of the test methods and agree the next ring<br />
trial programme for <strong>2013</strong>. During this meeting the updated<br />
test methods were reviewed and the next reproducibility<br />
trial for the assessment of in-place cleanability testing<br />
was initiated. Additionally, a new structure for the website<br />
listing of certified equipment was finalised to include more<br />
information about certified equipment produced by EHEDG<br />
Figure 1. Testing Scheme<br />
As a result of the day to day testing activities of the<br />
Institutes information is collected to provide equipment<br />
manufacturers with guidance on the selection of suitable<br />
pipe couplings and process connections for hygienic<br />
integration of equipment into processing systems. This<br />
list was revised in April 2011 and is available to download<br />
from the free documents section of the Guidelines area on<br />
the website. This list will be updated as new information<br />
becomes available.
EHEDG Subgroups 175<br />
Chairman:<br />
Andy Timperley<br />
Timperley Consulting<br />
GREAT BRITAIN<br />
Phone +44 1789 49 00 81<br />
Fax +44 1789 49 00 81<br />
E-mail andy.timperley@tesco.net<br />
Figure 2. EHEDG Certification Scheme<br />
EHEDG Subgroup “Training and Education”<br />
Knuth Lorenzen, e-mail: knuth.lorenzen@ewetel.net<br />
Background to the subject<br />
To facilitate undertaking worldwide EHEDG training courses<br />
in local languages requires a set of training materials which<br />
can be used by authorised EHEDG trainers to pass our<br />
uniform message of Hygienic Design on to all participants.<br />
Number of participants/meetings in 2012<br />
The Training & Education Subgroup has 21 active<br />
members who come from universities, faculties, institutes,<br />
consultancies and companies such as Unilever, Exaris and<br />
Givaudan. These members offer their expertise and input<br />
to accomplish the production of ready to use presentation<br />
material enabling EHEDG trainers to arrange and execute<br />
training courses worldwide. With the support of the members<br />
of the EHEDG regions this material has been and will<br />
continue to be translated. This makes lecturing in the local<br />
languages of the different member countries possible.<br />
To produce this training material we create and deliver easy<br />
to understand – both good and bad examples of hygienic<br />
design for the different process applications. We share<br />
our knowledge in our daily work and at our four Subgroup<br />
meetings every year.<br />
Proposed presentation material contents<br />
In visual aids and on DVDs the ready to use presentation<br />
material demonstrates the importance of hygienic engineering<br />
and design for improving food process installations and<br />
maintenance in order to comply with all legal requirements<br />
and to achieve safe food.<br />
The training modules cover the following topics:<br />
• Legal requirements<br />
• Hazards in hygienic processing<br />
• Hygiene design criteria
176 EHEDG Subgroups<br />
• Food grade lubricants<br />
• Materials<br />
• Test methods<br />
• Welding<br />
• Cleaning and disinfection<br />
• Packaging machines<br />
• Seals<br />
A questionnaire with 47 questions was developed and is<br />
used for the participants’ final exam.<br />
Timescale to publishing<br />
We are confident to have a full set of training materials ready<br />
in <strong>2013</strong>. This will enable us to run the three day Advanced<br />
Course in Hygienic Engineering and Design globally.<br />
At present, we are offering the EHEDG training course in the<br />
following languages and countries:<br />
• English, German, Spanish<br />
• in Denmark, Germany, the Netherlands, Spain and the<br />
USA.<br />
Segments of the EHEDG training material are used by our<br />
authorised EHEDG trainers globally at seminars, symposia,<br />
workshops or universities where EHEDG is involved.<br />
Special service<br />
All authorised EHEDG trainers as well as all those<br />
participants who have successfully attended the EHEDG<br />
Advanced Course in Hygienic Engineering and Design are<br />
listed on the EHEDG web page.<br />
Chairman:<br />
Knuth Lorenzen<br />
EHEDG President<br />
Flurstr. 37<br />
21445 Wulfsen<br />
Germany<br />
E-mail: knuth.lorenzen@ewetel.net<br />
Phone: (+49 4173) 8364<br />
EHEDG Subgroup “Valves”<br />
Ulf Thießen, e-mail: ulf.thiessen@gea.com<br />
Since the formation of the Subgroup in September 2009,<br />
the Subgroup saw some member fluctuation but meanwhile<br />
a consolidation has been achieved. The group has 14<br />
regular members with an average of eight participants at the<br />
meetings.<br />
This manageable size led to a rapid progress of work in the<br />
group and by the end of 2011 we succeeded to finalize the<br />
revision of<br />
• DOC 14: Requirements for valves in hygienic and<br />
aseptic processes (4th edition, 2011)<br />
The Guideline is currently being subedited for use of correct<br />
English and will afterwards be translated into various<br />
languages.<br />
The subsequent task of the Subgroup is now the revision of<br />
• DOC 20: Hygienic design and safe use of double-seat<br />
mixproof valves (July 2000)<br />
This work has already been started in 2012.<br />
Due to the complexity of the topic and the long period<br />
between its first release in 2000 and today, we have to bear<br />
in mind that many changes both in market structure and<br />
technology for hygienic and aseptic valves have to be dealt<br />
with.<br />
This will lead to a complete restructuring of the Document.<br />
Chairman:<br />
Ulf Thießen<br />
GEA Mechanical Equipment<br />
GEA Tuchenhagen GmbH<br />
Am Industriepark 2-10<br />
D-21514 Büchen<br />
Germany<br />
Phone +49 4155 49 2709<br />
Fax +49 4155 49 2423<br />
E-Mail ulf.thiessen@gea.com
EHEDG Subgroups 177<br />
EHEDG Subgroup “Welding”<br />
Peter Merhof, GEA Tuchenhagen GmbH, e-mail: peter.merhof@gea.com<br />
The Subgroup started in May 2012 to develop the concept for<br />
the new EHEDG guideline “Inspection of Hygienic Welds”.<br />
It is very important from both a hygienic and economical<br />
point of view that the demands regarding the quality of<br />
welds will be met in tubing systems used for food processing<br />
industry. This document should help the user to identify the<br />
right control method for an efficient and economical testing<br />
of the welds.<br />
The main target group of this document will be the user/<br />
manufacturer in the foot processing industry. Therefor the<br />
document has to be an easily understandable mixture of text<br />
and photos and graphic illustrations.<br />
The accepted inspection methods still in use will be described<br />
including with their advantages and limitations.<br />
Finally the document will give recommendations with the<br />
focus of documentation and shall supply standard operation<br />
procedures.<br />
Chairman:<br />
Peter Merhof<br />
Welding Supervisor<br />
GEA Tuchenhagen GmbH<br />
GEA Mechanical Equipment<br />
Phone +49 (0) 4155 / 49-22 07,<br />
Fax +49 (0) 4155 / 49-26 95<br />
Mobile +49 (0) 172 / 45 82 563<br />
E-mail: peter.merhof@gea.com<br />
www.gea.com
The easiest way to apply for EHEDG membership is via the EHEDG website www.<strong>ehedg</strong>.org. You can apply directly online.<br />
European Hygienic Engineering & Design Group<br />
Company Membership Application<br />
A company membership is open to companies, institutes and organisations. The annual contribution is based on the company’s<br />
turnover in food related business as outlined in the following table. Companies and institutes avail of at least one free individual<br />
membership as well as of the whole series of EHEDG guidelines.<br />
Company Turnover EHEDG contribution Free staff Training Toolbox<br />
member type in EUR p. a. in EUR p. a. members (Prices in EUR)<br />
1 over 500 millions 10,000 4 complimentary<br />
2 50 to 500 millions 5,000 2 complimentary<br />
3 10 to 50 millions 2,500 1 3,000<br />
4 1 to 10 millions 1,000 1 3,000<br />
5 less 1 million 500 1 3,000<br />
Institutes / Universities / Schools / EHEDG contribution Free staff Training Toolbox<br />
Research Centres / Governmental in EUR p. a. members (Prices in EUR)<br />
Authorities 500 up to 4 1,000<br />
My company / institution expresses commitment to become a company member of the EHEDG for the<br />
contribution of: EUR p.a. Our annual company turnover is: EUR p.a.<br />
(Please attach a company letter stating anual turnover p. a.)<br />
All corporate and personal data will be treated confidentially. Fields marked by * to be filled in mandatory.<br />
Company / Institution*<br />
Address*<br />
VAT number if within EC*<br />
Invoice address (if different from above)<br />
Name and position of company representative* (Please also attach business card)<br />
e-Mail*<br />
Phone*<br />
Fax<br />
Other free staff members (full names, only for company member types 1 and 2):<br />
1. 3.<br />
(Please also attach business cards)<br />
2. 4.<br />
We understand that our membership becomes effective upon receipt of our application by the EHEDG Secretariat who will then<br />
issue a membership invoice for the current year. To renew membership, subsequent invoices will be issued each during the first<br />
quarter of the following year, unless a written request for cancellation is sent to the Secretariat by the end of December of the<br />
current year.<br />
Date / Signature<br />
Please return to:<br />
EHEDG Secretariat Phone +49 69 66 03 12 17<br />
Lyoner Straße 18 Fax +49 69 66 03 22 17<br />
60528 Frankfurt am Main E-Mail secretariat@<strong>ehedg</strong>.org<br />
Germany Web www.<strong>ehedg</strong>.org
European Hygienic Engineering & Design Group<br />
Individual Membership Application<br />
I would like to become an individual member of EHEDG at an annual membership fee of EUR 100 (excl. VAT).<br />
Working party<br />
Corresponding<br />
Topics of interest:<br />
All corporate and personal data will be treated confidentially. Fields marked by * to be filled in mandatory.<br />
Name / First Name*<br />
Company / Institution*<br />
Address*<br />
e-Mail*<br />
Phone*<br />
Fax<br />
VAT number if within EC*<br />
Invoice address (if different from above)<br />
I understand that my membership becomes effective upon receipt of my application by the EHEDG Secretariat who will then<br />
issue a membership invoice for the current year. To renew membership, subsequent invoices will be issued each during the first<br />
quarter of the following year, unless a written request for cancellation is sent to the Secretariat by the end of December of the<br />
current year.<br />
Date / Signature<br />
Please return to:<br />
EHEDG Secretariat Phone +49 69 66 03 12 17<br />
Lyoner Straße 18 Fax +49 69 66 03 22 17<br />
60528 Frankfurt am Main E-Mail secretariat@<strong>ehedg</strong>.org<br />
Germany Web www.<strong>ehedg</strong>.org
European Hygienic Engineering & Design Group<br />
Published by<br />
EHEDG<br />
European Hygienic Engineering<br />
and Design Group<br />
Lyoner Str. 18<br />
60528 Frankfurt<br />
GERMANY<br />
ISBN<br />
978-3-8163-0640-5<br />
Publishing House:<br />
VDMA Verlag GmbH<br />
Lyoner Str. 18<br />
60528 Frankfurt<br />
GERMANY<br />
Printing:<br />
Franz Kuthal GmbH & Co. KG<br />
Johann-Dahlem-Str. 54<br />
63814 Mainaschaff<br />
GERMANY<br />
Executive Editor<br />
Julie Bricher<br />
Quiddity Communications<br />
677 SW Tanglewood Circle<br />
McMinnville 97128<br />
UNITED STATES OF AMERICA<br />
Copyright<br />
Copyright rests with EHEDG. All rights reserved.<br />
The copyright of the pictures and illustrations within the<br />
articles belongs to the authors, respectively the companies<br />
or institutes they represent unless otherwise stated.<br />
Illustrations:<br />
Cover:<br />
1. Scanjet Systems AB, S- Gothenburg<br />
2. Coperion GmbH, D-Weingarten<br />
3. Elmar Europe GmbH, D-Neuss<br />
4. Ecolab Europe GmbH, CH- Wallisellen<br />
5. GEA Westfalia Separator,D-Oelde<br />
6. seepex GmbH Food and Beverage, D- Bottrop<br />
7. HECHT Technologie GmbH, D-Pfaffenhofen<br />
8. VTT Technical Research Centre of Finland, FI- Espoo<br />
Contact<br />
EHEDG Secretariat<br />
Lyoner Str. 18<br />
60528 Frankfurt<br />
GERMANY<br />
Phone (+49 69) 66 03-12 17<br />
FAX (+49 69) 66 03-22 17<br />
E-mail: secretariat@<strong>ehedg</strong>.org<br />
Web: www.<strong>ehedg</strong>.org<br />
Copy Editor<br />
Juliane Honisch<br />
EHEDG Secretariat<br />
Frankfurt<br />
GERMANY<br />
Editorial Board<br />
Dr. John Holah, Campden BRI, GREAT BRITAIN<br />
Knuth Lorenzen, Wulfsen, GERMANY<br />
Huub Lelieveld, Bilthoven, NETHERLANDS<br />
Dirk Nikoleiski, Kraft Foods R&D Inc. Munich, GERMANY<br />
Eric Partington, Nickel Institute, Cirencester,<br />
GREAT BRITAIN
EHEDG Secretariat<br />
Lyoner Strasse 18<br />
60528 Frankfurt am Main<br />
Germany<br />
Phone +49 69 6603-1217 and -1430<br />
Fax +49 69 6603-2217 and -2430<br />
E-mail secretariat@<strong>ehedg</strong>.org<br />
Web www.<strong>ehedg</strong>.org<br />
ISBN 978-3-8163-0640-5