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EHEDGYearbook 2013/2014European HygienicEngineering & Design Group

European Hygienic Engineering & Design GroupContentsArticlesPageGreeting from the President, Knuth Lorenzen, EHEDG President 5News from the Treasurer, Piet Steenaard, EHEDG Treasurer 6News from the Secretariat, Susanne Flenner, EHEDG Secretariat 7EHEDG Executive Committee members 8EHEDG Company and Institute members 10EHEDG Membership 15EHEDG Certication Institutes 16Legal requirements for hygienic design in Europe, by Hans-Werner Bellin, BELLINconsult 17The importance of hygienic design: A process facility case study and checklist, 20by arolina Lpez rias, Krat-Foods Espaa part o ondelz InternationalSolving concrete kerb challenges to ensure hygiene and food safe wall protection 26in manufacturing environments, by Nick Van den Bosschelle, PolyStoHexagonal tile oors: The hygienic foundation of production areas, 28by Volker Aufderhaar, Argelith Bodenkeramikesearch on hygienic ooring systems: Particle and C emissions, 30chemical and biological resistance, and cleanability,by Markus Keller and Udo Gommel, Fraunhofer Institute for Manufacturing Engineeringand Automation IPA, Department of Ultraclean Technology and MicromanufacturingHygienic design of oor drainage components, by Martin Fairley, ACO Technologies plc 42Hygienic design of high performance doors for utilisation in the food industry, 47by Daniel Grüttner-Mierswa, Albany Door Systems GmbHPerformance testing of air lters for hygienic environments: 50Standards and guidelines in the 21st century,by Thomas Caesar, Freudenberg Filtration Technologies SE & Co. KGSpray cleaning systems in food processing machines and the simulation of CIP-coverage tests, 54by André Boye, Marc Mauermann, Daniel Höhne, Jens-Peter Majschak, Fraunhofer Application Centerfor Processing Machinery and Packaging Technology AVV, and Technische Universität Dresden,Faculty of Computer Science, Institute of Software- and Multimedia-Technology, Dresden, GermanyEnvironmentally friendly water based surface disinfectants, 60by Stephan Mätzschke, BIRFOOD GmbH & Co. KGFlow behaviour of liquid jets impinging on vertical walls, 66by Ian Wilson, Tao Wang and John F. Davidson, Department ofChemical Engineering and Biotechnology, University of Cambridgeptimisation of tank cleaning, by René Elgaard, Alfa Laval Tank Equipment A/S 70Effective tank and vessel cleaning: How different systems can help meet today’s demands, 76by Falko Fliessbach, GEA Tuchenhagen GmbHPractical considerations for cleaning validation, by Hein Timmerman, Diversey 83Integrated hygienic tamper-free production, by Stefan Åkesson, Tetra Pak 85Damage scenarios for valves: Identifying the potential for optimisation, 87by Willi Wiedenmann, Krones AGInfection-free preparation of bacterial cultures, by Ludger Hilleke, amixon GmbH 92Modern level detection and measurement technologies, by Daniel Walldorf, Baumer GmbH 94

Contents 3An example of the development process of hygienic process sensors: A hygienic level switch, 96by Holger Schmidt, Endress+HauserStorage in silos and pneumatic conveying of milk powder with up to 60% fat content, 99by Hermann Josef Linder, Solids Solutions Group, S.S.T.-Schüttguttechnik Maschinenbau GmbHMaterial and design optimisation calculated by EHEDG: Tubing systems, 103by Torsten Köcher, Dockweiler AGImproved hygienic design and performance of food conveyor belts, by Olaf Heide, Habasit AG 106Smart hygienic solutions for the food industry, 108by Peter Uttrup, Interroll España S.A and Lorenz G. Koehler, Interroll (Schweiz) AGExamination of food allergen removal from two at conveyor belts, 110by Dr. hinong an, Gary Larsen, Roger Schefer, and Karin Blacow. Intralox, L.L.C.The future of food-grade lubrication, by Taco Mets, Van Meeuwen Groep B.V. 115Hygienic automation technology in food production, by Alexander Wagner, Festo KG 117Cleanability test of a hygienic design-compatible washer, 120by Julia Eckstein, Application Consultant, Freudenberg Process Seals GmbH & Co. KGAspects of compounding rubber materials for contact with food and pharmaceuticals, 122by Anders G. Christensen, AVK GUMMI A/SNew developments for upgrading stainless steel to improve 124corrosion resistance and increase equipment hygiene,by Siegfried Piesslinger-Schweiger, POLIGRAT GmbHInternational Hygienic Study Award 2012, by Peter Golz, VDMA 128EHEDG Regional Sections, chairmen and contacts 130EHEDG Armenia 132EHEDG Belgium 133EHEDG Czech Republic 134EHEDG Denmark 135EHEDG France 136EHEDG Germany 137EHEDG Italy 138EHEDG Japan 140EHEDG Lithuania 141EHEDG Macedonia 141EHEDG Mexico 144EHEDG Netherlands 145EHEDG Russia 147EHEDG Serbia 148EHEDG Spain 148EHEDG Switzerland 150EHEDG Taiwan 150EHEDG Thailand 151EHEDG Turkey 152EHEDG Ukraine 153

4 ContentsEHEDG Guidelines – titles available and description 154EHEDG Congresses 163EHEDG Subgroup work 164EHEDG Subgroup “Air Handling” 164EHEDG Subgroup “Hygienic Building Design” 165EHEDG Subgroup “Chemical Treatment of Stainless Steel” 166EHEDG Subgroup “Cleaning Validation” 167EHEDG Subgroup “Conveyor Systems” 168EHEDG Subgroup “Dry Materials Handling” 168EHEDG Subgroup “Fish Processing” 169EHEDG Subgroup “Materials of Construction for Equipment in Contact with Food “ 170EHEDG Subgroup “Hygienic Design of Meat Processing Equipment” 170EHEDG Subgroup “Open Equipment” 171EHEDG Subgroup “Pumps, Homogenisers and Dampening Devices” 172EHEDG Subgroup “Seals” 172EHEDG Subgroup “Separators” 173EHEDG Subgroup “Tank Cleaning” 173EHEDG Subgroup “Test Methods” 174EHEDG Subgroup “Training and Education” 175EHEDG Subgroup “Valves” 176EHEDG Subgroup “Welding” 177EHEDG application forms 178Imprint 180

European Hygienic Engineering & Design GroupGreeting from the PresidentKnuth Lorenzen, President of the European Hygienic Engineering and Design Group (EHEDG),E-mail: knuth.lorenzen@ehedg.orgEHEDG values the cooperation and positive relationshipwith 3-ASSI (www.3-a.org). In our shared commitment wework together to advance hygienic equipment design. Bothorganisations exchange their draft guidelines and standards.The contents of all EHEDG guidelines are cross-referencedwith those of the 3-ASSI standards and are summarised ina matrix. In order to talk the same language and to furtherharmonise the documents, EHEDG and 3-ASSI expertshave jointly drafted the new issue of the EHEDG Glossary.To complement the scope of our services, we offer youseminars, symposia and workshops worldwide which impartand disseminate the EHEDG Hygienic Engineering & Designexpertise.The core business of the EHEDG, Hygienic Engineering &Design, is still an unknown territory for many target groups.State-of-the-art machinery and processing plant can onlyfull the todays needs of the food industry and meet withthe existing legal requirements if they are designed, built,installed and maintained according to hygienic designprinciples.University graduates are highly qualied experts trained tosolve complex engineering tasks and they are expectedto design and build innovative machinery that is safe tooperate. Nevertheless they are often unaware of HygienicEngineering & Design as it is not a mandatory part of theircourse contents.Machines used in the food industry need to be safe andhighly productive, but at the same time they have to meetfood hygiene requirements.In answer to these needs, the EHEDG expert networkwas established to close the existing knowledge gapsby developing teaching aids for practical use as well aseducation material for students, engineers and operatorswho are interested in learning more about the eld ofhygienic design & engineering.The specic and profound EHEDG expertise is collated in ourguidelines, in our training material and in other publicationswhich are developed by our motivated volunteers – all ofthem aiming to raise the awareness in food hygiene worldwide.EHEDG training courses on hygienic engineering & designare meanwhile offered by various authorised institutes anduniversities in Denmark, Germany, Japan, the Netherlands,Spain, Thailand, UK and in the USA. Attendees whosuccessfully passed their exam are given the opportunity tohave their name published on the EHEDG webpage www.ehedg.org.University lecturers involved in the EHEDG are lling thegaps in hygienic engineering & design education and haveintegrated such contents in their seminars.I invite you to benet from our knowledge which reects theexpertise of all volunteers involved into EHEDG, and I herebyexpress my sincere thanks to these enthusiastic experts fortheir tireless contribution and excellent input. Last but notleast, I should like to thank the EHEDG member companieswho support us – without them we would not be in a positionto offer our wide range of educational services.YoursKnuth LorenzenPresident of EHEDG

European Hygienic Engineering & Design GroupNews from the TreasurerPiet Steenaard, Dr. Catzlaan 19, NL-1261 CE Blaricum, e-mail: steenaard@kpnmail.nlApart from covering our administration costs, the positiveincome was partly used for giving the growing number ofexperts the possibility of joining Subgroup meetings andEHEDG congresses. In most cases we have been able tofund the attendance of Subgroup members without nancialback-up from a company or institute.At the end of each year, all Regional and Subgroup Chairmenare asked to send in their activity and budget planning for theyear to come and if in need of nancial support for upcomingEHEDG activities, we have approved most inquiries in thepast. Resulting from the growing number of Subgroups andRegions, about 50 regular EHEDG meetings plus many localevents, workshops and training courses are held annually.From a nancial point of view, the period 2011 - 2012was successful for the EHEDG. It was characterised byan increase in income thanks to a signicant growth inmembership and by more revenues from certication. On theother hand, as company members benet from downloadingthe guidelines free-of-charge from the EHEDG website,document sales have been decreasing at the same time.Institutes have been offered an advantageous membershipfee and since then, the EHEDG has gained more universitiesand institutions. This increase helps to strengthen thescientic recognition of the EHEDG. As a result, we are nowin a position to involve more scientists into the developmentof our state-of-the-art guidelines, along with our experts frommechanical engineering with their essential know-how. Manyinstitutes adopt and organise our regional activities andthey translate the EHEDG guidelines and our website intothe local languages. They are active in various Subgroupsand hold seminars and workshops to disseminate EHEDGknowledge.The EHEDG Subgroups are ideally composed of mechanicalengineers, microbiologists, food producers and academia.However, sometimes it is not easy to nd the right expertswho can jointly provide the well-balanced and comprehensiveknow-how on the topic in question. Therefore, active expertinput and EHEDG Subgroup participation on behalf of allrelated industries is always highly welcome – as long as itis considered on a basis of give-and-take. The EHEDG canoffer many benets to the industry if it actively joins our workcompanies are offered the opportunity to feed their interestsinto the discussion and they can provide inuence on settingglobal standards by actively contributing to the Subgroupwork. EHEDG helps to enhance the reputation of its membercompanies and makes them knowledge leaders in hygienicdesign and processing.Most companies encourage and support their employeesto participate in EHEDG activities, so they can develop orrevise guidelines, training material and test methods forequipment. We are thankful to all these companies for theircontinued support.In recent years, we brought all our Chairmen together onthe occasion of our annual Plenary Meetings to provideupdated information from EHEDG International, enhancenetworking and cooperation in our fast growing organisationand offer them an opportunity for experience exchange andnetworking.EHEDG participation in international exhibitions helps toestablish the new relationships and to expand our networkand we invite you to visit us on the occasion of e.g. Drinktec,Anuga FoodTec and other important events.We are interlinking more than 200 companies and 30academic institutions. To date, about 1,000 persons havejoined the EHEDG and more than 350 experts are activelyinvolved in our Subgroup work. They are aiming to developstate-of-the art documents and teaching aids for hygienicallydesigned machinery and equipment as well as for safe foodproduction processes. Any new members are welcome inorder to keep up this good work.It was an honour and a pleasure to take care of the EHEDGnances and to work with such highly committed people.Piet SteenaardEHEDG Treasurer

European Hygienic Engineering & Design GroupNews from the SecretariatSusanne Flenner, EHEDG Secretariat, susanne.enner@ehedg.orgApart from these virtual options, the EHEDG network isreal and we continue to bring the experts together in ourSubgroups to help them learn from each other. All who haveever attended an EHEDG seminar, workshop or congresswill not only have experienced the high quality of lecturesbut also the EHEDG spirit of those who are enthusiastic indisseminating our expertise.In our meetings and events, you will nd an open atmospherefar away from competition. We are not only enhancing theexpert dialogue and dissemination of specic HygienicDesign knowledge but are also streamlining our activitiesand knowledge exchange with other organisations such asour strong counterpart 3-ASSI Standards Inc. in the USA.Having experienced a strong growth in membership and anincreasing awareness of the EHEDG for its highly recognisedexpertise in the past years, this is to express our sincerethanks to all those who are involved in our activities today –whether on the part of our Subgroups, our Regional Sectionsor our members at large who support the EHEDG work.While global economic growth seems to be stagnating,at EHEDG we are continuing to expand and build ourwolrdwide network in Hygienic Engineering & Design. Thiscontinuous development is certainly seen as a successstory.On the part of the Secretariat, we are aiming to provideservice excellence and although our organisation is lean, it ishighly efcient and we can make our experts share the knowhowthey wish to have accessible – without overloading themwith information they dont need. A major part of the EHEDGknowledge is available from our website with its huge database where additional member information is available andwhere the EHEDG Subgroups build up and share theirworking les.By providing individual access rights to the differentdatabase sections, we can help our members nd exactlywhat they need and want to know. The webpage is going tobe continuously built-up by additional features and add-onslike i.e. an extended certicate database offering uploadingoptions to company members for their pictures and theproduct information of their EHEDG-certied components.Meanwhile, the webpage is available in 15 languages thanksto having been translated by our regional experts. Wewelcome about 8,000 visitors on the web monthly and ourNewsletter is sent out 6 times a year to keep our membersup-to-date on the most important recent and upcomingEHEDG activities.World-wide education in Hygienic Engineering & Designis our credo which is well reected by the many RegionalSections established to date and those which are going to beestablished in the future – all of them aiming to disseminatethe EHEDG know-how in their countries.Our members do not only recognise hygienic design as aknowledge advancement, but we help them to nd designsolutions which save both cost and time by ensuring highfood safety at the same time.About 400 EHEDG certicates issued by our accreditedtesting and certication institutes to date speak their ownlanguage. EHEDG certication is sought by many companiesas a proof of their capability in building easy to clean andmaintain equipment and machinery. The EHEDG helpsthese companies to become leaders in hygienic design and- hand in hand with our members from the food industry andfrom academia - this know-how is continuously developed.If you are not a member of the EHEDG network already, weherewith invite you on board. Thanks again to all members fortheir commitment and welcome to those who are convincedof the benets of joining the EHEDG after reading this book.Contact:Susanne FlennerHead Ofce ManagerEHEDG SecretariatLyoner Str. 1860528 Frankfurt am MainGermanyPhone +49 69 6603-1217Fax +49 69 6603-2217E-mail secretariatehedg.orgsusanne.ennerehedg.orgWeb www.ehedg.org

European Hygienic Engineering & Design GroupEHEDG Executive Committee membersMr Andrew Batley *Nestlé Product Technology CenterNESTEC LTD.SWITZERLANDPhone (+41 31) 7 90 15 86E-mail andrew.batleyrdko.nestle.comMr Erwan Billet *HydiacFRANCEPhone (+33 61) 2 49 85 84E-mail e.billethydiac.comProfessor Olivier Cerf *Alfort Veterinary SchoolFRANCEPhone (+33 1) 43 96 70 34E-mail ocerfvet-alfort.frNicolas Chomel *Laval Mayenne TechnopoleEHEDG FranceFRANCEPhone (+33 243) 49 75 24E-mail chomellaval-technopole.frLyle W. Clem **ESCElectrol Specialties CompanyUNITED STATES OF AMERICAPhone (+972 815) 3 89-22 94E-mail lyleclematt.netSusanne Flenner ***EHEDG SecretariatGERMANYPhone (+49 69) 66 03-12 17E-mail susanne.ennerehedg.orgDr. Peter Golz *VDMAFachverband Nahrungsmittelmaschinenund VerpackungsmaschinenGERMANYPhone (+49 69) 66 03-16 56E-mail peter.golzvdma.orgMr Richard Groenendijk *Stork Food & Dairy Systems B.V.NETHERLANDSPhone (+31 20) 6 34 86 48E-mail richard.groenendijksfds.euChristophe Hermon **Conservation des Produits AgricolesCTCPA - Centre Technique de laFRANCEPhone (+33 2) 40 40 47 41E-mail chermonctcpa.orgDr. Jürgen Hofmann *Ingenieurbüro HofmannHygienic Design ExperteGERMANYPhone (+49 8161) 8 76 87 99E-mail jhhd-experte.deDr. John Holah *Campden BRIGREAT BRITAINPhone (+44 1386) 84 20 41E-mailj.holahcampden.co.ukJana Alicia Huth ***EHEDG SecretariatGERMANYPhone (+49 69) 66 03-14 30E-mail jana.huthehedg.orgSalwa El Janati **Lactalis RDFRANCEPhone (+33 24) 3 59 52 18E-mail salwa.eljanatilactalis.frLudvig Josefsberg *Tetra Pak Processing SystemsSWEDENPhone (+46 46) 36 60 01E-mail ludvig.josefsbergtetrapak.comMr Jacques Kastelein *TNO - Quality of LifeNETHERLANDSPhone (+31 30) 6 94 46 85E-mail jacques.kasteleintno.nlHuub Lelieveld *NETHERLANDSPhone (+3130) 2 25 38 96E-mail huub.lelieveldinter.nl.netKnuth Lorenzen *GERMANYPhone (+49 4173) 83 64E-mail knuth.lorenzenewetel.netDirk Nikoleiski *Kraft Foods R&D Inc.Product Protection & Hygienic DesignGERMANYPhone (+49 89) 6 27 38 61 14E-mail dnikoleiskikrafteurope.comSusanna Norrby *Alfa Laval Tumba ABSWEDENPhone (+46 85) 3 06 56 33E-mail susanna.norrbyalfalaval.com

EHEDG Executive Committee members 9Andres Pascual *ainia centro tecnológicoSPAINPhone (+34 96) 1 36 60 90E-mail apascualainia.esArno Peter *GEA TDS GmbHNiederlassung BüchenGERMANYPhone (+49 4155) 49-24 27E-mail arno.petergeagroup.comTimothy R. Rugh **3-A Sanitary Standards, Inc.UNITED STATES OF AMERICAPhone (+1 703) 7 90 02 95E-mail trugh3-a.orgSatu Salo *VTTIndustrial Contamination ControlFINLANDPhone (+358 20) 7 22 71 21E-mail satu.salovtt.Tracy Schonrock *UNITED STATES OF AMERICAPhone (+1 703) 5 03 29 71E-mail ftracy1cox.netPiet Steenaard *EHEDG TreasurerNETHERLANDSPhone (+31 35) 5 38 36 38E-mail steenaardkpnmail.nlHein Timmerman *Diversey Europe BVBELGIUMPhone (+32 495) 59 17 91E-mail hein.timmermansealedair.comDr. Gun Wirtanen *VTTFINLANDPhone (+358 20) 7 22 52 22E-mail gun.wirtanenvtt.Mr Patrick Wouters *Unilever Research LaboratoryNETHERLANDSPhone (+3110) 4 60 50 28E-mail patrick.woutersunilever.comThis shows the Executive Committee as listed inDecember 2012:* regular members** liaison members*** EHEDG SecretariatAdvertisementVALVE TECHNOLOGYTYPE EL - CLASS IJULY 2011WE ARE ASEPTIC!DON‘T RUN A RISK!Use the PTFE-bellow technology by Rieger!/ no dead spaces/ long-living bellows last minimum 1.000.000 cycles/ suitable in aseptic filling machines up to 10 Mio. cyclesGATHER INFORMATION NOW! CONTACT US!Gebr. Rieger GmbH & Co. KGPhone +49 (0) 73 61/57 02-0 / E-Mail info@rr-rieger.deMADE IN GERMANYEin Unternehmen der NEUMO-EHRENBERG-GRUPPEwww.rr-rieger.de

European Hygienic Engineering & Design GroupEHEDG Company and Institute membersEHEDG thanks its members for their continued supportACO Technolgies plc,United KingdomAFM Sensorik GmbH, Germanywww.aco.co.ukwww.afmsensorik.deAviatec, DenmarkAVK GUMMI A/S, Greeceaviatecaviatec.dkwww.avkgummi.dkAFRISO-EURO-INDEX GmbH,GermanyAGORIA FederationMultisectorielle de LIndustrieTechnologique, BelgiumAgus Innovation Sp. z o.o.,Polandwww.afriso.dewww.agoria.bewww.agus.com.plAZO GmbH & Co. KG, GermanyNordischer MaschinenbauRud. Baader GmbH & Co. KG,GermanyBalluff GmbH, GermanyBari Samaratsi LLC, Armeniawww.azo.dewww.baader.comwww.balluff.comwww.barisamaratsi.amainia centro tecnológico, SpainAK System GmbH, GermanyAkvatekhavtomatika CJSC,AustriaAlbany Door Systems GmbH,Germanywww.ainia.eswww.ak-processing.comwww.akvatekh.narod.ruwww.albint.comBarry Callebaut Manufacturing(UK) Ltd., United KingdomBASF Stavebni hmoty Ceskarepublika s.r.o., Czech RepublicBaumer GmbH, GermanyBawaco AG, Switzerlandg.benguiriesbarrycallebaut.comwww.basf.comwww.baumergroup.comwww.bawaco.comAlfa Laval Tumba AB, SwedenAlvibra A/S, DenmarkAMEC, SpainAMH Technologies Sdn Bhd,Malaysiaamixon GmbH, GermanyAMMAG GmbH, Austrawww.alfalaval.comwww.alvibra.comwww.amec.eswww.amh.com.mywww.amixon.dewww.ammag.comBirfood GmbH & Co. KG,GermanyBJ-Gear A/S, DenmakrBlücher Metal A/S, DenmarkJoh. Heinr. Bornemann GmbH,GermanyRobert Bosch PackagingTechnologyB.V., Netherlandswww.birfood.dewww.bj-gear.comwww.blucher.dkwww.bornemann.comwww.boschpackaging.comAmmeraal Beltech srl, Italywww.ammeraalbeltech.itBosch Rexroth PneumaticsGmbH, Germanywww.boschrexroth.comAnderol BV, Netherlandswww.anderol.comBOSSAR - Rovema Ibérica S.A.,Spainwww.bossar.comAnderol Europe BV, NetherlandsAndreasen & Elmgaard A/S,DenmarkArgelith Bodenkeramik, GermanyArmaturenbau GmbH, GermanyArmaturenwerk HötenslebenGmbH, GermanyArol Spa, Italywww.anderol-europe.comwww.chemtura.com/petaddswww.aoge.aswww.argelith.comwww.armaturenbau.comwww.awh.dewww.arol.itBP Biofuels UK Ltd,United KingdomBrabender Technologie KG,GermanyBrinox Engineering d.o.o., SLOBühler AG, SwitzerlandBürkert GmbH & Co. KG,GermanyBurggraaf & Partners B.V.,Netherlandswww.bp.com/biofuelswww.brabendertechnologie.comwww.brinox.siwww.buhlergroup.comwww.buerkert.comwww.burggraaf.ccARSOPI S.A., Portugalwww.arsopi.ptCampden BRIwww.campden.co.ukAseptomag AG, Switzerlandwww.aseptomag.chCargill, Belgiumwww.cerestar.comCederroth AB, Swedenwww.cederroth.com

EHEDG Company and Institute members 11CENTA Centre of New FoodTechnologies and Processeswww.centa.catElmar Europe GmbH, Germanywww.elmarworldwide.comCFT S.p.a., Italywww.cftrossicatelli.comEndress + Hauser Japan, Japanwww.jp.endress.comChronos BTH, Netherlandswww.chronosbth.comEsenda Ingeniería, S.C., Spainesendaesenda.esCiptec Services, Finlandwww.ciptec.Eurobinox S.A., Francewww.eurobinox.com/Clyde Process Limited, UnitedKingdomCMS S.p.A., ItalyThe Coca-Cola Company, USACocker Consulting Ltd., IrelandConsulting & Training Center KEY,Macedoniacool it Isoliersysteme GmbH,GermanyCoperion Waeschle GmbH & Co.KG, Germanywww.clydematerials.comwww.gruppocms.comwww.coca-cola.comwww.cocker.iewww.key.com.mkwww.coolit.dewww.coperion.comFesto AG & Co. KGFIRDI Food Industry Researchand Development Institute,ThailandFood Coating Expertise SAS,FranceFood Masters Ltd. Engineering &Equipment Supply, IsraelFRAGOL Schmierstoff GmbH+Co.KG, GermanyFraunhofer- AnwendungszentrumVerarbeitungsmaschinen undVerpackungstechnik, Germanyhttp//www.festo.dewww.rdi.org.twwww.food-coating.comwww.foodmast.comwww.fragol.dewww.avv.fraunhofer.deJohn Crane GmbHGleitringdichtungssysteme,Germanywww.johncrane.deFraunhofer Institut fürProduktions-technik undAutomatisierung (IPA), Germanywww.ipa.fraunhofer.deCSF Inox S.p.A., Italywww.csf.itFreudenberg FiltrationTechnologies KG, Germanywww.freudenberg.dewww.freudenberg-lter.deIng. Johann Daxner GmbH,AustriaDerichs GmbH, GermanyDGL Deutsche Gesellschaft fürLebensmittelsicherheit, WasserundUmwelt, Germanywww.daxner-international.comwww.derichs.dewww.dgl-com.deFreudenberg Process SealsGmbH & Co. KG, GermanyFriesland Foods, NetherlandsFunke WärmeaustauscherApparatebau GmbH, Germanywww.freudenberg.de www.freudenberg-process-seals.dewww.frieslandcampina.comwww.funke.deDIL Deutsches Institut fürLebensmitteltechnik e.V.,GermanyDinnissen BV, NetherlandsDiversey Europe BV EMAHeadquarters, NetherlandsDMN MachinefabriekNoordwykerhoutB.V., NetherlandsDockweiler AG, Germanywww.dil-ev.dewww.dinnissen.nlwww.diversey.comwww.dmnwestinghouse.comwww.dockweiler.comGalleon Rus ltd., RussiaGEA GroupGEMÜ Gebr. Müller ApparatebauGmbH & Co. KG, GermanyGericke GmbH, GermanyGida Güvenligi Dernegi - TFSA -Turkish Food Safety Association,Turkeywww.galleon-rus.ruwww.geagroup.comwww.gemue.dewww.gericke.netwww.ggd.org.trDofra bv, Netherlandswww.dofra.nlGram Equipment A/S, Denmarkwww.gram-equipment.comDTU Technical University ofDenmark National Food Institute,DenmarkDöinghaus cutting and moreGmbH &Co. KG, Germanywww.food.dtu.dkwww.cuttingandmore.deGrontmij Industrial Division,NetherlandsHabasit AG, Switzerlandhäwa GmbH & Co. KG, Spainwww.grontmij.nlwww.habasit.comwww.haewa.deEaton Industries GmbH, GermanyEcolab Deutschland GmbH,Germanywww.eaton.comwww.ecolab.comHECHT Technologie GmbH,GermanyH.J. Heinz & Co Ltd, UnitedKingdomwww.hecht.euwww.hjheinz.ie/

12 EHEDG Company and Institute membersHengesbach GmbH & Co. KG,Germanywww.hengesbach.bizK-Tron Schweiz AG, Switzerlandwww.ktron.comHENKEL LohnpoliertechnikGmbH, Germanywww.henkel-epol.comKuipers Woudsend B.V.,Netherlandswww.kuiperswoudsend.nlHerding GmbH Filtertechnik,Germanywww.herding.deLABOM Mess- u. RegeltechnikGmbH, Germanywww.labom.comHES-SO University of AppliedSciences Western Switzerland,Switzerlandwww.hevs.chLAEUFER International AG FoodProcessing, GermanyLamican, Finlandwww.laeufer-ag.dewww.lamican.comHochschule Fulda - FBLebensmitteltechnologieFachgebietLebensmittelverfahrenstechnikwww.lt.hs-fulda.deLECHLER GmbH, GermanyLeibinger GmbH, Germanywww.lechler.dewww.leibinger.euIDMC Limited, Indiawww.idmc.coopLely Industries N.V., Netherlandswww.lely.comIlinox Srl, Italywww.ilinox.comLEWA GmbH, Germanywww.lewa.deInterroll (Schweiz) AG,SwitzerlandIntralox L.L.C. Europe ModularPlastic Conveyor Belts,Netherlandswww.interroll.chintralox.comGEBRÜDERLÖDIGEMaschinenbau GmbH,GermanyJürgen Löhrke GmbH, Germanywww.loedige.dewww.loehrke.com/Jentec GmbH Ingenieurbüro &Maschinenbau, Germanywww.jentec24.deD. Iordanidis S.A, Greece www.iordanidis-pumps.grJ-TEC Material Handling, BelgiumKanto Kongoki Industrial Ltd.,JapanKek-Gardner Ltd, United KingdomKHS GmbH Werk Bad Kreuznach,GermanyG.A. KIESEL GmbH, GermanyKieselmann GmbH, GermanyKing Mongkuts Institute ofTechnology Ladkrabang, Facultyof Engineering Department ofFood EngineeringMaschinenbau Kitz GmbH,GermanyKlüber Lubrication München KG,Germanywww.j-tec.comkanto-mixer.co.jpwww.kekgardner.comwww.khs.comwww.kiesel-online.dewww.kieselmann.dewww.kmitl.ac.thwww.maschinenbau-kitz.dewww.klueber.deLübbers Anlagen undUmwelttechnik GmbH, GermanyM & S Armaturen GmbH,GermanyMaga Metalúrgica, S.L., SpainMagnetrol International N.V.,BelgiumMarel Food Systems B.V.,NetherlandsMBA Instruments GmbH,GermanyMetal Industries Research &Development Centre, TaiwanMETAX Kupplungs- undDichtungstechnik GmbH,GermanyMettler Toledo AG ProcessAnalytics, SwitzerlandMGT Liquid Process SystemsIndustrial Area Maalot, IsraelMicrozero Corporation, Japanwww.luebbers.org/www.ms-armaturen.dewww.maga-inox.comwww.magnetrol.comwww.marel.comwww.mba-instruments.dewww.mirdc.org.twwww.metax-gmbh.dewww.mt.comwww.mgt.co.ilwww.microzero.co.jpKNOLL Maschinenbau GmbH,Germanywww.knoll-mb.deMikroPul GmbH, Germanywww.mikropul.deKOBOLD Messring GmbH,Germanywww.kobold.comMondelez / Kraft Foods R&D Inc.,Germanywww.kraftfoods.comKoninklijke Euroma B.V.,Netherlandswww.euroma.comMOOG Cleaning Systems,Switzerlandwww.moog.chKraft Foods R&D Inc., Germanywww.kraftfoods.deMQA s.r.o., Czech Republicwww.mqa.czKrones AG, Germanywww.krones.comMST Stainless Steel Sdn. Bhd.,Malaysiawww.minox.biz

EHEDG Company and Institute members 13Müller AG Cleaning Solution,Switzerlandinfomuellercleaning.comReitz Holding GmbH & Co. KG,Germanywww.reitz-ventilatoren.deMULTIVAC Sepp HaggenmüllerGmbH & Co. KG, Germanywww.multivac.deREMBE GmbHSafety + Control,Germanywww.rembe.deMunicipality of Karpos, MacedoniaNational Institute of R&D forMachines & Installations forAgriculture and Food Industries,Romaniawww.karpos.gov.mkwww.inma.roGebr. Rieger GmbH + Co. KG,GermanyRittal GmbH & Co. KG, GermanyRONDO Burgdorf AG, Switzerlandwww-rr-rieger.dewww.rittal.dewww.rondo-online.comNegele Messtechnik GmbH,Germanywww.anderson-negele.comRondotest GmbH & Co. KG,Germanywww.rondoshop.deNestlé S.A.Nestlé Headquarters,Switzerlandwww.nestle.comRULAND Engineering &Consulting GmbH, Germanywww.rulandec.deNocado GmbH & Co. KG,Germanywww.nocado.deSAMSON REGULATION S.A.,Francewww.samson.frNovozymes A/S, Denmarkwww.novozymes.comScanjet Systems AB, Swedenwww.scanjetsystems.comPack4Food, Belgiumwww.pack4food.beScan-Vibro A/S, Denmarkwww.scan-vibro.comPacko Inox nv, BelgiumParker Hannin CorporationPneumatics Div. Europe/Automation Group, UnitedKingdomwww.packo.comwww.parkermotion.com/pneu/foodSED Flow Control GmbH,Germanyseepex GmbH, GermanySEITAL Separatori Italia Srl, Italywww.sed-owcontrol.comwww.seepex.comwww.seital.itPAYPER, S.A., SpainPepperl+Fuchs GmbHPepsiCo, USAwww.payper.comwww.pepperl-fuchs.comwww.pepsico.comSEW Food & Process bv,NetherlandsSGS INSTITUT FRESENIUSGmbH, Germanywww.seworks.nlwww.de.sgs.com,www.institut-fresenius.dePneumatic Scale Angelus, USAPNR Italia, ItalyPoligrat GmbH, GermanyPolySto, Belgiumwww.psangelus.comwww.pnr.it/www.poligrat.dewww.polysto.comShanghai AOFUDE FluidEquipment Science TechnologyCo., LtdSICK AG, Germany“SIS Natural” LLC Canneryvil.Aghtsk Aragatsotn Region,Armeniawww.chinaavm.comwww.sick.dewww.sisnatural.amPOWER Engineers, Inc., UnitedKingdomwww.powereng.comSISTO Armaturen S.A.,Luxembourgwww.sisto.deProaseptic Technologies S.L.,Spainwww.proaseptic.com/SKF Sverige AB, Swedenwww.skf.comProCert Mexico / USA, Mexicowww.procert.chSMC Pneumatik GmbHwww.smc-pneumatik.deProdusafe B.V., NetherlandsProtek Engineering Solutions Ltd,United KingdomPurdue University, USAwww.produsafe.comwww.protekengineering.co.ukwww.purdue.eduSociedad Mexicana de Inocuidady Calidad para Consumidores deAlimentos AC (SOMEICCAAC),MexicoSolids Components Migsa, S.L.,Spainwww.someicca.com.mxwww.migsa.esQUIMIPRODUCTOS, S.A. deC.V., MexicoRadar process S.L., Spainwww.quimiproductos.com.mxwww.radarprocess.comSolids system-technik s.l., SpainSommer & Strassburger GmbH &Co. KG, Germanywww.solids.eswww.sus-bretten.deRattiinox srl, Italywww.ratiinox.comSONTEC Sensorbau GmbH,Germanywww.sontec.de

14 EHEDG Company and Institute membersSORMAC B.V., NetherlandsS.S.T. Schüttguttechnik GmbH,GermanySPX Flow Technology RosistaGmbH, GermanySteeldesign GmbH, GermanyGebr. Steimel GmbH & Co.Maschinenfabrik, Germanywww.sormac.nlwww.solids.dewww.apv.comwww.steeldesign.dewww.steimel.comVan Meeuwen SmeertechniekB.V., NetherlandsVDMA FachverbandNahrungsmittelmaschinen undVerpackungsmaschinen, GermanyVEGA Grieshaber KG, GermanyVienna University of Technology /Institute of Chemical Engineering,Austriawww.vanmeeuwen.nlwww.vdma.orgwww.vega.comwww.vt.tuwien.ac.atStephan Machinery GmbH,GermanyStork Food & Dairy Systems B.V.,NetherlandsStranda Prolog AS, Norwaywww.stephan-machinery.comwww.fds.storkgroup.comwww.stranda.netVikan A/S, DenmarkVISCO JET Rührsysteme GmbH,GermanyVolta Belting Technology Ltd.,Netherlandswww.vikan.comwww.viscojet.comwww.voltabelting.comSTW – Stainless Tube WeldingGmbH, Germanywww.stw-gmbh.devon Rohr Armaturen AG,Switzerlandwww.von-rohr.chSüdmo Components GmbH,Germanywww.suedmo.deVTT Technical Research Centre ofFinland, Finlandwww.vtt./Food Industry Swisslion Ltd.,MacedoniaTaiwan Filler Tech. Co., Ltd,ThailandTanis Food Tec b.v., NetherlandsTBMA EUROPE B.V., NetherlandsTetra Pak Packaging SolutionsAB, Swedenwww.swisslion.com.mkwww.twftc.comwww.tanisfoodtec.comwww.tbma.comwww.tetrapak.comWAM GmbH, GermanyWennekes Welding Support BV,NetherlandsWenzhou Aomi Fluid EquipmentScience & Technology Co., Ltd.,Peoples Rep. of ChinaHans G. Werner IndustrietechnikGmbH, GermanyWilco PM, Lebanonwww.wamgroup.comwww.weldingsupport.nl/www.wzaomi.comwww.werco.dewww.wilcopm.comTMR Turbo-Misch undRühranlagen, GermanyTokachi-zaidan, Japanwww.tmr-ruehrtechnik.dewww.tokachi-zaidan.jpWipotec Wiege- undPositioniersysteme GmbH,Germanywww.wipotec.comTPI Chile S.A., RCHwww.tpi.clWire Belt Co Ltd, United Kingdomwww.wirebelt.co.ukForschungszentrumWeihenstephan für Brau- undLebensmittelqualität TechnischeUniversität München, Germanywww.blq-weihenstephan.deWITTENSTEIN alpha GmbH,GermanyWright Flow Technologies Ltd,United Kingdomewww.wittenstein-alpha.dewww.idexcorp.comFaculty of Agriculture - Institute ofFood Technology -www.bg.ac.rsXylem, Inc., Germanywww.xylemowcontrol.comDep. of MicobiologyUniversity of Belgrade, SerbiaULMA Packaging TechnologicalCenter, Spainwww.ulmapackaging.com/Zeppelin Reimelt GmbH, UnitedKingdomZürcher Hochschule fürAngewandte Wissenschaften,Switzerlandwww.reimelt.dewww.lsfm.zhaw.chUnilever Research LaboratoryVlaardingen, Netherlandswww.unilever.comUniversity of Cambridgewww.www.cam.ac.ukUniversity of Osijek, Faculty ofFood Technology, Hungarywww.ptfos.unios.hrUniversity of Parma, Italywww.unipr.itURESH AG, Switzerlandwww.uresh.chList status as of December 2012

EHEDG membership 15EHEDG membershipThe EHEDG network is open to individuals,companies and institutes and comprises almost 1000persons who are the representatives ofCompanies for the manufacturing of food or ofequipment for the production of food, pharmaceuticalsand/or cosmeticsCompanies supplying engineering servicesScientic and research organisationsHealth authoritiesEHEDG is an “Institution for General Benet” and donationsmay be fully deducted from tax.Good reasons to become anEHEDG memberEHEDG creates a central, internationally recognizedsource of excellence on hygienic engineeringEHEDG provides networking on an international level,opportunities for the establishment of global contactsand are interlinking our Regional SectionsEHEDG is a platform for an exchange of state-ofthe-artknow-how and offer advancement in hygienicengineering knowledgeEHEDG provides inuence in setting global standardsand rules and have impact on regulatory bodiesEHEDG offers a legal basis by practicallydemonstrating how to follow existing requirementsand standardsEHEDG guidelines are referenced by internationalorganisations and provide practical know-howEHEDG guidelines are created by gathering theexpert know-how of our members who are equipmentmanufacturers of food and packaging machineryas well as food processing companies, researchinstitutes and health authoritiesEHEDG follows up new trends and help to share,disseminate and canalize hygienic design expertiseThe EHEDG mission is extended to ‘environmentalissues and aiming to support food safety andsustainabilityEHEDG evaluates hygienic design in relation to shelflifeEHEDG provides international, high-level training &education and our training material is developed byrecognized experts in the eldEHEDG provides equipment certication by EHEDGaccreditedtest institutesThe EHEDG certication methods are continuouslyfurther developed and complemented by new testmethodsEHEDG provides reference publications like theEHEDG Yearbook and press articles in scienticjournals and trade magazinesEHEDG enhances the reputation of our membercompanies and help them to become leaders inhygienic design and processingEHEDG provides an information and meeting platformat the EHEDG Congress, an international event heldbiannually in varying countries.

European Hygienic Engineering & Design GroupTest and Certication InstitutesThe following institutes and organisations are authorised by EHEDG to test and certify equipment:DENMARKDTU National Food InstituteDr. Jens Adler-NissenSøltoftsplads 221Dk-2800 Kgs. LyngbyPhone +45 4525 2629 / E-mail ehedgfood.dtu.dkwww.dtu.dk/English.aspxTesting and Evaluation:Dr. Per Væggemose NielsenPhone +45 4525 2631E-mail ehedgfood.dtu.dk, pvnipu.dkMr Jon J. KoldPhone +45 8870 7515E-mail jon.koldstaalcentrum.dkFRANCEAdria NormandieDr. Nicolas RossiAdria Normandie – Centre d Expertise Agroalimentaire, Dpt.ResearchBoulevard 13 Juin 194414310 VILLERS BOCAGEPhone +33 2 31 25 43 00E-mail nrossiadrianie.orgwww.adria-normandie.comGERMANYTU München Forschungszentrum Weihenstephan fürBrau- und LebensmittelqualitätDr. Jürgen HofmannAlte Akademie 3D-85354 FreisingPhone +49 8161 87 68 799Fax +49 8161 71 41 81E-mail jhhd-experte.de, juergen.hofmannehedg.orgwww.blq-weihenstephan.de/leistungen/hygienic-design.htmlNETHERLANDST Rheinland Nederland B..,Ilse Wasim-MoestaredjoP.O. Box 541NL-7300 AM ApeldoornPhone (+31 88) 8 88 78 88E-mail Ilse.Wasimnl.tuv.comwww.tuv.com/nl/index.htmlTesting and Evaluation:Jacques KasteleinTNOP.O. Box 360, 3705 MJ Zeist,Phone +31 88 86 61877E-mail Jacques.kasteleintno.nlwww.tno.nl/SPAINAINIA Centro tecnológicoA. Pascual VidalDepartamento de Calidad y Medio Ambiente,Parque Tecnológico de Valencia,c/Benjamin Franklin, n° 5-11ES-46980 Paterna (Valencia)Phone +34 961 366 090Fax +34 961 318 008E-mail apascualainia.eswww.ainia.es/web/acerca-de-ainiaUNITED KINGDMCampden BRILawrence StaniforthStation RoadGB-Chipping Campden, GLOS , GL55 6LDPhone +44 1386 842042E-mail l.staniforthcampden.co.ukwww.campden.co.uk/Mr Andy TimperleyPhone +44 1789 490081E-mail andy.timperleytesco.netUSAPURDUE UniversityProfessor Mark T. Morgan, P.E.Food Science Building, Room 1161745 Agriculture Mall DriveUSA-West Lafayette, IN 479072009In addition to the certication organisations above, thefollowing research institutes participate in the developmentof EHEDG test methodsAgence Francaise de Sécurité Sanitaire des Aliments,FranceInstitut Nationale de la Recherche Agronomique,FranceLund University, Department of Food Engineering,SwedenSIK - Swedish Institute for Food ResearchUnilever Research Vlaardingen, The NetherlandsVTT Biotechnology and Food Research, FinlandFor further information on EHEDG Test and CerticationInstitutes please refer to www.ehedg.org.List status as of December 2012

18 Legal requirements for hygienic design in EuropeEU Regulation 1935/2004 on materials and articlesintended to come into contact with food covers the followingequipment processing machinery and lling equipment, andkitchen equipment, containers, and packaging materials. Theregulation specically requires that food-contact materialsand equipment comply with the followingNo human health hazardsNo indefensible modication of food compositionNo detraction from organoleptic food propertiesNo misdirection of customersUse of ‘for food contact or the symbol (Figure 2). (Thissymbol is only needed, if there is no instruction manualand if it is not obvious that this is for food contact).Traceability on all manufacturing and distribution stepsEU Regulation 2023/2006 of 22 December 2006 on good manufacturingpractice (GMP) for materials and articles intended to comeinto contact with food requires that the following must be set up andinstalled for all producers of materials intended to come into contactwith food and are covered by EU Regulation 1935/2004Quality assurance systemQuality control systemDocumentationAccording to Article 2 of EC 2023/2006 “This regulation shallapply to all sectors and all stages of manufacture, processingand distribution of materials and articles, up to but excludingthe production of starting substances.” This means that,for example, all producers of plastic materials must have aquality system that includes the required documentation ifthey produce materials intended to come in food contact.Depending on the risk assessment, this documentation mustbe more or less detailed, corresponding to the known orpotential risk.To prevent consumers from absorbing toxic substancesthat may leach from plastics that come into contact withfoods, the European Commission has issued EU Regulation10/2011 on plastic materials and articles intended to comeinto contact with food. Rubber and silicone materials are notcovered by this regulation. Since there is nothing specicfor seals in Europe, the US Food and Drug Administration(FDA) Code of Federal Regulations (CFR) 21 is commonlyused in Europe.Food safety is the core interest of the European Commission.EC Directive 2006/42/EC, or the Machinery Directive, whichcame into force at the end of 2009, sets up the essentialrequirements for machinery. All machines brought to theEuropean market must full these requirements. The CEmark, which identies industrial equipment as in compliancewith all the of safety requirements established by theEuropean Union must appear on each unit (Figure 1).Annex I of the Machinery Directive describes in detail whathas to be taken into consideration to build safe machines.Of particular interest to the food industry is Chapter 2.1 ofAnnex I, entitled ‘Foodstuffs machinery and machinery forcosmetics or pharmaceutical products. This chapter not onlytakes into consideration potentially hazardous situationsfor equipment operators and the environment in which themachine is used, but it is the only chapter in this directivethat refers to the potential hazards for the consumer of theproduct produced on these machines. Essentially, this meansthat mistakes caused by neglecting these requirements canhave a strong impact on public health.The Machinery Directive states that all surfaces (with the exceptionof disposable parts), including joining areas that come into productcontact mustBe smooth, without ridges or crevicesReduce projections, edges and recesses to a minimumBe easily cleaned and disinfectedInside surfaces must have curves of a radius sufcientto allow sufcient cleaningFrom a hygienic design perspective, the following re quirementsare particularly noteworthyIt must be possible for liquids, gases and aerosolsderiving from products and from cleaning, disinfectingand rinsing uids to be completely discharged from themachinery.Machinery must be designed and constructed in sucha way as to prevent any substances or living creatures,in particular insects, from entering, or any organicmatter from accumulating.Machinery must be designed and constructed in sucha way that no ancillary substances that are hazardousto health, including the lubricants used, can come intocontact with products.Figure 2. EU food contact symbol used for marking materialsintended to come into contact with food in the European Union asdened in EU Regulation 1935/2004.For food processing machines, so-called “C-Standards”also are provided in some detail, including how the designof the machine (e.g., the roughness of the surfaces)should be addressed in machines used in contact withspecic products. The standards EN ISO 14159, “Safetyof machinery - Hygiene requirements for the design ofmachinery” and EN 1672-2, “Food processing machinery -Basic concepts - Part 2 Hygiene requirements” describe theaim of the Directive through examples.In addition to these standards, the European HygienicEngineering & Design Group (EHEDG) Guideline 8 criteriaand the EHEDG Guideline 13, Hygienic design of equipmentfor open processing, offer additional guidance. The content

Legal requirements for hygienic design in Europe 19of these two guidelines is comparable with the two EuropeanCommittee for Standardisation (CEN) standards, and insome cases, the examples used are the same. There aresome minor differences in the denition of the food zone,but the design of the units should be such that they can bereadily cleaned within an appropriate time. Ultimately, everymachine has to be cleaned, and depending on the overallcleanability of a machine and its components, this can betime-consuming. For this reason it is much cheaper for foodprocessors to invest in machines that are designed properlywith high cleanability rather than buying cheaper machineswith low cleanability, which might cause product spoilage orcontamination triggered by product residues and/or cleaningagents left behind.For machines that do not meet the “easy to clean”requirements of the Machinery Directive and the relevantstandards, the CE conformity is not valid. The only questionis, who decides if something is cleanable or not? For this,EHEDG provides certication for various types of equipment.This is a voluntary approval scheme that provides a highlevel of condence that the equipment conforms with theMachinery Directive. EHEDG is working on new certicationschemes and guidelines to improve the machines for moreefcient cleanability.3-A Sanitary Standards, Inc.Promoting Food Safety Through Hygienic DesignLeads the development of modern hygienic design standardsfor equipment and accepted practices for processing systems.Oversees the comprehensive Third Party Verification inspectionprogram required for 3-A Symbol authorization and voluntarycertificates for processing systems and replacement parts.Provides specialized education resources to enhance the knowledgeof equipment fabricators, processors and regulatory professionals.Learn, network, and share insights on hygienic design with some ofthe most qualified and trusted authorities from around the world.3-A Sanitary Standards Inc.3-A Sanitary Standards, Inc.www.3-a.org

European Hygienic Engineering & Design GroupThe importance of hygienic design:A process facility case study and checklistThe hygienic design of food processing facilities and equipment is becoming more importantto the food industry, since it allows for a maximisation of the efciencies of manufacturing linesand minimises the cleaning processes without penalising the operation’s effectiveness.Carolina López Arias, A Coordinator Sanitation, Mondele z Internationalemail: clopeza@mdlz.comFigure 1. Processing steps of a cream cheese manufacturing line.In this practical case study of a new cream cheesemanufacturing line installed in an existing facility (Figure 1),the hygienic design principles that should be incorporatedinto the operations of food processing facilities are describedwithin the framework of the phases of a project managementapproach. A checklist of the elements of hygienic designunder this construct is presented.Project ManagementFigure 2. Project management phases.Every project consists of four phases (Figure 2). There arecommon functions involved in these phases, which includethe project manager, and the quality assurance, sanitation,conversion, research and development, and supply changedepartments. The inverted pyramid in Figure 2 shows thatmore resources and time are required to accomplish Phases1 and 2 of a project (i.e., development and pre-engineeringdesign) than Phases 3 and 4. It is critical to allocate the rightamount of time and resources to each phase to successfullyimplement a project.Phase 1. Project development:feasibility and risk assessmentThe goals of Phase 1 are to evaluate the feasibility of theproject idea and estimate the risks, costs, benets andresources associated with the project. By using tools thatallow for the evaluation and measurement of the risksassociated with a project, such as brainstorming or failuremodes and effect analysis (FMEA), the project team caneffectively consider the elements that involve all of thedifferent key functions of the project.In this phase, it is imperative that the project team cover inits risk assessments, at a minimum, the following aspects ofthe production facility and operationsMicrobiological safety assessmentAllergen assessmentCleaning and hygiene (covering both clean-in-place[CIP] and clean-out-of-place [COP]Production capacityUtilities capacity

The importance of hygienic design: A process facility case study and checklist 21Phase 2. Project pre-engineering: DesignThe objective of this phase is to have hygienic designprinciples established for location and layout, piping andinstrumentation, and supplier specications.1. Location and layout determination. This involves threehygienic design principles, as followsa. Hygienic design principle 1:Separation. In the case of the cream cheese facility, a newlayout of the facility was needed in order to meet the thehygienic design principles. Determining a new layout, in thisexample, took into account the following considerationsSpace availability within the existing facilities.Physical separation between the raw area andpasteuriser area.Allergens segregation.b. Hygienic design principle 7:Proper ventilation and utility air. In order to ensure theproper ventilation of the different areas of the facility, thefollowing considerations need to be taken into accountAir quality (i.e., ltration requirements according toproduct sensitivity).Proper design of the installation that preventscondensation.Location of the supply and extraction systems areproperly located to avoid product contamination, andventilation system (i.e., fans) are properly located(Figure 5). Entrances for people to the manufacturing lineFigure 5. Ventilation map. Entrances for people to the manufacturing lineFigure 3. Initial layout of the cream cheese manufacturing facility.As a result of the evaluation, a new layout was proposed forthe facility (Figures 3 and 4).c. Hygienic design principle 2:Cleanability. It is essential that the position of the drains inthe processing room is 100% compatible with the layout ofthe processing line. For this specic case, it was possibleto t the layout of the processing line to the drains locationin the room (Figure 6). Entrances for people to the manufacturing lineFigure 4. Final layout of the facility after hygienic designevaluation. Entrances for people to the manufacturing lineFigure 6. Processing line and room layout in alignment with properpositioning of drains in processing room.

22 The importance of hygienic design: A process facility case study and checklist2. Piping and instrumentation diagram (P&ID). Thisinvolves one signicant hygienic design principled. Hygienic design principle 2:Cleanability. During the denition of the P&ID for theprocessing line, the following aspects should be consideredand includedIdentify all of the different equipment that are part ofthe process.Establish cleaning methods (i.e., CIP, manual, etc.)and cleaning regimes.Evaluate restrictions inw the process and determinealternative solutions to ensure that effective cleaning isachieved.In the cream cheese facility during the P&ID denition phase,it was determined that for the CIP cleaning of the scrapedsurface heat exchangers (SSHE), a reinforcement wasneeded to ensure effective cleaning of the system (Figure7). The red arrows represent the product ow and the pinkones CIP reinforcement.During the CIP cleaning additionally to the main route (redarrows) there is a ip that makes a closed loop with theSSHE, supported by a centrifugal pump.Figure 7. CIP cleaning route for the scraped surface heat exchangers (SSHE).3. Specications for different suppliers. Once the P&ID iscompleted, the next step is to dene the detailed function ofthe line (FDS), as well as the specications for the quality ofthe materials to be used. Once all this information is compiledthe specications can be sent to the different suppliers inorder to get an estimated quotation for the installation.Some hygienic design principles that are important to beconsidered when dening the specications aree. Hygienic design principle 2:Cleanability.Identify the method of cleaning (e.g., CIP, clean-out-ofplace[COP], foam, manual cleaning).Assess the capability of the equipment to handlefrequent CIP temperature exposure.Determine whether all of the equipment components,such as valves, are designed to be cleaned in place.Ensure that the process connections of all themeasurement devices are hygienically designed.Decide how many process connections are needed.f. Hygienic design principle 3:Compatible materials. All materials that may come intocontact with food should not be able to make the food untfor consumption (e.g. toxic). As such, all materials used inthe composition of food manufacturing equipment should behighly resistant to corrosion;nonporous with smooth surfaces;highly resistant to thermal variations;

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European Hygienic Engineering & Design GroupSolving concrete kerb challenges to ensure hygiene andfood safe wall protection in manufacturing environmentsUsing chemical- and water-resistant polymer composite kerbs and plinths help ensure that foodproduction facilities remain hygienic.Nick an den Bosschelle, PolySto, Lokeren, Belgium, e-mail: nick@polysto.com, www.polysto.comFor the past 25 years, sandwich panel constructions havebeen the most popular way to construct food safe rooms inEurope, because it offers fast installation, is easy to cleanand provides good insulation value. Nevertheless, sandwichpanels are very weak and quickly damaged. Often, kerbs inthis scheme have been made onsite in the manufacturingplant during construction, composed of concrete and coveredby the oor nishing. This system has some importantdisadvantages with regard to food safety, impact resistanceand maintenance.Concrete covered by any kind of ooring material is never amonolithic system and after some period of time, the bondingbetween the concrete and the oor material will break as theconcrete deteriorates due to exposure to humidity and acidsin the air and other physical impacts to the surface. Physicalimpacts from trollies, forklifts, hand pallets and cleaningmachines cause cracks to appear in the oor covering(Figures 1 and 2). The result is that dirt and cleaning waterstarts to leak through those cracks, building up behind theoor covering and absorbed by the concrete. This trappeddirty water will eventually begin to evaporate, creating a highpressure of humidity behind the oor covering. The pressureeventually breaks the bonding between the concrete andthe oor nishing, exposing the concrete and creating foodsafety issues as dirt builds up in the resulting crevices andprovides harbourage to harmful bacteria.Figures 1 and 2. Damaged concrete kerbs, as shown, createharbourage niches for dirt and bacteria in food processingenvironments.Figures 3 and 4. Kerbs and plinths for food safe environments.

European Hygienic Engineering & Design GroupResearch on hygienic ooring systemsParticle and C emissions, chemical and biologicalresistance, and cleanabilityIn the food industry, a hygienic manufacturing environment is an absolute necessity in order tominimise reject rates due to contamination and ensure low-germ or sterile conditions. Productquality is especially impaired by microorganisms but also by other forms of contamination, suchas particles and chemical residues. Today, some foods are already produced and packagedunder cleanroom conditions in the same way as practised by the pharmaceutical industry.Cleanroom technology guarantees the necessary controlled conditions, fullling air qualityrequirements such as those stated in the EU-GMP Guideline Annex 1 for the manufacture ofsterile pharmaceutical products. In order to minimise contamination risks during manufacturingprocesses, cleanroom environments need to be carefully planned to ensure that no sourcesof contamination will be present during later production. Materials used to make walls, oors,housings, joins and equipment systems need to be taken especially into consideration. Usingthe qualication of industrial ooring as an example, this article describes an assessment andclassication procedure that will help planners to make objective decisions about the choice ofmaterials.Markus Keller and Udo Gommel, Fraunhofer Institute for Manufacturing Engineering and Automation IPA,Department of Ultraclean Technology and Micromanufacturing, Stuttgart, Germany.e-mail: markus.keller@ipa.fraunhofer.deTo create controlled hygienic environments, appropriateroom solutions in suitable locations are needed with minimummicrobiotic base levels. To achieve this, the concentration ofparticles in the air has to be drastically reduced. In a normalurban atmosphere, a particle concentration of 0.5 to 35 billionparticles with a diameter of >0.5 μm is typical per cubic meterair volume. Cost-intensive ltration technology can reducesuch particulate concentrations to less than 3520 particles/m 3 >0.5 μm diameter. This is required, for example, in sterilepharmaceutical manufacturing environments and equatesapproximately to Cleanroom Class International StandardsOrganisation (ISO) 5 in accordance with the cleanroomclassication standard ISO 14644-1. 1 The pharmaceuticalindustry uses its own standard for the production of sterilemedicinal products, which also denes different zones forhygienic manufacturing environments and extends theconsidered contamination sources including particles tomicroorganisms. 2 In the food industry, microbiologicalcontamination is also especially relevant. 3 Particles between10 and 20 μm in size make up the majority of airbornemicroorganisms. 4 Another hygiene-related classicationsystem is based on the so-called “hospital guideline” DIN1946-4. 5 The food industry is currently implementing moreand more of the existing good manufacturing practice (GMP)pharmaceutical guidelines. A targeted reduction in airborneparticles >0.5 μm automatically means a reduction in airbornemicroorganisms. However, in hygienic manufacturingenvironments, additional parameters regarding the materialsused are also of interest chemical resistance, biologicalresistance, cleanability and antimicrobial properties. 6Solutions from other areas:Pharmaceutical industryAs many foods are produced and/or packaged under almoststerileconditions (milk products, meats, beverages), thefollowing section gives some brief background informationabout manufacturing environments in the pharmaceuticalindustry. In the process, many of the aspects mentionedcan be applied directly to manufacturing environments in thefood industry. A cross-industry viewpoint can be very helpfulwhen implementing clean and hygienic manufacturingenvironments because both the pharmaceutical and foodindustries have to combat the same sources of contaminationparticles and microorganisms.EU-GMP GuidelineThe European Commission Guide to Good ManufacturingPractice (EU-GMP Guideline) is implemented as astatutory standard in the manufacture of sterile drugs andother contamination-sensitive products. In Annex 1 of theEU-GMP guideline, a special emphasis is placed on therequirements of hygienic manufacturing environments.Clean zones for the manufacture of sterile productsare graded according to the environmental conditionsrequired. In order to minimise the risk of contaminatingthe product or material concerned with particles ormicroorganisms, each manufacturing process requires acorresponding degree of environmental cleanliness in anoperating state. In order to full operating state conditions,the zone has to be designed to achieve a certain degreeof air cleanliness when in a resting state. The restingstate is the state whereby the entire technical equipment

Research on hygienic flooring systems 31is installed and ready for operation but no employeesare present. The operating state is the state when allequipment is being correctly operated by the prescribednumber of employees.In compliance with the current EU-GMP Guideline Annex 1,Figure 2 gives information about the classication of GMPcleanliness classes according to the number of airborneparticles detected.EU-GMP Guideline Annex 1: Cleanliness ClassesIn the manufacture of sterile drugs, there are four cleanlinessclasses for the zones requiredCleanliness Class A: sterile zones. These arelocalised zones where high-risk work processes arecarried out (e.g., for lling processes, or areas wherecontainers with stoppers, open ampoules and bottlesare kept or sterile connections produced). Suchconditions are ensured using a laminar unidirectionalairow system with a ow rate of 0.45 m/s + 20%.Cleanliness Class B: sterile zones. Unless aninsulator is used, this is where aseptic products areprepared and lled; they form the antechamber of aCleanliness Class A zone.Cleanliness Classes C and D: clean zones.Laboratories and manufacturing areas for less-criticalsteps in the manufacture of sterile products.Cleanrooms of GMP Class E and F and CNC zones:areas without dened particle or biocontaminationlevel. These may be manufacturing areas,laboratories, documentation areas, ofces, breakrooms and other room types. Recently, a new type ofcleanroom class is also mentioned CNC (controlledbut not classied). These controlled zones do notrequire stringent tests to be classied. Dependingon the ofcial assessment, CNC areas may beinstalled in hermetically separate sterile manufacturingenvironments; for example, by using insulators, inorder to keep the extremely expensive tests anddocumentation involved in classifying zones as low aspossible. 7Figure 1 contains examples of work processes carried out inthe different cleanliness classes.GMP CleanlinessClassABCDExamples of work processesfor sterilised products in closedend-containersAseptic preparation and llingof products where the work steprepresents an unusual riskEnvironmental condition of CleanlinessClass A unless an insulatoris usedPreparation of solutions where thework step represents an unusualrisk, lling productsPreparation of solutions and ingredientsfor subsequent llingGMPCleanlinessClassMaximalpermissible countof particles per m 3-resting state-> 0.5 μm > 5 μm > 0.5 μm > 5 μmA 3,520 20 3,520 20B 3,520 29 352,000 2,900C 352,000 2,900 3,520,000 29,000D 3,520,000 29,000 Not xed Not xedFigure 2. Classication of air quality in the manufacture of sterileproducts airborne particles in compliance with EU-GMP Annex 1.In Figure 2, particle concentrations in the column “in a restingstate” must be attained in an area in an unmanned stateafter a short clean-up phase of approximately 15-20 minuteson completion of work processes. Particle concentrations inthe table for Cleanliness Class A in an operating state mustbe observed in the immediate product area if the product oropen container is exposed to the environment. In hygienicmanufacturing environments, the number of microorganismson surfaces and in the air also plays a major role. Figure 3shows the classication of cleanliness classes according tothe number of microorganisms detected.GMPCleanlinessClassRecommended limiting value formicrobiological contaminationAir sample[CFU/m 3 ]Maximal permissiblecount of particlesper m 3- operating state-Sedimentationplates(Ø 90 mm)[CFU/4 hours]Contactplates(Ø 55 mm)[CFU/plate]A

32 Research on hygienic flooring systemsHygienic materials suitable for usein the food industry using the exampleof ooring systemsAll surfaces in a clean manufacturing environment that arein contact with the ambient air are capable of contaminatingit. Consequently, they signicantly affect the attainmentand maintenance of a required degree of cleanliness. Forexample, if process water accumulates in the joint of aooring system sealed with poor quality sealing material, anymould spores present could ourish there due to the goodlocal growing conditions (humidity, temperature, nutrients)and become a major source of infection. If a materialcorrodes as a result of the effect of an aggressive cleaningagent, it not only loses its required material properties butmay become a dangerous source of particulate emissions.Chemical inuences may cause a ooring material tobecome brittle. If mechanical action is subsequently applied(transport rollers of a heavy preparation tank, etc.), crackscould form, representing a microscopic hazard because itwould be impossible to remove or inactivate effectively anymicroorganisms accumulating in the cracks. Among others,this aspect was considered in the requirements of the EU-GMP Guideline Annex 1 illustrated in Figure 4Extract from EU-GMP-guideline Annex 1:» in clean areas, all surfaces should be smooth, imperious and unbroken inorder to minimize the shredding or accumulation of particles ormicroorganisms and to permit repeated application of cleaning agents anddesinfectants where used «» The manufacture of sterile products is subject to special requirements inorder to minimize risks of microbiological contamination, and of particulateor pyrogen contamination.«ParticleBiol. Resistance andMicrobizidityCleaning andChem. ResistanceFigure 4. Extract from EU-GMP Annex 1 with derivable materialrequirements.Therefore, ooring systems installed in a hygienicmanufacturing environment need to be resistant to thechemicals used in cleaning and disinfection agents.Microorganisms may not colonise there or interact with them.Surfaces must be thoroughly cleanable. No substances maymigrate from materials to the product and the material maynot host any form of contamination. In some industries,material surfaces are treated with an antimicrobial agent.In such cases, it is not only important to be sure that theantimicrobial coating functions in practice but also that thematerial does not represent a hazard to human health in anyway.Due to the large surface area and associated contaminationrisk of ooring systems, they are now discussed in moredetail. First of all, the under-surface of a ooring systemmust be permanently sealable. Liquid residues from aprevious cleaning or disinfection process may remain on thesurface for a long time, making it extremely important for thesystem to be highly resistant to the chemicals used. To beable to clean edges and corners effectively, ooring must belaid so that it extends upwards to cover the bottom sectionof walls. The mechanical properties of the system must bedesigned to prevent damage from occurring as a result oftypical stresses (e.g., rollers of transport trolleys, high pointloads). To generally aid cleanability, roughness levels mustbe kept as low as possible. However, the need for a nonslipcoating, if required, may not be forgotten in the process.Where possible, the transmission between oor and wallsystems should be seamless.The biomaterial regulations in Annex 2 state that, for allprotective categories, surfaces are to be impermeable towater and easy to clean. From Level 2 upwards, biomaterialregulations require adequate resistance to acids, alkalis,disinfection agents and solvents. 8In the case of reactive systems (e.g., epoxy resin oors),care must be taken to ensure that the outgassing of organiccontamination is kept to a minimum in order to protectemployees and, if sensitive processes are concerned, alsothe product. No critical airborne particulate contaminationmay be generated on subjecting the ooring system totribological stress (e.g., rollers, stress due to walking,etc). Comparative tests need to be carried out on a widerange of materials to determine outgassing behavior andparticulate emission due to tribological stress, and theresults appropriately classied. 9,10 It must be possible toclean ooring systems effectively using dedicatedl cleaningmethods and agents.Material and methods:Comparative tests to classify materialsParticulate emissionIf a material is subjected to mechanical stress due tofriction from another material, material abrasion in the formof particle generation occurs. This also can be caused bysliding friction from rollers or static friction from walking overa ooring system wearing shoes. To obtain comparativeinformation about particulate emission from various ooringsystems due to tribological stress (friction), a specialtribological test bench has been constructed (Figure 5). It isoperated in a Class ISO 1 reference cleanroom to eliminatemeasurement errors caused by potential foreign particlesin the environmental air. 2 In the comparative classication,only sliding friction is considered. The counter sampleused in the tests is a standardised polyamide-6 roller thatsimulates the sliding friction caused by transport rollers.Both applied force and angular velocity are kept constant.The laminar unidirectional airow with a velocity of 0.45m/s, which ows from the cleanroom ceiling to the raisedoor in accordance with ISO specications for a Class 1cleanroom, ensures that particles generated during the testare transported downwards in a vertical direction towardsthe sampling probe installed downstream that detectsthe airborne particles (Figure 2). Using the principle ofscattered light, a particle counter detects all particles witha diameter >0.2 μm and classies the number of particlesinto predened particle size channels according to theirsize. To take single events appropriately into account, thetest is performed for a minimum of one hour. On cumulatingthe data and transforming coordinates, a result is obtainedthat gives an assessment of the test material with regard toparticulate abrasion due to tribological stress. The procedure

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34 Research on hygienic flooring systemsis standardised and explained in detail in the guideline VDI2083 Part 17. The material value obtained enables a directcomparison of ooring systems to be made and showshow much the system potentially contributes to particulatecontamination of the cleanroom environment when subjectedto tribological stress.layered construction also is accounted for in the plannedapplication. Glass dishes made of borosilicate glass areused as VOC-free carriers. Samples are preconditioned for aperiod of 30 days under controlled climatic conditions (roomtemperature 22+/-1°C, relative humidity of 45%. 12,13 Crosscontaminationof the samples during storage is preventedthrough the use of mini-environments with VOC ltration. TheVOC-reduced quality of the environment must be at leastone class better than the anticipated VOC assessment of thetest piece. 9 After storage, material samples are heated in amicrochamber at atmospheric pressure and a standardisedtemperature of 22°C +/-1°C for one hour. The VOCs emittedfrom the material sample are then advanced to a sorptiontube by a rinsing gas where they are adsorbed. The sorptiontube is then analysed via TD-GC/MS. Thermodesorptioncauses the VOC to be desorbed from the sorption tube andmade available for the subsequent analysis carried out incompliance with VDA 278. The SER m of the material is thenascertained from the results, which in turn can be expressedas a simple standardised material value ISO AMC m . 14,15Figure 5. Cleanroom-suitable tribological test bench at FraunhoferIPA to ascertain particulate emission from material surfaces. Toavoid cross-contamination, the test bench is installed in an ISOClass 1 cleanroom.C outgassingIn addition to particulate emission, the outgassing behaviourof hygienic ooring systems due to mechanical stress alsois becoming a more important issue. When using suitablematerials, statutory limiting values for workplace stress(MAK values) must be observed. Substances outgassingfrom materials (e.g., softeners, solvents, and other volatileconstituents of materials) contribute signicantly towardcontaminating the ambient air with airborne molecules (i.e.,airborne molecular contamination, AMC). Here, organicairborne contamination (volatile organic compounds, VOCs)is the most relevant. 11 Airborne molecular contaminationhas been identied as being the main cause of the socalled“sick building syndrome.” The procedure, outlinedhere, enables different ooring systems to be comparedwith regard to the emission of VOCs; a ranking list has beenderived for their selection and classication. The quantityof organic compounds released into the atmosphere isdependent upon surface area, outgassing time, age, andtemperature of the test material. The specic emission rate(SER) ascertained for each material is related to theseparameters and is expressed as mass per surface area andtime [g/m 2 s] at room temperature. To obtain comparableresults, a standardised test procedure using a microchamberis applied (Figure 6).Outgassing is assessed by collecting and accumulatingvolatile compounds in an adsorber, followed by analysis usingthermodesorption with gas chromatography coupled witha mass spectrometer (TD-GC/MS). Samples are selectedrepresentatively according to their geometry and surfacequality, taking the later application of the ooring systeminto consideration. In the case of multilayered materials, theFigure 6. Microemission chamber to ascertain VOC emissions froma material surface at Fraunhofer IPA.Biological resistanceThe international test standard Deutsches Institutfür Normung (DIN) EN ISO 846 has proven useful indetermining the biological resistance of materials to bacteriaand moulds. 16 Under the test conditions prescribed in thestandard, test materials are assessed to nd out if they areinert to moulds (Procedure A) and bacteria (Procedure C),or if microorganisms are able to interact with them. Testsamples are incubated at 24°C and 95% relative humidityin accordance with the parameters stated in ISO 846 andvisually evaluated after a period of four weeks. The numericalISO assessment of both Procedure A and Procedure Cenables classication according to a rating value based on aworst case of both procedures.The problem with the standard ISO 846 is the complicatedand time-consuming incubation procedure for the testmicroorganisms if the procedure is done completelyaccording to the standard. Also ISO 846 lacks a standardizedobjective assessment matrix for Procedure C to evaluatebacterial growth as the stated assessment matrix is onlyapplicable for the evaluation of mould growth according to

Research on hygienic flooring systems 35procedure A. So how bacterial growth should be evaluated?There is no method described in ISO 846. Therefore,as defeat strategy the majority of test laboratories andFraunhofer IPA use the assessment matrix for Procedure Afor the evaluation of procedure C. This lack has promptedthe Deutsches Institut für Normung (DIN – German Institutefor Standardisation) at ISO level to initiate a revision of thestandard. The aim is to replace subjective visual assessmentwith objective mechanical assessment through the use ofmore cost-efcient automated image analysis methods. Theguideline series ISO 4628-1 to -6 gives an example of anautomated analysis method that uses reference images andtheir black-and-white binarized images for comparison. 17As mentioned before, the ISO 846 standard – which hasremained unchanged since 1997 – is currently beingrevised. Interested institutes are invited to add their skills andtechnical knowledge to the discussion and are requested tocontact the author.Chemical resistanceThere are several internationally-recognised standards forassessing chemical resistance. Tests in accordance withthe DIN EN ISO 2812-1 immersion process have provenespecially useful in assessing the suitability of materials andsurfaces for use in hygienic manufacturing environments. 18To compensate for the fact that future cleaning or disinfectionagents are not known at this point, materials are tested witha representative spectrum of possible groups of chemicals.This approach permits a general assessment about thechemical resistance of materials to be made but not a specicassessment regarding dened cleaning or disinfectionagents. The concept was developed by the industrialalliance CSM under the management of Fraunhofer IPA andis standardised in VDI 2083 Part 17 and VDI 2083 Part 18. 9,19The resulting standard test assesses chemical resistanceto the following 10 representative reagents in dependenceupon their anticipated later maximum concentration incleaning and disinfection mediaWith regard to outgassing Formalin (37%) Hydrogen peroxide (30%) Peracetic acid (15%)With regard to alcohols Isopropanol (100%)With regard to alkalis as constituents of alkaline cleaningagents Caustic soda (5%) Ammoniac (25%)With regard to acids as constituents of acid cleaning agents Sulfuric acid (5%) Hydrochloric acid (5%) Phosphoric acid (30%)With regard to cleaning agents containing chlorides Sodium hypochlorite (5%)In accordance with the ISO 2812-1 immersion procedure,the entire material sample is placed in a receptacle lled withthe chemical, which is then hermetically sealed. If a coatingapplied to a substrate requires testing, care is to be taken toensure that all surfaces and edges of the carrier material aresealed with the coating concerned. In the modied spottingmethod according to VDI 2083-18, the test substance isplaced in a glass vessel. The test surface and a seal areplaced over it and then clamped into a device to create ahermetic seal. The test apparatus is then rotated 180° sothat the test chemical is in contact with the surface of thesample.The modication made to ISO 2812-4 requires a muchlarger volume of test chemical. 20 If only a droplet is applied,evaporation phenomena cannot be excluded. Test piecesare exposed to the respective reagents at room temperaturefor a period of one, three, six and 24 hours and subsequentlyexamined to see if there any visiible alterations. Using 10-fold magnication, the test surface is visually assessedconform to ISO 4628-1 to -5 with regard to the followingcriteria type of damage (alteration in degree of shine,discolouring or yellowing, swelling, softening or reducedscratch resistance); amount of damage (N-value); sizeof damage (S-value) and intensity of alteration (I-value). 17The analysis is carried out as follows “blistering, N2-S2” or“discolouring, I1”. The poorest value (N, S, I) obtained after24 hours is taken for the comparative assessment. In theCSM procedure, the mean of all 10 values from each ofthe previously mentioned chemicals gives the rating value,which is used for classication and comparison.Microbicidal propertiesSome ooring systems have microbicidal properties;these can be divided into bactericidal properties (effect onbacteria) and fungicidal properties (effect on moulds). Onemethod of assessing bactericidal effects is to implement theinternational test standard ISO 22196. 21 In the standard, therecommended bacteria strains Staphylococcus aureus andEscherichia coli are incubated on a surface sample treatedwith a bactericide and also on another sample without thebactericide. Other bacterial strains may also be utilised butthis must be clearly mentioned in the test report. Using thecontact plate method, the once-only assessment of thelogarithmic reduction factor R = log(CFU untreated /CFU treated ) ismade after a period of 24 hours by determining the number ofbacteria present on the reference surface, as well as on thesurface treated with bactericide. 22 CFU stands for “colonyformingunits” because bacteria can only be detected andcounted if they have grown during incubation to form visiblecolonies. With the contact plate method, a solid incubationmedium (casein-soya-peptone-agar or similar) with a surfacearea of approximately 50 cm 2 is applied to a at surface witha dened pressure over a dened period of time; specically,5 seconds, where possible, with sufcient force so that theentire surface is in contact with the medium but withoutany air bubbles forming. An application weight of 1 kg hasproved effective. Samples are incubated in the same way as

36 Research on hygienic flooring systemsother cultivation test procedures. The efcacy of fungistaticor fungicidal coatings can be assessed on implementingProcedure B outlined in ISO 846. Fungistatic or fungicidaleffects can be assessed if an inhibition zone is formed afterapplication of the material sample to a fully-colonised Petridish.CleanabilityIn order to assure hygienic processes and give productsa maximum shelf life, adequate cleanability is generallynecessary from a hygienic aspect. 23 A clean manufacturingenvironment is capable of minimising factors that could havea negative effect on sensitive products. 24 A standardisedtest procedure veries the degree of effectiveness withwhich particles can be removed from a ooring system bywipe-cleaning. A linear wiping simulator is used to ensurereproducibility of the cleaning (Figure 7). Before beingcleaned, test surfaces are reproducibly contaminated witha dened quantity of particles. Before and after the cleaningprocess, the concentration of particles present is determinedby a measuring device that detects particles on surfaces(PMT Partikel-Messtechnik GmbH, Heimsheim, Germany).This enables the relative cleaning success of differentsurfaces to be calculated, and gives a comparative valuebased on standardised surface cleanliness classes. 9,25,26Figure 15 shows the results of a cleanability test on amaterial surface.Particulate emissionThe classication of particulate emission is based on the aircleanliness classes dened in ISO 14644-1 (Figure 8). 2 It isprincipally assumed that all particles generated by a ooringsystem as a result of tribological stress are released into asurrounding volume of air of 1 m 3 . 9 The ISO class calculatedaccording to VDI 2083 Part 17 is, however, only a materialclassication value and cannot be directly correlated withthe cleanroom class in which the ooring system canbe implemented. To do this, the anticipated tribologicalstress also has to be taken into consideration. However,the material classication value established does enablethe abrasion resistance of different ooring systems to bedirectly compared.Figure 8. Classication of air cleanliness in accordance with ISO14644-1. The classication of particulate emission behaviour frommaterial samples is based on this classication..C outgassingFigure 7. Linear wiping simulator.ClassicationClassications regarding particulate emission, outgassing,chemical and biological resistance, antimicrobial propertiesand cleanability are explained below in detail as developedby the industrial alliance CSM and standardised in theguideline VDI 2083 Part 17. The clear comparability andsimple communication of information enables suitablematerials to be rapidly selected according to their futureconditions of use.To convert the SER value into an ISO AMC m class forthe type of contamination concerned (in this case volatileorganic compounds) the value is normed. The classicationis based on ISO AMC cleanroom classes in accordance withISO 14644-8 (Figure 9). 27 The actual detection limit is ISOAMC m (VOC) = -9.6. This material classication calculatedin accordance with VDI 2083 Part 17 does not correlatewith the corresponding ISO AMC cleanroom class. It doeshowever permit the outgassing behavior of different ooringsystems to be directly compared with one another. Based onthe material classication value ISO AMC m , the anticipatedISO AMC class can be estimated if all relevant operatingparameters are known (e.g., surface area, air-conditioningtechnology, volume of the manufacturing environment,etc.). 10,14

Research on hygienic flooring systems 37ResultsParticulate emission,C outgassing and microbiological resistanceFigure 11 shows the results from an assessment of theoor covering Sikaoor 390 in accordance with ISO 846Procedures A and C.Figure 11 Assessment of the oor covering Sikaoor 390 inaccordance with ISO 846 Procedure A and C.Figure 9. Cleanroom classication in accordance with ISO 14644-8 and classication of the outgassing behavior of volatile organiccompounds (VOC) from material samples.Chemical and biological resistance,microbicidityChemical and biological resistance and microbicidity areclassied according to Figure 10Figure 12 shows a summary of concrete materialresults regarding particulate emission, outgassing andmicrobiological resistance. Detailed data are available tothe public in the database at the websites www.ipa-csm.comand www.ipa.qualication.com.Figure 10. Classication of chemical and biological resistance andantimicrobial properties.

38 Research on hygienic flooring systemsFigure 14 shows the results from an assessment of thechemical resistance of a ooring system with variousexposure times (Exp.) in accordance with ISO 2812-1 andISO 4628-1 to -5Figure 12. Overview of examples of tested ooring systems,wall coatings and sealants with regard to outgassing, particulateemission and microbiological resistance. Note Not all tests werecarried out on all materials. Key Type “P” means panel material,“E” is epoxy-system, “F” is oor system, “S” is sealant, “P” is PUsystemand “A” is acrylic system.Chemical Resistance.Figure 13 shows an example of a classication of thechemical resistance of another ooring system.Figure 14. Assessment of the chemical resistance of a materialsample in accordance with ISO 2812-1 and ISO 4628-1 to -5.Photographic examples of the effects of two chemicals.CleanabilityFigure 13 Example of assessment of chemical resistance of amaterial sample in accordance with VDI 2083 Part 17.The cleanability of a material surface is currently expressedas a relative cleaning success. If, for example, a surfacecleanliness class of SPC = 6 (SPC class in accordance withISO 14644-9 [26]) is ascertained before cleaning and SPC= 4 after cleaning, the relative cleaning success is two SPCclasses. One method of standardisation would be to have adened level of initial contamination. As no valid standardsapply at the moment, the relative cleaning success isused as a comparable material value. For the purposesof comparison, an identical level of contamination wasapplied to the test materials listed below, which was thenmeasured, removed and the surface inspected again aftercleaning. Surface roughness values Ra in accordance withISO 4287 along and across the direction of grinding were

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40 Research on hygienic flooring systemsalso recorded. 28 Figure 15 shows a graphical illustration ofthe test results and corresponding SPC class of a materialsurface before and after cleaning. Figure 16 shows the nalresults from different material surfaces tested.Figure 15. Graph showing the test results and corresponding SPCclass of a material surface before and after cleaning. Particle sizesare shown on the x-axis. Particle concentrations are shown on they-axis. SPC class values have been taken from ISO/FDIS 14644-9.Figure 16. Overview of examples of material surfaces tested andrelative cleaning efciency.SummaryA comprehensive understanding of the various aspects ofcleanliness in hygienic manufacturing is required in order toselect suitable ooring systems for cleanroom constructions.Reliable procedures for testing and assessing the cleanlinesssuitability of materials make it possible to compare materialsobjectively. The procedure has been standardised in theguideline VDI 2083 Part 17. The ISO standardisationcurrently being carried out at international level is based onthe VDI guideline. By carrying out numerous tests on ooringsystems, a pool of knowledge has been created regardingthe cleanliness suitability of materials for use in hygienicmanufacturing environments.Under www.tested-device.com and www.ipa-csm.com, theworlds rst public database has been set up by FraunhoferIPA for materials and operating utilities suitable for use incleanrooms and hygienic manufacturing environments.The materials and results accessible to the public canbe viewed at any time. This enables appropriate ooringsystems to be selected for use in clean and hygienicmanufacturing environments even during the design phaseof a manufacturing environment.

European Hygienic Engineering & Design GroupHygienic design of oor drainage componentsDrainage is a critical component affecting the hygienic performance of food production facilities.This article considers surface drainage holistically at site level initially before focusing internallyto look at how features within the drain component itself might elevate hygienic performance.Martin Fairley, AC Technologies plc, e-mail: mfairley@aco.co.uk, www.aco.co.ukDrainage is a critical component that affects the hygienicperformance of food production facilities. Effective drainagehelps mitigate hazards from the external environment andis central to the safe and hygienic operation internally.Floor drainage specically provides three basic functions– interception, conveyance of uids, and the ability to actas a barrier. Despite its importance, relatively few academicstudies have focused on hygienic attributes of oor drains.Of greater concern are the numerous examples of drainageinstallations that exhibit some capacity to be termedhazardous. This is often a result of a oor-drain interfaceissue, but can equally apply to the component designitself. This article considers surface drainage holistically atsite level initially before focusing internally to look at howfeatures within the drain component itself might elevatehygienic performance.Such holistic consideration of drainage is necessary forany operation, but becomes critical where hygiene is ofimportance. While surface water sewers are now morecommon, many countries have a substantial legacy ofcombined surface and foul drainage systems of xedand often inadequate capacity. Should such a systemsurcharge – due to inux of large amounts of surface water sewer backow may occur. The risk can be managedthrough specication of adequate backow preventiondevices. Optimally, these sense backow and automaticallyclose, re-opening once the event has subsided. Figure 1illustrates such a device with the necessary twin valves,one operated by external power, in accordance with EN13564 type 3,Site level drainage considerationOf course, drains serve both internal and externalrequirements and it is worthwhile reviewing the increasingfocus on external drainage design. Many countries nowacknowledge the impact of changing weather patterns andthe implications for surface water management. The EUFlood Directive (2007) initiated local ood risk managementplans that spurred specic legislation related to this growingexternal hazard. In England and Wales, for example, theFlood and Water Management Act (2010) empowers localgovernment to coordinate ood risk management, and thistranslates directly to planning requirements that must besatised before building work commences.The implication for newly built construction is far more focusedon mitigating ood risk to people and property. At site levelthis requires consideration of a number of potential (model)storm events and drainage design to accommodate them.Ultimately, the degree to which the risk is managed is a choiceof the building operator. Storm events are commonly speciedby their frequency, duration and intensity; for example,it is necessary to consider the impact of a 1100-year (1%probability) storm in England, the duration and intensity ofwhich will depend upon the geographical area selected inthe model. The building operator may choose to manageless probable events; in other words, a 1200-year (0.5%probability) event logically produces greater water volumes,and therefore an appropriate drainage design should follow.As may be appreciated, these new challenges to site designare accommodated in newly built construction. Existingfacilities may well benet from an engineering assessmentof their drainage via a qualied professional conversant withlocal regulation, as many of the techniques used in a newlybuilt construction can be retrotted to existing sites.Figure 1. A sewer backow prevention device.In more modern schemes, site connection will be to surfacewater sewer only, and in many cases, no sewer at all. Insuch situations the risk of building ooding can be reducedby accommodating more storm water in the now ubiquitousunderground geocellular storage devices as shown in Figure2. Furthermore, the building operator may request that hisor her designer does not allow car parks or other areas ofthe production facility to be designated as ‘ood storage,which is becoming a common approach. Although in manycases this may be entirely justied on the grounds of costavoidance, food production facilities may prefer to adoptalternative measures. In any case, it is necessary to specifyadequate freeboard over the expected ood level withrespect to the building oor.

Hygienic design of floor drainage components 43Figure 2. Geocellular storage systems provide efcientunderground capacity to manage ood risk to the building and tomeet local volume discharge consents.Internal oor drainageIt is well recognised that drainage is an essential componentof effective hygienic operation. Global initiatives such as theGlobal Food Safety Initiative (GFSI 2012) and EuropeanEconomic Community legislation (EC 852) highlight therequirement for adequate drainage. Further denitionscan be sourced from the various European standardsas referenced in this article, as well as local building orconstruction regulations.Within the food production facility, surface uids present ahazard for which an appropriate risk assessment strategycan be devised. Fluids may be part of the cleaning process,or may originate from specic equipment discharge points,or be simply the result of accidental spillage. Quite oftenthe uid contains other components – organic matter beingprevalent. Floor drainage components cater for thesesituations through three core functionsInterceptionConveyanceBarrier capabilityFigure 3. Fluid interception and conveyance illustrated on the left ina slot linear channel, and localised point interception is shown onthe right through a tundish connected to a oor gully.Conveyance relates to uid movement or transport. Whileuid conveyance across oors should be minimised it isclear that linear channels exhibit good conveyance attributeswith the benet of generally keeping the drainage inverthigher than with a pure gully system. This is especially so inlarger areas. This attribute is also useful in drainage retrotschemes, where construction depths might be minimisedwith subsequently less disruption. Gullies on the other hand,convey only to the ongoing drain pipe.The ability to create a barrier that prevents uid bypassmay be important at specic locations, such as doorways.As such, drainage layout may be part of the wider schemeof segregation or zoning within the facility as illustrated inFigure 4.The main categories of oor drainage, gullies and linearchannels, differ in their performance of these functions.The property of interception can be related to the efciencyof surface uid removal, a function equally inuenced by thesource Point discharges can be most efciently interceptedby a gully, often with a tundish or funnel component on thecover or grate to minimise splashing. In cases in which largevolumes of uid discharge over a wider area, wide channelsystems provide interception along their length and preventbypass. Examples of both are shown in Figure 3.Figure 4. A common position for oor drainage.

44 Hygienic design of floor drainage componentsThat drains might contribute to segregation or zoning, andindeed their impact hygienically on the facility, is a matterfor debate, though reference to drainage is made in anumber of EHEDG derived publications (Lelieveld, Mostert,Holah 2003; 2005; 2011). Zhoa et al. (2006) in their studyof Listeria in poultry plants noted the importance of drains“Floor drains in food processing facilities are a particularlyimportant niche for the persistence of Listeria and can be apoint of contamination in the processing plant environmentand possibly in food products” (ibid, p. 3314).However, even when the provisions contained in componentstandards are adopted, these are not necessarily alignedwith best hygienic practice. For example, the standard EN1253 permits the design of gullies with an effective sump, asillustrated in Figure 6. Here, the obvious sump provides all ofthe potential ingredients for bacterial growth.More recent work by Berrang et al. (2012) studied Listeriamobilization from the drain by inadvertent water spray duringcleaning operations, with subsequent potential to transfer tofood contact surfaces. Of note, Berrang cites studies wheresuch bacteria have been detected in oor drainage evenafter extensive plant sanitation (ibid p. 1328).Reducing the potential for harbourage of such pathogensshould be a key concern of any oor drainage productmanufacturer concerned with hygienic principles.Figure 6. Horizontal gully as portrayed in BS EN 1253.Floor drainage issues in practiceGenerally, two main issues give rise to hygienic concernissues related to installation, and in particular the oor-todraininterface, and issues related to the component designitself. Here, the latter is considered.The choice of materials for drainage component manufactureis extensive and not necessarily constrained by the keyEuropean standard (EN 1253). Typically, where hygienicconsiderations apply, stainless steels are advocated. Withthe readily available supply of appropriate grade sheet,it should come as no surprise that many components arefabricated by none drainage-specic companies. Linearchannels in basic form, especially, can be easily fabricated,as can simple ‘box type gullies. It is estimated that morethan 200 suppliers fabricate drainage components in theEuropean Union (EU) alone (ACO 2009), the vast majorityof which are primarily fabrication companies with no specicexpertise in drainage. Consequently, there is huge variationin how oor drains are fabricated, two examples are shownin Figure 5.It thus becomes necessary to supplement general standardswith further guidance. In the case of the oor gully, manyof the design aspects of European Hygienic EngineeringDesign Group (EHEDG) guidance documents, particularlyDocument 13, may be economically incorporated in productdesign.ACO has sought to incorporate in its componentsContinuous welding of jointsRadiused cornersDrainabilityThe new horizontal gully in Figure 7 shows a oor drainbody that addresses the above points.Figure 5. A case for improved drainage component design.For the facility operator, specication of components thatmeet appropriate standards – Euronorms or their regionalcounterparts – ensures compliance with a number of criteria,not the least of which are load bearing and hydraulic capacity.As a matter of course, certication should be requested fromcomponent suppliers (e.g., for the internal oor gully therecommended reference is EN 1253 [2003]).Figure 7. Floor gully body addressing key principles of hygienicdesign.

ACO. The future of drainage.We take hygienic performance one step further.Deep-drawn body ensures smoothcontours eliminating crevices that cannest dangerous bacteria.All radiuses are largerthan 3mm which greatlyincreases the cleaningeffectiveness.Edge in-fill ensures stable anddurable transmission betweenthe gully and surrounding floorand helps to minimize the riskof floor cracks that preventsbacteria growth.Dry sump design, completely drainable- eliminating potential problemsof bacteria growth.ACO gully ACO pipe ACO slot channelACO tray channelACO gully design takes hygienic performance one step further. We focus on the exactingrequirements in the food production industry, applying standards reserved for food contactsurfaces EN 1672 and EN ISO 14159 to the gully design. All our building drainage productsare tested according to European standards EN 1253, EN 1433 or EN 1124.More than 60 years of drainage experience makes ACO the world class supplier ofdrainage systems.www.aco-buildingdrainage.com

46 Hygienic design of floor drainage componentsA further step necessary to ensure hygienic design andone that is not always taken in drain fabrication is the picklepassivation process. The benets of the process are wellunderstood. Given the nature of drains, passivation helpsprevent corrosion at points where inspection and cleaning ismore difcult, and as such, it should be part of the standardchecklist for any potential user.In summary it is useful to provide a quick checklist of the keyaspects of hygienic oor drainageCertied to EN 1253 or local equivalentPickle passivated stainless steel Grade 304, 316or higher to specicationKey hygienic design parameters of Document 13evidentSpecied according to the application requirementsfor trafc loadSpecied according to the application requirementsfor hydraulic owBibliographyACO (2009) Market survey of drainage component producers inEurope. Internal Report.Berrang, B.E. and J.E. Frank. (2012). Generation of airborne Listeriainnocua from model oor drains. Journal of Food Protection, Vol.75,71328-1331.Directive 2007/60/EC of the European Parliament and of the Councilof 23 October 2007 on the assessment and management of oodrisks.EN (BS) 12532003. Gullies for buildings. British StandardsInstitution (BSI). London.EN (BS) 135642002. Anti-ooding devices for buildings. BritishStandards Institution (BSI). London.EHEDG Document 13. Hygienic design of open equipment forprocessing of food. May 2004.Flood and Water Management Act (2010 ) England and Wales,Chapter 29, (2010). London. HMSOGFSI Guidance Document Sixth Edition Issue 3 Version 6.2 (2012).www.mygfsi.com/technical-resources/guidance-document/issue-3-version-62.html.H. L. M. Lelieveld, M. A. Mostert, and J. Holah. Hygiene in foodprocessing Principles and practice. Woodhead Publishing Series inFood Science, Cambridge 2003H. L. M. Lelieveld, M. A. Mostert, and J. Holah. Handbook of hygienecontrol in the food industry. Woodhead Publishing Ltd. Cambridge2005H. L. M. Lelieveld, M. A. Mostert, and J. Holah. Hygienic designof food factories. Woodhead Publishing Series in Food Science,Cambridge 2011Regulation (EC) No. 852/2004 of the European Parliament and ofthe Council of 29 April 2004 on the hygiene of foodstuffs.Zhao, T., T.C. Podtburg, P. Zhao, B.E. Schmidt, D.A. Baker, B. Cords,M.P. Doyle. (2006). Control of Listeria spp. by competitive-exclusionbacteria in oor drains of a poultry processing plant. Applied andEnvironmental Microbiology, Vol. 72, 53314-3320.

European Hygienic Engineering & Design GroupHygienic design of high performance doors for utilisationin the food industryIn order to protect human health stringent hygiene regulations are implemented throughout thefood industry, from small- to large-scale food production operations, to kitchens and canteens.The most important hygiene regulations are comprised of mandatory requirements regardingfood safety, many of which focus on ensuring that the design of and materials used in themanufacture of equipment, walls, oors, ceilings, and doors used in food production facilitiesmeet hygienic standards. In this article, hygiene regulations pertaining to doors providingentrance and exit from food manufacturing operations are discussed, as well as a door systemdesigned for hygienic ingress and egress from low-risk and high-risk areas.Daniel Grüttner-Mierswa, Albany Door Systems GmbH, D-59557 Lippstadt, Phone +49 (0 29 41) 766-644,e-mail: Daniel.Gruettner-Mierswa@assaabloy.com, www.albanydoors.comDoors regulate access to production, washing and storageareas, separate these safely from each other, and arebenecial for smooth-running logistical operations. Theyalso can be used as entrances to airlocks, which separateclean and dirty areas from each other (Figure 1). For thesereasons, the hygienic design of doors is critically important,and several European regulations and standards are in placeto help ensure that these building components contribute tothe sanitary conditions of food production facilities.The most important hygiene regulations are comprised ofmandatory requirements regarding food safety, such asEuropean Commission (EC) Regulation 1935/2004 forutilised materials, which regulates the general principles andthe requirements of the hygiene regulations for all foods.It stipulates, among others, that doors have to be easilycleanable and, if applicable, easy to disinfect.Figure 1. Doors can be used as entrances to airlocks, separatingclean from dirty areas in a food production facility.This high level of hygiene requires a special resistance ofthe utilised materials against aggressive cleaning agents,as well as smooth and water repellent surfaces. In addition,according to EC Regulation 852/2004, operators mustintegrate doors into their Hazard Analysis and Critical ControlPoints (HAACP) plans, the self-implemented food safety riskanalysis and management system. Specically, under Article5 of the regulation, food processors are obliged to introducea permanent procedure based on this system.An example of a door meeting hygienicrequirementsThe Albany Rapid Food Door is a good example of the typeof door that meets regulatory and other hygiene standardscriteria. The Rapid Food Door is certied with the Institutefor Occupational Safety and Health of the German SocialAccident Insurance (DGUV) test mark and has beenhygiene tested by the test and certication body of theGerman Berufsgenossenschaft BG Expert Committee forFood and Drug. The hygienic suitability of the Rapid Fooddoor also meets the requirements of the German ProductSafety Act, the DIN EN 1672-22009 and EC Regulation852/2004 regarding the cleanability of the curtain and easyaccess for cleaning to all surfaces and components.The side frames and the bottom prole of the door arecompletely made of stainless steel (V2A). Additionally,the door offers a slanted top roll cover and motor coverto ensure drainage. The top roll cover is hinged for easycleaning. The side columns are open at the bottom in orderto avoid the collection of excess cleaning water. Due tothe hinged side frames, it is possible to thoroughly cleanand disinfect the inside of the side columns. The draindrip on the bottom prole ensures that no liquid enters theclearance between the door curtain and the oor in order toavoid the contamination of foods. Additionally it is possibleto adjust the lower end position to stop the bottom prolefrom touching the oor. Therefore it is kept dry and cleanjust as the drain drip.The smooth door curtain made of transparent PVC with bluereinforcement stripes is resistant against cleaning aids andis not affected in its function or appearance by permanentcleaning, which meets the requirements of EC Regulation852/2004. The reinforcement stripes are available in anextensive variety of RAL colours, which means that thedoor can also be customised to its production surroundings.A curtain conforming to the regulations of the US Foodand Drug Administration (FDA), which stipulates therequirements for PVC that come into contact with food, isalso available.The Rapid Food Door also meets the requirements of theGlobal Food Safety Initiative (GFSI), which divides foodproduction facilities into three hygiene zones. Hygiene

48 Hygienic design of high performance doors for utilisation in the food industryZone 1 entails stringent requirements regarding hygieneand cleanability. Open products are processed in theseareas. Wood and glass are strictly prohibited. Access isonly granted in protective clothing after the disinfection ofhands. In Hygiene Zone 2, prepacked products are stored.Wooden sheets are tolerated. Stringent hygienic-basedaccess requirements similar to Zone 1 apply to this hygienezone. In the third, the lowest risk hygiene zone, packedgoods are stored. There are no stringent requirements forthis area.Figure 2. The Albany airlock system is used to ensure hygienicand continuous material ow from low-care to high-care areas atMilupas Fulda, Germany processing plant.An example of an application: Milupa, FuldaThe Rapid Food Door is utilised at Milupa, a member ofthe Danone Group, at its Fulda, Germany location. In theproduction of baby and infant foods, as well as clinicalproducts, stringent hygiene regulations are observed inorder not to endanger the health of children or adults.The company focuses on awless hygienic conditions inits food production facilities that exceed the mandatoryrequirements. Complex air lters and airlocks protect againstcontamination and create perfect conditions in production.While the raw material warehouse of Milupa is classiedas a ‘low care area, the production is classied as a ‘highcare area due to the latters stringent hygienic requirements.This conforms to Hygiene Zone 1 of the GFSI (Global FoodSaftey Intitiative). In order to ensure a continuous materialow from the low care area to the high care area, Milupaintroduced the Albany airlock system into its Fulpa facility.Due to the interlocking system, only one door at atime can be opened. Access to the high care area isnot granted unless the opposite door has completelyclosed. This ensures additional hygiene and offerssecurity to the warehouse staff. The red verticalreinforcement stripes indicate the change from thelow care to the high care area, and mark the strictseparation of the two areas. The stainless steel sideframes of the door conform to the stringent hygieneregulations of the food industry. Just like the curtain,they can be cleaned easily and thoroughly due to thesmooth surfaces. The company opted for this doortype not only because it meets the requirements ofthe Good Hygiene Praxis (GHP), which refers to thehygienic conditions of the surroundings and includeshygienic measures regarding room climate, protectionagainst pests and/or the surface design of the interior,but also matches the HACCP concept instituted byMilupa.

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European Hygienic Engineering & Design GroupPerformance testing of air lters for hygienic environments:Standards and guidelines in the 21 st centuryAir ltration is the key technology that supplies air of the required cleanliness to hygienicproduction areas and to ensure sufcient air quality for processes, products and humanbeings. Increasing demands for high-ltration performance and energy-efcient operationhave prompted recent updates of existing standards and guidelines and the denition of newinternational documents.Dr.-Ing. Thomas Caesar, Freudenberg Filtration Technologies SE & Co. KG, 69465 Weinheim, Germanye-mail: Thomas.Caesar@Freudenberg-Filter.comFor the manufacturing, testing, classication, installation andoperation of air lters in general, and in the food industry inparticular, various standards and guidelines must be heeded.The hygienic requirements for general building ventilationare laid down in the European standard EN 13779. Forcleanrooms and associated controlled environments thelter selection, installation, inspection and operation, inparticular of high efcient particulate air (HEPA) and ultra lowpenetration air (ULPA) lters, is dened in the internationalseries of standards International Standards Organisation(ISO) 14644. In the food industry, guidance documents ofthe Global Food Safety Initiative (GFSI) and of the EuropeanHygienic Engineering and Design Group (EHEDG) haveto be regarded, in particular EHEDG Document 30, whichoffers the dening guidelines on air handling in the foodindustry. This document is currently under revision.Unlike the hygienic requirements for building and productionarea ventilation, the manufacturer testing and classicationof air lters has not yet been standardised on a global level.In Europe, air lters are tested and classied according totwo standards, EN 779 for coarse and ne dust lters andEN 1822 for efcient particulate air (EPA), HEPA and ULPAlters. In the United States, this is standardised by the ANSI/ASHRAE standard 52.2. Currently, great efforts are madeto harmonise these standards globally and to add additionalaspects that have not yet been considered in the existingstandards and guidelines; in particular, naming standardsand guidelines on the energy performance of air lters.New IS standard for lter high efciency(EPA, HEPA and ULPA) ltersIn 2006, the ISO Technical Committee (TC) 142 “CleaningEquipment for Air and Other Gases” was reactivated, with theaim to harmonise the world of standards and guidelines forair and gas ltration on a global level. The rst internationalstandard from this committee, ISO 29464 “Cleaningequipment for air and other gases - Terminology“ waspublished recently, and standardises the terminology aroundltration. In October 2011, the standard ISO 29463 “Highefciencylters and lter media for removing particles in air”followed, dening in ve parts the testing and classicationof high-efciency air lters. This new international standardis based, in its essential elements, on the European standardEN 1822 and will likely replace it in the near future. As inEN 1822, high-efciency lters are subdivided into threedifferent groups by the new standard ISO 29463 (Table 1)EPA. Filters of this group can neither be leak-proof testedat the manufacturers premises nor after installation at theusers site. The efciency is ensured by test methods aspart of the manufacturers quality control system based onstatistical methods. EPA lters typically are used to removeyeast and mold from the air stream.HEPA. Filters of this group typically are used to effectivelyremove bacteria and viruses from the air stream, supplyingsterile air, and have to be individually leakage tested by themanufacturer. The reference test method is the scan testprocedure, where the whole surface of the lter element isscanned with particle counter probes measuring the localefciency values. Alternatively, other test methods aredened, such as the oil thread leakage test method.ULPA. Filters of this group are individually leak-prooftested by the manufacturer, in cases where the scan testmethod is the only suitable test method. ULPA lters areused in the strictest of cleanroom applications, such as inmicroelectronics.Table 1 Filter class denitions according to ISO 29463.GroupEPA(E)HEPA(H)ULPA(U)ISOClassClass toEN 1822Minimal efciencyfor MPPSISO 15 E E11 95% —ISO 20 E 99% —ISO 25 E E12 99,5% —ISO 30 E 99,9% —ISO 35 H H13 99,95% 0,25%ISO 40 H 99,99% 0,05%ISO 45 H H14 99,995% 0,025%ISO 50 U 99,999% 0,005%Maximum allowablelocal penetration(Leakage limits)ISO 55 U U15 99,9995% 0,0025%ISO 60 U 99,9999% 0,0005%ISO 65 U U16 99,99995% 0,00025%ISO 70 U 99,99999% 0,0001%ISO 75 U U17 99,999995% 0,0001%After installation, HEPA and ULPA lters must be leakagetested again at the end-users premises to ensure airtight tand freedom from leaks, as dened by ISO 14644, part 3.

Performance testing of air filters for hygienic environments: Standards and guidelines in the 21st century 51Similar to EN 1822, the new international standard ISO 29463denes the scan test method as the reference method, wherethe local and the integral particle collection efciencies aremeasured for the most penetrating particle size (MPPS).Table 1 denes the ISO lter classes and the related collectionefciencies and penetrations, respectively. In total, the testand classication procedure consists of four individual steps(1) Determination of the MPPS by measuring the fractionalcollection efciency curve as a function of the particle size onat sheet media samples (see part 3 of the standard); (2) leakprooftesting of the lter element (see part 4 of the standard);(3) determination of the integral efciency of the lter element(see part 5 of the standard); and (4) classication according toTable 1 (see part 1 of the standard). In part 3 of the standard,the required statistical methods are described.General ventilation air ltersCoarse and ne dust lters ensure sufcient indoor airquality in less critical production areas and in generalbuilding and ofce ventilation. In high care production areas,cleanrooms and associated controlled environments, theselters are used as pre-lters to the EPA, HEPA and ULPAlters. Coarse and ne dust lters are tested and classiedin Europe according to EN 779. In contrast to the testingof HEPA and ULPA lters, the procedure in EN 779 is adestructive test method, where the tested element is loadedwith a synthetic test dust known as ASHRAE dust. The lterclasses are determined from the average arrestance andthe average efciency as averaged over the dust loading.This standard has recently been revised and published asEN 7792012. The main modication in this revision is theintroduction of requirements for the minimum efciencies tothe lter classes F7 to F9, which gives higher operationalsafety to the end users with regard to the particle collectionefciency of lter elements (Table 2).Table 2. Class denitions to EN 7792012.GroupCoarse lterFine lterGMClassFinal testpressuredropAveragearrestance A mto ASHRAEdust in %G1G2250 Pa50 A m< 6565 A m< 80G3 80 A m< 90G490 A mM5Averageefciency E mto 0.4 μm in %Minimumefciency to0.4 μm in %— —40 E m< 60M6 60 E m< 80F F7 450 Pa — 80 E m< 90 35F8 90 E m< 95 55F9 95 E m 70To ensure a high condence level of end users with regardto the quality and design specications of ne air lters,the European Committee of Air Handling & RefrigerationEquipment Manufacturers (EUROVENT) introduced some yearsago a certication program, wherein the main performancecharacteristics of the products offered by the participants areveried by regular and independent checks (www.euroventcertication.com).On an annual base, the initial pressure—drop, the initial and minimum particle collection efciency, thelter class, and the energy efciency class of four randomlychosen ne lters from the participants product range areveried by independent laboratories.Figure 1. EUROVENT certication mark.Energy efcient operation of air ltersIn the context of increasing energy prices and the imperativeof reducing CO 2emissions, the energy consumption causedby air handling units has become the focus of attention. Inan average industrial plant approximately 10-20% of the totalenergy is consumed by fans in heating, ventilation and airconditioning (HVAC) systems. In high care production areasand in cleanrooms and associated controlled environments,this percentage is even higher. Approximately one-third isrelated to the ow resistance (pressure loss) of air lters,depending on the size and the design of the HVAC units.Besides investments in energy-efcient fans and variablespeed drives, for example, the optimisation of the lterefciencies used and the use of high quality, energy efcientair lters is a comparably easy possibility to achieve signicantenergy savings. Hence, a reduction of the pressure loss of airlter systems can make a signicant contribution to energysavings and reduction of carbon dioxide emissions whenused in conjunction with variable speed drives. At the sametime, the air quality targets have to be considered, whichmeans that ultimately the individual optimum of sufcientlter efciency with lowest possible energy consumptionmust be found.To guide the end user to the most energy efcient lterselection, EUROVENT published a new document, Eurovent4/11, which denes an energy efciency classicationsystem for air lters.Under the assumption that the volume ow rate suppliedby the fan is constant, and hence, does not depend on thelters‘ pressure drop, the energy consumption of air lterscan be calculated by Equation 1 (Goodfellow, 2001).q V ptW (1)The abovementioned assumption is valid if the fan iscontrolled by a frequency inverter to operate at constantvolume ow rate q V(in m³/s). In Eq. (1) W (in kWh) is theenergy consumed in the time t (in h). Since the pressure lossof an air lter increases with the dust collected during the timeof operation, in Eq. (1) the pressure loss p (in Pa) has to beintroduced as integral average value over the time interval t.The overall electromechanical fan efciency depends onthe design and the operating conditions of the fan. Modernfans can have an efciency of 70%; while for older modelsor when utilised in disadvantageous operating conditions,realised efciencies might be just 25% or even lower.

52 Performance testing of air filters for hygienic environments: Standards and guidelines in the 21st centuryIn air handling units mostly pocket or rigid lters are used intwo stages (Figure 2).group according to EN 779, different amounts of dust areused, considering the fact that lters of group F are typicallyused in the second lter stage where they are exhibited tosmaller dust concentrations compared to lters of group G orM, which are typically used in the rst lter stage.Figure 2. Examples of a pocket lter (left) and a rigid lter (right)used in air handling units.The energy performance of lters largely depends on theused lter media, the effective ltering area and the designand quality of converting. For example, progressivelystructured lter media made of polymer bers, with a berdensity and neness increasing in the air ow direction,store signicantly higher amounts of dust compared tohomogeneous structured nonwovens made of polymer orglass bers. A higher dust holding capacity results in a slowerincrease of the pressure loss over the time of operation,and hence, a lower energy consumption. Additionally, ahigh stiffness of the lter media results in self-supporting,stabile lter pockets when no additional energy is required toopen the pocket in the air stream and an optimal V-shape ofthe pocket is ensured. Also in rigid lters, in which the ltermedium typically is pleated into six or eight thin pleat panelsor one deep-pleated panel glued into a rigid lter frame, thestiffness of the lter medium and the pleat geometry stronglyinuence the energy consumption (Caesar, et al. 2002).The energy efciency classication system dened byEUROVENT 4/11 allows the end user to quantitatively comparethe different design aspects of different air lters accordingto their energy-efcient operation. The laboratory testprocedure used is mainly based on the lter test standardEN 7792012, where the tested lter element is loadedwith synthetic ASHRAE test dust at a constant ow rate of3400 m³/h (0.944 m³/s). The pressure loss curve measuredin this procedure as a function of dust loading is usedto determine the average pressure loss (Equation 1),representing one year of operation. Depending on the lterWith the average pressure loss, determined from the loadingcurve measured according to EN 779, by using Equation1, the yearly energy consumption of an air lter can becalculated. As a convention in the EUROVENT 4/11 document,the yearly operating hours are dened to 6000 h and theefciency of the fan to 50%. Based on this calculated annualenergy consumption, lters are classied depending on theirlter class into energy efciency classes given in Table 3.Additionally, EUROVENT-certied lter suppliers can use anenergy efciency label in a design well-known in Europe toreport and display the energy efciency classication of theirproducts (Figure 3).Freudenberg Filtration TechnologiesMaxiPleat lterMX95 1/13400 m³/h62601300F8Figure 3. Example of the energy efciency label used byparticipants of the Eurovent certication program.ATable 3 class limits of energy efciency in relation of ltration class according to EN 779 (established at bei 3400 m³/h) [6].Filter c las sG4M5 M6 F7 F8 F9MTE— — — MTE ≥ 35% MTE ≥ 55% MTE ≥ 70%M G = 350 g ASHRAE M M = 250 g ASHRAE M F = 100 g ASHRAEA 0 – 600 kWh 0 – 650 kWh 0 – 800 kWh 0 – 1200 kWh 0 – 1600 kWh 0 – 2000 kWhB > 600 kWh – 700 kWh > 650 kWh – 780 kWh > 800 kWh – 950 kWh > 1200 kWh – 1450 kWh > 1600 kWh – 1950 kWh > 2000 kWh – 2500 kWhC > 700 kWh – 800 kWh > 780 kWh – 910 kWh > 950 kWh – 1100 kWh > 1450 kWh – 1700 kWh > 1950 kWh – 2300 kWh > 2500 kWh – 3000 kWhD > 800 kWh – 900 kWh > 910 kWh – 1040 kWh > 1100 kWh – 1250 kWh > 1700 kWh – 1950 kWh > 2300 kWh – 2650 kWh > 3000 kWh – 3500 kWhE > 900 kWh – 1000 kWh > 1040 kWh – 1170 kWh > 1250 kWh – 1400 kWh > 1950 kWh – 2200 kWh > 2650 kWh – 3000 kWh > 3500 kWh – 4000 kWhFG> 1000 kWh – 1100 kWh > 1170 kWh – 1300 kWh > 1400 kWh – 1550 kWh > 2200 kWh – 2450 kWh > 3000 kWh – 3350 kWh > 4000 kWh – 4500 kWh> 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 53Summary and outlookThe world of lter standardisation is currently one of forwardmotion. Existing standards are being revised, updated andglobalised. For example, the European standard EN 779for the testing and classication of coarse and ne dustlters recently has been revised and a new internationalstandard ISO 29463 for the testing and classication of highefciencylters and lter media has been published, whichwill likely replace European standard EN 1822 in the nearfuture. With the new Eurovent document 4/11, a Europeanenergy efciency classication system for air lters has beendened. This will likely also be the basis for future Europeanlegislation for air lters in the context of the Eco-Designguideline of the European Parliament and Commission(Directive 2009/125/EC).In the framework of ISO/TC 142, currently more than 30standardisation projects are in process. Among them are theseries of standards ISO 10121 for the testing and classicationof gas adsorption lters and the series of standards for coarseand ne dust lters (ISO 16890), which is written in fourparts and will likely replace EN 779 in a few years. The nalpublication of ISO 16890, part 1, is planned for 2015.BibliographyAmerican Society of Heating. Refrigerating and Air-ConditioningEngineers. 2007. ANSI/ASHRAE Standard 52.2-2007. Method oftesting general ventilation air-cleaning devices for removal efciencyby particle size. Atlanta.Caesar, T. and T. Schroth. 2002. The inuence of pleat geometryon the pressure drop in deep-pleated cassette lters. Filtration +Separation, 39(9)49-54.DIN EN 779. Particulate air lters for general ventilation. Determinationof the ltration performance. Beuth Verlag, Berlin, 2012.DIN EN 1822. High efciency air lters (EPA, HEPA and ULPA), Part1-5. Beuth Verlag, Berlin, 2011.DIN EN 13779. Ventilation for non-residential buildings - Performancerequirements for ventilation and room-conditioning systems; Germanversion EN 137792007, Beuth Verlag, Berlin, 2007.EHEDG Guideline DOC 30. Guidelines on air handling in the foodindustry, 2005ISO 29464. Cleaning equipment for air and other, Beuth Verlag,Berlin, 2011European Committee of Air Handling & Refrigeration EquipmentManufacturers (Eurovent), 2011. Eurovent 4/11 Energy efciencyclassication of air lters for general ventilation purposes. Paris.Goodfellow, H. and E. Tähti. 2001. Industrial Ventilation. AcademicPress.International Standards Organisation. ISO 14644 Cleanrooms andassociated controlled environments. Series of standards. BeuthVerlag, Berlin. 1999-2012.International Standards Organisation. ISO 29463 High-efciencylters and lter media for removing particles in air. Parts1-5. BeuthVerlag, Berlin, 2011.CIP Rotary Valves and Diverters• Suitable for clean in place process systems• Rotary valves with wash through shaft seals• Diverters allowing a partial or full systemwash through• Certified levels of hygieneFeed your processDairy Rotary valves and Diverters• EHEDG Type EL Class I compliant• USDA Dairy Accepted• ATEX 94/9/EC CompliantDMN-WESTINGHOUSET +31 252 361 800dmn@dmn-nwh.nlCOMPONENTS FOR BULK SOLIDS HANDLINGwww.dmnwestinghouse.com

European Hygienic Engineering & Design GroupSpray cleaning systems in food processing machines andthe simulation of CIP-coverage testsThe intelligent usage of experimental and simulated cleanability tests is a further step towardthe reduction of machinery development time and costs and time of machinery for the food andpharmaceutical industry.André Boye 1 , Marc Mauermann 1 , Daniel Höhne 2 , Jens-Peter Majschak 11Fraunhofer I, Branch Lab for Processing Machinery and Packaging Technology A Dresden, Germany2Technische Universität Dresden, Faculty of Computer Science, Institute of Software- and Multimedia-Technology,Dresden, Germanye-mail: andre.boye@avv.fraunhofer.deDue to increasing hygienic requirements, more and moremachinery for the food industry is delivered with automatedclean-in-place (CIP) systems. By using such systems,hygienic risks may decrease and cleaning efciencies mayrise.The validation of the hygienic design of such systems, andthus the selection of specic nozzles for cleaning, theiralignment and built-in position has so far been done so faronly on a real prototype by means of CIP-coverage tests.The objective of this test is to verify that the cleaning systemsassociated with the machinery are capable of deliveringcleaning solutions to all exposed product contact surfaces. Ifthat is not the case, the cleaning system has to be adjustedand tested further until all surfaces are wetted with cleaningagent in the coverage test. This iterative optimisation isextremely time-consuming and has very high resourcerequirements (e.g., staff, material, etc.). Hence, many costsarise that are also hardly calculable when submitting atender offer.An approach to improving the hygienic design of foodprocessing machinery is to simulate the coverage testusing the computer-aided design (CAD) data of themachinery and the cleaning system. This paper presents asoftware solution that is capable of simulating the coverageof relevant equipment surfaces with cleaning uids fromnozzles by means of ray tracing. The main differencesbetween CAD and computational uid dynamics (CFD)methods are that the simulation is much easier to handle,simpler in degree of detail of the results, works in real-timeand can be used for optimising cleaning systems with ahuge number of nozzles. The main requirements for thesoftware design were that the software should not have highdemands on construction engineers with regard to the levelof simulating knowledge and should be very practicable forcomplex systems.For characterising the spray pattern as a precondition forintegrating different nozzles in this software, an adequatecleanability test was found. By means of the test rig,characteristics of different cleaning nozzles can beanalysed, classied and provided in an electronic format.In summary, the complete package consists of the softwareand new test method for spray pattern characterisation.Software for the simulation of spray shadows(a)(b)Figure 1. Screenshots of the developed (a) simulation software and(b) nozzle explorer for selecting a nozzle from the database.With the simulation software developed, engineers aregiven the opportunity to optimise their cleaning systems atcomputers before any components of a new machine haveto be manufactured (Figure 1). Thereby, the presented toolgives an estimation for the spray pattern on complex parts inrelation to the specic cleaning systems.Software usage and featuresImport CAD assemblyChoose viewInsert nozzlesFigure 2. Flow chart for software usage.Export position of nozzlesInspection of cleaningresults/ optimisationPositioning/ alignmentAs shown in Figure 2, there are a number of software usagefunctions and features. At rst, the user opens a new projectand loads the CAD assembly of the object to be cleanedby using standardised exchange formats. In the next step,the view can be chosen like in standard CAD software andthe 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 teststype as required, into the scene. The computer program isdirectly connected with a public nozzle database in whichthe specic characteristics of different nozzles are storedtogether with the related single spray pattern. Consequently,the same nozzle doesnt have to be measured twice at thesame operating parameters. The determination of a singlespray pattern can be managed with an adequate cleaningtest like that described below, or with impact measurementsfor example. After insertion, the nozzles can be positionedand aligned in the scene. The activated nozzle is markedwith a pyramid. This pyramid shows the maximum nozzledistance in which the nozzle was measured. If the nozzleis moved outside this range, no cleaning effect is shown onthe surface. The expected cleaning results are calculatedand shown in real-time, so the cleaning system can beoptimised (e.g., insert more nozzles or change theiralignment) in an iterative way without large response time.After all, the nozzles positions can be exported for using inCAD software.Functional principlesDepending on the application area, one could model theeffect of a nozzle as a stream or as a spray of single particles– omitting particle-particle interaction. In our experiments thelatter approach proved the most feasible. The behaviour ofsuch an isolated particle could be approximated using thefollowing formulaFigure 3. Projection principle, from 3D space onto 2D plane withdepth information (as Z). A brighter colour is equivalent to a shorterdistance to the projection plane. Note the intersection of the raywith the 2D plane.After identifying where the particles collide with the surface,the exerted inuences on the surface have to be computed.For this, every nozzle gets a spate of spray masks that aredetermined by cleanability tests or impact measurements(Figure 4).where the forces are dened asNumerical algorithms for solving the time integration can befound in Press et al. (2007) and are efciently computableon the GPU (graphics processing unit) as described byNguyen (2007). 1,2 But, solving the equation of motion formillions of particles is just one step. For the interestingeffect of a particle-surface interaction, the intersection of aparticle with a surface has to be found. Despite severalwell-known acceleration techniques, a lot of work had to bedone in every time step of the simulation. 3 But experimentsshowed that the process could be approximated as linearwith respect to the input parameter domain in focus. Theseexperiences effectively broke down the simulation to a onetimestep at which the intersection occurs. In the eld ofcomputer graphics this is known as ray-tracing, but insteadof tracing light, the rays linear particle paths are traced. 4 Arst implementation produced reasonable results for furtherinvestigations, but it was too slow to be used in interactiveapplications. Therefore, the process was modelled as aprojection of surface points in 3D space to 2D points on theescape plane of the nozzle which is exactly what graphicsprocessing units (GPUs) are good at doing (Figure 3).Figure 4. (Left) 2D impact map. Red means high impact. (Right) 2Dspray pattern. A black colour means a point got cleaned during thespray process.Thus, deciding whether a point is cleaned through the sprayprocess becomes essentially the inversion of the projectionmentioned before. This is equivalent to the functionalprinciple of a slide or movie projector. Here the nozzle is theprojector, the lm or slide to be projected is the impact orspray pattern and the to-be-cleaned surface is the functionalequivalent of the projection screen (Figure 5). In computergraphics this technique is known as projective texturemapping or perspective shadow mapping. 5-9

Spray cleaning systems in food processing machines and the simulation of CIP-coverage tests 57Soiling(a)For the 3D soiling of surfaces from complex parts a methodsimilar to spray paint processes was chosen (Figure 6). Inthat context, a model soil consisting of a polysaccharideand luminescent tracer was used and the surfaces of thetest object were coated with the viscose test solution. Themaximum layer thickness was limited by the avoidance ofrinsing test soil.(b)(c)Test rig for cleaningFor the experimental analyses a Washing Cabin test rig wasused. With it, cleaning tests for open surfaces of complexparts up to a dimension of (1x1x1) m³ with several nozzlesystems are practical. Furthermore, tank cleaning systemscan be analysed by using a special test tank (Figure 7).Figure 5. (a) Principle of projective texturing and the application ofprojection for (b) a full cone nozzle; (c) and a at fan nozzle.A characteristic of the presented approach is that a spray/impact map is only valid for a certain parameter conguration;i.e., nozzle model, pressure, distance and duration. Toenhance this range further, spray patterns for differentdistances were interpolated linearly between each other.Cleanability testFigure 7. Test rig ‘Washing Cabin (left) and test tank (right).For a cleaning test the CIP station is started up by activatingthe bypass (Figure 8). When the steady state is reached,the threeway valve switches and the cleaning process starts.During it, a camera takes continuous pictures while anultraviolet (UV) lamp system excites the remaining residualsoil.Figure 6. Example for a cleaning test of a complex part (1) Socketwith spray shadow in detail; (2) soiled test object; and (3) testobject after cleaning (green = soiled; black = clean).For verifying the simulated scenes in contrast to realexperiments, an adequate cleaning test was developed.With this method, it is possible to differentiate clearlybetween areas with direct nozzle impact and sprayshadows. Even rinsing water does not destroy the resultingspray pattern for a long period of time. Consequently, inthis context the test rig ‘Washing Cabin at FraunhoferAVV was used for testing single nozzles, different nozzlecombinations and tank cleaning systems combined withdifferent objects to clean.Figure 8. Scheme of the test rig Washing Cabin.

58 Spray cleaning systems in food processing machines and the simulation of CIP-coverage testsThe adjustable pressure range of the test rig is 0 - 4 barby a maximum ow rate of 16 m³/h. Both parameters werecontinuously measured. The highest frame rate is ninepictures per second but one frame per second has beendetermined as a useful value for the cleaning systemstested. Thereby, the exposure time of 0,35 s and apertureF4 were chosen. In order to exclude possible detectionfailures due to extraneous light, the test rig is completelydarkened.Spray pattern analysis(a)(b)Figure 10. Comparison of (a) cleaning and (b) simulation resultinside a test tank.In summary, the software gives a quite good estimation forthe expected spray pattern, but the user must always becritical with the simulation results. For example, if a nozzlesprays into a deep gap. In the front area of the gap theestimation is quite good but deeper into the gap there arentany cleaning effects as the simulation shows.Figure 9. Detection principle.The model soil of the presented cleaning test contains aluminescent tracer, which is important for the detectionof residual soil (Figure 9). In the cleaning processes, thesurfaces are excited by UV radiation and areas with residualsoil emit visible light. This is captured by taking pictures witha dened frame rate. After the cleaning test, the photos arerectied and a computer program checked to ascertain inwhich picture the stationary state of the spray pattern wasreached. This picture is used for the next steps of analysis,where it is binarily divided in cleaned areas (with directnozzle impact) and spray shadows (areas without directnozzle impact). Hence, in single nozzle test, the spraymasks are obtained and stored in the nozzle database. Forthis task, a semi-automated method also was developedand used.ConclusionThe software presented in this paper gives engineers acomputer aided constructive design and optimisation toolfor complex spray cleaning systems for the rst time. Sprayshadows can be avoided preliminary in the constructivestage before any parts of prototypes are manufactured.Furthermore, the developed qualitative cleanability testis a practical method for the detection of weak points ofspray cleaning systems and tank cleaners. Consequently,by combining the use of cleaning tests and simulation,hygienic risks are minimised and investment security isincreased.The software and experimental methods will be furtherdeveloped. For example, the implementation of tankcleaning systems with rotating nozzles is currently beinginvestigated. In the near future, the achieved cleaning effectwill be resolved quantitatively, and rinsing water, as a maincleaning component, will be considered.AcknowledgementericationThe simulation tool was veried by using specic geometricalphenomena, such as spraying with a nozzle over edgesor into a gap between two plates. Therefore, the resultsfrom cleanability tests and simulation were comparedqualitatively. In addition, the simulation was veried withcomplex parts, including a test tank that was cleaned insidewith two full cone nozzles (Figure 10). The simulation andcleaning tests led to nearly the same result.

Spray cleaning systems in food processing machines and the simulation of CIP-coverage tests 59References1. Press, W.H., S.A. Teukolsky, W.T. Vetterling, and B.P. Flannery.2007. umerical ecipes, rd Edition: The Art of Scientic Computing.Cambridge University Press. New York, NY, USA.2. Nguyen, H. 2007. GPU Gems 3. Addison-Wesley Professional.3. Langetepe, E. and G. Zachmann. 2006. Geometric Data Structuresfor Computer Graphics. A. K. Peters, Ltd. Natick, MA, USA.4.[PH04] Pharr, M. and G. Humphreys. 2004. Physically Based Rendering:From Theory to Implementation. Morgan Kaufmann PublishersInc. San Francisco, CA, USA.6. EIsemann, E., M. Schwarz, U. Assarsson, and M. Wimmer. 2011.Real-time shadows. CRC Press. USA.7. Fernando, R. 2004. GPU Gems: Programming Techniques, Tipsand Tricks for Real-Time Graphics. Pearson Higher Education.8. Stamminger, M. and G. Drettakis. July 2002. Perspective shadowmaps. In Proceedings of ACM SIGGRAPH, J. Hughes, (Ed.), AnnualConference Series, ACM Press/ACM SIGGRAPH, pp. 557-562.9. Whler, C. 2009. 3D Computer Vision: Efcient Methods and Applications,1st Ed. Springer Publishing Co., Inc.5. Williams, L. 1978. Casting curved shadows on curved surfaces. InProceedings of the 5th Annual Conference on Computer Graphicsand Interactive Techniques. New York, NY, USA. SIGGRAPH 78,ACM, pp. 270–274.SOLUTIONS FOR TOMORROW’S ENGINEERINGSEAL MATCHING ATYOUR FINGERTIPSYears of experience allows Trelleborg Sealing Solutions to offerthe Sealing Solutions Confi gurator, making future applicationseasier to specify. Innovation in online services means thatfood and pharmaceutical engineers have access to proven sealconfi gurations at the touch of a mouse or fi ngertip.Find more information at www.tss.trelleborg.comor check out www.seals-innovation.com

European Hygienic Engineering & Design GroupEnvironmentally friendly water based surfacedisinfectantsMarkets uctuate. Requirements change. And this is especially true in the highly sensitive areasof cleaning and hygiene in the production and preparation arms of the food industry. Demand isfor innovative solutions and cost-saving methods that conserve resources, are environmentallyfriendly, do not cause undue side effects to humans and are as safe as possible for the users.Stephan Mätzschke, Dipl.- ecotrophologist (FH), Member of the Management Board at BIRFD GmbH & Co. KGE-mail: s. maetzschke@birfood.de, Tel.: + 49 421 489 960 17The cleaning and disinfection of production plants in themeat handling industry are two intrinsically linked processesrequired to guarantee the proper hygienic production of foodin line with regulations. At a time when ultimate consumptiondate periods are getting longer and the requirements fromlegislators, trade and consumers are continually increasing,producers are forced to take the hygiene measures thataccompany their production processes to a new level.1It is standard practice in the meat handling industry today thatafter thorough cleaning the production plant is chemicallydisinfected using either a foam or a spray. Currently a wholerange of chemical disinfectants is available to the foodindustry, but despite the choice of products available, thisarticle will highlight the difference between two disinfectionmethods the inhibitive methods and the destructive methods.Some active agents like quaternary ammonium compoundsor aldehydes, for example, have an inhibitive effect onbacterial cells. This means that these substances do notdestroy the bacterial cells; instead, they prevent theirreproduction by disrupting the cellular metabolism. Suchsubstances are generally suitable for use on most surfacesand are user friendly; however, there are gaps in theireffectiveness. Certain groups of germs are less susceptibleto them and if the agents are used incorrectly, particularly ifthe wrong concentration is used over a long period of time,there is a risk that the bacteria will build up a resistance tothem.The alternative group of active agents have a destructiveeffect; specically, these agents destroy the bacterial cells.Active agents like peracetic acid, hydrogen peroxide andsodium hypochlorite belong to this group. This group ofactive agents has a broad spectrum of effectiveness andthere is no danger of resistance if the products are usedincorrectly. However, these agents are highly corrosiveand are therefore dangerous to use on material (especiallyaluminium and non-ferrous metals) as well as for the user.A further disadvantage is their relative instability in thepresence of organic matter.Non-hazardous water based surfacedisinfectantsIn contrast to the meat handling industry, the disinfection ofdrinking water and the drinking water supply network hasbeen carried out for years using electrochemical activation(ECA) technology as an alternative to chemical disinfection.ECA technology frequently is used successfully in countrieswith precarious water supplies and in very warm climates, aswell as in buildings with irregular water consumption wherethe water in the pipes must be held for longer periods (e.g.,hotels) as a reliable way of protecting against Legionellaand other germs. The idea of using this technology as anenvironmentally or user-friendly alternative to the chemicaldisinfection of surfaces in the meat handling industry isrelatively new.How ECA technology worksThe ECA technology is based on the treatment of drinkingwater by electrolysis. During the electrolysis process redoxpotential is generated by applying an electric voltage(Figure 1). This redox potential imparts the resulting ow ofmicrobiocidal properties.Figure 1. Electrolysis process.During a redox reaction (effectively a reduction oxidation reaction)an electron from one reactant is transferred to the other. As onereactant is reduced, the other oxidises. The redox potential (in thiscase, 1200 mV) serves as an indicator of the extent to which suchan electron transfer between reactants can take place. In doing so,it also demonstrates to a certain extent the level of the solutionsmicrobiocidal activity. When apparatus that has been treated withthe solution produced with ECA technology comes into contact withbacterial cells, electrons will be transferred. The bacterial cell willoxidise and die.The ECA solution works in the same way as peraceticacid, hydrogen peroxide or sodium hypochlorite that is,destructively. It oxidises the bacterial cell and with that, itdies. The advantage of ECA technology over these othersolutions is that it is neither a corrosive nor an irritant formaterial or users. It complies with the German Drinking WaterDirective because it does not contain anything dangerous.

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62 Environmentally friendly water based surface disinfectantsTestingAs a result of the limited number of surface disinfectionavailable for use by the meat handling industry, there hasbeen a lack of empirical scientic data allowing a judgmentto be made on the suitability of the technology for applicationin this environment. A project was undertaken that aimedto identify maintenance and improvement in plant hygiene,taking into consideration conservation of resources,reduction in hazardous substances, optimisation of costs,and increased safety of food products.In September 2011, all relevant actual data such as wateruse and working times were included with the originalcleaning methods (chemical disinfection). Over manyyears, certain factors regarding disinfectant use and themicrobiological hygiene levels in the plant were recordedand provided historical data from which to benchmark resultsof the ECA technology trials. At the end of September 2011,ECA technology was installed in the plant rooms at EdekaFleischwerk Nord GmbH. The concentrate produced usingECA technology was fed into the network in small amountsthrough an injection point in the cleaning line. As such theconcentration was measured so that the amount of chlorinein the water did not exceed 0.3 ppm and the water quality metthe requirements of the German Drinking Water Directive.The concentration was measured using a digital pistondiaphragm pump connected to a contact water meter. From4 October 2011, ECA technology was installed in individualdepartments. The equipment classied as “hard to clean”was checked for organic residue using ATP bioluminescenceafter cleaning but prior to sanitising with ECA water. Thisensured that the cleaning personnel had correctly completedthe required steps for the use of ECA water and that anydiscrepancies in the results could not be attributed to humanerror.Each day, water consumption in each department wascalculated using electronic contact water meters andultrasonic measuring procedures in order that only smallmeasuring tolerances occurred. Further, the concentrationof ECA in the water that was used was checked daily tomake sure it met the German Drinking Water Directive. Thiswas done photometrically. Swab samples were taken daily.During the trial period, more than 1,000 swabs were takenand sent to an accredited laboratory for analysis. Tests werecarried out on the mesophilic aerobic bacteria count and forenteric bacteria. The analysis of the swabs was performed inline with EC Decision 2001/471/EC.The project trials, which ran for six months, showed that thechemical disinfection and the subsequent neutralisation step couldbe replaced by ECA technology. Specically, the foam cleanermay be rinsed from surfaces using ECA water and in doing so themeat handling plant can achieve surfaces that are cleaner from amicrobiological perspective.A real-world studyIn August 2011, an initial risk analysis was done. Takinginto account the fact that an ECA solution could have beensimilarly unstable in the presence of organic inuences onthe contact surfaces as the group of chemical disinfectantsthat oxidise, the surfaces in the plant rooms were classiedas ‘easy to clean‘ and ‘hard to clean‘. Easy-to-cleansurfaces included all at stainless steel surfaces, such aslling machines, mixers, grinders, work benches etc., whileequipment such as carving belts, carving boards and aircylinders were classied as hard-to-clean.ResultsThe trial ended on 29 January 2012. With the exceptionof decomposition, zero values were recorded forenterobacteriaceae in all areas (Figures 2 and 3). This resultunderscores the necessity of using a foam cleaning agentwith a brush at the cut-off point during the exposure period.Over the course of the second half of the trial, this result wasalso recorded.A further nding was the signicant saving of drinking and/or hot water (Figure 4). A saving of 11.4% was recordedacross all of the meat companys departments. The mostsignicant savings were found in the departments with thehighest machine-to-space ratio, because more energy isused for rinsing disinfectant these areas than in corridors,for example.The results also showed a savings in working hours, withuse of the technology resulting in an average reduction inpersonnel costs by more than 12.5% across the company(Figure 5).

Environmentally friendly water based surface disinfectants 63Figure 2. Hygiene monitoring from 04.10.2011 – Total germ count - Zero values were recorded for enterobacteriaceae in all areasFigure 3. Hygiene monitoring from 04.10.2011 – Enteric bacteria - Zero values were recorded for enterobacteriaceae in all areas.

64 Environmentally friendly water based surface disinfectantsFigure 4. Comparison total water consumption/cost.Figure 5. Time required by cleaning personnel - Zero values were recorded for enterobacteriaceae in all areas

Environmentally friendly water based surface disinfectants 65ConclusionThis project showed that the use of ECA technology enablesa meat handling operation to improve the microbiologicallevels in the plant as compared to using the originalchemical disinfectants. Measurable savings were made tothe time required for cleaning, and the time saved using thenew cleaning procedures can now be used for production.A signicant decrease in water consumption was alsoexperienced. An important side effect of using this technologyis the automatic permanent disinfection of the drinking watersupply network into which the application solution is fed. Thisimproves safety, even in older supply networks. The annualthermal disinfection of the pipes that is frequently required,can be eliminated.Taking into consideration the results of the trial discussedhere, the use of ECA technology as a replacement forchemical disinfection of plants in the meat handlingindustry can be recommended. These trials were run in aplant producing sausages. In plants that primarily produceother products and where there are other (more) germson the surfaces from the outset (i.e., in an abattoir), acorresponding increase similar to the case study should beconducted before a recommendation about the suitability ofthe technology can be made.

European Hygienic Engineering & Design GroupFlow behaviour of liquid jets impinging on vertical wallsSurface cleaning devices such as spray balls and nozzles direct liquid onto walls and othersurfaces in the form of jets. Knowledge of the area covered by the ow as it spreads out from theimpingement point and drains down a wall or other surface is important for designing effectivecleaning systems. Recent work on modelling the ow pattern and predicting the stability of widedraining lms is summarised.Ian Wilson, Tao Wang and John F. Davidson, Department of Chemical Engineering and Biotechnology,Pembroke Street, Cambridge, CB2 3RA, UK, e-mail: diw11@cam.ac.ukImpinging water jets are widely used in cleaning walls,tanks and internals. The jets can be created by spray balls,xed or moving nozzles. Soil removal occurs either bydissolution of the fouling layer into the liquid or by physicaldisruption of the soil by the shear forces generated by theow. Improving the design of jet-based cleaning systemsrequires knowledge of the ow behaviour of the liquidafter it strikes a wall. Figure 1 shows an example of aow pattern generated by a horizontal impinging jet, seenlooking through the transparent impact surface, along theaxis of the jet.Figure 1. Photograph of ow pattern created by impinging water jet.The point of impingement is near the crossover of the ruler tapes.Figure 2 shows two of the possible ow patterns that can begenerated by a horizontal jet impinging on a vertical wall.Both feature a zone around the point of impingement wherethe liquid moves at high velocity radially outwards until itforms a jump similar to the hydraulic jump seen with tapwater in a sink. We term this a lm ump to differentiate itfrom the hydraulic jump because gravity has less inuencewhen the wall is vertical.The hydrodynamics of vertical liquid jets impinging onhorizontal surfaces and the formation of hydraulic jumps iswell understood. Jets impinging on vertical or inclined wallshave received less attention.Figure 2. Schematics of two commonly observed ow patterns fora horizontal liquid jet impinging on a vertical wall. (a) gravity ow;(b) rivulet ow. O denotes the point of impingement.For cleaning applications, we want to know the size of thelm jump, marked R in Figure 2, as the region within itinvolves higher velocities and larger shear forces. We alsowant to know the width of the falling lm, which is marked Won Figure 2 (a). W is larger than 2R because of the liquidowing around the lm jump, and it gives an indication ofthe area below the point of impingement that will be wetted

Flow behaviour of liquid jets impinging on vertical walls 67by the falling lm. Soil in this region will be removed by theaction of detergent and lower shear stresses, as reportedby Morison and Thorpe (2002). 1 Under some conditionsthe falling lm will narrow below the impingent plane andgive poor contact with the soil, as shown in Figure 2 (b). It istherefore important to be able to predict the transition fromthe wide, gravity, lm ow behaviour to the narrow, rivuletregime.Predicting the lm jumpA model for the lm jump has recently been developed. 2 Thisallows R to be predicted from¼ m 3 R cos (1)In this equation, m is the jet mass ow rate; is the viscosityof the liquid and is its density; is the surface tension, and is the contact angle of the liquid on the substrate.Figure 3 shows good agreement between experimentaldata and the model for water on Perspex. Nozzle sizes, d N,typical of those used in industrial practice have been tested.Comparison with other data sets, including those reportedin Morison and Thorpe (2002), are reported in Wilson et al.(2011) and Wang et al. (2013). 1–3surfactant molecules had time to collect at the solid/liquid/airinterface, gave poor agreement with the measured values.This indicates that dynamic surface tension effects areimportant in these ows.A second important nding reported in Wang et al. (2013)is that at higher ow rates and with larger nozzles, R wasindependent of the nature of the substrate. This indicatesa change in the phenomena controlling the ow pattern athigher ow rates from one controlled mainly by interfacialforces to one where uid inertia become important. Usinga contact angle of 90° in Equation (1) gave reasonablepredictions for R in these cases.Predicting the lm widthThe relationship between W and R cannot be obtained usingthe simple models behind Equation (1). Measurements ofW (= 2Rc in Figure 3) indicate that Rc 2R at lower owrates and approaches Rc 4/3R at higher ow rates. Theseempirical results allow W to be estimated.Falling lm ow patternsThe tendency to exhibit gravity or rivulet ow in the regionbelow the impingement plane has been found to follow thecriterion given by Hartley and Murgatroyd (1964) for thestability of wide falling liquid lms. 4 This says that lm will bestable if the wetting rate, dened as m/W, is larger than thecritical value given bym Wg cos (2)Here g is the acceleration due to gravity. Equation (2) holdsfor vertical surfaces; for inclined walls, g is modied toaccount for the angle of slope.We have found that Equation (2) gives reasonable predictionsof the transition from the gravity to rivulet regimes for thesefalling lms. Equation (2) has also been found to apply forsolutions containing a surfactant, using the values of and obtained from equilibrium contact angle measurements.Surfactants which promote wetting on the soil or substratewill give smaller values of and therefore, from Equation(2), reduce the ow rate required to avoid rivulet formation(as W is less sensitive to surfactant content).Figure 3. Comparison of experimental measurements of R withvalues predicted from Equation (1) for water on Perspex fordifferent nozzle sizes and temperatures. Reproduced from Wang etal. (2013) with permission.Equation (1) shows that R is larger for liquids with a smallcontact angle (i.e., ones that wet the surface) and for liquidswith a lower surface tension. Surfactants are often addedto promote wetting and change the contact angle. Recentwork has demonstrated that the effect of surfactants onR comes mainly through their inuence on the surfacetension. 3 Predictions of R using Equation (1) using contactangles measured under equilibrium conditions, where theFigure 4 shows an example for water jets impinging on avertical glass wall. Solid symbols indicate that the falling lmexhibited gravity ow, while open symbols denote rivulet owbehaviour.The data are plotted in terms of the Eötvös number, adimensionless width, and a dimensionless ow rate, F, givenbyandEo gW 2 (3)F gm 2 2 (4)

68 Flow behaviour of liquid jets impinging on vertical wallsApplication to cleaningSince R, and hence W, can now be estimated from Equation(1), we can obtain a reasonable estimate of the wall areacontacted by the liquid in the jet and the stability of the fallinglm generated. The inuence of surfactants or the effect ofcleaning the surface, which will change the contact angle,can also be assessed. Ongoing work in our group includesinvestigations of inclined jets and non-vertical surfaces,detailed analysis of the shape of the falling lms, andcleaning.AcknowledgmentThis work is not funded by a company or research council.A PhD scholarship for Tao Wang and input from projectstudents is gratefully acknowledged.References1. Morison, K.R., and R.J. Thorpe. (2002). Liquid distribution fromcleaning-in-place sprayballs. Food Bioproducts Proc., 80, 270-275.Figure 4. Plot indicating stability of falling lms generated byhorizontal jets impinging on a vertical glass wall. The lines show theHartley and Murgatroyd criterion, Equation (2), for water (in blue)and an aqueous 0.1 mM Tween 20 solution (in red). Data pointsopen symbols indicate that rivulet ow was observed, solid symbolsindicate gravity ow. Rivulet ow is expected for points lying on orabove the line. Test conditions 1 mm nozzle, 20C.The two lines on Figure 4 show the conditions under whichEquation (2) predicts a change in ow behaviour for waterand for a surfactant solution. The theory says that points lyingon or above the line should exhibit rivulet ow behaviour. Forthe ow rates tested here, water exhibits rivulet ow, whichis consistent with Equation (2).The presence of surfactant reduces the surface tension andgives a smaller contact angle, which causes the transitionlocus to move to larger Eötvös numbers. For similar owrates to the water tests, the surfactant solutions give widefalling lms, which is again consistent with Equation (2).2. Wilson, D.I., B.L. Le, H.D.A. Dao, K.Y. Lai, K.R. Morison, andJ.F. Davidson. (2011). Surface ow and drainage lms created byhorizontal impinging liquid jets. Chem. Eng. Sci., 68, 449–460.3. Wang, T., Davidson, J.F. and Wilson, D.I. (2013) 'Effect ofsurfactant on ow patterns and draining lms created by a horizontalliquid jet impinging on a vertical surface', Chem. Eng. Sci., 88, 79-94.4. Hartley, D.E. and W. Murgatroyd. (1964). Criteria for the breakupof thin liquid layers owing isothermally over solid surfaces. IntlJ. Heat Mass Transfer, 7, 1003-1015.

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European Hygienic Engineering & Design Groupptimisation of tank cleaningUsing hygienic sensors to monitor tank cleaningRené Elgaard, Managing Director, Alfa Laval Tank Equipment A/Se-mail: rene.elgaard@alfalaval.comTank cleaning is a time-honoured tradition essentialfor producing high-quality foodstuffs and beverages.Technological advances in tank cleaning have raised thestandards for food and beverage processing dramatically;the most drastic changes have occurred within the last 50years. To ensure the highest standards of hygiene, morerigorous standards and tougher regulations are now inplace, not only for the tank itself but also for tank cleaningequipment.The improvements in hygiene standards/guidelines are adirect result of equipment users demand, as well as supportgarnered through organisations such as the EuropeanHygienic Engineering and Design Group (EHEDG), whichshare the common aim of promoting hygiene duringfood and beverage handling, processing and packaging.The guidelines put forth for hygienic design of food andbeverage process equipment essentially put all equipmentmanufacturers on a level playing eld by establishingminimum standards for equipment quality.With all equipment being equal, it stands to reason thatproper control of the tank cleaning process is the primary wayto differentiate equipment based upon the level of cleaningefciency achieved. The objective to get accurate, reliableand repeatable tank cleaning results after the completion ofeach production cycle, whether a continuous process or abatch process is used.There are several ways to achieve the desired tank cleaningresults by controlling the tank cleaning process. However, itis important to understand the process of tank cleaning, thevarious tank cleaning methods and the product containedin the tank before determining the best method of control toachieve optimal cleaning efciency.Traditional tank cleaningThere are various parameters that contribute to effectivetank cleaning. These are perhaps best described by the“Sinner Circle,” which was developed by the chemicalengineer Herbert Sinner to illustrate how to obtain goodcleaning results. 1 Sinner dened four critical parameters thatmay be combined in numerous ways and applied to virtuallyany cleaning task, whether in a pipe, on a oor or in a tank.The parameters are time, action (or ow of cleaning uid),chemistry and temperature, or TACT for short (Fig. 1). Allfour parameters are important to secure optimal cleaningefciency; however, how they are combined is decisive inachieving optimal cleaning efciency.Figure 1. The Sinner Circle illustrating the cleaning parametersof TACT. Herbert Sinner dened four critical parameters – time,action (or ow of cleaning uid), chemistry and temperature, orTACT for short – which are important to secure optimal cleaningefciency.Applying effective chemicals or cleaning agents and optimumtemperature to the surface to be cleaned weakens thebond between the soil and the surface to a point where theavailable force (or action) can remove the soil. 2 The unknownfactor is the available force. Time, chemical concentrationand temperature can be controlled.What is the available force, and how is it applied to thesurface? This depends upon the method and technologyused to distribute the cleaning media in the tank.One of the oldest methods of tank cleaning, the “ll, boil anddump” approach, is still used by many industries for variousapplications. This simple cleaning method involves lling thetank with water and chemicals and heating its contents to therequired temperature. The mixture is kept in the tank for asufcient amount of time in order to allow the chemicals andtemperature to react with the soil. The tank is then emptiedor its contents “dumped.” This is a very expensive andtime-consuming cleaning method, and the amount of forceapplied is minimal.Tank cleaningTank cleaning-in-place (tank CIP) is a commonly usedcleaning method, which applies force to the tank surfacefor the removal of soil without having to open and enter thetank. There are three different types of technologies used forcleaning the tank interior1. Static spray ball (static cleaning device)2. Rotary spray head (dynamic cleaning device)3. Rotary jet head (dynamic cleaning device)

ptimisation of tank cleaning 71Whilst these technologies are not new, they have beendeveloped and improved over the past 50 years. Thetechnological advances to dynamic cleaning devices inrecent years are noteworthy. Some of the technologies havebeen tested and approved by the EHEDG; however, most ofthe equipment available today does not have approval fromany standards organisation.All three technologies apply force to the tank surface indifferent ways and with different degrees of efciency. Thelevel of efciency for the various technologies is determinedby the impact force (mechanical force) and the shear stress,which signicantly differ among the technologies.Static spray ballThe static spray ball continuously disperses cleaning uidthrough each perforated hole from a xed location in the tankonto a xed location on the tank surface (Fig. 2). As the jetshit the tank surface, they create an area, or footprint, wherethe impact force and shear stress are active. After impact,the jets change to cascades of cleaning uid, which rundown the sides of the tank, creating a free-falling lm. Thisfree-falling lm generates shear stress on the interior wallsof the tank in an uneven pattern. Here, time, chemistry andheat are the decisive factors that determine when the tank isclean. The wall shear stress of the free-falling lm is xed inthe range of 1 to 5 Pa, which is comparable to that present ina pipe in which the liquid is pumped at a speed of 1.5 m/s. 3Optimize toeconomizeSo where is all your energy going? The surprising factis that pumps account for as much as 50% of thepower consumption in some processes. Pump optimizationfor maximum efficiency in each process iskey, it could cut your bill considerably.Figure 2. Static spray ball. Static spray ball gently sprays cleaninguid onto the tank walls, enabling the uid to fall freely down thetank wall and provide uneven cleaning coverage.Rotary spray headUnlike the static spray ball, the rotary spray head is a dynamiccleaning device. The ow of the cleaning media releasedfrom the spray head causes the spray head to rotate (Fig. 3).This creates a swirling movement, which enables the uid tohit the tank surface with an impact force that is higher thanthe impact force of the static spray ball. The pulsating forceand impact created provide a combination of shear stressand variable falling lm of cleaning uid that covers all theinternal surfaces of the tank. Compared to the static sprayball, the rotary spray head reduces the amount of cleaningtime required to achieve the desired cleaning results.Watch our pump films:www.alfalaval.com

72 ptimisation of tank cleaningThe impact force and subsequent coverage create afootprint that is much larger and wall shear stress that ismuch higher than that provided by a static spray ball orrotary spray head. The magnitude of the wall shear stressin a rotary jet head footprint is approximately 104 Pa anddecreases to about 7.5 Pa at approximately 150 mm fromthe impact centre. 3 This is signicantly higher than the wallshear stress of between 1 and 5 Pa in the free-falling lmcreated by a static spray ball.Figure 3. EHEDG certied Rotary spray head. The rotary sprayhead has a higher impact force and higher wall shear stresscompared to the static spray ball. This reduces cleaning time.Rotary jet headOf the three automated tank CIP technologies, the rotaryjet head is by far the most effective because it creates thehighest impact force and highest shear stress (Fig. 4). Therotary jet head has between one and four cleaning nozzles,each of which disperses cleaning uid through a welldenedjet. The rotary jet head rotates at a predened speedto provide a full 360-degree indexed cleaning pattern. Thisensures that the tank surfaces are thoroughly covered aftera specied interval of time, which is dictated by the actualconguration of the machine.Figure 5. The wall shear stress in the footprint of an impingingjet from a rotary jet head, with water temperature at 20°C andpressure at 5 bar, is shown.The water from each jet of the rotary jet head creates amoving footprint on the tank walls in the 360-degree indexedcleaning pattern (as mentioned above). Because of thesignicantly higher impact force of the rotary jet head andsubsequent increase in wall shear stress, it is possible topredict the required cleaning time more accurately whenusing a rotary jet head (Fig. 5).Chemistry and temperature are therefore no longer the mostimportant parameters for cleaning efciency. Instead, impactforce is the most important parameter. By increasing theimpact force on the tank surface, it is possible to reduce thetime, ow, chemistry and temperature.In other words, when using a rotary jet head in most tankCIP scenarios, it is possible to cut the cleaning time required,reduce the amount of cleaning uids used and realiseenergy savings because the cleaning uids do not need tobe heated to high temperatures in order to achieve optimaltank cleaning efciency.Figure 4. EHEDG certied Rotary jet head. The rotary jet head isby far the most effective tank cleaning technology available today.Reduction of cleaning time and uidsconsumptionRecent studies indicate how the impact force from a rotary jethead is distributed in the impact area on the tank wall (Figures6 and 7). 4 The highest impact force occurs at the centre ofthe impact area; it then decreases by approximately 50% ata distance of 40 mm from the centre of the impact area. Itis also important to note that the rotary jet head effectivelycleans high-viscosity products, such as sticky foodstuffs,using water at ambient temperature in just 15 seconds afterthe jets hit the tank wall.

ptimisation of tank cleaning 73In many applications, using a rotary jet head can reducecleaning time by 50 to 70% and cut water and cleaninguid consumption by up to 90% compared with using theconventional ll-boil-dump method or static spray balltechnology. It is then easy to understand why so manycompanies are considering new ways to optimise tankcleaning performance yet maintain control over the tank CIPprocess.The Sinner Circle for tank cleaning with a static spray ballThe Sinner Circle for tank cleaning with a rotary jet headPerformancein good handsValidating the footprintFigures 6 and 7. Comparison of static spray ball and rotary jethead tank cleaning machines using the Sinner Circle. Adding theimpact force of the rotary jet head results in savings in cleaningtime, cleaning uids and energy due to reduced pump runningtime and less heating time of the tank cleaning uid.Ways to control the tank cleaning processBecause uptime is key to production efciency, optimisingtank cleaning performance is critical. It is therefore importantto optimise the tank cleaning process to ensure repeatabletank cleaning performance in the shortest possible amountof time.Although tank CIP systems are automated, these systems stillrequire monitoring and control. Temperature, ow rate andchemical concentration are among the critical tank cleaningprocess control parameters. However, the performance ofthe CIP system itself also requires monitoring and control toensure that it operates according to design parameters. Takethe rotary jet head tank cleaning system, for instance; it isimportant that the rotary jet head cleaning uids hit the tanksurface with the right impact force in order to ensure optimalcleaning efciency.The question remains Is it possible to ensure validation ofthe rotation and impact?Alfa Laval launches the improved and innovativeRotacheck. Validating the cleaning process insideany hygienic tank, cleaned by a rotary jet head. Thepatented teach-in and monitoring system ensures: of the cleaning head during cleaningMinimizing down time, optimizingproduction time!More on tank equipment:www.alfalaval.com

74 ptimisation of tank cleaningReal-time tank cleaning process controlProcess control depends upon reliable real-time in-linemeasurements using electronic sensors, such as theRotacheck sensor, to monitor and verify the performance ofa rotary jet head and tank CIP. Various such devices arereadily available today. However, it is important to considerthe response time of the device, as well as its ability toregister the actual pressure at which the jets hit the tanksurface.Fast response time is critical in order to measure the impactforce of the water jets accurately and reliably. A responsetime of less than 25 ms is considered necessary to registera jet hit against the tank wall; however, the response time formany sensors is too long, exceeding the 25 ms and thereforeproviding inaccurate measurements. Consequently, thesensors do not measure the entire actual impact andtherefore do not properly validate the effect of the jet.Furthermore, the signal remains “high” on the sensor evenafter the jet has passed and is no longer hitting the sensor.Registering the actual pressure at which the jet hits the tanksurface is equally important. This pressure is the actualimpact force that the jet exerts upon the tank surface. If theamount of pressure applied to the tank surface decreases,then the impact force decreases as well (Fig. 8). As thepressure decreases so too does cleaning efciency, whichconsequently causes the cleaning time to increase.Advanced sensors, such as the Rotacheck+ version thatcarries the 3-A symbol and has been EHEDG-certied, offerthe same advantages as basic sensors but include built-inintelligence. This consists of a teach-in function where thesensor records and stores the unique and actual cleaningpattern for any individual tank cleaning machine based uponits initial cleaning cycle, which has the design parameters(set point) intact.Every time a CIP process is initiated thereafter, the sensor willcompare the actual measurements to the recorded pattern(set point). Operators are immediately alerted during tankCIP if there is any deviation from the initially recorded time,pressure or registration of jet hits. This enables operators toact immediately to remedy the situation, thereby reducingthe risk of losing valuable production time. With the right CIPsensor in place, the process is under control.Figure 9. EHEDG certied Electronic verication tools, such as theRotacheck and Rotacheck+ sensors, validate the proper function ofrotary jet heads during tank cleaning.Figure 8. Jet impact prole of a rotary jet head when passing aRotacheck sensor. Typical pressure characteristics of a water jetfrom a rotary jet heat at 3 bar and at 5 bar shown.Selection of the right CIP process controlsystemChoosing the right system to monitor and control tank CIPprocesses can be challenging. It is important to dene yourobjectives for monitoring and control and to understand theavailable options and advantages.Basic sensors transmit a simple logic signal to the plantscontrol system, which indicates all jet hits and veriesthe operation of the rotary jet head. In addition to signaltransmission, some sensors also have a clear visual lightsignal that is visible to operators on the plant oor. Most areeasy to install anywhere on the tank, even on a pressurisedtank.Tank CIP process control optimises planthygiene and efciencyThere are several ways to achieve optimal tank cleaningefciency. To determine the right tank cleaning method fora particular process, it is important to dene the cleaningcriteria, understand the options available and consider thelevel of cleaning efciency and process control required.Selecting the right tank cleaning method puts the foodmanufacturer in control of the tank cleaning process andensures that the best cleaning results can be achieved interms of accuracy, reliability and repeatability.Whilst manual tank cleaning may seem sufcient forsome processes, there are advantages to switching to anautomated system, including cleaning consistency, reducedlabour costs and increased production time. Enhancingautomated tank cleaning processes also has its advantagesin terms of less downtime, higher energy savings andreduced water and cleaning uid consumption.

ptimisation of tank cleaning 75The addition of CIP process control systems, whether usingbasic or advanced sensors, can further enhance cleaningefciency. The only way to validate that an automated tankcleaning system is working effectively is to monitor and verifyits performance.With so much invested in hygienic food and beverageproduction, the additional expense of hygienic sensors tovalidate the tank cleaning process seems a small price topay to ensure the optimal cleaning efciency.References1. Sinner, H. 1959. The Sinner Circle “TACT.” Sinner’s CleaningPhilosophy. Henkel.2. Jensen, B.B.B. 2009. May the force (and ow) be with youimportance of ow in CIP. Food Safety Magazine, 1428-31, 51.3. Jensen, B.B.B. et al. 2011-2012. Tank cleaning technologyInnovative application to improve clean-in-place (CIP). EHEDGYearbook 2011-2012, pp. 26-30.4. Therkelsen, Niels Vegger. 2012. Methods to determine the efciencyof nozzles for cleaning process equipment. Masters thesis.BioCentrum-DTU, Technical University of Denmark.IntelligentReliabilityUnique Control LKB is an innovative valve automationunit with an integrated actuator. Flow automation hasnever been easier or more dependable, with onebuttonPush n’ Play self-configuration getting you upand running in a fifth of the time. The smart, robustdesign offers outstanding hygiene and durability.Welcome to Intelligent Reliability!Watch the film:www.alfalaval.com

European Hygienic Engineering & Design GroupEffective tank and vessel cleaning:How different systems can help meet today’s demandsContinuously developing tank cleaning technology with the aim of improving effectiveness andefciency will help to reduce the required amount of energy and media.Falko Fliessbach, GEA Breconcherry, e-mail: falko.iessbach@gea.com, www.gea.comEver higher demands for process hygiene, combined withsignicantly increased costs for the energy required toheat up and convey cleaning media and long downtimes,are typical challenges for many production plants. It istherefore logical to critically analyse the cleaning processesin production plants to determine and exploit the potentialfor optimisation. Developing tank cleaning technology toimprove effectiveness and efciency will help to reducethe required amount of energy and media, and increasehygiene in the plant environment.Cleaning components are used for cleaning in variousproduction plants in the food, beverage, pharmaceuticaland chemical industries. They allow the cleaning of tankvessel and reactor surfaces – irrespective of whether theyare in contact with product or not – to be integrated intothe process. Cleaning media such as water, detergentsor disinfectant solutions are applied to soiled surfaces.Depending on the application (i.e. whether vertical orhorizontal tanks with or without internal ttings are to becleaned and what type of residues are to be removed),various types of cleaning devices lend themselves to beused more effectively in some situations than others.Static cleanersStatic cleaners, also known as spray balls, are available withvarious spray patterns up only, down only or 360°, in varioussizes and with different capacities (Figures 1 and 2). Spraypatterns that direct liquid “up” are ideally suited for tankswithout internal ttings, because the full amount of cleaningsolution can be applied directly to the tank cover and thetank wall. “Down” spray pattern cleaners are best utilised fortanks that are open at the top, and “360°” spray patterns aredesigned for tanks with internal ttings. Depending on theapplication, the spray ball requires ow rates in the rangeof 30-50 litres per minute per metre of tank circumferenceto work efciently. Spray balls are usually available with athreaded connection or pipe clip. Using spray balls for thecleaning of tanks with internal ttings is recommendedonly if large parts of the tank can be cleaned by wettingall surfaces. If this is not the case, other cleaning devicesshould be selected.Users typically want answers to the following questionsWhat is the difference between the systems on themarket?Which system is the most effective and the mosteconomical for my type of application?Who has the expertise to advise me and develop thebest solution?The most popular systems on the market and detailsabout their technical characteristics and performancecapabilities are introduced below. Special processes alsoare described.Three groups of cleaner types are distinguishedStatic cleanersRotating cleanersOrbital cleanersFigure 1. Different types of spray balls.Figure 2. (a) Spray pattern “Down”; (b) Spray pattern “Up”; (c)Spray pattern “360°.”

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78 Effective tank and vessel cleaning: How different systems can help meet today’s demandsRotating cleanersRotating cleaners rotate around an axis, and they can befound as fast or slowly rotating types (Figures 3 and 4).Slowly rotating cleaners use at or round jet nozzles to spraythe cleaning solution on the tank wall. Unlike spray balls,the cleaner does not wet all inner tank surfaces at the sametime, but rather, applies a concentrated liquid jet to onesegment of the tank wall at a time. This means that the fullimpact energy of the jet can act on this particular segmentand that a thicker liquid lm forms on the tank wall, which,due to its higher energy, achieves better cleaning results asit runs down to the tank outlet. Without switching the supplypump on/off, this produces a pulse/pause type of operationfor each segment of the tank that allows the product residuesto be softened and rinsed off. This effect cannot be achievedby a spray ball.As a result, the mechanical cleaning effect of the slowlyrotating cleaner is much greater than that of a spray ball.This even applies if the cleaning solution ow rate is relativelylow. Under normal operating conditions the cleaning mediumconsumption is about 30-50% less compared to a sprayball.Figure 4. Rotating cleaner in the head of a mixing tank.Figure 3. Various types of rotating cleaners.Orbital cleanersThe special characterristics of this type of cleaner are theround-jet nozzles that rotate in two planes and producehighly focused high impact jets for intensive cleaning of theinside surfaces of tanks or vessels (Figure 5). Depending onthe type, the cleaners have two or four nozzles. The nozzleshave an inside diameter of up to 12 mm in accordance withapplication requirements. The horizontal and vertical rotarymovement is produced by a turbine gear unit, driven by thecleaning medium, or by a separate drive such as an electricor pneumatic motor. The continuous rotation in two planesproduces a nely meshed, net-like pattern of cleaning jetson the inside wall of the tank. At the end of a full cycle, eachand every point of the tank has been directly subjectedto mechanical impact from a strong jet. A complete cycletypically takes between 3 and 9 minutes. In practice, orbitalcleaners generally operate at pressures of 4 to 8 bar andcan easily cover an effective horizontal cleaning diameter

Fine-tuned UHT-plantsThe basis for aseptic product treatmentThe decisive factors in the selection of the appropriate UHT (Ultra High Temperature)process for thermal product treatment are product quality, production safety andefficiency. GEA TDS markets three different types of UHT-plants – with a capacityrange from 50 to 40,000 l/h for the treatment of low and medium viscosity products,but also allowing thermal and aseptic treatment of products with portions of fibresand particles.GEA TDS now offers an addition for a very smooth and gentle product handling:the new infusion technology for milk and juice. Applying this new direct heatingtechnology makes the product taste remain very fresh, especially when producingESL milk.GEA TDS GmbHAm Industriepark 2 – 10, 21514 Büchen, GermanyPhone +49 4155 49-0, Fax +49 4155 49-2724geatds@gea.comwww.gea.comengineering for a better worldGEA Process Engineering

80 Effective tank and vessel cleaning: How different systems can help meet today’s demandsof up to 33 metres, depending on the nozzle diameter used.This type of cleaner is especially recommended for largetanks, tanks and vessels with complex internal ttings, andfor products that are difcult to clean (Figure 6).Compared with a spray ball, the cleaning mediumconsumption is up to 70% less.Figure 6. Mixing tank for toothpaste, (a) before and (b) aftercleaning using orbital cleaners.Figure 5. Various types of orbital cleaners.Monitoring the functionStatic cleaners do not have any wearing parts so that theyare mistakenly regarded as operationally reliable. But likerotating and orbital cleaners, this type of cleaner also mustbe protected from particles that could block the roughly 200holes with a diameter of 1-3 mm each (e.g., by installing linelters). Regular inspection is required for all devices, even ifthe cleaning process has been validated.For devices that rotate around one or two axes there arevarious ways to monitor around the operation. On deviceswhere the turbine is tted outside of the tank, directmonitoring by proximity switches is easily possible. For theother cleaner types, various measuring devices, workingaccording to the principles of noise/vibration analysis,pressure pulse measurement and ow rate changes incombination with microwave measurement, are available onthe market. Depending on the manufacturer and the type ofsensor, installation is achieved quickly and easily or is rathercomplex, depending on whether, for example, separateevaluation electronics are required for the control system inthe control cabinet or not (Figure 7a/b).

Figure 7 a/b. (a) Monitoring sensor and (b) monitoring sensorinstalled.Tanks with internal ttingsFor cleaning tanks with internal ttings such as agitators,deectors, scrapers, and so on, it is essential that at leasttwo cleaning devices should be installed in the tank top,so that no spray shadows (i.e., areas left uncleaned) areproduced. The decisive factor is that the spray patternshould be 360°. For products that are difcult to clean, slowlyrotating cleaners or orbital cleaners are the best option.If agitators with several agitator blades are tted, it is alsopossible to use so-called “in-line sprayers,” which canbe moved into the tank after the process by a pneumaticextended in order to clean the underside of the agitatorblades (Figure 8a/b). While tanks with agitators are beingcleaned, these should generally turn slowly to ensurecomplete cleaning coverage. Accumulating a certain amountof clean-in-place (CIP) medium in the tank can support thecleaning of the lower tank sections.The Solution Finder.There is only one thing we will not separate:your process and our customized solution.We adapt machines to needs, not needs to machines.GEA Westfalia Separator Group GmbHWerner-Habig-Straße 1, 59302 Oelde, GermanyPhone: +49 2522 77-0, Fax: +49 2522 77-2488ws.info@gea.com, www.gea.comengineering for a better worldGE-90-01-011

Figure 8a/b. In-line sprayer (a) “closed” and (b) “open”.ConclusionThere is a large variety of tank cleaning devices available onthe market. However, this does not make selecting the rightone any easier. The most efcient and economic solutioncan only be chosen from the broad portfolio offered on themarket today if the cleaning problem is clearly analysed andall process criteria are assessed beforehand.

European Hygienic Engineering & Design GroupPractical considerations for cleaning validationHein Timmerman, Diversey, part of Sealed Air, Amsterdam, the Netherlands,e-mail: hein.timmerman@sealedair.com, www.diversey.comThe European Hygienic Engineering & Design Group(EHEDG) subgroup Cleaning Validation, chaired byProfessor Rudolf Schmitt of HES-SO in Switzerland, isworking on a new guideline pertaining to cleaning validationexpected to be published in 2014. Cleaning and/ordisinfection validation is dened as ‘obtaining documentedevidence that cleaning and/or disinfection processesare consistently effective at reaching a predened levelof hygiene, if properly implemented on equipment andproduction environment and used as intended. In contrast,cleaning verication is dened as ‘the application ofmethods, procedures, tests and other evaluations, inaddition to monitoring, to determine whether a controlmeasure is or has been operating as intended. Vericationis sometimes described as the documented evidenceshowing that an assigned entity continues to meet therequired (hygiene) specications. According to InternationalStandards Organisation (ISO) 22000, verication is the‘conrmation through the provision of objective evidencethat specied requirements have been fullled.The goal of developing the new EHEDG guideline isto provide a complete validation approach suitable forequipment manufacturers, cleaning product and equipmentmanufacturers and all industrial food producers, from smallandmedium-sized enterprises (SME) to multinationalcompanies. Cleaning validation is a documented processthat shows evidence demonstrating that the cleaningmethods that have been found applicable and acceptablefor a process/product, achieve consistently the requiredlevels of cleanliness.The objective of the cleaning validation is to demonstratethe effectiveness of the cleaning procedures in theremoval of product residues, degraded products,preservatives, allergens, and/or cleaning, disinfecting,cross- contamination and enzymatic agents that can posta risk to the consumer of manufactured food products.Together, validating cleaning, assuring a validationstandard and achieving consistent results is a topic of highpriority in the food processing industry. Cleaning validationis used to show proof that the cleaning system consistentlyperforms as expected and provides scientic data that thesystem consistently meets predetermined specicationsfor the residuals. However, when starting a new Greeneldplant, the integration of a validation approach from thedesign phase is a good base from which to achieve therequired result. When an existing plant or line requires aneffective and validated cleaning program, a huge amountof effort will be needed. More than 80 percent of cleaningprocedures and methods executed on a daily basis in thefood industry are not validated and are poorly documented.Lack of cleaning validation can be one of the root causesof food safety incidents as it relates to underperformingcleaning routines.The validation of process lines is more than the lineup ofsingle equipment. Implementation of a new validation planwill require a holistic approach. Validation can absorb ahuge amount of a dedicated teams time and will have aneconomic impact on the manufacturing operation. Findingthe balance between a theoretical and academic-provenmethod and the practical realisation of the validation planwill require good insights in current available technologiesand their practicality on the plant oor. In addition, a simpleengineered line modication, such as the changing of apump type or the addition of a valve or new instrument, cannecessitate a new validation of the entire process line.Validation requires a deep understanding of all elementsinvolved in the cleaning result, such as the importanceof design and development for an effective program; theprinciples and calculations of residue limits for a wide varietyof residue types; routes of administration; and dosagetypes the selection of available analytical methods, alongwith appropriate levels of analytical method validation.It also requires a knowledge base about the selection ofsampling methods and sampling sites, along with properselection of blanks and controls using the appropriatestrategies and documentation for sampling recoverystudies; the presence of a cleaning validation master planand/or policy components; the appropriate documentationfor cleaning validation protocols and reports; the tools usedfor monitoring, verication and revalidation; and validationmaintenance for validated cleaning processes.

84 Practical considerations for cleaning validationThe new EHEDG guideline will demonstrate a practicalapproach that takes into account all of the needed stepsto come to a validated cleaning. The partnership betweenthe food operator and cleaning chemicals suppliers andoptimisation of related services is essential to assure afocused and professional validation approach. However,it will be a crucial task to dene a balanced strategy ingrouping cleaning activities and simplifying the validationwork to keep the validation implementation a task that willnot disrupt the companys efciency.SMART SAFETYThanks to smart automation, the newTetra Alcip CIP unit uses exactly theright temperature, amount of water,detergent concentration and cleaningtime to achieve uncompromising foodsafety. While cutting the consumptionof water by 21% and chemicals by 6%.And delivering unique flexibility to meetevery CIP need. All at the lowest operationalcost.Certified equipment conforming to the guidelinesof EHEDG, of which Tetra Pak is an active member.www.tetrapak.comTetra Pak, , PROTECTS WHAT’SGOOD and Tetra Alcip are trademarksbelonging to the Tetra Pak Group.

European Hygienic Engineering & Design GroupIntegrated hygienic tamper-free productionThe challenge for producers is to secure food safety in their production line, protably. It isimportant to secure against operator mistakes, inconsistent product quality, and even againstmanipulation of the product. Adopting a holistic view on the entire production is the answer.Stefan Åkesson, Tetra Pak, Lund, Sweden, e-mail: stefan.akesson@tetrapak.comToday, production is integrated The product ows continuouslythrough the plant, from raw material intake to distribution,without stopping. This means that producers must controlevery step, both individually and as part of the whole.However, recurring problems with hygienic issues arereported from all over the world. Inconsistent food quality,manipulation of product, wilful tampering, human error – allof these reports have a huge impact on brands, protability,and consumer condence in the food industry as a whole.Securing tamper-free production is essential.Hygienic designIt all starts with hygienic design. Hygienic design ensures thatevery material that will ever come in contact with food – fromcomponents right down to connections and welds – is designedand constructed for cleanability. Using and following theEuropean Hygienic Engineering and Design Group (EHEDG)guidelines ensures state-of-the-art hygienic design. It is alsoimportant to conduct a hygienic risk assessment during thedevelopment and engineering phases of a project to analyseand evaluate hazards in order to eliminate or reduce hygienicrisks. Following hygienic design principles means that theproduction process is designed with quality control functionsthat ensure food safety from start to nish.With quality assurance operations in place, substandardproducts can be handled at an early stage, which minimisesproduct losses and increases product quality. One wayto secure food safety is to use guidelines – structuredprocedures – as an important aid in the daily work of a foodprocessing plant. Furthermore, the control system not onlyshould monitor the procedures, but it should also activelyprovide hygienic functionalities that help the producer avoidoperator mistakes, ensure quality control and secure atamper-free production environment.To assist the producers food safety management system,it is important that the quality control system monitors theimplementation and attainment of good manufacturingpractices (GMP) and identies measures to correct anyfailure to achieve GMP.Integration of hygienic, aseptic and control systems is shownin EHEDG Guideline 24.Tamper-free production solutionAdvanced control systems with recipe handling, productionmonitoring and production analysis access informationabout the ongoing process. To secure consistent productquality and avoid intentional tampering, the optimal tamperfreesolution should involve all phases of production, withmultiple levels of security (e.g., automated material handlingthat secures the mixing accuracy, even of manual ingredientadditions or monitoring of the cleaning sequence throughclean-in-place [CIP] sensors, and automatic adaption ofthe cleaning procedure, depending on the informationreceived and analysed). The control system also ensuresthat the product and cleaning agents are not mixed. Inthe warehouse, recipe handling functions should ensurethat the right material and amounts are stored, and stockmanagement should show continuous inventory information.The recipe handling also helps the operator to create thebatches according to the recipe and production schedule,and a unique batch identication (ID) number is generatedwhen ingredients are being prepared for different batches toensure that the right ingredients and amounts are added intothe right tanks (Figure 1).Figure 1. Cabinets containing the different ingredients haveautomatic locking system integrated with the recipe handlingsystem. The operator is prompted by the system to add ingredientsin a preset order, and through the cabinet locking system, theoperator can pick only the correct mixture, securing product quality.Another security function is in the mixing area. A stock-inand-outsolution is integrated with the weighing system anda scanner device that the operator uses to keep track ofall additions. In the process area next to the mixing tanksthe operator scans the generated batch ID barcode on theprepared bin and the barcode on the tank. If the codesmatch the automatic tank locking system the tank will open.The interlocking function makes sure that the right mixgoes into the right tank. Locks on both tanks and ingredientcontainers secure the integrity of the system and this ensuresconsistent product quality while reducing waste and productloss. Another feature of an automated control system is theavailability of reports Batch reports, stock reports, journals

86 Integrated hygienic tamper-free productionand audit reports are key performance indicators used tooptimise production through improved production planning,logistics and production analysis.The tamper-free production solution supports the foodsafety management system for food producers, by avoidingoperator mistakes, keeping track of all raw materials andingredients, and preventing intentional tampering and otherfood safety issues.HIGH-PRESSURE SAFETYSuper-efficient UHT treatment of highviscoussoups, sauces, tomato pastes, youname it. Based on a coil tubular heat exchanger– Tetra Vertico – that handles upto 350 bar pressure, giving less stickingand fouling, and up to 50% less productloss. Faster product changes. Easiercleaning. Safer for food. Safer for the environment.Safer for your business.Traceability is about trustA well-developed method that ensures traceability canprove invaluable to food safety while signicantly reducingthe cost of recalls and bad will. A sophisticated automatedcontrol system enables traceability quickly and efcientlythroughout the entire production chain, from raw materialintake to packaged product. Effective traceability is the resultof structured data acquisition, where the acquired data areaccessible and searchable. Traceability is essential if aproduct needs to be recalled, and it limits the size of therecall. With a traceability tree, the entire production ow canbe viewed and analysed, and performance can be improved.Advanced control systems with traceability technologiesimprove the speed and reliability of the entire productionprocess through real-time monitoring. In addition, completeautomation control secures traceability of the nal product.The system compares the product samples to the productionparameters. If the values are out of range, the system cangive alerts.Traceability can make production transparent and allowsanyone along the supply chain (including the consumer) todiscover the origin and route of any given food via an Internetportal. By tracking the origin of foods and their routes throughthe food supply chain, the risk of unexpected incidents canbe reduced and consumers trust in food production can bemaintained.Certified equipment conforming to the guidelinesof EHEDG, of which Tetra Pak is an active member.www.tetrapak.comTetra Pak, , PROTECTS WHAT’SGOOD and Tetra Vertico are trademarksbelonging to the Tetra Pak Group.

European Hygienic Engineering & Design GroupDamage scenarios for valves:Identifying the potential for optimisationWilli Wiedenmann, Krones AG, D- Neutraubling, e-mail: willi.wiedenmann@krones.com, www.krones.comIdeally, valves used in the production process would gounnoticed and remain problem-free throughout a linesentire functional lifetime. But valve integration cannot beignored quite so easily; after all, these components areindispensable for automated production processes to ensurethe appropriate routing paths and to shut off product ows.They are required to exhibit maximum reliability in terms ofdesign and function, and to be sturdy enough to effortlesslycope with any events occurring in the production process.Where exactly are the potential problems associated withvalves? Moving parts for opening and closing the shut-offcomponents, duty limits of seal materials as well as productcharacteristics, and the temperatures encountered in theproduction and cleaning processes all demand a lot fromthe components involved and inuence their useful lifetimes.Then there are the imponderables, such as water hammersor human error in handling the individual componentswhen removing and installing wear parts. By designing aradically new series of valves, Krones has taken on boardthe empirical feedback from operating aseptic and nonasepticproduction lines, and has created a family of valvesthat exhibit salient improvements for many of the problemsencountered in valve design. This involves valve design thatcontributes to safe and contamination-free product routing,and incorporates features that simplify the operators workand enhance personnel safety.Seal design for buttery valvesNumerous cases of damage when using valves areassociated with the seal. In the case of a buttery valve,for instance, volume changes will occur, caused by risesin temperature. These swellings on the seals protrude intothe product compartment, so that during the opening andclosing operations for the valve disc, the increased levelof friction causes small particles to be abraded, whichare then entrained in the product or the cleaning agent(Figure 1).The result is that the valve no longer closes properly, whichmeans that the liquids are no longer dependably separated,resulting in product contamination. For example, if the apis no longer being positioned in a 90° conguration, thefeedback signal from the proximity sensor is not being sent,and the system goes into fault mode, which entails substantialcosts in terms of lost production output (Figure 2).Figure 2. Swelling of the seal, with tear, in conjunction withimprecise closing of the buttery valve.With a seal design that incorporates two expansion groovesthe expansion caused by a change in temperature can bepurposefully conned to the seals installation space in thehousing, and the abrasion or damage in areas coming intocontact with the product can thus be avoided (Figure 3).Figure 3. Cross-sectional view of a buttery valve with optimuminstallation situation for the seal.Figure 1. Seal abrasion at the disc.And in order to prevent wear phenomena due to valveap movements, a smooth surface has been provided inthe product compartment, thus relocating the dividing lineto outside the product area. A lead-in chamfer on the seal

88 Damage scenarios for valves: Identifying the potential for optimisationsupports the switching mechanisms of the disc, so that allswitching operations are performed with minimum stress onthe material.Extensive tests on the capability of the valve design towithstand pressure chock (or water hammer) also provideprecise data on the production conditions under which thevalves can be operated. Thus, in the event of unexpectedwater hammers (which cannot be entirely ruled out in anyproduction operation), a clear statement can be made on thestate of the seal. (Figure 4).Figure 6. Sealing conguration at the valve plate.In the event of damage to the valve disc, safe andcontamination-free operation of the production line can onlybe restored by a time-consuming and expensive replacementof the valve plate.The frequently observed phenomenon of the seat sealstearing out at the opening and closing movements of thevalve discs is manifested with one-piece valve discs, whereinstallation of the seal is, in most cases, not easy, and inactual practice is also accompanied by a bit of “helping out”with the use of grease or washing up liquid.Figure 4. Seal torn out after a water hammer.The design of a two-part screwed-together valve disc with adened installation space for the seal ensures signicantlymore precise installation conditions, and concomitantly,reliable positioning of the seal. This provides concomitantgains in terms of reliability against pull out and uid behindthe seal. Leakage detection according EHEDG is warrantedbetween the parts of the valve disc. (Figure 7).Weak point: alve stem and seat sealIn the case of seat valves, it is not uncommon for traces ofwear at the valve disc and the valve shaft to be responsible forentraining dirt into the product area and for leaks (Figure 5).Figure 7. Sealing conguration at the seat.Similar phenomena can be observed with mix proof valves.Damage to the radial seal and traces of wear at the valvedisc can be prevented by providing a dened installationspace for the seal, and by designing the seal with a supportring (Figure 8).Figure 5. Traces of wear on the valve disc.This is prevented by integrating a second shaft seal, whichstrips off any dirt, and avoids any damage to the valve shaftfrom wear traces. Leakage detection according EHEDG iswarranted between housing and seat ring. (Figure 6)

Figure 8. Traces of wear on the valve disc.Moreover, since the seals are identical, there is no possibilitythat the product paths will be shut off incorrectly due toconfusion between the axial and radial seals (Figure 9).Figure 9. Identical seals for radial and axial sealing of the valvedisc at a mix proof valve.Compounds for high operating temperaturesIt holds true for all valve designs that newly developed highperformancecompounds have led to higher temperatureresistance. Whereas 10 years ago temperatures of up to160°C were customary for the steam involved, in systemsdesigned today the temperature spectrum has to beextended up to 210°C, which means the seal has to possesssignicantly enhanced performance capabilities. By utilisingthe nite element method (FEM), the framework conditionswere simulated by Krones during the design phase, andthe stress limits and expansion reproduced under denedtemperature conditions and with specied installationspaces. A comparison with a seal of conventional designrevealed denite advantages for the newly chosen sealconstruction.UNCOMPROMISING SAFETYAt Tetra Pak, exceptional efficiency goeshand in hand with uncompromising foodsafety. For example, our unique OneSteptechnology, which combines heat treatment,separation and standardization in asingle step, cutting the production time ofUHT or ESL milk by up to 90%, and cuttingoperational costs by up to 50%. Completewith aseptic buffering, it gives you an unbrokenchain of safety.Certified equipment conforming to the guidelinesof EHEDG, of which Tetra Pak is an active member.www.tetrapak.comTetra Pak, , and PROTECTSWHAT’S GOOD are trademarksbelonging to the Tetra Pak Group.

90 Damage scenarios for valves: Identifying the potential for optimisationAseptic – strong bellows essentialThe requirements involved are even more stringent inaseptic operations. Dependable separation of the productfrom its surroundings has been the strategy pursuedfor many years now. Integrating the bellows elementsas a seal at the valve disc can indeed create the desiredseparation; however, this introduces a not-inconsiderablesource of possible malfunctions. Defective bellows and theconcomitant possibility of rear inltration may be responsiblefor contamination phenomena not amenable to easydetection, causing substantial losses of productivity in actualoperation quite apart from a contamination of the productinvolved (Figure 10).The conditions for operators andmaintenance staffBesides replacing any worn seals, staff are also involvedin maintenance work on the valves and the actuators. Somaximised safety has to be assured. The foundations forthis are in place clients, and thus the valve manufacturerstoo, have to ensure that the design of their systems andcomponents is such as to fundamentally rule out any risk ofinjury during operation, and conforms to the requirementsof the EUs Machinery Directive (2006/42/EC) and the EUsPressure Equipment Directive (97/23/EC).With a welded version of the actuator (designed for onemillion switching cycles), the amount of maintenance workrequired is minimised, while the accident risk from openingup an actuator is eliminated as well. In this context, specialattention has been paid to easy handling of the actuators, asevidenced by the weight of < 25 kg in the case of nominaldiameters of up to ND 100. In addition, accident preventionin production mode is enhanced by covers for moving parts(valve yoke, feedback system) (Figure 12).Figure 10. Damage to the bellows means that contamination isinevitable.A study of the stresses acting on the stainless-steel bellowsunder a ow of p = 7 bar shows unequivocally (with differentprocess parameters and stroke positions) what vibrationsoccur in the bellows construction. This quickly reveals whya bellows breaks after only a very brief period of operation.In the newly designed valve series, this is remedied by anintegrated support body (Figure 11), which ensures that thebellows is properly guided and dampens the vibrations at theindividual pleats. Moreover, this also avoids damage to thebellows due to overstressing at removal.Figure 12. Personnel safety – protective feature at the valve yokeand feedback systemFigure 11. Support body for guiding the bellows.With a component inspection conducted by the TÜV Südtechnical control board, comprising a pressure test, a safetytest and a strength test, the new series of valves has beensubjected to all tests designed to document operationalsafety down to the tiniest detail.

Besides safety considerations, of course, features designedto facilitate care and maintenance work have also beenintegrated, such as quick and easy seal replacement in theproduct compartment without needing any special tools, and(as already mentioned) eliminating any risk of confusionwhen replacing seals.AdvertisementSummaryNew methods for determining the performance capabilitiesof components, plus a rigorous scrutiny of damageoccurrences, are indispensable as a basis for designenhancements. State-of-the-art components offer possibleapproaches for optimising the useful lifetime and for reducingcases of damage in actual production conditions.This new designs also score in terms of nancial aspects,since with lower compressed-air consumption, fast liftingtime and free cross-sectional areas in the product owenergy costs can be meaningfully reduced.Of the utmost importance are improvements in terms ofhygienic design of valves. It is an excellent idea to conrmthe cleanability of valves in the process through certicationby the European Hygienic Engineering & Design Group.Lödige supplies high-grade subsystems,components and services for technicalprocessing applications, in particular inPharmaceutical, Food and CosmeticsIndustry.We are spezialized in the fields of Mixing Granulating Coating Drying ReactingLödige Hygienic Design -Part of Your ExcellenceLödige Systems not only meet theGMP and FDA standards but alsofulfill all specifications regardingqualification and validation.www.loedige.deLÖDIGE - ALWAYS THE RIGHT MIX

European Hygienic Engineering & Design GroupInfection-free preparation of bacterial culturesThe preparation and compounding of freeze-dried bacterial cultures available in powder formrequires extremely high standards of hygiene. If the material is also deep frozen the mixingequipment must have very good insulation and meet increased strength requirements.Dipl.-Ing. Ludger Hilleke, amixon GmbH, D-33106 Paderborn, Phone: +49 5251 68 88 88-0, info@amixon.de,www.amixon.deToday, fermented specialities enhance nearly all of the mostcommonly produced dairy products. Whether in cheese,curd and yoghurt, or when used for improving meat, theycan be found everywhere. However, the production of thesepowdery granular materials is a real challenge, especially infurther processing environments, which demand a high levelof cleanliness, quality of handling, and a granular dust-freestructure.A determinant of the quality in this process is operationwith the minimum of interruptions; in other words, as nearlycontinuously as possible. High-purity bacterial cultures formby cell division, and for industrial production, the aqueoussuspension of bacteria is continuously diluted with nutrientsolution. After a constant dwell time, the matured suspensionis removed and washing processes follow. The cell divisionprocess does not stop until the extracted cultures are frozen.To facilitate handling, the cultures also are sometimes freezedried, which produces a loose powder or granulate with bulkdensities around 0.1 to 0.4 kg/dm 3 .In subsequent automated processing of bacterial culturesthere is often a mixing process. Naturally, a quick result isdesirable, with the mixing done in a way that avoids causingdamage and that work efciently under difcult conditions(i.e., differing lling degrees, bulk densities, particle sizes,rotational speeds, etc.). In addition, as a result of thealternating stresses that result from very high temperaturechanges in these processes, mixers must be speciallydesigned to avoid fatigue cracks.Meeting all of these challenges of producing powderformfreeze-dried bacterial cultures in a hygienic mannerrequires mixers that are designed with hygiene in mind.A good example is a single-shaft mixer whose mixingprinciple is based on a three-dimensional rearrangement,such as those produced by amixon GmbH (Figure 1). Insuch a mixer, the material in the periphery of the mixingchamber is screwed upwards and then ows downwardsin the centre. The helical mixing tool performs mixingvery gently at circumferential speeds of 0.2 to 0.9 m/s. Aparticularly useful feature is that the mixing process takesplace independently of the lling level. In this respect theemptying process also takes place without segregation,even when it takes a long time or occurs while pulsating.The high degree of residue emptying assists in keeping themixer highly sanitary.Figure 1. Example of a single-shaft mixer that can be used in themanufacture of powder-form freeze-dried bacterial cultures.Thorough cleaning of a processing plant in which mixingof powders occurs is also clearly essential. Avoidingcontamination is both a determinant of quality and anabsolute ‘must in producing foods free of allergens. Onesolution to this challenge is the automation of wet cleaningand drying of powder mixers. In one patented process, aclean-in-place (CIP) device is rmly installed on the mixingchamber and remains there permanently. For wet cleaning,the sealing plug in the mixing chamber opens and makesthe space available for the motion of a rotating wash lance.The latter moves into the mixing chamber with translatorymotion. With an applied water pressure of about 3.5 bar,the head rotates and three nozzles spray the entire mixingchamber interior. Depending on the size and execution ofthe mixer, three, four, or in some cases ve, washing headsare necessary for wetting the entire mixing chamber and allparts of the mixing tool.After completion of the wet cleaning, drying is essential.Bearing in mind that the specic heat capacity of water isabout nine times as great as that of stainless steel, the wetcleaning with hot water spontaneously heats up the mixer.This heat assists the steam stripping of the mixer. Additionalhot air entering via an inlet through the main connection ofthe CIP device accelerates the drying process.The entire mixer and the CIP system are dried. Only thendoes the rotating lance move out of the mixing chamber andthe sealing plug closes the container, gas-tight and liquidtight.

From the operators viewpoint, it is worth noting that thesequence of movements of the patented device requires onlya single electro-pneumatic drive, making it easy to control.It is employed with success in mixers, dryers, reactors andother systems. In specic cases the rotating washing nozzleis replaced by high-pressure aiming nozzles, particularly ifthe cleaning is to be done with a small amount of water bututilises high pressures.Ultimately, any mixer used in the preparation andcompounding of freeze-dried bacterial cultures mustbe built to sanitary standards in compliance with USFood and Drug Administration (FDA) requirements, 3-ASanitary Standards, and the requirements of the EuropeanHygienic Engineering Design Group (EHEDG).Individual andfuture-orientedplants for yourprocess.Tailor-made solutions for process systemsfor the food, beverage and pharmaceuticalindustries. Consulting, planning, constructionand service - all from a single source.Plant design at its best.RULAND Engineering & Consulting GmbHIm Altenschemel 5567435 Neustadt, GermanyPhone: +49 6327 382 400Fax: +49 6327 382 499info@rulandec.de, www.rulandec.de

European Hygienic Engineering & Design GroupModern level detection and measurement technologiesSticky media, foam, changing media and hygienic installation present challenges for ll leveldetection and measurement. In order to improve reliability and reduce the downtime of machineryit is crucial that a level sensor switches off when the tank, vessel or tube is empty, even if the tipis still covered with the medium. Any medium that produces foam is especially tricky becausean overow protection has to detect it, whereas a level measurement and an empty detectionshould mask the foam. A modern level measurement and detection should also work even if themedium changes. This article gives a guideline of technologies to solve these challenges, aswell as some information on hygienic mounting.Daniel Walldorf, Baumer GmbH, Friedberg, Germany, dwalldorf@baumer.com, www.baumer.comFrequency sweep technologyfor level switchesFrequency sweep technology for level switches detects lllevel of a tank, vessel or tube on the basis of the DK value.As opposed to a classical capacitive sensor, this technologyopens the possibility to distinguish different media (e.g.,liquid and its foam) and adhesions from sticky media to afull tank (Figure 1). Clever set-up strategies make it possibleto use the same sensor with the same set up for a largevariety of media. Advanced sensor versions usually make itpossible to do visual set up and to get a measurement outputfrom the sensor (e.g., for condition monitoring of a tank).Figure 2. Setup of a sensor for sticky media (chocolate).Figure 1. The frequency sweep technology opens the possibility todistinguish different media and adhesions from sticky media.The working principle involves analysing an inductorcapacitor(LC) circuit for its resonance frequency where themedium to detect inuences the capacitor. Therefore, theresonance frequency depends on the medium in front of thesensor tip. At the resonance frequency, power consumptionis at its minimum.Hydrostatic level measurementOne might think that measuring level by hydrostatic pressureis not very modern. Nevertheless, it is with reason thatthis measurement approach remains the most populartechnology. The food, beverage and pharmaceutical industryfacilities typically operate machinery using a wide temperaturerange from 0°C to 140°C. Therefore, it is critical to use apressure sensor with good temperature compensation.This is typically reached by sensor manufacturers with aninternal temperature measurement and an identication oftemperature compensation for each individual sensor duringthe production process. In most data sheets, the temperatureerror is indicated either as temperature coefcient or as avalue for a total error band available in the compensatedtemperature range.

Modern level detection and measurement technologies 95Hygienic connection of pressure sensors are inside therecommended tubings. For the mounting in tanks thereare fewer possibilities with standard connections. Mostmanufactures offer special cavity-free process connectionsfor tanks together with the tting welding parts. The user andplanner should look at the European Hygienic Engineering& Design Group (EHEDG)-certied connections to be on thesafe side.Altogether, hydrostatic level measurement offers a verygood and cost-effective method for tanks from about 1 min height and up, which corresponds to a pressure range ofabout 100 mbar. For tanks under 1 m high, the use of othertechnologies should be investigated.Capacitive contact-less level switchingStandard capacitive switches can be used to detect amedium in a tank through the tank wall. This is especiallyinteresting because no hygienic process connection isneeded and the set up can be extremely compact and easyto add to an existing tank.Potentiometric level measurementFor tanks heights lower than about 1 m, potentiometric levelmeasurement technology offers a very good alternative.This technology uses a metallic rod inside the tank andmeasures the level by detecting the length of the rod, whichis connected to the tank wall by a liquid.The technology masks foam as well as adhesions by stickymedia. It is very interesting that sensors based on thisprinciple do not have to be set up to the used medium.Hygienic applications are matched by taking care of specialprocess connections that are typically together with ttingwelding parts for tanks. A short response time of a fewmilliseconds is typical, so that even for fast lling processes,this technology offers a great alternative.However, the technology is limited in that the medium shouldbe liquid, homogeneous, and must have at least a smallconductivity. In most applications in the food, beverage andpharmaceutical industries, the parameters are inside theselimits.ConclusionThere are several options that enable accurate measurementof the level in tanks with liquids, even if the product is stickyor has a layer of foam. Moreover, available technologies canbe applied in a hygienic way.Figure 3. Capacitive sensor setup at a glass tube.As a limitation this only works through plastic tanks or glasswindows.

European Hygienic Engineering & Design GroupAn example of the development process of hygienicprocess sensors: A hygienic level switchThe development of new technologies usually follows predened pathways. The developmentof sensors for use in hygienic processes has additional requirements. This article shows theimpact of hygienic design in the product development process.Holger Schmidt, Grad. Brewmaster, Endress+Hauser, Weil am Rhein, Germany,e-mail: holger.schmidt@de.endress.com,Some developments start with a good idea that seems tocome out of the blue and the result is a useful technology.More often, the market has a specic need and the newdevelopment is based on changing an existing instrument,automation technology or process. It could also be basedon an economic need to improve the process. But usually,customers want to improve safety, quality and performanceof their plant, so that their operations and facilities remainstate-of-the-art.The Liquipoint FTW33 point level switch was born out of thelatter desire. The need for a reliable high- or low-level signaland pump protection in point level switch technology waspreviously achieved successfully over a number of yearsby using tuning fork technology for nearly all applicationsin hygienic processing. However, the successful use of thistechnology was limited in highly viscous media in which small“voids” are created around the vibrating forks that can causeuncertainty in level detection. Another challenge with tuningfork and capacitance level technologies is related to theiringressing parts, which makes cleaning more demanding,time-consuming and costly than necessary. This is especiallytrue if mechanical support is required such as the use of acleaning ball in pipes.Driven by these needs, the goal was clear Design asensor that works in highly viscous media without buildupissues. The design would need to be ush-mounted toallow sufcient cleaning such as is outlined in the EuropeanHygienic Engineering & Design Group (EHEDG) Guidelines8 and 10.1well as global customers who require additional processconnections. For this sensor, an adapter concept waschosen to ensure necessary exibility without compromisingany of the hygienic requirements set forth in the originalgoals. It was important to focus on a smart design of theconnecting parts and gaskets. The design needed to ensureexposure of the seal at the right place, and also protect itagainst mechanical stress.Document 10 of the EHEDG Guidelines backs up thesedesign criteria with a focus on corners, dead ends, edges,gaskets, seals, and the connection of different materials. Theparts that are in contact with product, but also the housing,only show even surfaces.The denition phaseThe engineering phase begins with determining whichtechnology best meets the specied goals. In this case, therewas already good know-how in capacitance and conductivitymeasurement available within the engineering team. Thesensor design approach focused on a combination of bothtuning fork and capacitance technologies. The design startedwith understanding the guidelines in which hygienic designis described. For the food and beverage Industry, these areprimarily the EHEDG and 3A Sanitary Standards guidelines.It includes EHEDG Document 8, which describes how todene the choice of material, cleanability, tightness againstintruding microorganisms, geometry, surface treatment,installation and self-draining requirements.The choice of appropriate process connections was anotherimportant decision to take in the sensor developmentprocess. Standards like DIN 11864 were considered, asFigure 1. Polished surfaces and crevice-free welding at wetted partsand housing.The sensor must also be protected against the cleaningprocesses of the food and beverage industry. Even ifa high pressure jet cleaner typically spreads dirt andmicroorganisms more so than manual mechanical cleaningmethods do in a given plant, the deisgn of the sensor shouldensure its reliability and ruggedness on a daily basis.To meet the development objectives, EHEDG Document 37,which details function and design of sensors for hygiene andsafety, also was taken into consideration. For the Liquipoint,

98 An example of the development process of hygienic process sensors: A hygienic level switchthe fulllment of these requirements led to a design thatworks with very smooth angles on a nearly at plate. Theslight warp is needed to ensure the support of a self-cleaningprocess and ensures, together with the active build-upcompensation, high reliability in nearly all media. Theprecondition for reliable level detection is the requirementfor a conductivity of more than 1μS.The materials of the Liquipoint — 316L stainless steel andvirgin PEEK as an isolator — are combined in a specicprocess that ensures long-term, crevice-free tightness ofthe sensor (Figures 1 and 2). All materials follow FDA andEuropean requirements (EN 1935/2004) as described inEHEDG guidelines. The surfaces of wetted parts have asurface nish better than 0.76 μm. The sensor is compactenough to t in small process connections, but also supportsan adapter concept. It is self-draining, and has no gaps orcrevices.Production considerationsFollowing the design and testing process, there are severalsignicant production considerations that must be takeninto account in producing the sensor. First, production ofequipment to be used in hygienic installation must meetall specic regulatory requirements. In ISO 9001 andattached norms, the specic considerations are describedand equipment and component manufacturers are chargedto follow good manufacturing practices. It starts with thepurchasing of raw material, internal handling and traceability,and continues through to a clean working environment. Thewetted parts, including all materials that are in contact withthe product, such as cleaning media or lubricants, must followthe international regulations for food-contact materials. Ifafter cleaning the product prior to completion there remainsany cleaning solution or lubricant residues, there must bevalidation that they cannot cause any harm. Periodic reviewof procedures and the resulting products ensure that thepackaged sensor is of the expected quality.Figure 2. Liquipoint point level switch, ush mounted, even surface.The resulting design results in less shear forces on thesensor, especially in agitated vessels, and offers the abilityto install the sensor in areas with very little space. The naldesign fullls the basic technical requirement a reliableswitch signal under all conditions.ConclusionOn the one hand, the development of a specic technologyfor the hygienic industry is demanding. On the other, it iseasy, because there are clear guidelines and customerexpectations to meet. EHEDG supports efforts to join the twomarket participants recommendations and expectations.The supplier can be condent that by following the EHEDGguidelines the sensor will be market-ready. And the useris sure that he receives a hygienically designed processcomponent that will have a positive impact on the safety,quality and performance of the manufacturing plant .In this case, the technical requirements dictated the basicdesign denitions, which led to the development of animproved, safe and reliable switch that works with differentmedia—specically with high- or low-viscosity media—isunaffected by build-up, is easy to handle, and is safe toinstall and operate. But even if measuring technology drivesthe development, it is possible to use hygienic guidelinesto ensure proper design. The Liquipoint FTW33 is a goodexample of how the product development process and resultof such a process can look.The eld testing phaseThe denition of applications for testing the new devicewas easy in this case, because market recommendationsled to this product development. Targeted installations were“sticky” and demanding processes, including products suchas yogurt, jam, cream cheese, smoothies, dough or ketchup.In these applications, the sensor must show how it can copewith build-up, cleaning cycles, and sterilisation, and mustshow its exibility in dealing with changing products. Theinstallation and set-up must be easy. In-house tests withspecic treatments were added to the eld test. In a shorttime, a high number of cycles could be simulated throughthese in-house tests. Finally, a mandatory step in productdevelopment in the food and beverage industry is to showhow the sensor behaves in a dened cleaning cycle. In thiscase, the sensor was tested using the EHEDG cleanabilitytest rig as a reference.

European Hygienic Engineering & Design GroupStorage in silos and pneumatic conveying of milk powderwith up to 60% fat contentHermann Josef Linder, Solids Solutions Group, S.S.T.-Schüttguttechnik Maschinenbau GmbH, Landsberg, Germany,Phone: +49-8191-3359-0, e-mail: H.Linder@solids.de, www.solids.deThe storage and ow of ne food-based powders with highfat content is a challenge. An investigation conducted byHausner-Zahl in 1996 showed that for these types of powdersa very high degree of compaction occurs during conveyingand storage. This results in the categorisation of the productin its deposited state as “non-owing,” which presentsfurther quality and food safety control issues associated withstorage capacity in silos. 1 In addition, according to Geldart(1973) in his assessment of pneumatic conveying, when aclassication in Group C (i.e., ne powders) was carried out,owability of these products was cohesive, difcult or notable to uidise. 2Solid Solutions Group (S.S.T.) has conducted complexinvestigations of materials used for storage andtransportability, partially under simulation of the operatingconditions, that have led to ne powder processing andapparatus technical solutions. The primary goal was todesign pneumatic conveying apparatus and storage silosthat comply with the European Unions (EU) MachineryDirective 2006/42/EC, Annex 1, Clause 2.1, including foodprocessing equipment, as well as with the DIN EN1672/2hygiene requirements. In addition, equipment had tofollow the European Hygienic Engineering and DesignGroup (EHEDG) guidelines and the U.S. Food and DrugAdministration (FDA) good manufacturing practices (GMP)and related rules and recommendations. Goals for thedevelopment of hygienically designed equipment systemsused in the production and storage of ne powders includedThe entire system should be free of dead spaces,should be capable of being completely emptied andshould be easily cleanable.Where possible, dry cleaning by air ushing ispreferable, but wet cleaning is also possible when anunavoidable greasy lm is present in the process orsystem.During storage, particularly during the pneumaticconveying, the primary grain size, bulk density andappearance of the product should be maintained andloss of product quality should be avoided.To ensure the owability of ne milk powder with up to 60%fat content, and thus the products storage capacity, S.S.T.conducted investigations as outlined by Jenike (1964).Due to the inuence of the fat content, these investigationswere extended to include various storage temperatures andstorage periods.Avoiding owability and storage problemsthrough hygienic designHigher fat content in ne powders leads to signicantdeterioration of the owability of the product. Reducingtemperatures in the product during storage results inan increase of the bulk resistance, which leads to thedeterioration of both owability and storability. In just a fewhours of storage time, very high levels of fat in a producttypically result in high consolidation stress, which means thatachieving ow without discharge aids is no longer possible.Higher temperatures worsen the wall friction values, whichleads to distinctive adhesion afnity.To make the process storage and pneumatic conveyingcontrollable, a distinction was made in terms of fat contentMilk powder with a fat content of

100 Storage in silos and pneumatic conveying of milk powder with up to 60% fat contentStorage in mass ow siloFigure 1. Solids mass ow silo in hygienic design.The resulting mass ow silo designed in compliance withhygienic design goals is characterised by a horizontal dropof the product level. The product in the entire silo crosssectionis in motion during the discharge. There are no deadzones, and thus no product residue. The total mass has auniform residence time. The premise of “rst-in rst-out” isupheld. During the discharge over the entire cross-sectionthere is a backmixing of the material, which was probablysegregated before when lling in.Figure 3. Solids Vibration bin discharger provided in mass ow silo.For the support and assurance of the mass ow at areasonable outlet diameter, vibration bin dischargers wereprovided (Figure 3). All surfaces that are in contact with theproduct have an average surface roughness of Ra

solidscomponents andcomplete plantsThe solids solutions group is specialised in the development and manufacturing of componentsas well as in the engineering and realisation of complete, automatic bulk handling systems.The group members are offering individual solutions acc. to the EHEDG-guidelines.HYGIENIC DESIGNfor powder handlingMinimal cleaning costs atmaximum production hygienesolids Vibration bin dischargersolids Pneumatic conveyorsolids Rotary valveBulk solids installation: storage, discharge, conveying,feeding, weighing/metering, process automationsolids Dosing screwsystem-technik GmbHLechwiesenstr. 2186899 Landsberg / GermanyPhone: +49 8191 / 3359-0Email: info@solids-systems.desolids system-technik s.l.Iñurritza Torrea, Extepare 620800 Zarautz / EspañaPhone: +34 943 / 830 600Email: systems@solids.esS.S.T.-Schüttguttechnik GmbHLechwiesenstr. 2186899 Landsberg / GermanyPhone: +49 8191 / 3359-50Email: info@solids-service.desolids components MIGSA s.l.Erribera Kalea 120749 Aizarnazabal / EspañaPhone: +34 943 / 147 083Email: comercial@migsa.eswww.solids.eu

102 Storage in silos and pneumatic conveying of milk powder with up to 60% fat contentThe connection of the pneumatic conveyor occurs withcentred connecting components with gap-free sleeves. Thematerial inlet valve is a disc valve in hygienic design, easilydisassembled and cleaned by a divided housing and gapfreeconnection by centring anges and a seal that conformswith FDA requirements as published in the U.S. Code ofFederal Regulations (Figure 4).The pneumatic conveyor is free of dead zones, has gapfreecentred mounting connections with FDA-conforminggaskets. Mass ow during emptying with vibration supportand air ood cleaning minimise the need for cleaning. For wetcleaning, the pneumatic conveyor with the entire conveyingline system is CIP-able and piggable.SummaryThe owability of a product is inuenced signicantlyby moderate fat content. Longer periods of storage ortemperature variations, even when fat content is

European Hygienic Engineering & Design GroupMaterial and design optimisation calculated by EHEDG:Tubing systemsThe development and manufacturing of tubing for EHEDG-compliant production are demandingtasks that require careful engineering. They depend not only on detailed hygienic design,but also targeted optimisation with an emphasis on ow resistance, maintenance costs andergonomic criteria.Dr. Torsten Köcher, Sales Manager, Dockweiler AG, D – Neustadt-Glewe,e-mail: t.koecher@dockweiler.com, www.dockweiler.comProducts manufactured according to European HygienicEngineering & Design Group (EHEDG) hygienicrequirements generally follow a series of steps that applyto a variety of machines and system stations. Accordingly,they must be transported as intermediate products from oneprocess step to the next. Provided production quantitiesexceed a certain amount, engineers use tubing designedand constructed in compliance with EHEDG requirementsfor liquid and semi-liquid products. In addition to productlines, the design of the gassing lines mounted onto thecorresponding vessels also have to meet these strictguidelines.EHEDG compliant tubing: strictrequirementsThese requirements are signicant. They are aboutachieving the level of purity and avoiding the dead spacerequired by EHEDG, as well as ensuring that the unhinderedow of material through the tubing system is accounted forin dimensioning and planning. The potential dead spacegeometry must also account for ow rates. A permissiblen x D ratio (e.g. 2xD, distance of valve – main tube) at a lowow rate can cause problematic dead space (Figure 1). Theengineering expense is worth it, because the user protsfrom lower operating costs and minimised maintenanceexpenses, among other things. However, comprehensiveknow-how and production capabilities custom-tailored tothis challenging task are an absolute must. This point iselaborated in this article using case studies from DockweilerAGs development and production portfolio.Figure 1. A permissible n x D ratio (e.g. 2xD, distance of valve - maintube) at a low ow rate can cause problematic dead space.Source material: Stainless steel tubingThere are three essential methods for producing tubing1. In the production of seamless tubing, a thick-walledtube, a so-called blank or hollow, is stretched using aplug drawing. In doing so, the wall becomes thinner.There can be many steps to the process. In general,tubing up to approximately DN 25 is manufactured inthis way. The drawing process causes displacement ofthe crystalline areas along the crystallographic planes.The metal ‘ows through the tool and is smoothed.Grid tension causes the metal to harden and deformationmartensite occurs. A nal heat treatment isnecessary for maintaining homogeneous austeniticstructures.2. In the manufacture of welded tubing, cold-rolled steelfrom a coil with the best surface qualities available isused as the primary material for producing tubing ofexcellent quality. The steel sheet from the coil runsthrough a series of shaping rollers, on the ends ofwhich the welding of the longitudinal seam occurs.

104 Material and design optimisation calculated by EHEDG: Tubing systemsAfter additional production steps, such as grinding,annealing and leveling, the tubing must undergo eddycurrent testing in order to ensure the quality of the longitudinalweld seam.3. The third method plays a role in renery and powerplant technologies, which use tubing with wall thicknessesexceeding 16 mm. Hot rolled steel is typically theprimary material. It is formed into tubing with the aid ofpresses that exert hundreds of tons of pressure ontothe material and then longitudinally seam welded.The mastery and exploitation of such manufacturingprocesses means achieving optimal material properties. Thesuitability of the material for further processing is equallyimportant. Analysis is made possible by the countless materialand surface testing procedures currently available. The mostwell-known method is the measurement of Ra values. Theresults of surface prole measurements, however, are limitedin validity because they do not provide information aboutthe microstructure. Additional inspections are necessary forproving suitability of the tubing, for example, welding tests,electrolytic polishing tests and microscopy.Important: Materials selectionThe right selection of suitable materials determines, amongother things, cleaning qualities and system life. Today, thereare a multitude of alloys on the market that possess thenecessary stable properties to stand up against differenttypes of corrosion. In order to fully utilise their properties,however, they must be properly processed. The applicationand its particular inuencing factors, such as medium,concentration, time and temperature determine the selectionof materials and surfaces.Figure 2. Beyond standards Example of a customised branchsolution.Manifolds: Dead space minimisation is theobjectiveFigure 3 shows a manifold with attached valve, for example,for dosing an additive into a base uid. Conspicuous here isthe short distance between the central tubing and the valvebase plate. As a result, a tiny dead space occurs when thevalve is closed. In comparison to conventional constructionwith T-pieces, the potential dead space volumes are reducedby approximately 38%; at the same time, the component isclearly more compact (Figure 4).Branch conduits: Know-how is in the detailsThe production of geometrically simple and frequentlyused components, such as branches, demonstrates thecomplexity of implementing EHEDG guidelines. Thisbegins with the selection of materials. This is the onlyway that optimal welding can be ensured. Furthermore,the processing methods must be adjusted to the futureapplication.Different techniques (boring, saddle, and collaringmethods) are available for the processing of T-pieces, eachof which have their merits, but also their application limits.Dockweiler uses the collaring method for branch conduitswith a diameter of 19.05 to 168.30 mm and also producesspecial T-pieces, for example, with inclined or eccentricoutlets (Figure 2). The advantages are exact geometry andcomplete drainability of the production system. Dockweilersolely uses the Wolfram Inert Gas Process (WIG) orbitalwelding method for producing components. Validateddocumentation is available for all welding seams andsurfaces; depending on requirements, components areelectropolished after production. If desired by the customer,pressure calculations or X-ray testing can be conducted forcritical components.Figure 3. The minimisation of dead space is an important designobjective for many EHEDG-compliant tubing components.Figure 4. Compact and hygienic Short branch with valve base plate.

Material and design optimisation calculated by EHEDG: Tubing systems 105The orbital welding method enables tubing to be connectedwith a continuous 360 welding seam (Figure 5). Toaccomplish this task, Dockweiler AG uses orbital weldingequipment, among other tools, with welding electrodespositioned on the inside of the tubing. The result is acontinuous, high-quality welding seam that prevents deadspace, ridges, etc., and thus fulls hygiene requirements.At the same time, narrow dimensional tolerances aremaintained and the branches from manifolds and specialparts can be designed to be extremely short. This method isused to engineer a variety of manifold designs for food andpharmaceutical production.Figure 6. Thermowell Tube section with immersion rod for ‘inlinemeasurement in product ow.Example: Optimising design duringengineering phaseAnother example A manufacturer with a complex systemdesires two individual valves for the material feed and twovalve blocks, each with three hand-operated shut-off valves,which need to be mounted directly onto the respective entryand outlet openings on the backside of the system. DockweilerAGs engineering team determined that the valves, whichmust be regularly controlled during system operation, wouldbe too inaccessible. An alternative was developed thatallows an operator to control all eight ttings from one centralstation that is also at an easily accessible height (Figure 7).Additional functions can be included with this basic concept,for example, a sequence for each of the eight lines.Figure 5. Orbital welding enables the optimal design of hygienictubing components.Special components for sensors underEHEDG conditionsDockweiler AG also develops and produces customisedtubing components for EHEDG-compliant sensors, forexample, for detecting the temperature of media in tubingsystems. This includes, among other things, a tube sectionwith an dip tube where the sensor is housed (‘thermowell).The medium ows past the dip tube and is subject to thestrictest hygiene requirements. The entire constructionshould be designed so that disruption of ow and turbulenceare avoided (Figure 6). Measurement results that are actuallyreproducible are obtained in this way.Figure 7. Clearly better results can be achieved through optimisationof design during the engineering phase.Strict requirements for documentationThe ‘correct production methods and engineeringcompetency are important when it comes to putting EHEDGcompliantspecial constructions into practise. These examplesdemonstrate the importance of designing and producingtubing that meets the highest standards of hygiene. Thisapplies not only to basic processes like drawing, boring,expanding and welding, but also surface treatments thatemploy processes like grinding, honing, pickling and electropolishing.All production steps are documented in detail sothat the traceability of each individual component as well asthe reproducibility of the processes is possible. Using thisholistic approach means that manufacturers and operators ofEHEDG-compliant systems can ensure and credibly documentthat their tubing meets the highest quality standards.

European Hygienic Engineering & Design GroupImproved hygienic design and performance of foodconveyor beltsOlaf Heide, Habasit AG (Headquarters), CH - 4153 REINACH-BASEL, e-mail: olaf.heide@habasit.comFood conveyor belts can be found in nearly all industrial foodprocessing and packaging lines. They are integral to ensuringa smooth and trouble-free process ow on the productionline. For example, unexpected failures or breakdownscan be costly and cause severe problems in a continuousproduction. Hence, conveyor belts that are designed tobe reliable and rugged in the production environment cancontribute signicantly to process efciencies and protability.Furthermore, they typically come into direct contact with foodas an integral part of a process line, and therefore play animportant role in terms of safe and hygienic food processing.The European Hygienic Engineering & Design Group(EHEDG) and all of its member companies aim to supportand improve safe food production through hygienic designof equipment and components. Several leading conveyorbelt manufacturers are members of EHEDG and activelycontribute to various subgroups. As part of the equipmentdesign process, EHEDG assesses hygienic design ofdedicated belting solutions for direct food contact. Anexample is the Habasit HyCLEAN CIP system, Followingthorough evaluation and implementation of improvements,EHEDG recently assigned for the rst time a certicate ofcompliance to Habasits plastic modular belt types M5060and M5065 with sprocket and clean-in-place (CIP) system.All three components comply with hygienic design principlesbut utilise their full potential when incorporated as a packageinto food conveyors and equipment.Challenges related to food conveyor beltsThe vast variety of food products, processes, manufacturingmethods and equipment requires belts that are able to copewith mechanical, chemical and environmental conditions.Each single aspect of production, from size, weight andshape, to consistency or temperature of conveyed goods,can have an impact on the performance and lifetime ofa food conveyor belt. Needless to say, there is not oneuniversal solution that can address all of these aspects. Beltshave to be designed and selected for the intended use andassociated requirements of the manufacturing operation.This article focuses on improving the hygienic design andperformance of synthetic conveyor belts using plasticmaterials as a main design element, since steel beltsfollow a different design pathway and thus require separateconsiderations.If this is not done correctly it can cause process problemssuch as unexpected breakdowns, yield reduction, productand allergen contamination by foreign objects and/ormicrobial contamination and improper hygiene conditions.All of these aspects have an impact on the food processorscosts and protability.Scratched / damaged Plastic Surface damages on coatedModular Belt (Meat cutting line) fabric belt (Fish processing)Waste and soiled belt surface(dough processing)Fraying belt edges(Pizza processing)Figures 1. Things you do not want to see in a food process.Problems, as shown above, can be avoided by dedicatedselection of belts for their specic application. There aremany solutions on the market to improve durability, chemicalresistance, good release of sticky goods and cleaningefcacy. But there is more to consider, including the threepillars of conveyor belt hygieneFood contact material legislationHygiene and food safety requirementsImpact of equipment hygienic design and cleaningPillars of conveyor belt hygieneFood conveyor belt manufacturers not only must care for thedesign of their products, but also ensure that all materialsused in belt construction comply with food contact legislation.It is especially important to understand and follow therequirements of regional legislation where food processesare located and/or where the equipment is put into operation.Many equipment and component manufacturers also maintaincompliance with the US Food and Drug Administration (FDA)regulations pertaining to food-contact materials; however,these rules are not sufcient for operations in the EuropeanUnion (EU). In Europe, the most important regulation is theframework directive EC 1935/2004 and its amendments,which cover materials and articles intended to come intocontact with food. EU regulation 10/2011 (also known asPlastics Implementation Measure [PIM]) is a dedicatedregulation governing the use of plastic materials, such as

Improved hygienic design and performance of food conveyor belts 107plastic conveyor belts. Conformity with these rules must beensured and declared by the belt supplier with a documentof compliance that must be provided for each belt type soldto a food processor or equipment manufacturer.In addition to consideration of hygienic design principlesand use of safe materials and articles that are allowed tocome into contact with food, all equipment and componentmanufacturers also should understand the challenges andrequirements involved in cleaning and sanitation. Cleaningcan be a nightmare if this important activity is not consideredthoroughly during the design phase of food processingequipment and components.DesignFood safetyProcess hygieneCleaningRegulationsExperience / Innovation / TrainingHow to identify the ideal belting solutionKnow theIndustry,process andapplicationsAnalyzeconveyedgoodsEvaluateproblems andneeds foroptimization5 Tips to upgrade hygiene of foodconveyor beltsSelect andinstall properequipment &componentsEvaluate your currently installed equipment andcomponents. Check if they are up-to-date and complywith advanced hygiene requirements, standards andlegislation.Work with experienced partners who understand yourindustry, processes, applications and challenges.Aim for upgrades and/or improvements.Check the ability of your belting supplier to deliver them.In addition to selecting equipment and components thatprovide ideal solutions for the target applications, makesure to consider the cleaning and maintenance as partof the total costs of ownership.Figure 2. Design, cleaning and regulations compose the threepillars of conveyor belt hygiene.No pillar can stand without a good foundation. To achieve gooddesign that takes into account regulatory and cleanabilityrequirements, the food conveyor belt manufacturer will needa solid foundation of experienced people, the willingness tostrive for innovative solutions, and commitment to ongoingeducation and learning (Figure 2). Establishing thesefoundational elements are vitally important for food conveyorbelt manufacturers who aim to achieve the ultimate goals ofthe EHEDG To ensure food safety and process hygiene forall food manufacturing operations.

European Hygienic Engineering & Design GroupSmart hygienic solutions for the food industryDespite a stagnant economy, food and beverage companies intend to increase investmentsinto developing new products and technologies to fuel business growth and improve revenues,according to a recent survey by the global audit company KPMG. While investing in growth,many companies remain focused on keeping costs low and efciencies high, while at the sametime emphasising compliance with food safety standards and global regulatory mandates. Thisarticle describes continuing food safety threats and the food industry’s motivation to incorporatesmart hygienic solutions to overcome these challenges.Peter Uttrup, Interroll España S.A., Barcelona, Spain, phone +34 677 462 788, e-mail: p.uttrup@interroll.comand Lorenz G. Koehler, Interroll (Schweiz) AG, Sant’Antonino, Switzerland, phone: +41 91 850 25 21,e-mail: l.koehler@interroll.com, www.interroll.comProactive risk management is the key to success in todayseconomically challenging global market. For businessesin the food supply chain, this means keeping abreast ofchanges in the global regulatory environment, especially newfood safety and hygiene standards and laws, and investingin business strategies and technologies that reduce risk tothe companys brand reputation and nancial health. Someof the risks that remain high on the list of concern for the foodsector are foodborne illness outbreaks, food product recalls,and quality control gaps in manufacturing facilities and otherpoints along the supply chain.Foodborne illnesses – a constant threatA foodborne disease is any illness resulting from theconsumption of food that is contaminated by pathogenicbacteria, viruses, parasites or chemical agents. Foodbornediseases pose a growing threat to public health worldwide.The most common effect of foodborne diseases takes theform of gastrointestinal symptoms, but such diseases canalso lead to chronic, life-threatening conditions includingneurological or immunological disorders, multi-organfailure, cancer and death. Recent global developments areincreasingly challenging international health security. Thesedevelopments include the growing industrialisation and tradeof food production and the emergence of new or antibioticresistantpathogens.Although we do not currently have an exact gure of the globaleconomic impact of foodborne diseases on societies, businessesand trade, the latest estimations project the costs in hundredsof billions of U.S dollars. Some of the most signicant estimatesincludeThe U.S. Center for Disease Control and Prevention(CDC) estimates that there are roughly 48 millioncases, 3,000 deaths, and 128,000 hospitalisations fromfoodborne pathogens each year in the United Statesalone. Children, the elderly, pregnant and post-partumwomen and individuals with compromised immunesystems are at highest risk of developing complicationsfrom foodborne illness.A new study by a former U.S. Food and DrugAdministration (FDA) economist estimates the totaleconomic impact of foodborne illness across the U.S.to be a combined $152 billion annually.According to the CDC, in industrialised countries, thepercentage of the population suffering from foodbornediseases each year has been reported to be up to 30%.Thirty-one (31) known pathogens are responsiblefor 9.4 million illnesses (20% of the total), 55,961annual hospitalisations (44% of the total) and 1,351deaths (44% of the total), according to CDC data.The remaining unknown/unspecied pathogens areresponsible for 38.4 million illnesses (80% of the total),71,878 annual hospitalisations (56% of the total) and1,686 deaths (56% of the total).These statistics illustrate why companies throughout thefood sector continue to invest in food safety and hygienetechnologies and systems that will effectively mitigatepotential risks of foodborne illness associated with theirproducts.Food recall risksFood sector companies also are increasing their vigilancein monitoring the quality and safety of foods they place onmarket shelves to avoid costly product recalls. A food recalloccurs when there is reason to believe that a food maycause consumers to become ill. A food manufacturer ordistributor initiates the recall to take foods off the market. Insome situations, food recalls are requested by governmentagencies. A food recall can cost millions and is potentiallyfatal to a business. Public perception and attitudes toward acompanys products can be negatively affected by bacteriarelatedrecalls that make the headlines.Risk reduction technologiesAs a consequence of these challenges, one can expectfurther pressure on food manufacturers to improve qualitycontrol in the coming years. Risk management and reductionis the foundation of better food safety practices. To helpfood manufacturers all over the world comply with the strictnational and international regulations in terms of hygienein their material handling processes, many equipmentmanufacturers and component makers are investing theirexpertise into creating innovative hygienically designedproducts to assist industry with improving quality controlmeasures to reduce contamination risks.

Smart hygienic solutions for the food industry 109Advances in hygienic conveyor drives provide a goodexample of how hygienic design is helping the food sectorcontrol food safety risks on the production line. Conventionalgear motors are bulky, complex to install, require expensivecabinets and guarding, and most importantly, are not testedand veried as cleanable by the independent DanishTechnological Institute. In comparison, todays drum motorsare designed to be regularly cleaned and disinfected to agreat degree of hygiene, even in environments where highpressure water, steam and chemicals are used (Figure 1).This helps food manufacturers achieve the highest possiblehygiene standards.Drum motors that meet the European Hygienic Engineering& Design Group (EHEDG) Guidelines, and that usematerials in compliance with EU Regulation 1935/2004raise the users condence that the drum motor utilisedoffers optimum cleanability, providing for the lowest possiblelevels of Salmonella, Listeria, E. coli and other harmfulmicroorganisms in the food processing environment.Further, drum motors with standard IP66 and IP69k sealingsystems are well-suited for wet and high pressure washdownapplications (Figure 2).Interroll drum motors meet all of these hygienic requirementsand are therefore suited for application in environmentsin which high and constant exposure to great amounts ofsanitation chemicals and/or water is the norm.Figure 2.Hygienically designed drum motors are well-suited for wetand high pressure wash-down applications.Figure 1.Drum motors should be designed to withstand regularhigh-pressure washdown procedures at food processing plants.

European Hygienic Engineering & Design GroupExamination of food allergen removal from two atconveyor beltsFood allergens are an increasing public health concern. Allergen contamination can occur throughcross-contact with equipment surfaces. Designing hygienic, sanitary equipment is essential forreducing allergen contamination risks and its consequent food recalls. The need for effectiveallergen removal calls for improved dry-cleaning technologies. The results of the study illustratedin this article demonstrate that solid, homogeneous, smooth-surface plastic at belts can be usedin combination with a dry-cleaning tool as an alternative to fabric-reinforced at belting in orderto reduce allergen carryover risk during dry food processing.Dr. hinong Yan, Gary Larsen, Roger Schefer, and Karin Blacow. Intralox, L.L.C., Amsterdam,Netherlands, e-mails: zhinong.yan@intralox.com gary.larsen@intralox.com roger.schefer@intralox.comkarin.blacow@intralox.comFood allergens are a growing public health concern. In theUnited States, an estimated 9 million adults and 6 millionchildren are affected by food allergies. 1,2 The prevalence offood allergies and associated anaphylaxis appears to be onthe rise. According to a study released in 2008 by the USCenters for Disease Control and Prevention, an increase ofapproximately 18% in incidences of food allergies occurredbetween 1997 and 2007. 3 Undeclared allergens are theleading cause of food recalls. A summary of US Food andDrug Administration (FDA) recall data from 2010 noted thatmore than 60 recalls were due to undeclared allergens,making it the second most prevalent reason for declaring arecall, behind only Salmonella contamination. 4 In addition,the second annual report of the US FDAs Reportable FoodRegistry showed that undeclared food allergens accountedfor 30.1% and 33.3% of food hazard adulterations in 2009and 2010, respectively. 3There is no cure for food allergies, so strict avoidanceof allergen-containing foods and early recognition andmanagement of allergic reaction are the only viablemeasures for preventing severe health consequences. TheUS Food Allergen Labeling and Consumer Protection Act(2004) requires clear food allergen labeling in order to avoidpotential consumption of foods that contain one of eightmajor allergens (milk, eggs, sh, crustacean shellsh, treenuts, peanuts, wheat, and soybeans).Allergen contamination can occur during any stage of foodprocessing. Cross-contact during food manufacturing isan increasing concern, especially when different typesof food are processed along the same production lines orequipment. Removal of allergens from shared equipment orprocessing lines has been identied as an important aspectof an allergen-management program. 5 Poorly designed ormaintained equipment can make allergen removal moredifcult. A set of 10 principles of equipment design forlow-moisture foods has been developed by the GroceryManufacturers Associations (GMA) Sanitary Design WorkingGroup in the United States. This group also has developedan equipment checklist. More detailed information can befound in the European Hygienic Engineering and DesignGroup (EHEDG) Guidelines.Conveyor belts —critical food-contact surfacesOf all the types of equipment used for food processing,conveyor belts are the most likely food-contact surfacesto become allergen cross-contact points if not cleanedthoroughly. There are three major conveyor belt typesemployed in dry-food processing fabric-reinforced atbelting; continuous, homogenous positively driven at belts(e.g., ThermoDrive ® belting from Intralox); and modularplastic belts. These belts materials (plastics, fabric), surfaceproperties (roughness, crevices), and manufacturingmethods (extrusion, fabric reinforcement) need to beconsidered in relation to belt designs and uses in order tofully follow the 10 principles of sanitary equipment design.However, few studies regarding these conveyor beltsease of cleaning and sanitation have been carried out. Yan(2011) investigated the potential bacterial-contaminationrisks of fabric-reinforced belts during normal processing,nding that bacteria could penetrate the surface of thefabric and migrate to foods during conveyance, especiallywhen driven by friction between the belt and motor. 6 Thissame migration process also might occur with allergens. Al-Taher and Jackson (2011) tested dry-steam vacuuming forremoving allergenic food from a urethane-faced conveyorbelt. 7 This study demonstrated that a recent commercialiseddry-steam cleaning unit may not effectively remove variousallergens from the fabric at belt, though the efcacy of thiscleaning device may depend upon which different allergensare applied to the belt surface. The recent development ofsolid, homogeneous, positively driven smooth-plastic atbelting might reduce the problems of cleaning and sanitationoccurring on fabric materials. However, no comparativetesting has been conducted to date.Cleaning is considered the most fundamental method forpreventing allergens due to cross-contamination from sharedequipment or processing lines. Therefore, developing andapplying effective cleaning methods is critical for removingallergens. The most powerful tool for removing allergens fromsurfaces or interior equipment is water. For environmentsthat process wet mixes with oor drains, water is the bestchoice. However, for the manufacturing of low-moisturefoods, introducing water into the equipment or environment

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112 Examination of food allergen removal from two flat conveyor beltsmay lead to microbial growth, especially of pathogens likeSalmonella that are resistant to dry conditions and that growwith minimal moisture. Hence, dry cleaning methods forlow-moisture food production have been a focus in recentyears, especially with the frequent incidence of Salmonellacontamination in various dry foods.Currently, methods for dry cleaning are limited to brushing,vacuuming, sweeping, scraping, use of compressed air, andpushing through, or wiping with cloths. However, allergencleaningprotocol using these tools remains challenging foreffective and acceptable allergen removal. For instance,compressed air can blow food debris from hard-to-reachareas where brushing is difcult, but it also poses risks offuture allergen contamination to food-contact surfaces fromthe oor or hidden areas. Recently, several companies havedeveloped dry-steaming (< 5% moisture) and vacuumingsystems that demonstrate great potential to clean equipmentand environments for dry food processing.Figure 2. Polyurethane ThermoDrive at belt.As common food-contact surfaces, conveyor belts maybe the most critical points for food allergen contamination.However, allergen removal on the fabric-reinforced andhomogenous at plastic belts that are used in some dry-foodprocessing has not been much investigated. The objectiveof this study was to assess the cleanability of allergens onthe above two types of at conveyor belts using a new drysteamcleaning system. 6Cleanability of two at conveyor belts:A studyA vinyl fabric-reinforced belt (Figure 1) and a polyurethanesolid-homogenous-plastic at belt (Figure 2) were installedonto two different conveyors with friction drive and positivedrive, respectively. Three allergen-containing foods —creamy peanut butter, soy protein, and egg whites — werespread onto the belts to form a set of thin soils (ca. 1 mm)within marked areas (10 x 10 cm), then air dried until thesoils were stuck onto belt surfaces (Figures 3 and 4).Figure 3. Peanut butter on fabric at belt.Figure 4. Peanut butter on ThermoDrive belt.Figure 1. Vinyl fabric at belt.A steam vacuum-cleaning device was then placed onthe belt surface (Figure 5). The temperature in the steamgenerator was set to 180°C, which passed steam to thechamber with 5% moisture and reached 77-82°C and 90psi. The chamber was designed to clean and vacuum thedebris into a container connected to the chamber while thebelt runs at the speed of 10 meters/min. for eight revolutionsuntil visibly clean.

Examination of food allergen removal from two flat conveyor belts 113Figure 5. Steam vacuum chamber installed on the conveyor.(Photo provided courtesy of AmeriVap.)Reveal 3-D peanut, soy, and egg test kits (Neogen) wereused to validate the effect of allergen cleaning. Each kitcontains a sterile cotton swab, buffer solution, a sampletube, and a Reveal 3-D test device. The standard testingprotocol provided by Neogen was followed. The devicewas read ve minutes after reaction. The allergenacceptable limit was determined by the testing kits supplierto be < 5 ppm.The effect of allergen cleaning was tested on each belt.Each allergen-belt combination was tested three times withsix swab samples each time for a total of 18 samples.Table 1. Allergen testing results on fabric-reinforced at belt.Replication AllergenPeanut Soy Egg white1 4/6 0/6 0/62 5/6 0/6 1/63 5/6 1/6 0/6Total 14/18 (78%) 1/18 (6%) 1/18 (6%)As shown in Table 1, after dry-steam vacuum cleaningon the fabric reinforced at belt, 78% of the samplestested positive for peanut, 6% tested positive for soy, and6% tested positive for egg whites. Allergens were notsatisfactorily cleaned, especially for peanut butter, usingthis steam-cleaning system.Table 2. Allergen testing results on homogenous smooth urethaneat belt.Replication AllergenPeanut Soy Egg white1 0/6 0/6 0/62 0/6 0/6 0/63 0/6 0/6 0/6Total 0/18 0/18 0/18As indicated in Table 2, the three allergens were effectivelyremoved from the solid smooth surface of the urethane atbelt using the steam vacuum cleaning device.DiscussionThe results of the allergen cleaning tests using the steamvacuumsystem clearly demonstrate that allergens cannotbe removed from fabric-reinforced at belts to a levelwhere it cannot be detected with the applied test methodwith its specic detection limits, using the system. Thiswas consistent with the testing carried out by Al-Taher etal. (2011) on urethane-faced fabric belts using a dry-steamcleaning device to clean peanuts, non-fat milk, and wholeeggs. The results showed that no egg soils were detected –with the method applied – for all the cleaning times tested,while peanut and milk soils were still detected after cleaningthe belt for 10 minutes using the same test kits as used inthis study. The results also demonstrated that the efcacy ofthe dry-steam-cleaning unit on fabric at belts depends onthe type of food soil applied to the belt surface, which wasalso in agreement with the results obtained in this study –that peanut butter was more difcult to clean than soy andegg whites.On the other hand, the smooth, solid homogeneousurethane belt employed in this study showed effectiveremoval of all allergens using the same cleaning system asthe fabric at belt. The difference with respect to allergencleaning could be due to the belts homogenous surfaceproperties, which fully meet the requirements for hygienicdesign of equipment developed by GMA. The fabricreinforcedat belts thin, laminated surface may not befully enclosed, which could entrap allergen molecules. Inaddition, the fabric materials on the belts back side canabsorb moisture accumulated from steam. The beltsfriction-driving mechanism allows that moisture to squeezebetween the drum and the belt itself, which can result inallergens and other soils migrating to the top layer of thebelt.In conclusion, the results from this study demonstratedthat the newly developed solid-plastic at belt can be usedto reduce the potential allergen contamination during dryfood processing in combination with the dry-steam vacuumsystem.AcknowledgementThe authors are grateful to AmeriVap Company for allowingthe use of their dry-steam cleaning unit to carry out thisstudy.References1. The Food Allergy & Anaphylaxis Network (FAAN). Food AllergyFacts and Statistics for the U.S. www.foodallergy.org/les/FoodAllergyFacts andStatistics.pdf. Accessed August 10, 2012.4. US Food and Drug Administration (FDA). 2011. The reportablefood registration second annual report Targeting inspectionresources and identifying patterns of adulteration. www.fda.gov/Food/FoodSafety/FoodSafetyPrograms/RFR/ucm200958.htm.Accessed August 10, 2012.3. Branum, A., M.S.P.H. and Susan L. Lukacs, D.O., M.S.P.H. 2008.Food allergy among U.S. children Trends in prevalence andhospitalizations. http//www.cdc.gov/nchs/data/databriefs/db10.pdf.Accessed August 10, 2012.

114 Examination of food allergen removal from two flat conveyor belts4. US Food and Drug Administration (FDA). 2010. FDA 2010 recalls,market withdraws and safety alerts. www.fda.gov/Safety/Recalls/ArchiveRecalls/2010/default.htm. Accessed August 10, 2012.5. Jackson, L., F.M., Al-Taher, M. Moorman, J. DeVries, R. Tippett,K. Swanson, T.-J. Fu, R. Salter, G. Dunaif, S. Estets, S. Albillos,and S. M. Gendel. 2008. Cleaning and other control and validationstrategies to prevent allergen cross-contact in food-processingoperations. J. Food Prot. 71 445-458.6. Yan, Zhinong. 2011. Examining the microbial contaminationpotential of fabric-reinforced at conveyor belts. Technical presentationat International Association for Food Protection Annual Meeting.July 31 – August 3, 2011. Milwaukee, WI.7. Al-Taher, F., C. Pardo, and L. Jackson. 2011. Use of a dry steambelt washer for removal of allergenic food residue. P1-43. Abstract.International Association for Food Protection Annual Meeting. July31 – August 3, 2011. Milwaukee, WI.8. Yan, Z. 2011. Examining the microbial contamination potential offabric at belts. EHEDG Yearbook 2011/2012: 49-52.Solutions for handlingpharmaceuticalsProcess safety:Unsurpassed precisionHermetically tight – leakage-freeLong-term operational stabilityRepeatable flow ratesMember ofBatch and continuous operationLEWA GmbH · Ulmer Straße 10 · 71229 Leonberg · Germany · Phone +49 7152 14-0 · lewa@lewa.dewww.lewa.com

European Hygienic Engineering & Design GroupThe future of food grade lubricationFood safety is and will remain the most important issue in the food production industry. Issuessuch as 100% machine availability and cost-cutting and efciency programs also are importantto a processing plant’s performance. As food processors aim to meet the objectives of bothfood protection and production efciencies in a slow economy, it is important to consider howfood grade lubricants can play a positive role in many operations.Taco Mets, an Meeuwen Groep B.., NL-1382 L Weesp, e-mail: tm@vanmeeuwen.nlFortunately, the going concern of the food industry is not atstake Everybody will continue to consume food. Despitethe economic crisis resulting in a global manufacturingslowdown, the food industry continues to run strong.However, margins are always under pressure and manypeople do not realise what is essential to keep productionplants operating efciently. Today, not only are food safetyrules and regulations becoming increasingly strict butcompany budgets are getting tighter and more limited fortechnical departments driven by mandatory cost-efciencyprograms. These realities make it more important than everfor food manufacturing operations to nd ways to achieveboth objectives simultaneously.Differences in lubricants for food processingapplicationsCreating a mindset for preventive maintenance is themost important factor in establishing an environment inwhich signicant advantages can be achieved with qualitylubricants. Food manufacturers should make sure to use H1registered lubricants, which are allowed for incidental foodcontact (Figure 2). Many experts in the lubrication sectorbelieve products that are H2 registered (products for thefood industry that are absolutely not allowed to come intocontact with food) will disappear from the market. Either theprocessor uses a food grade lubricant, or not, that is the keychoice. Todays technology makes it possible to formulate aH1 registered lubricant for (almost) every application.Figure 1. Lubrication maintenance is key to sustainable andhygienic performance of production lines.Food processors can maximise their current machineryperformance by focusing on maintenance of all equipmentand components along the production line. There is littleto be gained by a costly revision of a whole production lineand not optimising every aspect of maintenance of this lineto guarantee a long sustainable performance after revision(Figure 1). Lubrication is key in this process. A focus onthe lubrication aspect of maintenance means investing inquality lubricants, combined with performing a structuraltrend analysis. Together, these will result in both hygienicproduction and signicant cost savings.Figure 2. Food manufacturers should select the right type oflubricant for the right application.Processors may also have heard about 3H lubricants.These 3H registered lubricants (to be differentiated from H3lubricants that represents soluble and edible oils that preventrust) are allowed to come in direct food contact. There arecertain applications and situations in which contact withthe food product is inevitable, and in these situations, a 3Hregistered lubricant is a good choice.It is important to note that sometimes the status of NSFInternational (US) and/or InS Services (UK) non-foodcompound certication is unclear. Both registration institutesuse the similar U.S. Department of Agriculture/U.S. Foodand Drug Administration (USDA/FDA) guidelines. Therefore,a lubricant needs to have an H1 or other registrationregardless of whether certication is from NSF or InS.

Monitoring machines and lubricants offerother benetsBy monitoring the machine conditions and lubricants by oilanalysis, thermography and/or ultrasonic measurements,both the machine availability and lubricant lifetime can andprobably will increase. In addition, energy saving is denitelypossible without compromising on food safety, especially ifthe right lubricant is chosen for the right machinery. Mostimportantly, processors should monitor machines beforeswitching the lubricant, shortly after the switch and thencontinue measuring both energy and wear patterns for afew months. Why is wear key? Because although somelubricants can create energy savings, they also can damagemachines.To make sure the lubrication maintenance is secured, alubrication inspection can be conducted by the lubricantmanufacturer or supplier. Such an inspection should includequestions likeAre all critical control points lubricated with H1lubricants?How is the lubrication organised and is it efcient?Are there any unsafe food processing or handlingsituations in the production area? (Figure 3)Figure 3. These are all situations found in food production facilitiesthat can clearly be improved.A summary of the ndings can be shared with individuals inupper management to effectively show the key importanceof investing in lubrication-related matters to guarantee bothefcient production and safe food products for consumers.Stand out from the crowdwith NSF CertificationThe symbol of food safety andquality in over 80 countries Safe products for food andbeverage processing www.nsf.org

European Hygienic Engineering & Design GroupHygienic automation technology in food productionHow clean design automation products support food safetyAlexander Wagner, Festo AG & Co. KG, Esslingen, Germany, e-mail: awn@de.festo.com, www.festo.comProtecting the consumer and the manufacturers brand arethe key benets of hygienic and efcient automation in foodproduction. The aims are two-fold high productivity andperfect tasting food.The key questions for food safety in the automationtechnology areWhat are the potential hazards in food production andprocessing?What are the valid standards and directives forhygienic automation technology?What standards are to be respected in the materialselection and design for hygienic machinerycomponents?How are machinery parts in the food sector to becleaned?How is a hygienic food production system to beimplemented?Recognising and preventing risksSalmonella in sausages, Listeria in cheese – the list offoodborne illness outbreaks and scandals is endless.Signicant hazards in the food sector are caused byBiological factors illness caused by microorganisms ortheir toxinsChemical factors cleaning and disinfecting agents andlubricantsForeign particles from machines, often caused bycorrosion or abrasion, or from other sourcesWhen ensuring that a machine‘s design is hygienic, allknown and potential hazards must be taken into account,and action must be taken to reduce these risks.Figure 1 Resistant surfaces and a high IP protection class, suchas those of the pneumatic valve terminal CDVI, are componentfeatures that meet requirements for hygiene regulations.Machinery Directive 2006/42/ECThis directive focuses on health and safety requirementsput in place to protect machinery operators. Possible risksshould be eliminated. Special hygiene requirements apply tomachinery intended for the preparation and handling of food.The machinery must be designed and constructed in such away as to avoid any risk of infection, sickness or contagion.This directive forms the basis for the EC conformity mark.The basics – standards and directivesStandards and directives form the basis that allows peopleto enjoy food with reduced risk of adverse health effects fromconsuming contaminated products (Table 1). Implementingthese regulations during production reduces the risks for themanufacturer and the consumer. The aim of the EuropeanCommission (EC) Machinery Directive 2006/42/EC is theprotection and safety of consumers and operators whereverfood comes into direct contact with machine parts andcomponents. The application of standards and directivesfor design (EN 1672-2 and European Hygienic Engineering& Design Group [EHEDG] Documents 8 and 13) andmaterials (US Food and Drug Administration [FDA] Code ofRegulations Title 21, International Standards Organisation[ISO] 21469, and EC Regulation1935/2004/EC) provideadditional support for food safety.Figure 2 The threadless design for the bearing cap as it is usedin the stainless steel round cylinder CRDSNU reduces the riskof contamination. In addition, the self-adjusting end positioncushioning system is designed without adjusting screws, which aresusceptible to contamination.

118 Hygienic automation technology in food productionThe three production zonesThe European standard EN 1672-2, Food processingmachinery - Basic concepts, denes three production zonesThe food zoneThis zone encompasses all system parts andcomponents that are mounted directly in the foodow and come into contact with foodstuffs. Food maybecome contaminated and end up back in the productow. System parts and components that come intocontact with foodstuffs must be easy to clean anddisinfect. They should be corrosion-resistant, non-toxicand non-absorbent (Figure 2). A smooth, continuousor sealed surface reduces the chance of food gettingcaught and leaving residue that is difcult to remove,making it a contamination risk. In addition, only specialfood-compatible lubricants may be used.The splash zoneIn the splash zone, machine parts and componentscome into direct contact with foodstuffs, but thefood does not end up back in the product ow.Nevertheless, these parts must be designed and builtaccording to the same criteria as those in the foodzone.The non-food zoneIn this zone, the machine components do not comeinto contact with the product. However, the systemparts used in this zone should be manufactured fromcorrosion-resistant materials and be easy to clean anddisinfect, as sources of infection can develop over time.Selecting the materialIn order to protect food, the machine components mustnot deposit any substances during the production processthat are harmful to health or that impair the taste or aroma,through either direct or indirect contact with the food. Tomake certain that the work carried out during the cleaningphase is safe, the materials used for the machine partsmust not react with the cleaning agents or the antimicrobialchemicals (disinfectants). They must be corrosion-resistantand mechanically stable to prevent the surface from beingadversely affected.Figure 3 Quick and easy cleaning can be accomplished with largeradii, such as those of the standard cylinder Clean Design DSBF.Common materialsAustenitic stainless steelHigh-alloy stainless steel is usually the logical choiceof material for the construction of a productionsystem in the food industry. Typical materials includeAISI-304, AISI-316 and AISI-316L (DIN material no.1.4301/1.4401/1.4404).AluminiumAluminium is frequently used for construction. It isaffordable and easy to work with and process. Typicalaluminium grades include AlMg2Mn0.8, AlMgSi1 andAlMgSi0.5. Aluminium components can be renderedresistant to cleaning agents through the application ofan additional coating or anodised oxide layer.PlasticsPlastic components permitted to come into directcontact with food must comply with Regulation1935/2004/EC and the Plastics Directive 10/2011(which replaces Regulation 2002/72/EU) or theapprovals of the FDA (CFR 21, Sections 170-199).In addition to resistance to strain, ease of cleaningalso is an important factor in the selection of suitableplastic materials. They must not give off or absorb anyhazardous substances.LubricantsLubricating greases and oils must comply with FDAregulations (especially Section 21 CFR 178.3570) orISO 21469. For parts that will unavoidably come intosporadic contact with foods, approved lubricants as perNSF-H1 must be used.Hygienic component designThe application of EN 1672-2, ISO 14159 and DOC 8+13of the EHEDG forms the basis for the hygienic design ofmachines and components. These standards take intoaccount the fundamental design elements that can be usedin the construction of components and systems.SurfacesA high surface nish is absolutely essential oncomponents that come into contact with the productin order to reduce microbial contamination. This canbe achieved by using a mean peak-to-valley height of0.4 to 0.8 μm within the food zone. Components with apeak-to-valley height of 3.2 μm are often used in thesplash zone.Connecting pieces, threadsConnecting components, such as screws, bolts,rivets and so on, may cause hygiene problems. Openthreads are difcult to clean and provide the perfectbreeding ground for bacteria. Any threads that cannotbe avoided should therefore be closed off with suitablecovers and seals.Inner angles, corners and radiiVery small radii and corners are always a hygiene riskas they are difcult to clean. The prescribed minimumradius is 3 mm (Figure 3).

Hygienic automation technology in food production 119The fundamental challenge of cleaningAll manufacturers are liable for their products. In the food andbeverage industry, complete product safety, especially froma microbiological standpoint, must be ensured to protect theconsumer. As such, one important aspect involves designingcomponents and systems with hygiene and ease of cleaningin mind in order to guarantee exemplary cleanliness, shortestpossible cleaning times and minimal expense.To avoid drives failing in aggressive environments, forexample, the component materials must have certainqualities that make them suitable for reliably withstandingthe prevailing ambient conditions, as well as guaranteeingfull functionality and a long service life. This applies to boththe materials used for the drive unit and those used forinterface components, such as connections and seals.Seals and lubricants that comply with FDA regulationsmust be used for system components that come intocontact with food. Depending on the requirements of thespecic application, there is a choice of valve types eitherfor normal cleaning or for applications using intensive foamcleaning. Intensive cleaning of machine parts also canwash out the lubricating grease and impair the operationof the components. Using dry-running seals ensures thatthe washed out machine components still function reliably(Figure 4).Figure 4 Dry-running seals are indispensable for a reliablefunctionality, even when the lubricant has been washed out.Clean and safe!Many potential sources of contamination in food andpackaging systems such as bacteria, chemical inuencesor corrosion particles in the factory can be eliminated withjust a few design tweaks. Easy-to-clean, corrosion-resistantsystem components make food production safer.When buying food, the consumer expects high-qualityproducts that have been hygienically produced, dispensedand packaged by the food industry. That is why customerspecicprocess and factory automation solutions are animportant part of any hygienic value-added chain.Table 1. Important European standards and legislation pertainingto hygienic design of equipment and components used in foodproduction environments.2006/42/ECISO 21469EN 1672-2ISO14159EHEDG Doc 8EHEDG Doc 10EHEDG Doc 131935/2004/ECPlastics Directive10/2011FDA CFR 21FestoDirective 2006/42/EC of the EuropeanParliament and of the Council of 17May 2006 on machinery, and amendingDirective 95/16/EC (recast)Safety of machinery – Lubricants withincidental product contact – HygienerequirementsFood processing machinery – Basicconcepts – Part 2 Hygiene requirementsSafety of machinery - Hygiene requirementsfor the design of machinery (IS=1412002)Hygienic equipment design criteriaHygienic design of closed equipmentfor processing of liquid foodHygienic design of open equipment forprocessing of foodRegulation (EC) NO 1935/2004 of theEuropean Parliament and of the Councilof 27 October 2004 on materialsand articles intended to come into contactwith food and repealing Directives80/590/EEC and 89/109/EECCommission regulation (EU) No10/2011 of 14 January 2011 on plasticmaterials and articles intended to comeinto contact with foodFood & Drugs, Part 11 “ElectronicRecords, Electronic Signatures”Product overview for the food andbeverage industry, 7 th edition

European Hygienic Engineering & Design GroupCleanability test of a hygienic design-compatible washerProcess Seals has developed a hygienic washer with elastomeric sealing ring for use in thefood and beverage, pharmaceutical and biotechnology industries. The rings are made for staticsealing that is free of dead-spaces between bolts and dome nuts. This article illustrates how anEHEDG testing method conrms the cleanability of such hard-to-reach equipment components.Julia Eckstein, Application Consultant, Freudenberg Process Seals GmbH & Co. KG, Weinheim, Germany,e-mail: julia.eckstein@fst.com, http://www.freudenberg-process-seals.comWhen it comes to protecting bolt heads and nuts from beingcontaminated with products from the food and beverage,pharmaceutical or biotech industries, many plant andmachinery manufacturers that supply the process industriesuse complicated (and often “home-made”) solutions. This isproblematic because the complete cleaning of these pointsis the only safeguard for the producers of perishable foodsand beverages and high-purity medications. Threadedconnectors generally come into contact with the product, andafter use, only the residues can be removed via disassembly.But todays facilities are predominantly cleaned withoutdisassembly, using clean-in-place (CIP), wash-in-place(WIP) and sterilisation-in-place (SIP) methods.With this problem in mind, a hygienic seal has beendeveloped. It is based on a standard design of rings fornon-food applications to simply and affordably protectnon-moving machine parts from uid and gaseous media.The ring consists of a combination of metallic at seal andelastomeric sealing ring for static sealing. The resilient,trapezoidal sealing ring can be vulcanised on either the inneror outer diameter of the metal disk to match applicationspecicrequirements. However, their “hard-to-cleandesign” makes these sealing elements used in mechanicalengineering poorly suited to (and/or not approved for) foodprocessing applications.In response, the design has ben reworked completely.Together with hexagon bolts with ange and dome nutsdesigned according to DIN EN 1665, the revised designforms an easy-to-clean combination, which has been testedand approved by the Weihenstephan Research Center forBrewing and Food Quality using the European HygienicEngineering and Design Group (EHEDG) CleanabilityMethod (Fig. 1).Elastomeric sealing ringmade of high-performance compoundIn traditional threaded connectors, uids are able to collectunder the bolt head or in the threading. This is by no meansEHEDG-compliant and is highly unhygienic. In contrast,the improved design ensures the clean sealing of DIN EN1665 bolt heads with anges in aseptic isolators and inareas where they could come into contact with the product.This optimal sealing prevents the medium from penetratingunder the bolt head, which can lead to the multiplication ofmicrobes. The washers design, which is tailor-made forhexagon bolts with anges, ensures that the sealing ringis cleanly seated on the ange, precluding the formation ofspaces where microorganisms can accumulate (Fig. 2).The black 70 EPDM 291, a premium compound for staticsealing in the food and beverage and pharmaceuticalindustries, is used as the elastomer for the sealing ring.Critical process conditions and aggressive media in thefood, beverage and pharmaceutical production demandthe usage of highly stable seals. The 70 EPDM 291 witha temperature range of up to +180°C offers considerablyhigher stability in water vapour, can stand up to +210°Cfor a short time, and is ideally resistant to CIP-, WIPandSIP-methods. It is accepted by the US Food andDrug Administration (FDA) and also satises the criteriaof the European regulation EU (VO) 1935/2004. Itsbiocompatibility has also been tested and approved for usein pharmaceutical components and facilities in keeping withUSP Class VI requirements 1 .EHEDG – Test and resultsThe EHEDG has developed a testing method in whichmicroorganisms are allowed to collect in hygienicallyproblematic areas, in so-called dead spaces. A subsequentcleanability test identies those critical points that cannotbe adequately reached by the cleaning medium. 2 The samemethod was used to test the cleanability of the redesignedbolt/dome nut combination using a standard size M6 bolt. Inthis test, the cleanability of the hygienic seal was comparedwith that of a reference pipe with a known low inner surfaceroughness (Ra = 0.5 μm).However, before this test could be started, the elastomerused had to be tested for antibacterial components, so asto rule out a potential skewing of the test results. As the testcould not nd any evidence of antibacterial properties in theEPDM material, the hygienic seal then was ready for thecleanability test.In order to test their cleanability, components areintentionally soiled with a suspension that contains sporesof a thermophilic bacterium. These spores not only remainstable at high cleaning temperatures; they also are resistantto the cleaning media. Following the soiling, components areCIP cleaned using a 1.0-percent concentration detergentat a temperature of +63°C for 10 minutes, followed by arinsing with water. The test area is then coated with an agargrowth medium, which is allowed to incubate for 18 hoursat a temperature of +58°C. In the last step, the colour of theMSHA agar medium, which changes from violet to yellow inresponse to microbial growth, is assessed. 3

Cleanability test of a hygienic design-compatible washer 121To ensure that the results are representative, the cleanabilitytest is conducted a total of four times. In the case of the newseal, none of the four tests showed a yellow discolourationfollowing the incubation of the agar coating covering the boltand dome nut. The yellow discolouration in the referencepipe was present in an average of 13 percent of its innersurface, which is within the tolerance range of +5 to +30percent stated in EHEDG Guideline Doc 2 and correspondsto an acceptable level of contamination after the very mild(test method) cleaning cycle. As such, the new design clearlydemonstrated better cleanability than the reference pipe.In June 2012, the TUM (Forschungszentrum für BrauundLebensmittelqualität) at Weihenstephan (Germany)declared ofcially that the new design, which Process Sealshas named “Hygienic Usit,” meets the Hygienic EquipmentDesign Criteria of the EHEDG.Fig. 2. The Hygienic Usit combines metallic at seal andelastomeric ring in one component.References1. U.S. Pharmacopeia, USP 29, General Chapter Biologicalreactivity tests, in vivo, USP 29 – NF24, page 2526.2. European Hygienic Engineering and Design Group (EHEDG).EHEDG Guideline Nr. 2, Method for Assessing the In-placeCleanability of Food Processing Equipment, 3rd Ed, July 2004,(Revised June 2007).3. European Hygienic Engineering and Design Group (EHEDG).EHEDG Report 01 Cleanability Test, Hygienic Usit with Bolt.Weihenstephan Research Center for Brewing and Food Quality,TU Munich. December 5, 2011.Fig. 1. The Hygienic Usit provides simple and FDA-compliantsealing for threaded connectors with anges, while also fulllingthe criteria of hygienic design.

European Hygienic Engineering & Design GroupAspects of compounding rubber materials for contactwith food and pharmaceuticalsEquipment and equipment components made with rubber materials that come into contactwith food in processing lines must comply with regulatory requirements such as FDA’s Codeof Federal Regulations (CFR), 3-A Sanitary Standards, and US Pharmacoepia (USP) Class Istandards. It is also necessary to consider the working conditions in which the gasket will beused, including what products are produced, the cleaning and sterilization agents utilized inthose processes, and temperatures or other factors that may impact the efciencies of equipmentand components throughout the process line. In order to maintain a high hygienic standard, avery good cleanability of any equipment component with a rubber surface must be achieved andthorough documentation provided.Anders G. Christensen, Sales and R&D Director, AK GUMMI A/S, Mosegaardsvej 1, DK-8670 Laasby, Denmark,email: avk@avkgummi.dk, www.avkgummi.dkFor many years the food processing industry has referredto regulatory guidelines and standards that cover the useand compliance of rubber materials that come into contactwith food. Among these are rules outlined in the U.S. Foodand Drug Administration (FDA) 21 CFR 177.2600 (Rubberarticles intended for repeat use) and the recommendationsof the German BfR XXI (Commodities based on naturaland synthetic rubber) or XV (silicone oil, resins and rubberrequirements). Recently, 3-A Sanitary Standard 18-03 alsohas become a de facto standard for many food processingsectors beyond the dairy industry from which it originates.This standard not only regulates rubber materials that comeinto contact with food, but also the manufacturing conditions,taking hygienic standards and traceability into consideration.EN 1935/2004 is an attempt to have a common set of ruleswithin the European Union (EU). While this regulation isfully operational with regard to metals and plastics, it is stilla work-in-progress with regard to rubber materials. Untilpositive lists of approved ingredients that can be used infood-contact rubbers and associated testing methods are inplace, the FDA and BfR lists, together with extraction tests,appear to be the most relevant regulations for food-contactrubber materials. The member states have now begun to turnthis framework into statutory instruments; however, this maybe at the cost of uniformity and transparency.Other standards-related developments are affecting requirements as well. For example, the Danish Ministryof Food is enforcing the rules of traceability and goodmanufacturing practices (GMPs) by means of third-partyinspection of manufacturers facilities and process lines. Forpharmaceuticals, normally Class VI under the USP Monograph88, testing is required. Alternatively, the customer can ask forin vitro testing, either according to USP Monograph 87 orInternational Standards Organisation (ISO) 10993-5.In addition, end users require documentation for cleanabilityof equipment surfaces. Most often this is provided by meansof an European Hygienic Equipment Design Group (EHEDG)cleanability test of the component in which the rubber partis present. Except for the geometry and the correspondingow prole, the rubber surface is typically the most criticalmaterial when conducting any hygienic test.For this reason, it is important to consider the afnity betweenrubber compounds, products and cleaning agents. Long-termeld studies, such as those conducted by AVK GUMMI, havebeen conducted and have led to easy-to-clean formulation ofcompounds within the families of ethylene proplene rubber(EPDM), hydrogenated nitrile (HNBR), uorocarbon (FPM)and silicone.Material performanceIn addition to ensuring that food-contact rubber materialshave the relevant approvals, meet appropriate compliancerequirements and have traceability documentation, itis important to consider material performance. No twoformulations are equal. Even if two manufacturers developa compound for the same application, the end user willexperience different performances with each due tovariabilities ranging from the food being produced, theproduction line systems, and the level of hygienic operationsin the processing plant and performed on equipment, amongothers. The reason for this is shown in Figure 1Figure 1. Example comparison of good quality compounds versuslow-cost compounds as recipes for an EPDM 70 Sh A material.

Aspects of compounding rubber materials for contact with food and pharmaceuticals 123Figure 1 assumes two different compound recipes of anEPDM 70 Sh A material, both of which aim for FDA AqueousFood compliance. The “good” compound is of a very goodquality, while the other “cheap” compound is made fromlow-cost materials. Several factors can be used to comparethe two recipes in order to determine the differences, andultimately, judge the material performance parameters.For example. in looking at the EPDM polymer, one can seethat this could either be a very pure material with no residuesfrom the catalysts and no residual monomers (Good) or lowmolecular weight oligomers (Cheap). The polymerisation isvery well controlled, giving a uniform molecular architectureand molecular weight distribution. Also, the batch-to-batchvariation is kept at a minimum. Or it could be the opposite,which clearly would reduce the cost. Both compounds canbe formulated to meet the same standards, ie. FDA orBfRFrom an end user point of view, this relates to durability,compression set, taste and smell, uniformity of the productand extraction of residues to the product.The next functional group is carbon black, which acts as areinforcing agent. Basically, this is soot, which is producedby combusting a hydrocarbon source in a controlledatmosphere. The type and amount is regulated to someextent. For the good compound as shown in Figure 1,a carbon black is used for which the hydrocarbon sourceis clean and well dened. For the cheap compound, thehydrocarbon source has a higher content of sulphur andconsists of many different molecules, preventing a uniformend product. The end user will see a difference in taste andsmell and extraction of residues.When aiming for a cheap compound, it is common practiceto “dilute” the compound by using chalk. This will increasethe hardness of the material and so it is necessary to addmore plasticiser in order to reach the same hardness. Theusage of chalk will increase swelling in aqueous solutions,and the chemical resistance will suffer.Plasticiser is added to these compounds to ensurehomogeneity and to adjust the hardness. For EPDM mineraloil is used. This can be either a medical grade oil, whichis also used as edible oil and in healthcare products, or atechnical grade oil, which will have a higher content ofnaphthenics and aromatics. Again, the user will notice thedifference in the taste and smell, as well as extractables.Finally, a curing system must be decided upon. This is whatmakes the nal product elastic. While a thermoplast, whichis uncured, will deform permanently upon load, rubber willregain the original shape due to the cross-linking of thepolymer chains. For EPDM, two curing systems are normallyused. Peroxide curing gives excellent thermal stability,compression set, taste and smell and chemical resistance,but the manufacturing process is more expensive. Asan alternative, a sulphur system may be used. Themanufacturing cost goes down, but so does the performanceas described for the peroxide system.The example illustrates the complexity of choosingmaterials and suppliers. As the gure illustrates, end usersof food-contact rubber materials in food or pharmaceuticalmanufacturing lines should specify functional requirementsrather than material, ask for documentation, and choosea rubber supplier who can successfully translate specicneeds into rubber solutions.

European Hygienic Engineering & Design GroupNew developments for upgrading stainless steel toimprove corrosion resistance and increase equipmenthygieneSiegfried Piesslinger-Schweiger, POLIGRAT GmbH, 81805 Munich, Germany, e-mail: petra.ressmann@poligrat.de,www.poligrat.deNew developments enable the upgrading of stainless steel toimprove the corrosion resistance of manufacturing equipmentand components. Unlike the state-of-art techniques that usehigher alloyed steel to produce corrosion-resistant equipmentand components, new methods have been developedthat can be applied as nal treatments after productionand elevate the passive layers independently from theunderlying metallic base. One of these methods is basedon a signicant increase of the chrome/iron ratio within thepassive layers by extraction of iron and iron oxides, leavingprimarily chrome oxide. The second is a heat treatment thatchanges the structure and thickness of the passive layer.The latter application can be utilised on all types of nishesand in nearly all commonly used alloys.These new methods result in a substantial increase of theresistance against any type of corrosion. They also allow aneffective restoration of corroded surfaces, and with regularapplication, can maintain corrosion resistance even incases in which stainless steel is not long-term resistant. Thetreatments also can be applied to scale and heat discolorationwithout pre-treatment, which could widely replace pickling ormechanical descaling.Since these methods are based on a treatment with a waterbasedsolution of special organic compounds, they arebiodegradable, environmentally friendly, and produce nofumes or nasty smells. The new methods also allow selectionof the best alloy and structure in terms of hardness, strengthand weight. They open a wide and commercially importantpotential for additional applications of stainless steel.Basics of corrosion-resistant stainless steelAccording to the state of the art, the corrosion resistanceof stainless steel is considered a secondary propertyof alloy and structure. To increase corrosion resistanceit is necessary to select a higher alloy quality. To meetthe objectives of development a fundamentally differentapproach to stainless steel and its functional behaviour isnecessary.Stainless steel is a composite consisting of a metallic baseand an oxidic cover layer, and the passive layer is similar toaluminium and titanium. The metallic base determines thematerials mechanical, electric and magnetic properties andprovides the metals for the formation of the passive layer.The passive layer determines most of its other properties,including corrosion resistance. As soon as passive layersare locally damaged, local corrosion of the metallic baseoccurs, such as pitting corrosion, crevice corrosion, Ironinducedcorrosion, stress corrosion cracking (SCC), andmore.Passive layers completely and densely cover the surfaceof stainless steel as long as it does not corrode. Passivelayers are 10 to 15 nm thick and are formed by the reactionof the metallic base with oxygen from the environment.They primarily consist of chrome oxides and iron oxides.Additionally, they contain metallic chrome and iron, andeventually, other metals like nickel and molybdenum.Passive layers on stainless steel are not insulators likethe oxides on aluminium and titanium. They are crystallinesemiconductors with all the special properties of thesematerials. Thus, the approach to understanding corrosion onstainless steel should include semiconductor physics.The ratio of chrome oxides to iron oxides (chrome/ironratio) typically is within the range of 0.8 to 2.0. The higherthis ratio, the better the corrosion resistance. That means,that chrome oxides increase and iron oxides reduce thecorrosion resistance.Methods to increase corrosion resistanceTo improve the corrosion resistance of stainless steel twomethods are promising success. The rst is to improve thechrome/iron ratio within the passive layer and the second isto improve the crystalline structure.Conventional state-of-art method. According to the currentstate-of-the-art approach, the method for raising the chrometo-ironratio within passive layers consists of reducing theconcentration of iron in the metallic base and increasing theconcentration of chrome, and eventually nickel, in the alloy.This secondary effect leads to a higher chrome/iron ratioin the passive layers. The structure of passive layers is notinuenced. The concentration of alloying elements besidesiron is only needed within a surface layer of less than 10-nm thickness to provide the metal for the formation of thepassive layer.There are a few downsides to the conventional method ofproducing corrosion-resistant stainless steel. The adaptionof total alloy and structure to form the passive layersubstantially determines the other properties of the alloy.A potential consequence of this is that expensive detailsof construction like wall thickness and weldability must beadapted. The adaption of alloy and structure to achievegains in the level of corrosion resistance can only occur inthe production of steel. This means that a great number ofqualities of stainless steel must be produced and be availableas semi-nished product, which reduces the exibility in thematerials application and increases costs.

New developments for upgrading stainless steel to improve corrosion resistance and increase equipment hygiene 125New methods. Unlike the conventional method, newmethods have been developed to produce the desiredlevel of corrosion resistance by changing the consistencyand structure of existing passive layers on stainless steel,independently from the alloy and structure of the metallicbase. These methods—one chemical and one thermal—areapplied as nal treatments after fabrication and substantiallyincrease corrosion resistance.Chemical treatment. A precondition for the application ofthe new chemical treatment method is that the stainlesssteel to which it is applied must have an existing passivelayer. Therefore, its application immediately following apickling process is not effective.The chemical treatment selectively breaks the iron oxideswithin passive layers and extracts the iron without affectingor removing the passive layer. In this way, the concentrationof iron in passive layers is strongly reduced and the chrome/iron ratio is substantially increased up to values of 6 to 8 (Fig.1). This treatment of stainless steel substantially increasesthe resistance to all types of corrosion (Figures 2 and 3). Theresistance to thermal discolouration is raised to 100-150°C.Fig. 2. Structure of passive layer on stainless steel AISI 316 Ti -original condition.Fig. 3. Structure of passive layer on stainless steel AISI 316 Ti –chemically treated.Fig. 1. The chemical treatment signicantly reduces theconcentration of iron in passive layers and the chrome/iron ratio issubstantially increased up to values of 6 to 8.The applied chemicals are water-based solutions of organicand biologically degradable substances, mainly comprisedof a special combination of chelating and complexingagents. They do not contain mineral acids or their salts andhave a pH value of about 4.0. Application does not produceharmful fumes or foul odours. Since no dissolution of metalor passive layers takes place, the liquid does not containheavy metals in noticeable concentrations.Application can be done by dipping, spraying or wiping duringa three- to four-hour period. The temperature in dipping tanksshould be kept above a minimum of 50°C to avoid biologicaldegradation. Higher temperatures increase the effect of thetreatment, while longer treatment times do not. All types ofnishes and nearly all types of stainless steel can be treated.However, when the chrome content in the alloy is less than15% the required temperature, concentration and time oftreatment must be modied.Thermal treatment. The effect of chemical treatment canstrongly be increased by a subsequent controlled-heattreatment. The heat treatment optimises the structure anddistribution of elements in the passive layer and increasesits thickness. The thermal treatment leads to the formation ofa second layer containing iron oxides on top of the existingpassive layer mainly formed by chrome oxides. These layersare semiconductors forming a n/p-transition and immediatelyprovide a further substantial increase in corrosion resistance(Fig. 4).The heat treatment takes place under atmospheric conditionsat temperatures in the range of 120-220°C, dependant onthe alloy, and for a time of 5 to 10 minutes.

126 New developments for upgrading stainless steel to improve corrosion resistance and increase equipment hygieneFig. 4. Structure of passive layer on stainless steel AISI 316 Titreatedwith combined chemical and thermal process.Fig. 7. Comparison of pitting corrosion potential on differentmaterials before and after treatment with the chemical and with thecombined chemical/thermal treatment.ApplicationsCorrosion resistance. The chemical treatment andespecially the combined chemical and thermal treatment ofstainless steel each substantially improve the resistance tomost types of corrosion, except in the cases in which hightemperature and wear are factors. Test results and practicalexperience have shown that local mechanical damage,such as scratches, do not result in corrosion when thenew treatments are used. For example, in one study (twoyears test study by BMW), the chemical treatment wasapplied to car parts made of stainless steel (AISI 304 withbrushed nish). After more than ve years no corrosion wasobserved due to mechanical impact or by de-icing salt orcrevice corrosion (Figures 5 and 6). Fig. 7 shows the resultsof a comparison of pitting corrosion potential on differentmaterials before and after treatment with the chemical andwith the combined chemical/thermal treatment.Organic pickling and passivating. In addition to theincrease in corrosion resistance, the chemical treatmentremoves iron and iron oxides from scale and heat tint. Itconverts the thermal oxides into effective passive layers.Therefore, it is not necessary to remove heat tint andlocal scale by pickling or mechanical cleaning prior to thetreatment (Figure 9).Fig. 9. Use of the chemical treatment makes it unnecessary toremove heat tint and local scale by pickling or mechanical cleaningprior to the treatment.Figures 5 and 6. The stainless steel chemical treatment protectedcar nishes from corrosion over a give-year period.The treatment also removes iron and rust contamination. Itdoes not change the nish and can be applied to constructionconsisting of various qualities of stainless steel. There is nodanger of crevice corrosion initiated by residual picklingacid. Consequently, in numerous cases the treatment canreplace pickling and passivating with mineral acids andavoid associated environmental risks and health hazards, aswell as problems with wastewater and fumes.Cleaning and maintenance. For application outside ofdipping tanks and to existing structures on site, a cleaner alsohas been developed that can be applied at environmentaltemperatures. Regular and repeated application of thecleaner can maintain corrosion resistance under conditionsin which the stainless steel otherwise would not be resistantlong-term. Finally, the chemicals do not attack or degrade

New developments for upgrading stainless steel to improve corrosion resistance and increase equipment hygiene 127other materials such as glass, plastic, lower alloyed stainlesssteel and seals. The cleaner can be applied to completeinstallations and assembled components without priordismantling.Restoration. After corroded surfaces on stainless steel arecleaned, the corrosion resistance will be restored at a higherlevel. Corrosion marks remain visible, but are passivated ontheir surface. Even chloride-induced pitting corrosion hasbeen removed and the corrosion resistance successfullyrestored without prior pickling. This new technique has beenshown to have successfully repaired a considerable numberof damaged equipment and components made of stainlesssteel in production plants for chemical and pharmaceuticalproducts, on railway coaches and handrails on seashores,and on components for ships and offshore components.ConclusionTo a substantial degree, the corrosion resistance of stainlesssteel can be upgraded independently from alloy and structure,as well as independently from the mechanical and otherproperties of the base metal. The new methods describedhere enable the selection of materials with higher strengthsand lower weights, which eventually should result in reducedcosts. The new methods also extend the lifetime of stainlesssteel with upgraded corrosion resistance, maintenance andrestoration.PROTECTING WHAT’S IMPORTANTANDEROL ® Specialty Lubricants are the experts in long life,synthetic lubricants for industrial applications.Total H1 plant lubrication for industries serving the food, animal feedand pharmaceutical markets worldwide, and a specialization in gascompression and vacuum applications.Protect critical equipment today with Anderol tailoredlubricant solutions.ANDEROL ® Europe B.V.Tel: +31 43 352 41 90Fax: +31 43 352 41 99Email: info@anderol-europe.nlwww.anderol-europe.com

European Hygienic Engineering & Design GroupInternational Hygienic Study Award 2012Happy awardees in alenciaDr. Peter Golz, DMA, Frankfurt, Germany, phone: +49 69 6693-1656, e-mail: peter.golz@vdma.orgProf. Dr. Jens-Peter Majschak, Technische Universität Dresden, Dresden, Germany,phone: +49 (351) 463 3 4746, e-mail: jens-peter.majschak@tu-dresden.deSince 2009, the communication and information platformwww.hygienic-processing.com and its partners have held acompetition for the annual Hygienic Study Award to honouroutstanding, innovative, high-quality diploma, bachelor andmaster degree theses of studies in the eld of hygienicdesign. In 2012, the Hygienic Study Award expanded itsglobal reach to recognise and strengthen the network ofinternational institutions engaged in academic education andresearch in the eld of hygienic design. Fifteen renownedresearch institutes and universities from eleven countrieswere invited to partake in the competition. Seven abstractsfrom ve countries were submitted.The European Hygienic Engineering & Design Group(EHEDG) World Congress 2012 in Valencia, Spain, hostedthis years award ceremony where two rst prizes and onesecond prize were awarded to young research fellows fromCambridge and Dresden. Hygienic Study Award 2012 wassponsored jointly by EHEDG and VDMA.Winner of 1st prize:Hannes Stoye, University of DresdenDevelopment of a test set-up for pulsed spray cleaningexaminationsAbstract: As part of this work, one of the test rigs existingat the Fraunhofer AVV was modied in such a way thatcleaning investigations could be carried out with pulsatinguid jets on vertical plates of stainless steel. The controlunit enables it to vary two factors, pulsation frequency andduty cycle. The detection of the cleaning process could beensured by use of a phosphorescent food model soil.For the evaluation of the tests regarding cleaning timeand cleaned surface, a program was created that allowscomparison of different forms of falling liquid lm and thedistinction between cleaning due to ‘direct impingementand cleaning due to falling liquid lms. The verication ofthe complex of experimental set-up, including experimentalevaluation, was based on measurements of coherentdistilled water jets from distilled water. Here, in case ofcleaning due to falling liquid lms, the potential savings ofcleaning medium was 50% and in the case of cleaning dueto ‘direct impingement cost savings of up to 60% could berealised. In addition, variation of the volume of ow wasperformed with the aim of advancing a rst user-friendlyapproach to the establishment of the pulsating jet cleaningsupply.(From left) Prof. Dr. Majschak of TU Dresden congratulates thewinners of the Hygienic Study Award 2012 rst prizes Dr. PatrickGordon, University of Cambridge, and Hannes Stoye, University ofDresden, at the award ceremony on occasion of the EHEDG WorldCongress 2012 in Valencia, Spain (Source H.-W. Bellin).Winner of 1st prize:Dr. Patrick Gordon, University of CambridgeDevelopment of a scanning uid dynamic gauge forcleaning studiesAbstract: This thesis describes the development of ascanning version of a uid dynamic gauge (sFDG) tostudy the cleaning of soft layers from rigid substrates,such as the food soils encountered within an automaticdishwasher. The sFDG measures the thickness of such

International Hygienic Study Award 2012 129layers within a liquid environment, in real time, as they areremoved, enabling the inuence of solution temperature,composition and shear stress to be quantied betweenor within experiments. It is shown to offer signicantimprovements over previous uid dynamic gauge(FDG) variants, including improved resolution (±5 μm),reproducibility, automation, data quantity and the ability togenerate topographical images.The sFDG is used to study the stages of swelling andremoval during the cleaning of gelatine, egg yolk, starchbasedand oil/albumin layers. The FDG technique couldalso be applied to several novel applications, includingthe study of crossow microltration and fragile biolms. Asecond-generation sFDG, optimised for cleaning studieswithin an industrial research laboratory, has been designed,constructed and commissioned. This technology transfer willallow the technique to contribute toward future developmentsin commercial dishwasher formulations.Winner of 2nd prize:Dr. Ing. Martin Schöler, University of DresdenAnalysis of cleaning procedures for complex geometriesin immerged systemsAbstract: Industrial cleaning processes are of greatimportance for ensuring hygienic production conditions.Furthermore, they represent a target for economicoptimisation due to their high consumption of energy andnatural resources. To improve the efciency of cleanin-placesystems (CIP) it is essential to understand themechanisms controlling complex cleaning processes. Theinvestigation of cleaning phenomena shows two majordifculties. First, there is a need for parameters that canprovide comparability between investigations that arecurrently isolated because they have used different materialcombinations or different experimental setups. Second,the availability of monitoring methods to investigatethese phenomena is limited. In this work the novel localphosphorescence detection (LPD) method is presented toinvestigate the cleaning performance. It combines the useof complex cohesive food soil, complex pipe geometriesand continuous observation of the cleaning progress toinvestigate the mechanisms of cleaning in immersed CIPsystems. Cleaning tests on a sudden expansion werecompared to soil and swelling investigations, as well as CFDresults conducted by other scientists. It was shown that thetested cleaning conguration was controlled by the masstransfer of the detached parts of the soil. The mathematicalparameters provided can help to determine the apparentcleaning mechanisms based on soil characteristics and theconditions of uid ow.Interested in taking part in the HygienicStudy Award 2013?Next year, drinktec in Munich will host the award ceremony.Interested research and university institutes are requestedto contact Prof. Dr. Jens-Peter Majschak, TU Dresden(jens-peter.majschaktu-dresden.de). drinktec 2013 –the world‘s leading trade fair for the beverage and liquidfood industry – will take place from September 16 throughSeptember 20 at Munich Trade Fair Centre. Deadline forsubmitting abstracts is June 30, 2013.Consult www.hygienic-processing.com to get full abstracts ofthe studies awarded.

European Hygienic Engineering & Design GroupEHEDG Regional SectionsChairmen and contactsThe Regional Sections are the local extensions of the EHEDG and are created to promote hygienicmanufacturing of food through regional activities. EHEDG has established Regional Sections invarious countries in Europe and overseas. These groups organise local meetings, courses andworkshops.ARMENIAProfessor Dr. Karina BadalyanArmenian Society of Food Science and Technology(ASFoST)Phone (+374 10) 55 05 26 / e-mail foodlabinbox.ruDr. Suren MartirosyanArmenian Society of Food Science and Technology(ASFoST)Phone (+374 10) 56 40 29E-mail surmar.3137gmail.comBELGIUMHein TimmermanDiversey Europe BVPhone (+32 495) 59 17 81E-mail hein.timmermandiversey.comFrank MoermanPhone (+32 9) 3 86 65 44E-mail fmoermantelenet.beCZECH REPUBLICMV Dr. Ivan ChadimaMQA s.r.o.State Veterinary Authority of the Czech RepublicPhone (+420 607) 90 99 47E-mail ivan.chadimamqa.czPetr OtáhalMQA s.r.o.Phone (+420 724) 13 81 68E-mail petr.otahalmqa.czDENMARKBjarne DarréGEA Liquid ProcessingPhone (+45 87) 94 11 38E-mail bjarne.darregea.comJon KoldStålcentrumPhone (+45 88) 70 75 15E-mail jon.koldstaalcentrum.dkFRANCEErwan BilletHydiacPhone (+33 61) 2 49 85 84E-mail erw.billetinfonie.frNicolas ChomelLaval Mayenne TechnopolePhone (+33 243) 49 75 24E-mail chomellaval-technopole.frGERMANYITALYDr. Jürgen HofmannTU München / Wissenschaftszentrum WeihenstephanPhone (+49 8161) 8 76 87 99E-mail jhhd-experte.deHans-Werner BellinBELLIN.ConsultPhone (+49 6120) 97 99 62 0hans-werner.bellinbellinconsult.deDr. Giampaolo BettaUniversity of ParmaPhone (+39 05) 21 90 62 34e-mail giampaolo.bettaunipr.itJAPANTakashi HayashiKanto Kongoki Industrial Ltd.Phone (+81 3) 39 66-86 51E-mail hayashikanto-mixer.co.jpHiroyuki OhmuraJFMA – The Japan Food Machinery ManufacturersAssociationPhone (+81 3) 54 84-09 81E-mail ohmurafooma.or.jpLITHUANIADr. Raimondas NarkeviciusKaunas University of TechnologyPhone (+370 68) 4 32 26E-mail r.narkeviciuslmai.ltProf. Dr. Rimantas VenskutonisKaunas University of TechnologyPhone (+370 37) 30 01 88E-mail rimas.venskutonisktu.ltMACEDONIAProfessor Dr. Vladimir KakurinovConsulting and Training Center KEYPhone (+389 070) 688-652E-mail vladimir.kakurinovkey.com.mk

EHEDG Regional Sections 131MEICOProfessor Marco Antonio León FélixMexican Society for Food Safety and Qualityfor Food Consumers (SOMEICCA)Phone (+52 55) 56 77 86 57E-mail cuccalmexicoyahoo.com.mxNETHERLANDSJacques KasteleinTNO Kwaliteit van LevenPhone (+31 30) 6 94 46 85E-mail jacques.kasteleintno.nlErnst PaardekooperFoundation Food Micro & InnovationPhone (+31 73) 5 51 34 70E-mail e.paardekooperplanet.nlNORDIC (FI, N, S)Dr. Gun WirtanenVTT Technical Research Centre of FinlandPhone (+358 20) 7 22-1 11e-mail gun.wirtanenvtt.Stefan AkessonTetra Pak Processing Systems ABResearch & TechnologyPhone (+46 46) 36 58 69E-mail stefan.akessontetrapak.comPOLANDDr. Matuszek, TadeuszGdansk UniversityPhone (+48 58) 3 47 16 74E-mail tmatuszepg.gda.plRUSSIAProfessor Dr. Mark ShamtsyanSt. Petersburg State Institute of TechnologyPhone (+7 960) 2 72 81 68E-mail shamtsyanyahoo.comSERBIAProfessor Dr. Miomir NikiUniversity of Belgrade, Faculty of AgriculturePhone (+381 63) 7 79 85 76E-mail miomir.niksicgmail.comProfessor Dr. Victor NedoviUniversity of Belgrade, Faculty of AgriculturePhone (+381 11) 2 61 53 15E-mail vnedovicagrif.bg.ac.rsSPAINAndrès PascualAINIA Centro TecnológicoPhone (+34 96) 13 66 09 0E-mail apascualainia.esIrene Llorca / Rafael SoroAINIA Centro TecnológicoE-mail illorcaainia.es, rsoroainia.esSWITZERLANDProfessor Rudolf SchmittUniversity of Applied Sciences Western SwitzerlandPhone. (+41 27) 6 06 86 52E-mail rudolf.schmitthevs.chMatthias SchäferGEA Tuchenhagen GmbHPhone (+41 61) 9 36 37 40E-mail matthias.schaefergea.comTAIWANDr. Binghuei Barry Yang*FIRDI Food Industry Research and Development.Phone (+886 6) 3 84 73 01E-mail bbyrdi.org.twTHAILANDDr. Navaphattra NunakKing Mongkuts Institute of Technology, BangkokPhone (+66 2) 7 39 23 48E-mail kbnavaph2yahoo.comTURKEYSamim SanerTFSA - Turkish Food Safety Association, IstanbulPhone (+90 216) 5 50 02 23E-mail samim.sanerggd.org.trUKRAINEUSAProfessor Yaroslav ZasyadkoNational University of Food Technologies, KyivPhone (+38 44) 2 87 96 40E-mail yaroslavnuft.edu.uaProfessor Ivanov SergiyNational University of Food Technologies, KyivPhone (+38 44) 2 89 95 55E-mail yaroslavnuft.edu.uaProfessor Mark MorganPurdue UniversityDepartment of Food SciencePhone (+1 765 ) 4 94 11 80E-mail mmorganpurdue.eduMore EHEDG Regional Sections are in the process ofbeing formed. These are:BulgariaCroatiaRomaniaSlovakiaSouth AfricaUnited KingdomList status as of spring 2013

132 EHEDG Regional SectionsEHEDG ArmeniaKarina Grigoryan, Laboratory of Biological Control of Food Products, Yerevan State University, Faculty of Biology,A.Manoogyan1, Yerevan Armenia, 0025 (phone: 37410550526; e-mail: asofst@gmail.com)and Suren Martirosyan, Chair of electrochemistry, Department of Chemical Technologies and EnvironmentalProtection, State Engineering University of Armenia, Teryan 105, Yerevan 25009 Armenia, (phone: 3741054742;Fax: 37410587284; e-mail: surmar.3137@gmail.com)Late in 2010, the Armenian Regional Section of the EHEDGparticipated in the PRODEXPO 2010 exhibition. HuubLelieveld and Piet Steenaard, were invited to participate inthis event. A number of meetings in UNIDO were carried outin American University of Armenia and in food processingcompanies. More than a hundred people visited the EHEDGexhibition pavilion.Doc. 10 Hygienic design of closed equipment for theprocessing of liquid food;Doc. 29 Hygienic design of packing systems for solidfoodstuffs.The following Guidelines are in the process of beingtranslatedDoc. 31 Hygienic engineering of uid bed and spraydryer plants;Doc. 35 Welding of stainless steel tubing in the foodindustry;Doc. 37 Hygienic design and application of sensor;The Guidelines presented below, are currently beingadapted to the Armenian Standards on hygienic design offood processing factoriesDoc 11 Hygienic packing of food productsDoc 8 Hygienic equipment design criteriaDoc 13 Hygienic design of equipment for openprocessingIn 2012, the Armenian Society of Food Science andTechnology started the creation of their own web page.A course of lectures “Hygienic design” will be introducedfor the departments of Food Processing Technologies andHygiene in Engineering and Agricultural State Universitiesduring the master study courses in 2012/2013.In 2012, the Armenian Regional Section carried out severalactivities to spread the requirements of EHEDG hygienicdesign among Armenian companies. Seminars have beenorganized at EHEDG company members and for othercompanies as well.Figure 1. EHEDG exhibition pavilion in PRODEXPO 2010In 2012, the EHEDG Armenian Regional Section focused itsefforts in Guideline translation.EHEDG Armenia has the following Guidelines ready forpublicationDoc. 21 Challenge tests for the evaluation of thehygienic characteristics of packing machines for liquidand semi-liquid products;Doc. 38 Hygienic engineering of rotary valves inprocess lines for dry particulate materials;Doc. 12 The continuous or semi-continuous owthermal treatment of particulate foods;The Armenian Regional Section also published severalnewsletters about the EHEDG and hygienic design, whichhave been distributed among the food industry, some foodequipment manufactures and universities.UNIDO partnership has been established with the EHEDGto strengthen national capacities and producers in meetinginternational standards and quality management fordevelopment of hygienic conditions in the food industry. Aseries of Round Tables and Seminars were conducted tointroduce EHEDG Guidelines and principles.

EHEDG Regional Sections 133In October 2012, a seminar with representatives fromstate organizations was carried out in UNIDO and FoodSafety Agency. During this seminar our Regional Sectionpresented possibilities of cooperation with EHEDG, e.g.the organization of trainings and providing certicationof the equipment in food factories. Using the materials ofEHEDG presentations, joint seminars were organized withagricultural and engineering universities.Figure 2. Meetings and seminars in UNIDOCompany-members of EHEDG have been successful,due to our collaboration, i.e. the introduction of EHEDGGuidelines and the organization of meetings and seminarsat the manufacturers locations.The food companies of Armenia which co-operate with thefollowing subgroups are presented below“Bari Samaratsi” LTD – “Meat Processing” subgroup.“Akvatechavtomatika”LTD – “Fish Processing”subgroup.In these enterprises interesting research work is carried out,the results of which are the basis for determining the materialfor the corresponding subgroups, for exampleInuence of technology of processing surfacesand equipment by biocides, on survival rate ofthe microorganisms, causing safety and quality offoodstuff;Use of modern methods of packing and storage offresh sh.In 2012, mass media were actively used for the advancementof EHEDG in Armenia; these are transfers on Armenian TVand radio.Figure 3. Meeting at Yerevan Sate Agrarian University, Departmentof Food TechnologiesContactProfessor Dr. Karina BadalyanArmenian Society of Food Science and Technology(ASFoST)Phone (+374 10) 55 05 26E-mail foodlabinbox.ruDr. Suren Martirosyan ASFoSTPhone (+374 10) 56 40 29E-mail surmar.3137gmail.comEHEDG BelgiumHein Timmerman, Diversey Belgium, a Sealed Air Company, E-mail: hein.timmerman@telenet.beA Regional Section on the riseFor EHEDG Belgium, 2012 was a busy year. A number ofpeople from Belgium have been active in EHEDG work forquite some time. Finally, after many years of involvement,the team has taken up the task of founding the Belgiumsection. EHEDG Belgian Regional Section has created alegal identity as non-prot organisation (vzw or “stichting”in Dutch, and “Vereinigung ohne Gewinnerzielungsabsicht”in German). This legal identity is required to legally protectthe individuals and to be able to receive and send outaccountable invoices.

134 EHEDG Regional SectionsThe following positions have been conrmedChairmanHein TimmermanVice-chairman Laurent Paul, and looking afterWalloon and German regionVice-chairman Johan Roels, and looking afterFlemish regionSecretaryFrank MoermanTreasurerNoel Hutsebaut3. Preparation of a three day EHEDG Advance Course onHygienic Design training course in the Walloon regionby exploring the possible cooperation with EHEGDFrance4. Organisation of an EHEDG seminar as instigator ofthe initiative, with possible cooperation of Agoria andFlanders Food5. Establishing links to different Flemish and Walloon universitiesand technical colleges in order to promote ouradvisory function to legislators and standards groups6. Expanding the network to all major food producers inthe Flemish and Walloon regions7. Expanding a networking platform for local experts inhygienic design.The legal papers were ofcialised during the Food & FeedValue Added Services Event on Wednesday September 19,2012 at Fortress Singelberg, Antwerp.The bylaws were signed at the EHEDG annual meeting inValencia in November 2012.He main objectives for 2012-2013 are1. Creation and publication of the bylaws of EHEDGBelgium vzw in the “Belgisch staatsblad”. From the dayof publication the organisation will be ofcialised.2. Organisation of a three day EHEDG Advance Courseon Hygienic Design training course in the FlemishregionContactFor more information and if interested in the activities ofEHEDG Belgium, please contactHein TimmermanE-mail hein.timmermantelenet.bePhone +32 495 591781EHEDG Czech RepublicNew Regional SectionIvan Chadima, MQA s.r.o., phone: (+420 607) 90 99 47, e-mail: ivan.chadima@mqa.czWith help of the general secretary of EHEDG SusanneFlenner, a small group of EHEDG members organised an“EHEDG Day” in the Czech Republic on 11th September2012. The aim was to promote ideas of hygienic designbetween participants from Czech and Slovak food and foodmachinery industry and teachers from universities. PresidentKnuth Lorenzen and general secretary Susanne Flennerparticipated in this event, too.Three presentations showing hygienic design from differentviewpoints were presented (Knuth Lorenzen from EHEDG,Ivan Chadima from MQA s.r.o. and Jií Loníek from ACOIndustries k.s.). There was also a fruitful informal discussionabout the founding of a Czech Regional Section.Potential members of the Regional Committee were invitedto a separate meeting in November 2012 where Regionalcommittee members was conrmed and the future ofEHEDG in the Czech Republic discussed.Contact:MQA s.r.o.Dr. Ivan ChadimaJevineves 5827705 SPOMYSLCZECH REPUBLICPhone (+420 607) 90 99 47E-mail ivan.chadimamqa.cz

EHEDG Regional Sections 135EHEDG DenmarkJon J. Kold, regional chairman EHEDG, general manager Staalcentrum, e-mail: jk_innovation@yahoo.comEHEDG Denmark can boast an increase of both companyand individual members that joined the EHEDG. Newmembers have also joined relevant subgroups to share thework of determining the future trend for hygienically designedequipment.Figure 3. Display at international conferenceEHEDG Denmark have been actively in contact withthe Danish technical magazines in order to promote theawareness of hygienic design of processing equipment.Very good connections have been made with several editorsand journalists from these magazines.Figure 1. Display at the international conferenceIn November 2011, EHEDG Denmark and Staalcentrumheld an international conference “Food Processing Hygiene– Future demands from markets and Authorities” at HotelComwell in Kolding. Included in the program were more than60 B2B meetings. Furthermore four workshops covering thefollowing topics were held Robots in Production, AlternativeMaterials to Stainless Steel, Testing and Certication andMicrobiology.Since the Danish Technological Institute stopped theirtesting and certication, EHEDG Danmark have beencooperating with the Danish Technical University (DTU)in Lyngby, north of Copenhagen, in order to transfer thetesting and certication experience to them. The chairmanfor the Subgroup for Testing Methods has visited the siteand advised the management at DTU how to proceed. It isexpected that a new test rig will be in operation before theend of 2012.In November 2012, a seminar was held in connection withthe FoodTech exhibition in Herning, the subject was newdevelopments in open equipment design as open andaccessible construction and the importance of integratingall EHEDG Guidelines when designing processing lines.The use of certied equipment has to go hand in hand withhygienic design guidelines for construction. Testing andcertication at DTU was part of the seminar.Figure 2. Lecture at the international conferenceThe focus of the programme was to look into the future andsee how demands from the market could be implemented inthe future design of equipment as well as the documentationfor hygienic design. More than 70 persons participated in the2 day programme.The Danish EHEDG CommitteeChairmanJon J. Kold, StaalcentrumSecretaryUlla Stadil, Novozymes A/STreasurerBjarne Darré, GEA Liquid A/SMembersMogens Roy Olesen, Grundfos A/SPeter Uttrup, Interroll A/SKjeld Bagger, AVS Denmark ApSBo Boje Busk Jensen, Alfa Laval A/SPer Væggemose Nielsen, IPU / DTU

Exceptionalease ofcleaningAutomaticallyhygienicEHEDG France:Seven years of existenceNicolas Chomel, Secretary of EHEDG France,e-mail: nchomel@ehedg.frCreated in the end of 2005, the French Regional Sectionis now well established in the national landscape of thefood industry. EHEDG France has 76 members, including57 industrial companies, and is directed by an administrationcommittee of 15 people.The new president, Erwan Billet, elected in 2010, wished fora closer collaboration with the EHEDG, and 2011 has beena key year from this point of view.After his rst visit to Laval in September, Knuth Lorenzenreturned in November to give a presentation at the “AutumnConferences” of EHEDG France.The collection of 41 guidelines has been translated intoFrench, and 59 documents were sold in 2011.French members are involved in nine international Subgroupsand their contribution is growing, especially through thecreation of “mirror groups“ connected to international groups.The rst “mirror groups“ have already taken up their jobsfor “Cleaning validation“, “Air handling“, and “Education &training“. EHEDG France will also initiate a new internationalsubgroup on “CIP“ and probably another one regarding thehygienic design of brushes.In the framework of the last international conference FoodFactory in July of 2012, EHEDG France was involved inthe organization of the “SME day“, gathering technicalpresentations on hygienic design.AZO ® Easy to cleansolutions:• clean• fast• residue-freeThe No. 1in mixer feedingwww.azo.comM E M B E RFood Factory 2012, Laval, July 5.ContactErwan Billet*HydiacPhone (+33 61) 2 49 85 84E-mail e.billethydiac.comNicolas ChomelLaval Mayenne TechnopolePhone (+33 243) 49 75 24E-mail chomellaval-technopole.fr

EHEDG Regional Sections 137EHEDG GermanyDr. Jürgen Hofmann, Hygienic Design Weihenstephan, Postfach 1311, D-85313 Freising, Germany;Phone +49(0)8161-8768799, e-mail: jh@hd-experte.deHans-Werner Bellin, BELLINconsult, Heidestr. 3, D-65326 Aarbergen, Phone: +49/(0)6120/9799620,mobile phone: +49(0)151/42415256 , e-mail: Hans-Werner.Bellin@BELLINconsult.de.EHEDG Germany/Austria has a total of 283 members andabout 90 member companies (2 from Austria) which is anincrease of more than 50% within the last two years. Thesecompanies generate more than 40 % of the total income ofEHEDG.The experience made during these tests has been used forfurther training courses and seminars.The idea of hygienic design has a long tradition in Germanyand goes back right to the beginnings of the EHEDG and itshistory. Hygienic design research continues at the “Lehrstuhlfür Verfahrenstechnik disperser Systeme” (formally“Lehrstuhl für Maschinen- und Apparatekunde”, TechnicalUniversity of Munich) whilest the University of Dresden(Professur Verarbeitungsmaschinen / Verarbei-tungstechnikwith Prof. Dr. Majschak) does research on topics such as thecleaning effect on open surfaces and is now involved in theSubgroup Training & Education to develop training material.The German Section is very active in Training and today hassix EHEDG authorized trainers Dipl.-Ing. Martin Barnickel(Technikerschule in Kempten), Dipl.-Ing. Hans-Werner Bellin(BELLIN.consult), Knuth Lorenzen (EHEDG President,Chairman of the Training & Education Subgroup), Dr. JürgenHofmann (Hygienic Design Weihenstephan), Prof. Dr. JensMajschak (TU Dresden) Dr. Marc Mauermann (FraunhoferAVV), and Ferdinand Schwabe (HD-Consultant).The “Forschungszentrum Weihenstephan für Brau- undLebensmittelqualität” is an authorised EHEDG Test Institute.With approximately 50 EHEDG components assessed toprovide of optimization guidance about design and withmore than 30 EHEDG certicates in 2012, it is one of themost active test labs for the EHEDG. The highlight last yearwas the cleanability testing of a self-priming centrifugalpump. This kind of pump is able to transport air in the liquidphase and has different chambers and tends to be difcultto clean. The important requirement of self-draining also hasto be considered.Another highlight was the rst certicates of Type EL AsepticClass I to be issued. The item tested was a pressure sensorfor mounting in pipe lines, sealed with an O-ring. Thiscerticate was followed by an air-operated pinch valve.Figure 2. left to right Dr. J. Hofmann, K. Lorenzen, Dr. Fischer,H-W.Bellin, D. NikoleiskiThe German Section has an annual meeting which is part ofthe HygieniCon in Karlsruhe (www.hygienicon.com).At this meeting, the members receive the latest news aboutwhat has been happening during the last year within theEHEDG and new strategies are discussed. This year, theRegion Germany was made public by the signature of theBy-Laws through Dr. Jürgen Hofmann, Chairman, Hans-Werner Bellin, Secretary, Dr. Sven Fischer, Treasurer andDirk Nikoleiski, Member of the EHEDG Executive Board.Figure 3. Presentation of the EHEDG test during the HygieniCon2012Figure 1. Speech of the EHEDG President Knuth Lorenzen at themeeting of the German Group during the HygieniCon, KarlsruheAt the 2012 Anuga FoodTec (March 12) in Cologne EHEDGorganized a Symposium with international speakers andaround 70 participants. The EHEDG had their own boothwhich helped to establish contact with many people from allover the world.

138 EHEDG Regional SectionsCurrently, there are at least three Hygienic Design coursesper year held by members of the German Section. The“Hygienic Design Weihenstephan Akademie” will startthe additional training which will communicate the idea ofEHEDG mainly to non-EHEDG-members.The training courses are scheduled for each February,July and October in Munich, Cologne and Stuttgart. Moredetails are available under http//www.hygienic-designakademie.de/.ContactFigure 4. The EHEDG both on the Anuga FoodTec with SusanneFlenner and Knuth LorenzenChairmanDr. Jürgen HofmannIngenieurbüro HofmannFichtenweg 8 a85604 ZornedingE-mail juergen.hofmannehedg.orgSecretaryHans-Werner BellinBELLIN.consultHeidestr. 365326 AarbergenE-mail hans-werner.bellinbellinconsult.deFigure 5. The EHEDG Symposium at the Anuga FoodTec inCologne, March 12EHEDG ItalyGiampaolo Betta, Università degli Studi di Parma, e-mail: giampaolo.betta@unipr.itNews from the Italian Regional SectionThe Italian food industry, along with agriculture, relatedactivities and distribution, is the foremost economic sectorin the country. It buys and processes about 70% of domesticraw materials. It is also the ambassador of “Made in Italy” inthe world, since 76% of the food exports consist of industrialbranded products.The Italian food industry has a turnover of € 120 billion,with 6,400 companies (with more than nine employees)comprising a total of 386,000 employees. Exports amountedto € 19.84 billion (Data 2008).61% of the total turnover is achieved in the Lombardy, EmiliaRomagna, Veneto and Piedmont regions, making this areathe most important “food valley” of Europe.Within this area, the Province of Parma distinguishes itselfas 23% of all employees of the food industry of the entireregion Emilia Romagna work in that province.The province of Parma is home to historically consolidatedfood products, such as “Prosciutto di Parma” PDO,“Formaggio Parmigiano Reggiano” PDO and tomatoproducts. Currently, Parma is the location of many well-knownfood manufacturing and food-equipment manufacturinggroups.In addition, Parma is the headquarters of the StazioneSperimentale Industria Conserve Alimentari (SSICA), aninstitute of research and experimentation founded in 1922.Finally, Parma is home to the European Agency for FoodSafety Authority (EFSA) and, as such, is often the privilegedmeeting place for working groups, seminars and conferencesinvolving top European experts.Since 2007, Parma has also been the location of the ItalianSection of the European Hygienic Engineering and DesignGroup.

EHEDG Regional Sections 139Members and SubgroupsThe Italian Section ofcially started on 17 October 2007,the date of the “Hygiene Requirements and Standards forFoodstuffs Machinery” Conference, which took place atParma at the time of the CIBUSTEC2007 Exhibition.Italy supports EHEDG with 10 company members (Table 1),10 individuals and Italian members actively work in 8Subgroups (Table 2).Italian Company Members (2012)Ammeraal Beltech S.r.l.AROL S.p.A.CFT S.p.A.CSF Inox S.p.A.Ilinox S.r.l.PNR Italia S.p.A.RattiInox S.r.l.Seital Separatori S.r.l.S.K.F Industrie S.p.A.Vincas S.r.l.Table 1 EHEDG Italian Company Members in 2012Subgroup with Italian membersSeals and ValvesPumps, Homogenizers, Dampening DevicesChemical treatment of stainless steelMaterials of ConstructionSeparatorsTest MethodsTraining and EducationTable 2 Subgroups with Italian membersCompany / InstituteDocumentsBardiani valvole S.p.A. 14,20,Centro Inox Milano 32CFT S.p.A. 2,8,10Csf Inox S.p.A. 14,17,20,25GEA-Niro Soavi S.p.A. 17GEA-Procomac 8CFT S.p.A. 13, 34IVG Colbachini S.p.A. 32Omac Pompe S.r.l. 17Parmalat S.p.A. 8,34Sidel S.p.A 2,8,10,34Stazione Sperimentale per lIndustria delle 8Conserve AlimentariUniversity of Parma 2,8,10,13,14,17,20,25,32,34Table 3 translation working groupsEHEDG Italy EventsThe Italian Regional Section frequently participates in Italiancongresses, seminars and conferences with speeches onHygienic Design and Engineering. Some examples areshown in Table 4.The Italian Regional Section is also a candidate for hostingand organizing the 2014 EHEDG World Congress.Participation in eventsDateMcT Alimentare - Bologna 19-06-2012R2B - Bologna 11-06-2011Gruppo CMS Updating - Modena 20–05-201151° AITB - Bari 23-09-2010Table 4 participation in eventsTranslationsBy now (September 2012) the Documents 2, 8, 10, 13, 14,17, 20, 32, 34 have been translated and are hence availablein the Italian language; Documents 25, 1, 3 and 6 are underrevision.A frequently updated list of the translated documents isavailable in the web-page www.ehedg.unipr.it Guidelines.Many companies and institutes joined the translationworking groups of the Italian Section. The list is shown inTable 3.TrainingThe Italian Regional Section participates in the Training andEducation Subgroup.Training on basic and advanced hygienic design andengineering is offered in English and in Italian language. Forfurther information please contact giampaolo.bettaunipr.itContactFor more information and also if you are interested in theactivities of EHEDG Italy, please contact Dr. Giampaolo Betta,e-mail giampaolo.bettaunipr.it Phone +39 0521 90 62 34or the EHEDG Secretariat.

140 EHEDG Regional SectionsOutline of activities of EHEDG JAPANHiroyuki Ohmura, JFMA The Japan Food Machinery Manufacturers’, ohmura@fooma.or.jpWith the full support from the Japan Food MachineryManufacturers‘ Association (FOOMA), EHEDG JAPANmainly pursues the following activities Translation ofEHEDG guidelines, holding seminars on EHEDG guidelines,and EHEDG PR activities.Translation of EHEDG guidelinesEHEDG JAPAN considers the translation of EHEDGguidelines to be its foremost task.In Japan, there is a strong need for translations of thefollowing guidelines Doc. 9, Doc. 18, Doc. 20, Doc. 23, Doc.32, and Doc. 37. EHEDG JAPAN set up a special translationworking group for each of these documents.The translations of Doc. 20 and Doc. 23-2 have alreadybeen completed.EHEDG seminarTo spread the knowledge about EHEDG guidelines, EHEDGJAPAN held a free seminar intended for food machinerymanufacturers and food manufacturing engineers in Japan.EHEDG President Mr. Lorenzen was invited as a lecturer(Fig 3/4).Topic Materials of Construction for Equipment Cominginto Contact with Food (Doc. 32)Date and time June 6, 1000–1230Attendants 230 peopleWith the rst FOOMA JAPAN having been held in 2009,EHEDG JAPAN this year already held its fourth EHEDGseminar. The audience has increased every year. This year,with an audience of 232 people, the venue was almost bookedout.(The number was 180 last year.) All these activities haveboosted publicity for EHEDG in Japan considerably.Seminars on EHEDG guidelines, and EHEDGPR activitiesEvery year in June, FOOMA organises the “FOOMAJAPAN“, a comprehensive exhibition on food machinery andtechnology industry. About 650 companies from all over theworld participate in this exhibition. The number of visitorsruns up to about 100,000. This year, FOOMA JAPAN washeld for four days from June 5 through 8 at Tokyo Big Sight.Throughout the exhibition period, EHEDG JAPAN performedPR activities at a booth provided by FOOMA and held a freeseminar to make EHEDG guidelines known.Figure 2. EHEDG seminar in FOOMA JAPAN 2012PR booth of EHEDGAt the EHEDG booth (Fig. 1), EHEDG pamphlets andyearbooks were distributed to visitors. In addition, paneldisplays were set up to explain the hygienic structure of foodprocessing machines as dened in the Codex AlimentariusCommissions “Food Hygiene – Basic Texts” and ISO/JIS, aswell as the relationship between these documents.Figure 3. President Lorenzen acted as the speakerContactFigure 1. EHEDG PR boothHiroyuki OhmuraJFMA - The Japan Food Machinery Manufacturers AssociationFooma Bldg., 3-19-20 ShibauraMinato-ku108-0023 TOKYOJAPANE-mail ohmurafooma.or.jp

EHEDG Regional Sections 141EHEDG LithuaniaDr.Raimondas Narkevicius, regional chairman EHEDG, Food Institute of Kaunas University of Technology,e-mail: r.narkevicius@lmai.ltIn May 2012, a workshop on topical issues of food safetyand innovations was held in Kaunas. At this workshoprepresentatives of food manufacturing companies, foodresearch and safety control organisations participated. Itwas there that the decision was reached to establish theEHEDG Lithuanian Section.An agreement between Kaunas University of Technologyand EHEDG was duly signed and the Food institute ofKaunas University of Technology was appointed as theregional representative of EHEDG in Lithuania.In the rst year of existence, the main tasks of the LithuanianEHEDG section weretranslation of EHEDG Guidelines into Lithuanian andspreading the Guidelines among food processingcompaniesorganisation of and participation in events aimed atpromoting the hygienic manufacturing of foodpresentation of EHEDG activities and spreading theknowledge about EHEDG amongst Lithuanian foodmanufacturers.In November 2012 at the annual conference of FoodInstitute of Kaunas University of Technology, the EHEDGwill be widely presented and we expect to persuade foodmanufactures and other professionals to join the EHEDG.Mr. Huub Lelieveld giving a presentation at the Workshop inLithuaniaFor more information please contactRaimondas NarkeviciusKaunas University of TechnologyDepartment of Food TechnologyTaikos pr. 9250254 KAUNASLITHUANIAPhone +370 68 4 32 26E-mail r.narkeviciuslmai.ltEHEDG Macedonian Regional SectionProf. Dr. ladimir Kakurinov, Consulting and Training Centre KEY, Macedonian Regional Section Chairman,Phone/Fax: +389 2 3211-422; e-mail: vladimir.kakurinov@key.com.mkConsulting and Training Centre Key, the headquarters ofthe Macedonian EHEDG Regional Section, has organizedthe First EHEDG World Congress in Hygienic Engineeringand Design. This event was a Summit of Hygienic Designexpertise, where over 230 participants from 31 countriesworldwide came for an experience exchange, and discussednew developments and innovations.The EHEDG World Congress took place in Hotel Granit inOhrid, Macedonia, 22 - 25 September, 2011.EHEDG World Congress in HygienicEngineering and Design 2011 – MacedoniaDuring the Conference organized by RUSFoST (4 –5 October, 2010 in St. Petersburg, Russia), EHEDGMacedonian Regional Section was chosen to host the FirstWorld Congress for Hygienic Engineering and Design.Figure 1. World Congress opening

142 EHEDG Regional SectionsThis event was a Summit of Hygienic Design expertise:more than 230 participants from 31 countries worldwideexchanged their experience, new developments andinnovations in this area.The Congress had full media coverage. Its content,participants, new developments and ideas were covered notonly by media in Macedonia, but in the region and worldwide.42 presentations in two parallel sessions1. Hygienic Designand2. Food Quality & Safety and Food Production & Processinggave an insight into the various elds of expertise of thehigh-class EHEDG lecturers and academia representativeswho offered the delegates two highly informative days.All participants were more than satised with the successfuloutcome as is documented in the 1st Journal of HygienicEngineering and Design. The journal consists of 75 highqualitypractical and science based papers, peer to peerreviewed, by 32 Congress Scientic Committee members.Figure 4. World Congress media coverageThis great event was organized by Consulting andTraining Center KEY, the headquarters of the EHEDGMacedonian Regional Section.Beside the working part of the Congress, there was a specialsocial programme, where all participants had an opportunityto get familiar with our beautiful country, its traditions,heritage and Macedonian hospitality.You can nd more information about the EHEDG WorldCongress in Hygienic Engineering and Design atFigure 2. World Congress sessionhttp//www.ehedg.mk/categories/view/430The sponsor companies of the event Van Meeuwen, TensidChemie Cmbh, Swisslion, Tetra Pak, Danfoss, Kozuvcanka,Scanjet, GEA, Serendipity, SKF, Skovin, and Makprogreswere able to present their latest products and services in theexhibition space. It was an excellent and unique opportunityfor them to attract new customers, reafrm long-termcustomer relationships and present their most innovativeproducts, equipment, materials and services in the area ofsafe food production.The Congress turned out to be an excellent platform fornetworking and meetings, especially on its nal ‘BrokerageEvent’ day, where business deals were concluded reachinga total of more than € 10 million.Figure 3. World Congress Brokerage eventJournal of Hygienic Engineering and DesignThe Journal of Hygienic Engineering and Design isa platform for publication of evidence-based studies,investigations, research and experience on all scientic andexpert aspects for equipment and components, hygienicprinciples, processing, utilities, services, food productionand processing, food quality and safety, and education. Itis a peer-reviewed and open access journal intended toreveal new approaches, innovations, expert opinions andthe highest possible global scientic standards.The rst JHED volume was issued in 2011 for the rst WorldCongress in Hygienic Engineering and Design. This rstissue included 75 papers from 19 countries worldwide TheNetherlands, Germany, France, Great Britain, Denmark,Finland, Belgium, Spain, Poland, Bulgaria, Ireland, Sweden,Macedonia, Serbia, Croatia, Montenegro, Russia, Armeniaand USA. This issue was published as a print copy. By noweach paper is available in electronic form and downloadablefromhttp//www.ehedg.mk/categories/view/413.The publisher of the Journal for Hygienic Engineering andDesign, Consulting and Training Center KEY, will continuepreparing the second and other following web based issuesof this Journal. Authors all over the world are invited tosubmit their articles for the second issue.

EHEDG Regional Sections 143Beside the manuscripts, JHED content is extended to meetindustry and consumer needs. On a regular basis, at theJHED web page, all new developments, technologies andinnovations within the food and beverage industry worldwidewill be updated. In this way, JHED aims to be a source ofinformation and a networking platform for all key decisionmakers throughout the world and will be an essential readfor anyone involved in this sector.Guidelines translation into MacedonianThe translation of EHEDG Guidelines is an important part ofthe EHEDG Macedonian Regional Sections regular activities.Seeing that all activities were focused on the organization ofthe EHEDG World Congress in 2011, for that year EHEDGMacedonia translated ve Guidelines into the Macedonianlanguage. Macedonian titles are shown in Table 1.More information about the Journal of Hygienic Engineeringand Design can be found athttp//www.ehedg.mk/categories/naslovna/Doc.2Title Info DaysIn order to promote the EHEDG Congress in September,2011, the Macedonian EHEDG Regional Section hadorganized 4 informative days1. South-eastern region Strumica2. Region Pelagonia Bitola3. Macedonian Chambers of Commerce State level4. Economic Chamber of Macedonia State levelIn 2012, two more Info Days were held. The rst EHEDG InfoDay took place in February 2012, with a main topicHygienic engineering and design of buildings for thepharmaceutical and food industry.The second Info Day was organized in April, 2012, with anaccent onHygienic engineering and design of equipment andits components and machinery intended for foodproduction and processing.Both Info Days were attended by more than 80representatives from civil engineering and architecturalcompanies engaged in food industry design and building(construction), equipment producers, producers anddistributors of materials and components intended for foodand pharmaceutical companies, food and pharmaceuticalcompanies. Both events inspired huge interest among theparticipants and broader public and it was covered by allmedia. Also, National Television Telma prepared specialshows broadcasts solely dedicated to these events.Figure 5. EHEDG Info Day special broadcast121526 - 37 Table 1 EHEDG Guidelines translated in 2011In 2012, the EHEDG Macedonian Regional Section translatedtwelve EHEDG Guidelines into Macedonian (one per month,as planned in the activity plan for 2012). Macedonian titlesare shown in Table 2.Doc.569Title 14 16 20213017293640 T - , Table 2 EHEDG Guidelines translated in 2012(more on http//www.ehedg.mk/categories/view/429)

144 EHEDG Regional SectionsHygienic Engineering and Design ConferenceThe First Conference for Hygienic Engineering and Design inthe Republic of Macedonia will take place on 9th of October,2012, at the Municipality Karpos Conference Hall in Skopje.Invited speakers at this Conference areMr. Huub Lelieveld who will speak on the topics of Hygienicengineering and design requirements for buildings andEU legislation, standards and codes regarding hygienicengineering and design, while Prof. Dr. ladimir Kakurinov,Chairman of the Macedonian EHEDG Regional Section willspeak about hygienic engineering and design requirementsregarding machinery and equipment.EHEDG Macedonian Regional Section members will alsospeak at the Conference and share their experience.This event will be attended by representatives from the food,pharmaceutical and cosmetics industry, food machinery,equipment and components manufacturing companies,companies supplying engineering services, the Food andVeterinary Agency and inspection bodies.ContactYou can nd more detailed information about EHEDGMacedonia and Journal of Hygienic Engineering and Designat http//www.ehedg.mk/categories/naslovna/EHEDG MexicoIn 2011, the very rst year of the EHEDG Regional Section Mexico, SOMEICCA A.C. as therepresentative has organised the 4th International CUCCAL Congress on Food Safety, Qualityand Functionality with EHEDG support and an informative breakfast about the aims and tasks ofEHEDG. Sponsors of SOMEICCA, such as Lex and Dantek, promoted EHEDG.León Félix Marco Antonio. Sociedad Mexicana de Inocuidad y Calidad para Consumidores de Alimentos,SOMEICCA, A.C. 28 de diciembre 87 Col. Emiliano Zapata. Coyoacn, D.F.C.P.04815 México.www.someicca.com.mx ;marcoelp@lex.com.mx4th International Congress CUCCAL on FoodSafety, Quality and Functionality in the FoodIndustry and in Foodservice.In October 2011, 400 attendees from México, Cuba, Chile,Brazil, Venezuela and the United States of America enjoyedthe sessions, workshops and roundtables during theCongress. The EHEDG was represented by Huub Lelieveldwho was the trainer of the “hygienic design in food facilities”workshop and speaker at the conference. 16 delegatesattended the workshop and the entire conference wasattended by 50 persons, including students participation.It was very interesting to note that having Cancun as thehosting city, the attendees were from Foodservice ratherthan the Food Industry, but they were very pleased by thecourse. Of course, the congress also had academia andindustry representatives.Figure 1. Closing Award session during the 4th InternationalCUCCAL Congress at Cancún México.Figure 2. Attendees during the EHEDG session.

EHEDG Regional Sections 145To promote EHEDG and to let the Mexican Chambers andUniversities know about the Congress results, SOMEICCAorganised an informative breakfast in December 2011.The twelve attending guests were from the Industrial FoodChambers (Seafood, Bakery and Dairy) as well as fromUniversities that teach Food Science and Nutrition careers.Before the Congress, SOMEICCA offered an informativesession about what the EHEDG is, for the most importantfacilities processing seafood in México and Latin America.Professor León Félix was present and explained theEHEDG goals and invited Seafood enterprises to attendthe EHEDG workshop during the 5th International CUCCALCongress.Figure 3. EHEDG´s Breakfast for Mexican Food Chambers andUniversities5th International CUCCAL Congress onFood Safety, Quality and Functionality forFood service and IndustryIn October 2012, SOMEICCA held the 5th InternationalCUCCAL Congress at Mazatlán, Sinaloa,México with twoEHEDG speakers, both for a short course on HygienicDesign in Food Facilities and for conferences and roundtable sessions on the importance of hygienic design.SOMEICCA also held an informative session with the mostimportant facilities for Seafood Processors in Latin Americaat Mazatlán, Sinaloa.The EHEDG was represented by Huub Lelieveld and PietSteenaard as speakers both for a workshop on HygienicDesign in Food Facilties and for a conference and roundtable sessions about the importance and impact of hygienicdesign on food safety and quality. The Congress gatheredMexican and International experts on Food Safety, Qualityand Functionality from México, Brasil, Venezuela, UnitedStates of America and the Netherlands.Figure 4. CUCCAL Congress poster with EHEDG logoContactProfessor Marco Antonio León FélixSociedad Mexicana de Inocuidad y Calidadpara Consumidores de Alimentos AC(SOMEICCAAC)Phone (+52 55) 56 77 86 57E-Mail lex04yahoo.com.mxEHEDG NetherlandsE.J.C. Paardekooper, info@ehedg.nle-mail, info@ehedg.nlTranslation of GuidelinesAt this moment, 32 guidelines have been translated intoDutch, 22 of which are available as print-versions. Eight ofthe 32 versions are still waiting for nal approval. The planis to translate the remaining guidelines into Dutch and tonalize all translations in 2013.The Dutch Society for Food Entrepreneurs(OS) & Dutch Food Business Events (MT):EHEDG Netherlands was present at the SVO EVENTOctober 27th, 2011 in Velp about Hygienic Design ofConveyor BeltsEHEDG Netherlands Seminar “Hygienic Design & Allergens”with the Dutch Food Magazine VMT was held December 4th,2012 in Utrecht.

146 EHEDG Regional SectionsTrainingTraining and education materials remain the main topic topromote hygiene awareness and understanding amongstaff/personnel involved in the food chain, ‘from farm to fork.Knowledge disseminationOther channels of spreading knowledge are magazinesand online publications. Targeted were Dutch media suchas Voedingsmiddelentechnologie (VMT), WEKA and EismaVoedingsmiddelenindustrie (EVMI) with 12 articles publishedin total.Several in-house training sessions were organised forfood companies as well as for equipment suppliers andengineering rms. Most food equipment suppliers and alarge number of food companies in the Netherlands arefamiliar with the EHEDG.A signicant number of seminars was held introducingdevelopments fullling EHEDG requirements and somelectures were held at fairs, p.e. Industrial Processing, SolidsFairs, Technivent and Stainless Steel World; in total about 30lectures with a total exposure of more than 700 participantswere presented.Board members of EHEDG Netherlands are active in theSubgroups Building Design, Tank Cleaning and Testing &Certication.Joint activities with other associationsInterest has arisen from the metal industry to enter into acooperation introducing EHEDG requirements in the metalindustry.ContactErnst PaardekooperFoundation Food Micro & InnovationPhone (+31 73) 5 51 34 70E-mail e.paardekooperplanet.nlJacques Kastelein*TNO Kwaliteit van LevenPhone (+31 30) 6 94 46 85E-mail jacques.kasteleintno.nlHigh Technology Solutionsin the dairy and fruit processing industries.bawaco ag · Stauffacherstrasse 77 · CH-3014 Bern / Switzerland · www.bawaco.chbawaco gmbh · Poststrasse 15/1 · D-71384 Weinstadt / Germany · www.bawaco.de

EHEDG Regional Sections 147EHEDG RussiaProf. Dr. Mark Shamtsyan, St. Petersburg State Institute of Technology (RUSFoST),e-mail: shamtsyan@yahoo.comIn 2012, the Russian Section of EHEDG made good progressin translating EHEDG Guidelines and started translatingpresentations for training courses.On April 22-24, the First North and East European Congresson Food was held in Saint Petersburg. The congress wasorganised by RUSFoST and the St. Petersburg StateInstitute of Technology (Technical University) in cooperationwith EHEDG, GHI, IUFoST and EFFoST.The congress programme focused on recent developmentsin the elds of innovative technology, food safety,manufacturing and design of food equipment, functionaland bioactive food, new trends in food safety, and impactof food on human health. More than 120 delegates from 28countries participated in the congress.During the congress, EHEDG and its activities werespecically introduced.Figure 2. Mr. Huub LelieveldFurther contributions in the development of food scienceand technology in Eastern Europe were given by ProfessorSergiy Ivanov, Chair of the Ukrainian Section of EHEDG,Rector of National University of Food Technology of Ukraineand also by Professor Kostadin Fikiin, specialist for foodrefrigeration (Technical University of Soa, Bulgaria). It wasdecided to hold the second NEEFood Congress in May 2013in Kiev, and after that every second year.ContactFigure 1. First North and East European Congress on FoodOne of the founders of the EHEDG, Mr. Huub Lelieveld,was awarded a special prize of NEEFood Congress forhis lifetime achievements and great contribution in FoodScience and Technology.St. Petersburg State Institute ofTechnology (RUSFoST)Technical UniversityMoskovsky prospect 26ST. PETERSBURG 198013RUSSIAN FEDERATIONE-mail shamtsyanyahoo.comPhone (+7 960) 2 72 81 68

148 EHEDG Regional SectionsEHEDG SerbiaA new EHEDG regional section was established in SerbiaProf. Dr. Miomir Niksic, University of Belgrade, Faculty of Agriculture, Dep. of Industrial Microbiology,E-mail: miomir.niksic@gmail.comOn the 24th of May 2012, at the meeting organised inconjugation with CEFood2012 in Novi Sad, EHEDG Serbiawas founded as a formal organization according to theSerbian Civil Code, with the election of Chairman, Secretary,Treasurer and Members at Large. The regional section isstrongly supported by Serbian Microbiological Society andthe Society for Nutrition and Society for Food Technology.On the 25th September 2012 regional section were ofciallyestablished on the rst Info day-mini Symposium on Hygienicengineering and Design for Food Machinery, organizedin Belgrade in conjunction with Chamber of Commerce ofSerbia. At the meeting EHEDG Treasurer Piet Steenaardand Huub Lelieveld and Regional Section Chairman, Prof Dr.Miomir Niksic signed off the Regional Section By-Laws.Figure 2. Participants at the constitutional meeting EHEDG-Regional Section SerbiaThe Serbian EHEDG Committee will schedule meetingsand training courses to be held quarterly in different regions/cities, probably in conjunction with other regional events.A number of actions at the end of 2012 and in 2013 areplanned, including translation of guidelines, yers, theSerbian version of the EHEDG web-site and we hope to gainever more attention from local companies to disseminatehygienic design issues.ContactFigure 1. Signing the foundation of EHEDG regional section SerbiaAt the symposium several topics were presented by HuubLelieveld and Piet Steenaard including Hygienic design offood factories, Safe use of lubricants in the food industry,Hygienic design of equipment and Management of hygienein food factories. Approximately 50 attendees from differentcompanies, from both food processors and academiaparticipated in this meeting.Professor Miomir NiksicUniversity of BelgradeFaculty of AgricultureDepartment of Industrial MicrobiologyPhone (+381 63) 7 79 85 76E-mail mniksicagrif.bg.ac.rsEHEDG SpainRafael Soro, AINIA Technological Centre, alencia – Spain, e-mail: rsoro@ainia.esThe Spanish Regional Section continues topromote EHEDG activities and to increasethe awareness of hygienic design amongthe Spanish food industry and equipmentmanufacturers.The rst EHEDG event in Spain was in 2001, when the 11thInternational Conference was, for the rst time, combinedwith a Training Workshop on hygienic engineering that washeld in Valencia. The 3-day conference “Food in EuropeBuilding in Safety” was organised by AINIA, and attractedmore than 200 attendees from European food companiesand food equipment manufacturers.Four years later, in 2005, the Spanish Regional Section wascreated under the initiative of AINIA Technological Centre.In the following years, the Spanish Regional section carriedout several activities to spread the requirements of hygienicdesign and EHEDG among Spanish companies. Seminars

EHEDG Regional Sections 149and advanced courses have been organised and heldin Valencia and Barcelona. In 2006, the translation of theEHEDG published guidelines was initiated.A relationship was established with AMEC (Spanish FoodEquipment Manufacturers Association) aiming to disseminateEHEDG activities in Spain. A Spanish EHEDG website wascreated. Ainia has also published several newsletters aboutEHEDG and hygienic design that have been distributedamong most of the Spanish food industries and many foodequipment manufacturers.Recent activitiesDissemination activities have been organized to spreadrelevant information on the EHEDG among Spanish speakingprofessionals. Different communication channels have beenused for this purpose (ainia webpage, Tecnoalimentaliaelectronic bulletin, etc.).Representatives of the Regional Section participated asspeakers with lectures related to the EHEDG and hygienicdesign in 6 events during 2011CED Annual Meeting. Detergency and Cosmetics.Barcelona. Rafael SoroMeeting at FIAB (Association of food and beveragescompanies). Madrid. Andrés PascualJornadas Técnicas sobre el mantenimiento en laIndustria Alimentaria. AEM. Burgos. Irene LlorcaSeminar on clean rooms. AICE (Spanish Association ofthe Meat Industry). Madrid. Rafael SoroFood Safety Master. Veterinary Faculty. Madrid. IreneLlorcaAMEC. Hygienic Design and Food Safety. Barcelona.Rafael SoroThe fourth edition of the Advanced Course on Hygienic Designwas held at Ainia in June 2012. As in previous occasions,both food industries and equipment manufacturers wererepresented among delegates. The 3-day course waspresented from a very practical viewpoint, relating thetheoretical fundamentals of the different subjects to practiceby means of examples on video, pictures, samples and theEHEDG Toolbox. The course included some case studiesthat were developed in a pilot plant and was held by expertsfrom the EHEDG Training & Education Subgroup. Thecourse was given in English and Spanish, with simultaneoustranslation.The process of guideline translation has continued sinceits beginning in 2006. Currently, forty guidelines have beentranslated into Spanish, some of which them are alreadyavailable from the EHEDG website. For some, review is stillpending or the original guideline is being updated.Hygienic design course 2012 at AiniaSince the EHEDG webpage had been translated intoSpanish in previous years, the activity now has turned intoa continuous translation of updated contents. In November2011 a representative of the Regional Section was trainedin webpage management to be able to keep the Spanishlanguage contents updated and contribute with othernational contents. These translation activities are consideredcrucial for the Regional Section since it is a very effectiveway of spreading EHEDG and hygienic design issues notonly in Spain but also in other Spanish speaking countries.EHEDG World Congress on HygienicEngineering and Design 2012 SpainThe EHEDG World Congress 2012 will be held inValencia-Spain, co-organized by EHEDG and ainia CentroTecnológico. More than 20 experts coming from all over theworld will offer lectures on topics related to hygienic designand other hygiene issues.Parallel activities are organised to complement and enrichthe Congress programme. Among others, 1:1 businessmeetings have been arranged to encourage interaction andfuture business relations of the participants, as well as anexhibition area for companies and a posters sessionsarea.The Plenary Meeting of all EHEDG ExCo Members,Regional and Subgroup Chairpersons will take place on thepre-congress day at ainias facilities.More information on the Congress is available at www.ehedg-congress.org.ContactRafael Soro Martorellainia centro tecnológicoc/ Benjanmin Franklin, 5-11Parque Tecnologico de Valencia46980 PATERNA (VALENCIA)SPAINE-mail rsoroainia.es

150 EHEDG Regional SectionsEHEDG SwitzerlandMatthias Schäfer, e-mail: matthias.schaefer@gea.comIt is one of the objectives of the EHEDG Regional SectionSwitzerland to promulgate the knowledge on “HygienicDesign” in Switzerland. Shortly after the foundation ofthe Regional Section, the Regional Committee agreed onfollowing this objective by organising at least one seminar on“Hygienic Design” every year.One seminar was organised in 2010 at the biggest Swissbrewery “Feldschlösschen” belonging to the CarlsbergGroup. More than 100 participants from three differentcountries came to enjoy six presentations on different topicsrelated to “Hygienic Design” and of course also to participatein the brewery tour offered by “Feldschlösschen”.The 2011 seminar was hosted by “Bühler AG” in Switzerland.Our host is the biggest food machinery manufacturer inSwitzerland and also a company member of EHEDG. About90 people joined this seminar to listen to six speakers comingfrom different food business related elds.It has to be mentioned that the EHEDG received great supportfrom “Feldschlössen” and “Bühler” when they were hostingour seminars. Nevertheless it also has to be mentioned thatthe organisation of each seminar was a big effort for oursmall Regional Committee. People have worked hard to putthe programs together and to nd the right speakers andtopics ensuring interesting and attractive lectures.The nancial success of these seminars made it possibleto give a direct nancial support to the work of the EHEDGSubgroup “Cleaning Validation” which is headed byDr. Rudolf Schmitt from the “University of Applied SciencesWestern Switzerland” who also acts as the Chairman of theRegional Section.The next milestone of the development of this RegionalSection was the completion and enhancement of theRegional Committee during the general assembly in 2012. Atotal of nine persons from different industries are now goingto ensure that the successful work will continue. Thank youvery much to all companies and people who have supportedthe work of the Regional Section Switzerland during the pasttwo years. We can be proud that this “just” 4 year old sectionis already such a success story!Contact:Matthias SchäferGEA Tuchenhagen GmbHPhone +41 61 936 37 40, Fax +41 61 936 37 49Mobile +41 79 304 80 43matthias.schaefergea.comSeminar at Bühler AG in Uzwil, Switzerland.EHEDG TaiwanA growing regional section outreaching in Far EastB. Barry Yang, Ph.D., Director, Southern Taiwan Service Center, Food Industry R&D Institute,e-mail: bby@rdi.org.twSeminarEHEDG Taiwan was present at a Hygienic Design Seminar heldby the Bürkert Fluid Control Systems and Food Industry R&D Institute(FIRDI) in October of 2011. At this seminar, Dr. B. Barry Yang,Regional Section Chairman, gave his presentation introducing theEHEDG Guidelines and theirs relative applications. Moreover, anexpert from Bürkert, Mr. Mike Rodd also talked about the importanceof EHEDG and the industrial application of different types ofconnections. Besides, Ms Andrea Borowsky, manager of media &communications of the German Trade Ofce in Taipei also attendedthis seminar to give support to Bürkert as a company of Germanorigin. Approximately 120 attendees from more than 40 companies,both from food processors and the machinery manufacturing industry,participated in this seminar.

EHEDG Regional Sections 151Translation of GuidelinesAt the present time, a total of 27 guidelines have beentranslated into Traditional Chinese. 12 of these are beingcorrected and proofread by experts in their special areas asrequired by these document subjects. These guidelines arescheduled to be submitted for publication by the end of 2012.The translation of the remaining Guidelines is under way.TrainingDr. Yang gave an introduction of EHEDG guidelines at the HygienicDesign SeminarIn order to facilitate training and practice for the hygienicdesign of food process equipment, FIRDI has set up ateam to build a test laboratory for the EHEDG equipmentassessing methods including Doc. 2, Doc. 4, Doc. 5, Doc.7, Doc. 15, Doc. 19, and Doc. 21. The major tasks of thisteam are to demonstrate the hygienic design concept offood equipment and its related validation methods to foodequipment manufacturers and food processing companies.ContactFor more information and if interested in the activities ofEHEDG Taiwan, please contact Dr. B. Barry Yang, Phone+886-6-3847301, e-mail bbyrdi.org.tw.EHEDG ThailandThai Regional SectionNavaphattra Nunak, Taweepol Suesut, King Mongkut’s Institute of Technology Ladkrabang, Faculty of Engineering,Thailand, e-mail: kbnavaph@kmitl.ac.thEHEDG Thailand was established in 2009. The Thai Sectionwas initiated between EHEDG centre and King MongkutsInstitute of Technology Ladkrabang (KMITL). The ThaiSection ofcially started on April 20, 2009. At present, justone Institute member from KMITL is member of EHEDG.However, several industrial companies are interested andattended the activities of the Thai Section.Translation Guideline no. 8 has already been published on EHEDGwebsite. Guidelines no. 1, 11, 27, 28 and 37 have already beentranslated into Thai. Guidelines no. 2, 4, 6, 10, 13, 14, 15, 17, 20, 23,24, 30, 32, 34 and 38 is now in the process of beingtranslated. Website Translation is also now in the process of beingtranslated.EHEDG Thailand Seminar 2012There were two seminars on EHEDG guidelines in 2012. Therst seminar was organised by EHEDG Thailand (KMITL),Kasetsart University and HABLA-Chemie GmbH and CPC-Holding Ltd, at KU, Bangkok on 25th June, 2012 under thetopic of “Update on Environmental-friendly Cleaning andSanitizing in the Food and Beverage Industry and RapidMethods of Assessing Cleaning Efciency” (Fig. 1). Asecond seminar was organized by EHEDG Thailand underthe topic of “Hygienic application of Instruments for FoodIndustry” on July 27, 2012 at KMITL, Bangkok (Fig. 2). About50, 120 participants respectively attended the seminars. Theparticipants could be divided into 4 groups as followsGovernment ofcersTechnical and engineering consultantsOwner and staffs from food factoriesStudents

152 EHEDG Regional SectionsFigure 1. Update on Environmental-friendly Cleaning andSanitizing in the Food and Beverage Industry and Rapid Methodsof assess Cleaning Efciency” (25th June 2012)Figure 2. “Hygienic application of Instruments for Food Industry” on27th, July 2012Contact PersonFor more information and if you are interested in the activitiesof EHEDG Thailand, please contactDr. Navaphattra NunakEmail kbnavaphkmitl.ac.thDr.Taweepol SuesutEmailkstaweepkmitl.ac.thPhone +66 2 3298356-8EHEDG TURKEYDr. Samim Saner, Turkish Food Safety Association (TFSA), Turkey, e-mail: samim.saner@ggd.com.trNews from a new Regional SectionEHEDG Turkey was ofcially established at the 3rd FoodSafety Congress which was held on May 3-4, 2012, inIstanbul. The event was hosted and organized by the TurkishFood Safety Association (TFSA) with about 700 delegatesfrom Turkey and abroad. Dr. Patrick Wouters (Unilever,EHEDG Vice President) and Dirk Nikoleiski (Kraft Foods,EHEDG Executive Committee Member) were invited tolecture during the Hygienic Design Session of the Congressand experienced a lot of interest in their topics.On the second congress day, the EHEDG ‘By-Laws (RegionalSection agreement) were ofcially signed by TFSA PresidentDr. Samim Saner, the Turkish Committee members and theabove mentioned representatives of EHEDG International.Recent ActivitiesEHEDG Turkey has formed its Regional Committee andimmediately started its activities. The translation of theEHEDG website has already been completed. Starting inthe 4th quarter of 2012, EHEDG Turkey is already busilytranslating EHEDG guidelines.An article about the EHEDG and its activities was published inTurkish Food Safety Magazines latest issue. This magazineis distributed to 5000 people consisting of food producers,food engineers, managers, equipment manufacturers andhealth authorities and will help to spread the news aboutEHEDG in Turkey.ContactFor more information and if interested in the activities ofEHEDG Turkey, please contactDr. Samim SanerGida Güvenligi DernegiTFSA - Turkish Food Safety AssociationHasan Amir Sok. Dursoy Is Merkezi No.4KIZILTOPRAK ISTANBUL 34724TURKEYPhone +90 0216 550 02 23 - 550 02 73E-mail samim.sanerggd.org.tr

EHEDG Regional Sections 153EHEDG UkraineProf. Yaroslav Zasyadko, National University of Food Technologies, Kyiv, e-mail: yaroslav@nuft.edu.uaIn the years 2011 to 2012, the Ukrainian Regional EHEDGSection was engaged in a number of projects. As it hasbecome our usual routine, the main effort has been assignedto the translation and adaptations of the EHEDG Guidelinesto the Ukrainian State Standards where applicable. On topof the listed in the previous issue of EHEDG Yearbook, thefollowing Guidelines are ready for publicationDoc. 9 Welding stainless steel to meet hygienicrequirements.Doc. 10 Hygienic design of closed equipment for theprocessing of liquid food.Guidelines Doc. 11 through to Doc. 17 are currently in theprocess of being adaptated to the Ukrainian Standards.We have nalized translation of the EHEDG webpage intoUkrainian and also developed a website of the UkrainianRegional EHEDG Section linked to the main EHEDG website.The Ukrainian Regional EHEDG Section has developeda program of teaching materials including a syllabus ofthe MS lecture course “Food Safety and Hygienic Designand Operation of Food Manufacturing Equipment”. The 18hours course contains a brief account of food contaminationsources, case studies, and practical examples. The coursealso contains the EHEDG cleanability testing procedurelm subtitled in Ukrainian and Russian. The course will beintroduced at the National University of Food Technologies(Kyiv) for MS students majoring in Mechanical Engineeringin 2013 year.During this period we have held three EHEDG-UkrUFoSTConferences aimed at strengthening our relations withthe industry, engagement of new members, and thepopularisation of EHEDG practices.At the Conference held on April 4, we presented theGuidelines that had been properly prepared for publicationand explained the procedure of EHEDG Certication to therepresentatives of the industry.In September 2012, the Ukrainian Regional EHEDG Sectionbecame a co-organizer of the Round Table which wasconducted within a framework of the National ExhibitionINTERPRODMASH. The issues of the EHEDG activities inthe EU and in Ukraine were among the topics discussed atthe Round Table. The representatives of Dutch companiesactive in Ukraine with their presentations paid specialattention to the necessity to comply with the EHEDGGuidelines on every stage of the technological process.Huub Lilieveld, honorary representative of the EHEDG,co-chaired the event together with Professor YaroslavZasyadko, Ukrainian Regional EHEDG Section ExecutiveDirector, and gave comprehensive presentations describingthe EHEDG activities.Recently, we have established a number of useful contactswith the industry and with the National Certication Bodies.UkrEHEDG were invited to give a presentation depictingthe EU Food Safety Regulations and Legal Practices andthe EHEGD activities by the Ukrainian State EnterpriseUKRMETROTESTSTANDARD which is the main UkrainianBody responsible for all aspects of certication, testing andstandardisation of food products in Ukraine. As a result ofthe meeting we have jointly marked some steps that maylead to common projects in the future.Figure 1. The Round Table event. Co-chairs Huub Lelieveld andYaroslav ZasyadkoFigure 2. Yaroslav Zasyadko giving presentation about the EHEDGactivities at the SE UkrMETRTESTSTANDARDContactProf. Yaroslav ZasyadkoNational University of Food Technologies Kyiv68, Volodymyrska Str.01033 KYIVUKRAINEE-mail yaroslavnuft.edu.ua

European Hygienic Engineering & Design GroupEHEDG GuidelinesEHEDG Guidelines can be ordered from the Webshopby non-members and individual members. They arefree for EHEDG Company and Institute Members whileIndividual EHEDG Members receive a 50 % discount.Doc. 1. Microbiologically safe continuouspasteurisation of liquid foodsFirst edition, November 1992 (17 pages)There are many reasons why, in practice pasteurised productssometimes present a microbiological health hazard. Due todistribution in residence time, not all products may reach thetemperature required for pasteurisation or may do so for tooshort a time. Further there may be a risk of contaminationwith a non-pasteurised product, or the cooling medium. Thisdocument describes the requirements particularly for liquidfoods without particulates.Languages availableDutch, English, French, Spanish, UkrainianDoc. 2. A method for assessing the in-placecleanability of food processing equipmentThird edition, June 2007 (16 pages)The method is intended as a screening test for hygienicequipment design and is not indicative of the performanceof industrial cleaning processes (which depend on thetype of soil). See Doc 15 for a test procedure designed formoderately-sized equipment.Training DVD available.Languages available Armenian, Dutch, English,French, German, Italian, Macedonian, Russian,SpanishDoc. 3. Microbiologically safe asepticpacking of food productsFirst edition, January 1993 (15 pages)This guideline stresses the need to identify the sources ofThis guideline stresses the need to identify the sources ofmicro-organisms that may contaminate food in the packagingprocess, and to determine which contamination rates areacceptably low. It claries the difference in risk of infectionbetween aseptic processing and aseptic packing andrecommends that aseptic packing machines be equipped withllers that are easily cleanable, suitable for decontaminationand bacteria-tight. Requirements for the machine interiorinclude monitoring of critical decontamination parameters.See also Doc. 21 on challenge tests.Languages availableArmenian, Dutch, English, French, Spanish,UkrainianDoc. 4. A method for the assessment ofin-line pasteurisation of food processingequipmentFirst edition, February 1993 (12 pages)Food processing equipment that cannot be or does not needto be sterilised may need to be pasteurised to inactivaterelevant vegetative micro-organisms and fungal spores.It is important to test the hygienic characteristics of suchequipment to ensure that it can be pasteurised effectively.This document describes a test procedure to determinewhether equipment can be pasteurised by circulation withhot water.Training DVD available.Languages available Armenian, Dutch, English,French, Spanish, UkrainianDoc. 5. A method for the assessment ofin-line sterilisability of food processingequipmentSecond edition, July 2004 (9 pages)Food processing equipment may need to be sterilised beforeuse, and it is important to ensure that the sterilisation methodapplied is effective. Thus, it is necessary to determine underwhich conditions equipment can be sterilised. This paperdetails the recommended procedure for assessing thesuitability of an item of food processing equipment for in-linesterilisation. It is advisable to conduct in-place cleanabilitytrials (ref. Doc.2) prior to this test in order to verify thehygienic design of the equipment.Training DVD available.Languages available Armenian, Dutch, English,French, German, Macedonian, Spanish,UkrainianDoc. 6. The microbiologically safe continuousow thermal sterilisation of liquid foodsFirst edition, April 1993 (26 pages)Thermal sterilisation is aimed at eliminating the risk of foodpoisoning and, when used in conjunction with aseptic lling,at achieving extended product storage life under ambientconditions. Whereas pasteurisation destroys vegetativemicro-organisms, sterilisation destroys both vegetativemicro-organisms and relevant bacterial spores. Thisdocument presents guidelines on the microbiologically safecontinuous sterilisation of liquid products. The technique ofOhmic heating was not considered in this paper but maybe included in an update being prepared. See Doc. 1 forguidelines on continuous pasteurisation of liquid foods.Training DVD available.Languages available Armenian, Dutch, English,French, Macedonian, Spanish, Ukrainian

EHEDG Guidelines 155Doc. 7. A method for the assessmentof bacteria tightness of food processingequipmentSecond edition, July 2004 (10 pages)This document details the test procedure for assessingwhether an item of food processing equipment, intendedfor aseptic operation, is impermeable to micro-organisms.Small motile bacteria penetrate far more easily throughmicroscopic passages than (non-motile) moulds and yeasts.The facultative anaerobic bacterium Serratia marcescens(CBS 291.93) is therefore used to test bacteria-tightness orthe impermeability of equipment to micro-organisms. Themethod is suitable for equipment that is already known to bein-line steam sterilisable (see also Doc. 5).Training DVD available.Languages available Armenian, Dutch, English,French, Spanish, UkrainianDoc. 8. Hygienic equipment designcriteriaSecond edition, April 2004 (16 pages)This guideline describes the criteria for the hygienic designof equipment intended for the processing of foods. Itsfundamental objective is the prevention of the microbialcontamination of food products. It is intended to appraisequalied engineers who design equipment for food processingwith the additional demands of hygienic engineering in orderto ensure the microbiological safety of the end product.Upgrading an existing design to meet hygiene requirementscan be prohibitively expensive and may be unsuccessfuland so these are most effectively incorporated into the initialdesign stage. The long term benets of doing so are notonly product safety but also increased life expectancy ofequipment, reduced maintenance and consequently loweroperating costs.This document, rst published in 1993, describes inmore detail the hygienic requirements of the MachineryDirective (98/37/EC ref.1). Parts of it have subsequentlybeen incorporated in the standards EN1672-2 and EN ISO14159.Training DVD availableLanguages available Armenian, Dutch, English,French, German, Italian, Japanese, Macedonian,Russian, Spanish, Thai, UkrainianDoc. 9. Welding stainless steel to meethygienic requirementsFirst edition, July 1993 (21 pages) – update in progresssince 2010 in conjunction with Doc. 35This document describes the techniques required toproduce hygienically acceptable welds in thin walled (< 3mm) stainless steel applications. The main objective wasto convey the reasons and requirements for hygienicwelding and to provide information on how this may bestbe achieved. This document is superseded by Doc 35,recently published. The subgroup will continue with aguideline on inspection of the quality of welds in foodprocessing machinery.Training DVD availableLanguages available Dutch, English, French,Japanese, Macedonian, Spanish, UkrainianDoc. 10. Hygienic design of closedequipment for the processing of liquid foodSecond edition, May 2007 (22 pages)Using the general criteria for the hygienic design of equipmentidentied in Doc 8, this paper illustrates the application ofthese criteria in the construction and fabrication of closedprocess equipment. Examples, with drawings, show howto avoid crevices, shadow zones and areas with stagnatingproduct, and how to connect and position equipment in aprocess line to ensure unhampered draining and cleaningin-place. Attention is drawn to ways of preventing problemswith joints, which might otherwise cause leakage orcontamination of product.Training DVD availableLanguages available Dutch, English, French,German, Italian, Macedonian, Russian,UkrainianDoc. 11. Hygienic packing of food productsFirst edition, December 1993 (15 pages)Products with a short shelf-life, or whose shelf life isextended by cold storage or in-pack heat treatments, do nothave to conform to such strict microbiological requirementsas aseptically packaged foods (Doc 3 discusses asepticpacking). This paper discusses the packing of food productsthat do not need aseptic packing but which neverthelessneed to be protected against unacceptable microbialcontamination. It describes guidelines for the hygienicdesign of packing machines, the handling of packingmaterials and the environment of the packing machines.See also Doc. 21.Languages availableDutch, English, French, Spanish, Thai, UkrainianDoc. 12. The continuous or semi-continuousow thermal treatment of particulate foodsFirst edition, March 1994 (28 pages)Thermal sterilisation is a process aimed at eliminating therisk of food poisoning and, when used in conjunction withaseptic lling, it aims to extend product storage life underambient conditions. This is achieved by the destruction ofvegetative micro-organisms and relevant bacterial spores.Liquid foods containing particulates are inherently moredifcult to process than homogenous liquids due to heattransfer limitations in particulate-liquid mixtures and theadditional problems of transport and handling. This paperpresents guidelines on the design of continuous and semi-

156 EHEDG Guidelinescontinuous plants for the heat treatment of particulate foods.Ohmic heating techniques are not covered. See also Doc. 1on continuous pasteurisation and Doc. 6 on sterilisation ofliquid products without particles.Languages availableDutch, English, French, Spanish, UkrainianDoc. 13. Hygienic design of equipmentfor open processingSecond edition, May 2004 (24 pages) –update to be published in 2013It is important that the plant design takes into accountfactors affecting the hygienic operation and cleanability ofthe plant. The risk of contamination of food products duringopen processing increases with the with the concentrationof micro-organisms in the environment and their opportunityto grow in poorly designed equipment. This means thatin open plants, environmental conditions, in addition toappropriate equipment design, have an important inuenceon hygienic operation. The type of product and the stageof the manufacturing process must also be taken intoconsideration.This paper deals with the principal hygienic requirements forequipment for open processing and applies to many differenttypes, including machines for the preparation of dairyproducts, alcoholic and non-alcoholic drinks, sweet oils,coffee products, cereals, vegetables, fruit, bakery products,meat and sh. It describes methods of construction andfabrication, giving examples as to how the principal criteriacan be met. See also guidelines on hygienic design criteriaDoc 8, hygienic welding Doc 9, and the hygienic design ofequipment for closed processing Doc 10.)Languages availableDutch, English, French, German, Italian,Japanese, Macedonian, UkrainianDoc. 14. Hygienic design of valves forfood processingSecond edition, July 2004 (17 pages) –update in progress since 2009Valves are essential components of all food processing plantsand the quality used strongly inuences the microbiologicalsafety of the food production process. These valves musttherefore comply with strict hygienic requirementsThe guidelines apply to all valves used in contact with foodor food constituents that are to be processed hygienicallyor aseptically. Aside from general requirements with regardto materials, drainability, microbial impermeability and otheraspects, additional requirements for specic valve types arealso described. See also Doc. 20 on double-seat mixproofvalves.Training DVD available.Languages available Dutch, English, French,Italian, Macedonian, SpanishDoc. 15. A method for the assessment ofin-place cleanability of moderately-sized foodprocessing equipmentFirst edition, February 1997 (12 pages)This document describes a test procedure for assessingthe in-place cleanability of moderately sized equipment,such as homogenisers. The degree of cleanliness is basedon the removal of a fat spread soil, and is assessed byevaluating the amount of soil remaining after cleaning byvisual inspection and swabbing of the surface. This methodis not as sensitive as the microbiological method describedin Doc. 2.Languages availableArmenian, Dutch, English, German, Macedonian,Spanish, UkrainianDoc. 16. Hygienic pipe couplingsFirst edition, September 1997 (21 pages)This paper identies and denes critical design parametersfor welded pipe couplings easily cleanable in-place; easilysterilisable in place; impervious to micro-organisms, reliableand easy to install.Gaskets of various types were tested for reliability andhygienic aspects using EHEDG cleanability test methodsand repeated sterilisation. The objective was to provide areliable dismountable joint which is bacteria-tight at theproduct side under the conditions of processing, cleaningand sanitation.Training DVD available.Languages available English, French, German,UkrainianDoc. 17. Hygienic design of pumps,homogenisers and dampening devicesSecond edition, September 2004 (16 pages) -update to be published in 2013This paper sets the minimum requirements for pumps,homogenisers and dampening devices for hygienicand aseptic applications. The scope includes all pumpsintended for use in food processing, including centrifugal,piston, lobe rotor, diaphragm, screw and gear pumps. Therequirements also apply to valves integral to the pumphead and the complete homogeniser head. Design aspectsand the characteristics of materials, surfaces and sealsare discussed and additional requirements for asepticequipment are identied. This document is currently beingupdated.Training DVD available.Languages available English, French, German,Italian, Macedonian

EHEDG Guidelines 157Doc. 18. Passivation of stainless steelFirst edition, August 1998 (13 pages) –update to be published in 2013Passivation is an important surface treatment that helpsassure the successful corrosion resistant performance ofstainless steel used for product contact surfaces (eg. tubing/piping, tanks and machined parts used in pumps, valves,homogenisers, de-aerators, process monitoring instruments,blenders, dryers, conveyors, etc).The purpose of this document is to provide manufacturers,users and regulatory personnel with basic information andguidelines relative to equipment passivation. The completepassivation process is described and environmental, as wellas safety, concerns are discussed.Training DVD available.Languages available Armenian, Dutch, English,French, German, Macedonian, Russian,Spanish,Doc. 19. A method for assessingthe bacterial impermeability of hydrophobicmembrane ltersFirst edition, June 2000 (9 pages)Research has shown that hydrophobic membrane lters,with a pore size of 0.22μm, do not retain micro-organismsunder all process conditions. Investigations were conductedinto risk assessment of sterilising hydrophobic membranelters, evaluating the performance of the lters under arange of operating conditions.To validate the bacterial retention ability of sterilising gradehydrophobic membrane lters, a bacterial aerosol challengetest methodology was developed.Languages availableDutch, English, SpanishDoc. 20. Hygienic design and safe use ofdouble-seat mixproof valvesFirst edition, July 2000 (20 pages) –update in progress since 2009This document describes the basic hygienic design andsafe use of single-body double-seat mixproof valves. Today,food process plants incorporate various multifunctional owpaths. Often one piping system is cleaned while anotherstill contains product. This simultaneous cleaning canpotentially result in the dangerous situation where productand cleaning liquid are separated by just one single valveseat. Any cleaning liquid that leaks across such a seat willcontaminate the product. Therefore, often two or threesingle seat valves in a “block-and-bleed” arrangement areapplied.Training DVD available.Languages available Dutch, English, French,Japanese, Macedonian, RussianDoc. 21. Challenge tests for theevaluation of the hygieniccharacteristics of packing machinesfor liquid and semi-liquid productsFirst edition, July 2000 (32 pages)After documents 3 and 11, this is the third test methodin the series. It discusses how packing machines shouldbe designed to comply with hygiene design criteria andthereby with the requirements specied in Annex 1 of theMachinery Directive1. To determine whether those criteriaare met requires validation of the design and measurementof essential parameters. Proven methods for testing theperformance of the various functions of packing machinesare described.These methods may also be used by the manufacturer tooptimise or redesign a packing machine and by the foodprocessor who may want to compare different packingmachines.Upon delivery, a packing machine needs to be checked by acommissioning procedure to be agreed in advance betweenthe food processor and the supplier. Commissioning mayinclude physical as well as microbiological tests. Additionaltests are specied for commissioning of machines foraseptic packing.1 Machinery Directive 98/37/EC – Annex 1, point 2.1, AgrifoodstuffsmachineryLanguages availableArmenian, English, French, Macedonian,Russian, SpanishDoc. 22. General hygienic design criteriafor the safe processing of dry particulatematerialsFirst edition, March 2001 (23 pages) –update in progress since 2012Dry food processing and handling requires equipment thatare different from those typically associated with wet andliquid products. This is the rst in a series of documentsthat go beyond equipment design and covers installationand associated practices. In the case of dry materials, otherconsiderations include material lump formation, creation ofdust explosion conditions, high moisture deposit, formationin the presence of hot air, and material remaining in theequipment after shutdown. Appropriate cleaning proceduresare described, dry cleaning being favoured to reduce risksof contamination.Languages availableDutch, English, French, Macedonian, Russian,Spanish

158 EHEDG GuidelinesDoc. 23. Production and use of food-gradelubricants, Part 1 and 2Second edition, May 2009 (Part 1: Use of H1Registered Lubricants - 23 Pages / Part 2: Productionof H1 Registered Lubricants - 10 Pages)Lubricants, grease and oil are necessary componentsfor the lubrication, heat transfer, power transmissionand corrosion protection of machinery, machine parts,instruments and equipment. Incidental contact betweenlubricants and food cannot always be fully excluded andmay result in contamination of the food product. This riskapplies to all lubricants equally. PART 1 of this guidelinecovers the hazards that may occur when using food gradelubricants and describes the actions and activities requiredto eliminate them or to reduce their impact or occurrenceto an acceptable level. PART 2 of this guideline laysdown the general requirements and recommendationsfor the hygienic manufacturing and supply of food-safelubricants.Training DVD available.Languages available Dutch, English, French,German, Japanese, Macedonian, SpanishDoc. 24. The prevention and control oflegionella spp (incl. legionnaires’ disease)in food factoriesFirst edition, August 2002 (21 pages)There are many locations in food industry sites where thepotential for the proliferation of Legionella spp in watersystems exists. These bacteria can give rise to a potentiallyfatal disease in humans, which is identied as legionellosisor legionnaires disease.This document applies to the control of Legionella spp. inany undertaking involving a work activity and to premisescontrolled in connection with a trade, business or otherundertaking where water is used or stored and where thereis a means of transmitting water droplets which may beinhaled, thereby causing a reasonably foreseeable risk ofexposure to Legionella spp.The guidelines summarises the best practice for controllingLegionella in water systems. It consists of two parts; namely,Management Practices and Guidance on the Control ofLegionella spp. in Water Systems.The rst section describes a management programmerisk identication and assessment; risk management (inclpersonnel responsibilities); preventing or controlling risk ofexposure to the bacteria; and record keeping.The second part provides guidance on the design andconstruction of hot and cold water systems as well as themanagement and monitoring of these systems. Watertreatment programmes, with attention to cleaning anddisinfection, are also discussed.Languages availableDutch, English, MacedonianDoc. 25. Design of mechanical seals forhygienic and aseptic applicationsFirst edition, August 2002 (15 pages) –update in progress since 2012This guideline compares the design aspects of differentmechanical seals with respect to ease of cleaning, microbialimpermeability, sterilisability or pasteurisability. It canserve as a guide for suppliers and users of this importantcomponent. Using EHEDG denitions, mechanical sealsare classied according to use in the food industry intothree categories Aseptic, Hygienic equipment Class I,and Hygienic Equipment Class II. Both single and dualmechanical seals fall under the rst two categories, which bydenition, are subject to more stringent hygienic demands.General design criteria and basic material requirements forfood applications are explained. Materials covered includecarbon-graphite, ceramics, elastomers and metals. Hygienicimplications of seal elements and components are alsodiscussed. Finally, installation requirements are describedand illustrated, taking into account the product environmentside, the ushing side and the cartridge design.Languages availableArmenian, English, GermanDoc. 26. Hygienic engineering of plants forthe processing of dry particulate materialsFirst edition, November 2003 (30 pages)This document describes general engineering guidelinesto be applied to ensure that buildings, individual equipmentitems and accessibility of equipment when integrated withinthe plant layout are designed so that aspects of the processoperation, cleaning and maintenance comply with hygienicdesign standards. It details requirements related to plantenclosure, including hygienic zoning, building structuresand elements (from oor to ceiling) as well as process lineinstallation. Attention is also given to air stream and waterrelated aspects within the plant as well as cleaning andcontamination aspects. See also Doc. 22.Languages availableDutch, English, French, Macedonian, SpanishDoc. 27. Safe storage and distribution ofwater in food factoriesFirst edition, April 2004 (16 pages)Water is a vital medium used for many different purposes inthe food industry. Systems for storing and distributing watercan involve hazards, which could cause water quality to fallbelow acceptable standards. It is therefore critical to ensurethat water storage and distribution in a food manufacturingoperation takes place in a controlled, safe way. This Guidelinesummarizes the best practice for three water categoriesused in the food industry product water, domestic water andutility water. See also Doc. 24.Languages availableArmenian, Dutch, English, French, Macedonian,Spanish

EHEDG Guidelines 159Doc. 28. Safe and Hygienic Water Treatmentin Food FactoriesFirst edition, December 2004 (21 pages)Water is a vital medium used for many different purposesin the food industry. Systems for storing and distributingwater can involve hazards, which could cause water qualityto fall below acceptable standards. It is therefore criticalto ensure that water storage and distribution in a foodmanufacturing operation takes place in a controlled, safeway. This Guideline summarizes the best practice for threewater categories used in the food industry product water,domestic water and utility water. See also Doc. 24.Languages availableArmenian, English, French, SpanishDoc. 29. Hygienic design of packing systemsfor solid foodstuffsFirst edition, December 2004 (24 pages)This document addresses packing systems of solid foodproducts and supplements earlier guidelines. Solid foodis characterised as having a water activity of >0.97, lowacid, not pasteurised or sterilised after packaging, anddistributed through the cool chain. Examples include freshmeat and some meat products, cheeses, ready meals, cutvegetables, etc. Hygiene requirements of the packagingoperations, machinery as well as personnel, are describedand reference is made to the American Meat Institutesprinciples of sanitary design. See also Docs. 3 and 11.Languages availableArmenian, Dutch, English, MacedonianDoc. 30. Guidelines on air handlingin the food industryFirst edition, March 2005 (43 pages) –update in progress since 2012The controlled properties of air, especially temperature andhumidity, may be used to prevent or reduce the growth rateof some micro-organisms in manufacturing and storageareas. The particle content - dust and micro-organisms -can also be controlled to limit the risk of productcontamination and hence contribute to safe foodmanufacture. Airborne contaminants are commonlyremoved by ltration. The extent and rate of their removalcan be adjusted according to acceptable risks of productcontamination and also in response to any need for dustcontrol.These guidelines are intended to assist food producersin the design, selection, installation, and operation of airhandling systems. Information is provided on the role ofair systems in maintaining and achieving microbiologicalstandards in food products. The guidelines cover thechoice of systems, ltration types, system concepts,construction, maintenance, sanitation, testing,commissioning, validation and system monitoring. Theyare not intended to be a specication for construction ofany item of equipment installed as part of an air handlingsystem. Each installation needs to take account of localrequirements and specialist air quality engineers shouldbe consulted, to assist in the design and operation of theequipment.Languages availableArmenian, English, MacedonianDoc. 31. Hygienic engineering of uid bedand spray dryer plantsFirst edition, May 2005 (19 pages)Because these plants handle moist products in an airbornestate, they are susceptible to hygiene risks, includinga possible transfer of allergens between products. It istherefore critical to apply hygienic design considerations toboth the process and machinery to prevent occurrence ofsuch risks.Starting from the basics with regard to design, constructionmaterials, layout, and zone classication of the dryingsystems to meet hygienic requirements, this paper outlinescomponent design aspects of the processing chamber, withparticular attention to the atomization assembly and thedistribution grids for uidization. Systems for both supplyand exhaust air should operate in a hygienic manner andrecommendations for the use and installation of varioustypes of lters are listed. Finally, operational aspects,including sampling, control and general housekeeping arebriey discussed.Languages availableDutch, English, SpanishDoc. 32. Materials of construction forequipment in contact with foodFirst edition, August 2005 (48 pages) –update in progress since 2012This guideline aims to offer a practical ‘handbook for thoseresponsible for the specication, design and manufacture offood processing equipment. It offers guidance on the ways inwhich materials may behave such that they can be selectedand used as effectively as possible. The properties andselection procedures with regard to metals, elastomers andplastics are covered in detail. Potential failure mechanismsand inuenced of manufacturing processes are alsodiscussed. A more general overview of composites, ceramicsand glass and materials is provided.The guideline can serve as an aide-memoir during the designprocess, so that equipment manufacturers and end-userscan together ensure that all aspects of materials behaviourare taken into account in designing safe, hygienic, reliableand efcient equipment which can be operated, maintainedand managed economically.Training DVD available.Languages available Armenian, English, French,Italian, Macedonian

160 EHEDG GuidelinesDoc. 33. Hygienic engineering ofdischarging systems for dry particulatematerialsFirst edition, September 2005 (16 pages)The introduction of the product into the processing systemis a key step in maintaining the sanitation and integrity ofthe entire process. Discharging systems are designed totransfer, in this case dry solids, from one system into anotherwithout powder spillage, contamination or environmentalpollution. Many dry systems do not have any additionalprotective heating steps, as they are merely specialtyblending processes. Therefore, any contamination thatenters the system will appear in the nished product.Guidelines for the design of bag, big bag, container andtruck discharging systems are presented. They are intendedfor use by persons involved in the design, sizing, andinstallation of bag, big bag and truck discharging systemsoperating under hygienic conditions.Languages availableDutch, English, SpanishDoc. 34. Integration of hygienic andaseptic systemsFirst edition, March 2006 (45 pages)Hygienic and/or aseptic systems comprise inter aliaindividual components, machinery, measurement systems,management systems and automation that are used toproduce for example food products, medicines, cosmetics,home & personal products and even water products.This horizontal guideline is about the hygienically safeintegration of hygienic (including aseptic) systems in a foodproduction/ processing facility.Systems and components are frequently put together in away that creates new hazards, especially microbiologicalones. Deciencies during the sequence of design,contract, design-change, fabrication, installation andcommissioning are often the cause of these failures,even when specic design guidelines are available andare thought to be well understood. Errors in sequencingand content can also result in major penalties in termsof delays and in costs of components and construction.This document examines integration aspects that canaffect hygienic design, installation, operation, automation,cleaning and maintenance and uses system ow chartsand case studies describing the integration processes anddecision steps. It does not provide detailed guidance onspecic manufacturing processes, products, buildings orequipment.Training DVD available.Languages available Armenian, English, Italian,MacedonianDoc. 35 Welding of stainless steel tubingin the food industryFirst edition, July 2006 (29 pages) - update in progresssince 2010 in conjunction with Doc. 9Abundantly illustrated, this paper provides guidelines forthe correct execution of on-axis hygienic (sanitary) weldingbetween pipe segments, or between a tube and a controlcomponent (e.g. valve, ow meter, instrument tee, etc.) Itdeals with tube and pipe systems with less than 3.5 mm wallthickness, built in AISI 304(L) (1.4301, 1.4306 or 1.4307),316(L) (1.4401, 1.4404 or 1.4435), 316Ti (1.4571) or 904L(1.4539) and their equivalents. The requirements for aweld destined for hygienic uses are rst described, thenthe possible defects which can affect the weld are listed,and at the end the procedure for a state-of-the-art weldingexecution is illustrated, including preparation of pipe ends,nal inspection and a trouble shooting guide.It mainly refers to the part of the weld in contact with thenished or intermediate product and the only welding methodconsidered is the GTAW (Gas Tungsten Arc Welding,commonly known as TIG) without ller material (autogenousweld), since this technique is capable of assuring the bestperformance in the execution of welds for the fabrication ofthin wall stainless steel tubing. Inspection of welds will becovered in more detail in the next project.Training DVD available.Languages available Dutch, English, French,German, Macedonian, SpanishDoc. 36. Hygienic engineering of transfersystems for dry particulate materialsFirst edition, June 2007 (21 pages)Transfer (also known as transport or conveying) of dryparticulate materials (products) between or within plantcomponents in a process line is well practiced in the foodindustry. The transfer operation must be carried out ina hygienic and safe manner and the physical powderproperties must not be affected during this operation. In thisdocument, hygienic transfer systems for transport of bulkmaterials within a food processing plant are described. Thisdocument also covers situations where transfer systems areused as a dosing procedure.In principle, the less the need for product transfer withina food processing plant, the easier it is to make a factoryhygienically safe. Furthermore, with a minimum of producttransfer between equipment, there are the added advantagesof a more compact plant, lower energy consumption andreduced cleaning time. Less product handling results in lessadverse effects on product properties.This guideline is intended for use by persons involved inthe design, technical specication, installation and use oftransfer systems for dry bulk particulate materials operatingunder hygienic conditions.Languages availableDutch, English, French, Macedonian

EHEDG Guidelines 161Doc. 37. Hygienic design and applicationof sensorsFirst edition, November 2007 (35 pages)According to their working principles, all sensors rely on aninteraction with the material to be processed. Therefore, theuse of sensors is commonly associated with hygiene risks.In many cases, the basic measuring aspect of a sensor andthe optimum hygienic design may conict.This guideline is intended to advise both, sensor designersand manufacturers as well as those in charge of productionmachinery, plants and processes about the appropriatechoice of sensors and the most suitable way for applicationin dry and wet processes.Sensors are crucial in the monitoring of the critical processsteps as well as the CCP´s as established by the HACCPstudy of the process. Therefore validation and calibration ofsensors in time sequences are essential.This guideline applies to all sensors coming into contactwith liquids and other products to be processed hygienically.However, it focuses upon sensors for the most commonprocess parameters, particularly temperature, pressure,conductivity, ow, level, pH value, dissolved oxygenconcentration and optical systems like turbidity or colourmeasurements.Languages availableEnglish, French, German, MacedonianDoc. 38. Hygienic engineering of rotaryvalves in process lines for dry particulatematerialsFirst edition, September 2007 (13 pages)Rotary valve selection and operation has a considerableinuence on the hygiene standard of a process line andthus, the end-product quality of the dry material handled.Incorrect selection of valve type and size must be regardedas a serious hygienic risk in the food industry. Hence, onlyvalves strictly conforming to hygienic design standardsand suited for hygienic operations must be used.This guideline applies to rotary valves that are in contactwith dry particulate food and/or food related materialsbeing processed hygienically in designated dry particulatematerial processing areas. The objective of this guidelineis to provide guidance on the essential requirements forhygienic rotary valve design and operation. The guidelineis intended for persons involved in the design, selection,sizing, installation and maintenance of rotary valvesrequired to operate under hygienic conditions.Languages availableArmenian, English, French, SpanishDoc. 39. Design principles forequipment and process areas foraseptic food manufacturingFirst edition, June 2009 (14 pages)In many areas there is an increasing demand for self stableproducts. However, microbial product contamination limitsthe shelf life of sensitive products which are not protected byany preservatives or stabilised by their formulation. Productswhich fail this inherent protection have to be sterilisedand in consequence, the equipment must be cleanableand sterilisable. Micro-organisms which are protected byproduct residues or biolms are very difcult or impossibleto inactivate and the same applies to process areas ifresulting in a recontamination risk. This guideline is intendedto describe the basic demands for equipment and processareas for aseptic food manufacturing.Languages availableEnglish, French, SpanishDoc. 40. Hygienic engineering of valvesin process lines for dry particulate materialsFirst edition, October 2010 (26 pages)Every process plant is equipped with valves. In dryparticulate materials processing, valves full numerousfunctions shut-off and opening of ow lines, direction andow control, protection against excessive or insufcientpressure and against intermixing of incompatible mediaat intersection points in the process. The quality of thevalve has a considerable inuence on the quality of theproduction process and hence, the product itself. Hygienicdeciencies resulting from poor valve design must beregarded as a production risk in the food industry whichmust ensure that only valves strictly conforming to hygienicrequirements are used. This Guideline describes in detailthe hygienic requirements of buttery valves, slide gatevalves and ball segment valves. It also briey mentionspinch-off valves, ball and plug valves as well as conevalves. The hygienic design requirements of rotary anddiverter valves are subject of separate EHEDG Documents(Doc. 38 and 41).Languages availableEnglish, French, SpanishDoc. 41. Hygienic engineering of divertervalves in process lines for dry particulatematerialsFirst edition, February 2011 (23 pages)Every process plant is equipped with valves, which fullnumerous functions. These include line shut-off, opening,change-over and control of product ow, while also givingprotection against both excessive or insufcient pressureand intermixing of incompatible media at intersection pointsin the process line.

162 EHEDG GuidelinesWhen dry particulate material (product) ow has to bediverted into several directions during processing or productcoming from different lines converges into one line, divertervalves are applied. In the area of dry product handling, thesevalves need a dedicated design.This Guideline deals with the hygienic aspects of divertervalve design.Valve construction, however, has a considerable inuence onthe quality of the production process and hence, the productitself. Hygienic deciencies resulting from poor valve designmust be regarded as a production risk in the food industrywhich must ensure that only valves strictly conforming tohygienic requirements are used.Languages availableEnglishThis guideline covers the hygienic aspects of disc stackcentrifuges used to separate fractions of liquid food productsor to remove dense solid matter from products. The hygienicoperation of a disc stack centrifuge, which is a complexmachine with the purpose of collecting non-milk-solids(NMS) or other solid matter from liquid products, relies onproper cleaning by CIP/COP. Therefore, this guideline dealswith cleaning as well as design.The guideline does not cover cyclonic types of separators,decanters, basket centrifuges or other types of devices.Languages availableEnglishDoc. 42. Disc stack centrifugesFirst edition, April 2013 (24 pages)Special demands are made with regard to CIP-capabilityof disc stack centrifuges used in the food processingand pharmaceutical industry. These requirements, theirimplementation and related design principles are handled indetail in this guideline.Webshop:http//www.world-of-engineering.eu/EHEDG390.html

EHEDG Guidelines 163EHEDG CongressesShare our know-how and enhance your hygienic design network!The EHEDG World Congress on Hygienic Engineering& Design from 7 – 8 November 2012 in Valencia / Spainwas a gathering of more than 260 delegates from 24countries world-wide who are decision makers, foodsafety and quality specialists, engineers and designersas well as other high level representatives of food-relatedindustries and academia. During 25 lectures varioustopics were discussed including the role that EHEDGplays to help ensuring food safety, e. g. the principlesand latest developments in hygienic equipment andfactory design, the layout of a hygienic processenvironment and the adequate use of constructionmaterials, advanced welding technology, EHEDG testmethods and certication as well as new trends incleaning and disinfection.Sponsoring companies found excellent opportunitiesfor presenting themselves at the congress venue of theChamber of Commerce Valencia and the programmewas enriched by scientic poster presentations, One toOne business meetings, face-to-face expert talks andmany opportunities for experience exchange.The next opportunity for sharing in this high-level expert platform will be theEHEDG World Congresson Hygienic Engineering & Designfrom 30-31 October 2014 in Parma/Italyin conjunction with Cibus Tec.We kindly invite you to participate and details are available from www.ehedg-congress.org.

European Hygienic Engineering & Design GroupEHEDG SubgroupsWithin the EHEDG a number of international experts gathered in Subgroups are responsible forthe development of Guidelines. Each Subgroup is responsible for an area of expertise, and withineach area certain specic scopes are dened.The EHEDG Subgroup specialists meet regularly to updateexisting and draw up new Guidelines. They originate frommany different countries ensuring the international validity ofthe work. Participants with the relevant expertise are alwayswelcome to join these Subgroups and share in the work andcontribute their expertise and point of view.EHEDG is grateful for the participation of these volunteerswho share their expertise and invest their time for theadvancement of EHEDG – for the good of all. Without theseexcellent specialists the good work of EHEDG would not bepossible as it is.New guidelines still in the process of beingdrawn up are Building design Cleaning validation Conveyor systems Hygienic design requirements for the processing offresh sh Meat processing between slaughtering and packaging Seals Test methods /Test institutes Dry Materials Handling Bakery Equipment Tank cleaning systemsCurrently under revision:Hygienic design of equipment for open processing(Doc. 13) Hygienic design of valves for food processing (Doc. 14and 20)Design of mechanical seals for hygienic and asepticapplications (Doc 25)Chemical treatment of stainless steel (to substituteDoc 18 Passivation of stainless steel)Materials of construction for equipment in contact withfood (Doc 32)Hygienic welding of stainless steel tubing in the foodprocessing industry (Doc 9 and 35)Guidelines on air handling in the food industry(Doc 30)The following guideline topics are currentlybeing planned: CIP / Hygienic brushes Food refrigerationPasteurization of liquid food”, Doc. 6 “Themicrobiologically safe continuous ow thermalsterilisation of liquid foods”, Doc. 12 “The continuousor semi-continuous ow thermal treatment ofparticulate foods”Update of EHEDG Guidelines on “Packaging”(Doc. 3, 11, 21, 29)Update of EHEDG Guidelines on “Water treatment”(Doc. 27 and 28)EHEDG Subgroup “Air handling”Dr. Thomas Caesar, e-mail: Thomas.Caesar@Freudenberg-Filter.comThe Subgroup Air Handling is currently editing and revisingthe GuidelineDoc 30 Guidelines on Air Handling in the Food Industryto bring it up to date. The last issue dates back to 2005 andis in need of revision.A wide range of food products must be protected againstairborne contamination during the manufacture and primarypacking stages. Subject to a product risk assessment airhygiene and quality control is one of a number of factorsnecessary that promote good manufacturing practice toensure that safe, wholesome food is produced. TheseGuidelines are intended to assist food producers in the

EHEDG Subgroups 165design, selection, installation, and operation of air handlingsystems with regard to hygienic requirements. Informationis provided on the role of air systems in maintaining andachieving microbiological standards in food products. Theguidelines cover the choice of systems, ltration types,system concepts, construction, maintenance, sanitation,testing, commissioning, validation and system monitoring.Compared to the previous version, the scope in the ongoingrevision, has been narrowed and focused on air handlingsystems used for building ventilation and to make upatmospheric pressure process supply air. Supply systems forpressurized air and exhaust air systems such as grease ltersystems or dust removal units are excluded from the scopeof the document. These systems are signicantly differentfrom the air handling systems dealt with in this documentand require their own Guidelines.Chairman:Dr. Thomas CaesarFreudenberg Filtration Technologies SE & Co. KG69465 WeinheimGermanyPhone +49 (6201) 80-2596Fax +49 (6201) 88-2596E-mail thomas.caesarfreudenberg-lter.comEHEDG Subgroup “Hygienic Building Design”Dr. John Holah, e-mail: j.holah@campden.co.ukWith its inaugural meeting on 4th October 2011, the BuildingDesign Subgroup is tasked with providing guidelines onall aspects of construction detail relating to the hygienicdesign of food factories – a signicant challenge giventhe complexity and diversity of operations in a global eld.Some 18 participants attended the rst meeting – a healthycross section of producers, consultants, contractors andbuilding product manufacturers ensured productive debate.Whilst comprehensive design guidelines exist at anindividual food manufacturer or organisation level there areno public documents. This situation may give rise to differentspecications from food producers with the potential tocause conict for building suppliers in their ability to meetall requirements. It was accepted that a common referencewould be extremely valuable to the industry.A focus was decided on food processing operations withthe remit covering detailed hygienic design in wet and dryfactories. Furthermore the guidance should acknowledgeEU legislation and the Global Food Safety Initiative. It wasenvisaged that the document would consist of text but berich in illustrations, ideally showing both ‘good and ‘badexamples.Given the complex nature of building design and constructionthe group decided to dene what should be included in termsof hygienic requirements. Agreement was made on thefollowing aspects Defence against external hazards Defence against internal hazards – Internal ows to prevent cross-contamination Security against deliberate contamination Maintaining hygienic conditions via structure rigidityMaintaining hygienic conditions via materialdurabilityCompliance with customer/GFSI best practiceA separate working group was set up for oors, drains,kerbs and doors – coordinated by Martin Fairley of ACO.Work groups like this present a fantastic opportunity topull together experience and expertise from a varietyof perspectives to the benet of the industry as awhole; however there can clearly be cases for conictbetween competing technologies or between competing

166 EHEDG Subgroupsmanufacturers within the same technology eld. A numberof mechanisms have allowed successful conclusion to thework groups tasks, includingThe breadth of the groups experiences - the ooringteam consisted of manufacturers, academics, and anational agency, the drainage team had more than onerepresentative from each company.Where competition is direct, then work toward commonagreement before wider group presentation. The interrelationships between building components –for example oors and drains.Intermediate stage presentation of intended structureof the proposal at the central Building Design Groupmeetings.Taking part in the extra meeting the ooring group hadrepresentation from ANSES - Brigitte Carpentier; Argelith– Volker Aufderhaar; BASF Ucrete – Phillip Ansell; withfurther input from Prof Vladimir Kakurinov. Key themesof the ooring group included a hygienic oors checklist;challenges in ooring; gradients; joints, materials; installationand waterproong.The Drainage group from ACO – Martin Fairley, VaclavKralicek and Jiri Lonicek; and Blucher Metal A/S – MartinFrølund and Palle Madsbjerg. Key themes from the drainagegroup included ow and capacity, layout, application areasand examples, materials, installation considerations andoor interface details, maintenance and cleaning. Input fromthe door industry was supplied solely by manufacturer coolit– Kristian Kissing. Many others have made contribution tothese teams as they progressed.As might be expected such an extensive overall workprogramme from the Building Design Group has potentialto raise issues worthy of debate; one such issue related tothe denition of segregation and zoning – critical elementsof overall hygienic design principles in modern productionfacilities. A separate work group comprising of 5 participants(Kraft Foods, Unilever, Cargill, Heinz and Campden BRI), isto further the discussion on this central topic. Zone denitionscould includeFactory site – between the perimeter fence and thebuilding envelopeNon food production area, e.g. locker rooms, canteens/restaurants, smoking areas, boiler rooms, workshops,machinery rooms, laboratories, ofces, meeting rooms,living accommodationEnclosed product areas, e.g. warehouses, despatchareas, cleaning storesRaw material processing zone, e.g. slaughter house,vegetable washing, waste disposalGeneral processing zone, e.g. ingredients suitable forfurther processing, exposed packaging and processedproducts often termed Low risk, Low care or GMPareasControlled zones for decontaminated products,microbiologically driven and often termed High Careor High Risk areas for chilled RTE products or thePrimary Salmonella Control Area for dry RTE productsControlled equipment, e.g. clean to aseptic handlingand llingIt is anticipated that the Group will have its draft proposalsin place by the end of 2012 or the beginning of 2013. If it ismet then a substantial piece of work has been produced in arelatively short timescale of just a little over a year – a greatachievement.Chairman:Dr. John HolahCampden BRIFood Hygiene DepartmentChipping CampdenGLOUCHESTERSHIRE GL55 6LDGREAT BRITAINe-mail j.holahcampden.co.ukphone (+44 1386) 84 20 41EHEDG Subgroup“Chemical Treatment of Stainless Steel”Dr. Gerhard Hauser, e-mail: gerhardwrhauser@yahoo.deThe task of the group was to review EHEDG Doc.18“Passivation of Stainless Steel” published in 1998 whichgives essential recommendations to one of the mostimportant properties of stainless steels for product contactsurfaces in the food and beverage industry.Food equipment manufacturers and users choose stainlesssteels as the predominant material of construction becauseof their excellent mechanical properties combined with ahigh level of corrosion resistance and cleanability. The lattertwo attributes are the primary determinants of the materialshygienic behaviour. They rely upon the ‘passive surfacelayer, a chromium-rich oxide lm which naturally forms onall stainless steels. This layer is adequately protective for thevast majority of food and beverage applications.

EHEDG Subgroups 167Given a clean surface and sufcient oxygen from the airor from water, stainless steels will naturally and rapidlyestablish a tenacious passive layer on all exposed surfaces.If the passive layer is physically damaged during or afterthe fabrication of the equipment, it must be afforded theopportunity to repair itself, which it will do rapidly as soon asthe surface is clean and exposed to oxygen again.Nevertheless, for particularly demanding applications,the strength of the passive layer can be improved by atreatment known as chemical passivation. For highly-criticalapplications, the hygienic quality of the surface can be evenfurther enhanced by electro-polishing. However, the need forthe enhancement of the passive layer should be regarded asthe exception rather than the rule.The heat of welding can destroy the passive layer local tothe weld and leave a distinctive, coloured ‘heat-tint whichwill exhibit reduced resistance to corrosion. In this casewelding must be followed by a pickling procedure specicallydesigned to remove heat-tint and allow the passive layer toreform naturally.Pickling, chemical passivation and electro-polishing shouldbe seen as separate treatments and not as alternatives. Eachtreatment should only be carried out with care. It also mustbe remembered that the chemical used for those treatmentsin an integrated system may adversely affect elastomeric,plastic and glass materials. It is therefore important to applyto assembled equipment only surface treatments which areappropriate to all the materials with which they might comeinto contact.Because of the described different inuences to ensureand improve the hygienic performance of the productcontact surface, the group decided to integrate pickling,and electro-polishing in addition to passivation into the newdraft “Chemical Treatment of Stainless Steel”. It was nishedduring the last meeting in August 2012 and has beensubmitted to the EHEDG Guideline approval procedure.Chairman:Dr. Gerhard HauserGoethestr 4385386 EchingE-mail gerhardwrhauseryahoo.deFax (+49 81 61) 71 42 42EHEDG Subgroup “Cleaning alidation”Dr. Rudolf Schmitt, rudolf.schmitt@hevs.chIn June 2011 the Subgroup “Cleaning Validation” becameactive. More than 30 participating experts in this groupare ample proof for the strong interest in this particularsubject.The purpose of this Subgroup is to prepare a new EHEDGguideline on the basics and principles of “CleaningValidation” in the food sector. An inadequate cleaningprocess may result in residue being carried forward.This residue may then contaminate the next batch to bemanufactured in the same equipment.The most signicant contaminants in the food sectorare product from the previous batch, microorganisms,allergens, cleaning agents and lubricants.Cleaning validation is necessary to prove the consistencyand effectiveness of established procedures that havebeen found acceptable. This document shall describehow design principles and the qualication of equipmentare employed in a validation scheme that givesdocumentary evidence of the effectiveness of the cleaningprocedure.The guideline shall cover validation in the food sector ina general way and can be applied for different purposes.However, the development of further specic guidelinesfor particular applications i.e. the validation of CIP, thevalidation of manual cleaning, the validation of drycleaning, and the validation of disinfection, is stronglyrecommended.Chairman:Dr. Rudolf SchmittHES-SO ValaisInstitute of Life TechnologiesRue du Rawyl 641950 SionSwitzerlandPhone +41 27 6068611Fax +41 27 606 86 15E-mail rudolf.schmitthevs.ch

168 EHEDG SubgroupsEHEDG Subgroup “Conveyor Systems”Jon J. Kold, e-mail: jk_innovation@yahoo.comIn January 2011 the EHEDG Subgroup “Conveyor Systems”became active.The group has collected a huge amount of material and is inthe process of editing the content.The purpose of the Subgroup is to prepare a new EHEDGGuideline on the hygienic design of conveyor systems to beused in food manufacturing or processing. The Subgroupconsists of approximately 15 professionals from companiesand institutions. This underlines the industrys broad interestin the subject.Conveyor systems are widely used in food manufacturingfor moving raw materials, processed food and packagedproducts. The upcoming guideline is primarily aimed atconveyors used in high risk areas, i.e. the processing ofnon-packaged foods in direct contact with the conveyor ortransported in open boxes.There are several reasons to reduce the hygiene risk byapplying hygienic design to conveyor systems.The guideline may be used as a communication toolbetween purchasing companies and suppliers making surethat new conveyors comply with hygienic requirementsspecication.The Subgroup “Conveyor Systems” is chaired by EHEDGDenmark who have previously elaborated a guideline forhygienic deign of conveyers for the food industry.Hygienic design of conveyor systemsThe hygienic design of conveyor systems is complex anddemanding. Many solutions with regard to function, design,cleanability and service of the equipment must be consideredthoroughly.The equipment should be as open as possible for easyaccessibility and cleaning. The number of guards shouldbe minimised to what is necessary for reasons of safetyand should not prevent efcient cleaning. Guards shouldbe removable during cleaning/disinfection, either throughopening or by unhinging.Topics which are being dealt with during the working periodDifferent types of beltsLateral guides for beltsLateral guides for productDrive stationsDrum motorsGear motorsCIP cleaning systemsTime scheduleThe new guideline is intended to be nalized within the next12 – 18 months.If you are interested in joining this Subgroup please contactthe chairman, Mr. Jon J. Kold, jon.koldstaalcentrum.dk, orthe EHEDG Secretariat jana.huthehedg.org.ChairmanJon KoldFredensvang 387600 STRUERDENMARKPhone(+45 40) 57 13 46E-mail jkinnovationyahoo.comEHEDG Subgroup “Dry Materials Handling”Karel Mager, e-mail: karel.mager@givaudan.comWhen the EHEDG started in 1989 most of the availableknowledge on hygienic design was about liquid handling andliquid processing equipment.In the following years a couple of documents about testmethods and design principles concerning this topic werepublished.In the area of dry particulate materials (powders) there was aneed for similar documents design principles and guidancefor hygienic engineering for the safe processing of dryparticulate materials.The subgroup started in 1998 and since then has publishedeight documents.Published guidelinesDoc. 22 General hygienic design criteria for the safeprocessing of dry particulate materials (2001)

EHEDG Subgroups 169Doc. 26 Hygienic engineering of plants for theprocessing of dry particulate materials (2003)Doc. 31 Hygienic engineering of uid bed and spraydryer plants (2005)Doc. 33 Hygienic engineering of discharging systemsfor dry particulate materials (2005)Doc. 36 Hygienic engineering of transfer systems fordry particulate materials (2007)Doc. 38 Hygienic engineering of rotary valves inprocess lines for dry particulate materials (2008)Doc. 40 Hygienic engineering of valves in process linesfor dry particulate materials (2010)Doc. 41 Hygienic Engineering of Diverter Valves in theDry Materials Handling Area (2011)Currently the subgroup is working on a document onepowder pack-off systems.Furthermore, members of the subgroup have been active inthe organization of conferences, seminars and workshops.Participants have also contributed by giving several lecturesin the area of Dry Materials Handling.The work of this Subgroup attracts a great deal of interest.Many requests to join this Subgroup and share the workloadhave led to the decision to start a second group which willdeal with other aspects of similar topics. This Subgroup hasyet to get started.Chairman:Karel MagerGivaudan Nederland B.V.Huizerstraatweg 281411 GP NaardenNetherlandsPhone +31 35 6 99 21 86Fax +31 35 6 94 37 19E-mail karel.magergivaudan.comEHEDG Subgroup “Fish Processing”Dr. Sanya idacek, e-mail: svidacek@pbf.hrThe future EHEDG document “Hygienic DesignRequirements for the Processing of Fresh Fish” willdescribe and illustrate how the design principles of theEHEDG GuidelinesandDoc. 8 Hygienic Equipment Design CriteriaDoc. 13 Hygienic Design of Equipment for OpenProcessingcan be applied to the mechanised and/or automatedprocessing of sh.This document will cover the processing of fresh shfrom grading, gutting, de-heading, deboning, pin-boning,trimming, lleting, skinning and portioning (includingits ice producing system) until packaging. Its scope willnot, however, cover further sh processing including thesmoking, cooking, frying, marinating etc. or the manualprocessing of sh.Specic hygienic risks related to the sh and the processingconditions will be dened. The document will describe thespecic hygienic requirements of the processing lines andthe processing environment as well as the requirements forwater and ice and hygienic sh packaging. Cleaning anddisinfection practices and environmental issues associatedwith sh processing will be discussed.So far, the Subgroup has identied the risks and is puttingtogether the requirements for the hygienic processing ofsuch a sensitive product. The guideline is due to be nishedin the course of 2013.Chairman:Dr. Sanya VidacekUniversity of Zagreb.Faculty of Food Technology&BiotechnologyPierottijeva 610000 ZagrebCroatiaPhone +385 1 4 60 51 26Fax +385 1 4 60 50 72E-mail svidacekpbf.hr

170 EHEDG SubgroupsEHEDG Subgroup “Materials of Constructionfor Equipment in Contact with Food”Eric Partington, e-mail: eric@effex.co.ukEHEDG Doc. 32 “Materials of Construction for Equipmentin Contact with Food” offers practical guidance about theways in which materials may behave such that they can beselected and used as effectively as possible. The Guidelineis intended to serve as an aide-memoir during the designprocess, so that equipment manufacturers and end-userscan together ensure that all aspects of materials behaviourcan be taken into account in designing safe, hygienic, reliableand efcient equipment which can be operated, maintainedand managed economically.The Guideline was rst published in 2005. Its 54 pagesaddressed legislation, materials behaviour, hygienic designand cleanability. The materials covered included metallics,elastomers, plastics, composites, ceramics and glasses,and the characteristic ways in which each group of materialsbehaves were discussed. Potential failure mechanisms wereidentied, together with the conditions under which there isthe greatest risk of them occurring.But since that rst issue was written, much has changed inthe world of Food Contact Materials including revisions ofthe Framework Directive and the Machinery Directive, newconstraints on the selection and application of some nonmetallicmaterials, advances in composites, glasses andanti-microbial materials and the advent of nano-materials. Itis now time for Doc. 32 to be reviewed and updated.A successful rst meeting of the re-formed SG Materials ofConstruction was held on 27 June 2012. It established abase for the revision of Doc 32 the structure of the newGuideline would generally follow the format of the original,each group of materials (e.g metallics, plastics, elastomers,ceramics) being discussed in its own separate sectionprepared by a small team of experts in those materials.The SG Materials of Construction currently comprisesexperts in legislation, metals, cleanability and some areasof plastics and elastomers but would welcome offers ofassistance in the elds of ceramics, glasses, composites,anti-microbial surface treatments and biocidal materials,metallic surface coatings and intelligent materials wherethey apply to Materials of Construction. If you would like toparticipate in the updating of Doc. 32, the secretariat and theChairman would be very pleased to hear from you.Chairman:Eric PartingtonNickel InstituteWell CroftAmpney St. MaryGloucestershire GL7 5SNUnited KingdomPhone +44 1285 610 014E-mail ericeffex.co.ukEHEDG Subgroup“Hygienic Design of Meat Processing Equipment”Dr. Aleksandra Martinovic, e-mail: aleksmartinovic@t-com.meIn March 2011, the new EHEDG Subgroup “Hygienic designof meat processing equipment” again became active after along period since the rst kick off meeting held in Belgradein 2009.The purpose of the subgroup is to develop a guideline tospecify and illustrate the hygienic design of machineryand equipment used in the meat processing industry. Thedocument will provide guidance by highlighting good andbad design examples as well as by describing installations,operations and maintenance of such equipment accordingto the state-of-the-art achievements in the eld. The scopeof the new EHEDG guideline in progress will focus on ‘Meatprocessing between slaughtering and packaging.The subgroup consists of some 15 professionals fromcompanies and institutions. This underlines the industrysbroad interest in the subject.Poorly designed equipment may increase the risk ofcontamination of food products such as meat and meatproducts with micro-organisms, and different stages ofprocessing and manufacturing may demand different levelsof hygienic design. The fundamental principle, however, isthat the design of any piece of equipment must not allow anyincrease in the concentration of relevant contaminants.The guideline will cover the hygienic aspects of equipmentdesign, engineering unit processes, transportation systems,production procedures, cleaning and disinfection proceduresand specic environmental requirements.

EHEDG Subgroups 171It will address different types of equipment in connectionwith the various operations during meat processing, suchas deboning and trimming, freezing, cutting and slicing,marinating, tumbling, mixing and grinding, forming andcoating as well as other types of handling devices.Time scheduleThe new guideline is intended to be nalized within the next24–30 months. It is planned to have three meetings per yearto evaluate progress.New participants from manufacturers of meatprocessing equipment and machinery welcomeAdditional experts in this eld who wish to contribute to theworkare welcome.If you are interested in joining this Subgroup please contactthe chairman, Dr. Aleksandra Martinovic or the EHEDGSecretariat.Chairman:Dr. Aleksandra MartinovicUniversity of MontenegroBiotechnical FacultyMihaila Lalica 181 000 PodgoricaMontenegroPhone +382 69 737 403E-mail aleksmartinovict-com.meEHEDG Subgroup “Open Equipment”Guideline on Essential Hygienic Design Requirements for Equipment used In Open ProcessesDr. Gerhard Hauser, e-mail: gerhardwrhauser@yahoo.de; Dr. Jürgen Hofmann, e-mail: jh@hd-experte.deThe objective is to cover all equipment in food and beverageprocessing plants between the ceiling, oor, and wallswhich are not intended to be in direct contact with food. Inthis context the term equipment comprises all items whichare supposed to have a potential impact on product safetywhen integrated into open equipment machinery or openprocesses (axillaries items, integration items).The decision as to whether an item has an adverse inuenceor not must be based on a risk assessment. It must decidewhat kind of equipment design is essential and howequipment must be cleaned (CIP, automatically with foam,or manually) to avoid cross-contamination.The basic strategy for selecting hygiene measures for thedesign shall includeidentication of the process for which the equipment isintended;identication of hazards associated with the product(s)produced;risk assessment associated with each hazardidentied;hygienic design methods/measures which caneliminate hazards or reduce risks associated withthese hazards;means of verication of the effectiveness of the hazardelimination - or the risk reduction method;description of residual risks and any additionalprecautions necessary in the information for usewhere applicable.The subgroup is divided into 3 working groups to achievemore effectiveness.The topics of Group 1 contain the design of (e.g.)cables and their connections, eld busses, wiring,cable trays, sensor installation, HMI, signal devices,lamps and pneumatics.Group 2 deals mainly with motors and gear boxes,pumps, process connections, covers, and thermalinsulation.Group 3 is involved in (e.g.) climate units, controlboxes, enclosures and mountings, movable equipmentwith wheels, steel structures, frameworks andsupporting feet.At the last Subgourp meeting (January 2012) the input ofthe groups has been discussed and partly integrated intothe nal draft.Chairmen:Dr.-Ing. Gerhard HauserGoethestr. 4385386 Echinggerhardwrhauseryahoo.deDr. Jürgen HofmannFichtenweg 8 a85604 Zorneding(+49 8161) 8 76 87 99jhhd-experte.de

172 EHEDG SubgroupsEHEDG Subgroup“Pumps, Homogenisers and Dampening Devices”Ralf Stahlkopf, e-mail:ralf.stahlkopf@gea.comFor the last four years the Subgroup has worked on the 3rdrevised edition of the EHEDG Guideline and will be nishedin spring 2013.Doc. 17 “Hygienic Design of Pumps, Homogenisersand Dampening Devices”The revised edition is scheduled to be published in 2012.The objective of this Guideline is to provide a set of minimumrequirements for pumps, homogenisers and dampeningdevices for hygienic and aseptic applications, to ensure thatfood products are processed hygienically and safely.These requirements will apply to all pumps intended foruse in food processing, including centrifugal pumps, pistonpumps, lobe rotor pumps, peristaltic pumps, diaphragmpumps, water ring pumps, progressive cavity pumps, screwpumps, and gear pumps and also to homogenisers anddampening devices. It will include any valves integral withthe pump head and the complete homogeniser head.A classication of the pumps discussed is provided togetherwith illustrations and pictures to explain graphically theissues, problems (such as gabs and dead-ends) and theirsolutions.Chairman:Ralf StahlkopfGEA Tuchenhagen GmbHAm Industriepark 2-1021514 BüchenGermanyPhone +49 4155 49 25 78Fax +49 4155 48 27 76E-mail ralf.stahlkopfgeagroup.comEHEDG Subgroup “Seals”Dr. Till Riehm, e-mail: till.riehm@fst.comThe Guideline “Seals” covers all aspects of seals andseal design relevant to the construction of hygienicequipment for food processing and packaging. It detailsboth the European and international regulations currentlyapplicable to elastomeric seals used in the food andbeverage industry. It then discusses the general designprinciples which have to be taken into consideration whendesigning a sealing point and it includes a practical guideon failure analysis.In conjunction with the Sub-Group “Materials ofConstruction” (Doc. 32) it was decided that “Materials ofConstruction” should describe the properties of elastomers,leaving the Guideline Seals to recommend basic sealdesign principles and to discuss which parameters have tobe taken into consideration according to the surroundingconditions.The Guideline “Seals” therefore identies both the relevantlegislation and the most critical design parameters and thengives hands-on advice for the construction and design ofsuch components.Chairman:Dr. Till RiehmFreudenberg Process Seals GmbH & Co. KGLorscher Str. 1369469 WeinheimGermanyPhone +49 6201 80 89 19 00Fax +49 6201 88 89 19 69E-mail till.riehmfreudenberg-ds.com

EHEDG Subgroups 173EHEDG Subgroup “Separators”Reinhard Moss, e-mail: reinhard.moss@gea.comThe Subgroup Separators is working on a new EHEDGdocument dealing with the hygienic aspects of disc stackcentrifuges. These machines are used to separate fractionswith different densities of liquid food products or to removedense solid matter from products. Doc. 42 “Disc StackCentrifuges” will be nished in spring 2013.Many of the design principles applicable to this kind ofequipment are already shown in the EHEDG GuidelinesDoc. 8 Hygienic equipment design criteria; Doc. 9 Weldingstainless steel to meet hygienic requirements; Doc. 10Hygienic design of closed equipment for the processing ofliquid food; Doc. 16 Hygienic pipe couplingsDoc. 9 Welding stainless steel to meet hygienicrequirementsDoc. 10 Hygienic design of closed equipment for theprocessing of liquid foodDoc. 16 Hygienic pipe couplingsDoc. 17 Hygienic design of pumps, homogenizers anddampening devicesDoc. 32 Materials of construction for equipment incontact with foodDoc. 35 Welding of stainless steel tubing in the foodIndustryThe document was revised several times and descriptionsfor the hygienic design of special areas were added. Alsoillustrations, drawings and pictures were added to getthe sanitary problem zones across to the users of theguideline.The Subgroup has dened specic rules applicable to theCIP-cleaning capability of separators which are not yetcovered by existing EHEDG documents. Also other specialhygienic design features necessary for this kind of machineryare also described.A nal draft of the Guideline is currently going through theEHEDG Guideline approval process.Chairman:Reinhard MoßGEA Mechanical EquipmentGEA Westfalia Separator Group GmbHOperative Technical ServicesPhone +49 2522 77-2571Fax +49 2522 77-32571Mobile +49 172 536 8803E-mail reinhard.mossgea.comEHEDG Subgroup “Tank Cleaning”Design of tanks for cleanability and using cleaning devicesBo Boye Busk Jensen, e-mail: bobb.jensen@alfalaval.comThe workgroup started at the beginning of 2012. Theobjective of the guideline has been discussed and is currentlydescribed as“This guideline is intended to provide recommendations oncleaning aspects and hygienic design of vessels. It is limitedto product contact surfaces of tanks for liquid processing,both vertical, horizontal and of any arbitrary shape. Excludedare the selection of chemistry and temperature for cleaningspecic products.”The guideline will cover many different aspects related to thehygienic design of tanks, their appurtenances, the installationof such in tanks and the cleaning technology chosen for CIPcleaning. The focus of the guideline is on how the differencesin the choice of tank cleaning technology inuence thehygienic design criteria for appurtenances used in and ontanks. The available tank cleaning technology and its designwill be presented from the point of view of its functionality inorder to allow users to make the most sensible choice of tankcleaning equipment for their tank, tank design and product.The cleaning mechanisms during tank cleaning somewhatdiffer from those encountered in a closed pipe system. Thetanks and appurtenances are rarely cleaned by a pressurizedliquid owing through the tank, but rather by a lm or localhigh impact cleaning. Also, the category of soil may inuencethe best value for money choice when selecting tank cleaningtechnology and cleaning strategy.Finally, validation of tank cleaning is also included as this isa prerequisite for a satisfactory and consistent cleaning of aChairman:Bo Boye Busk JensenAlfa Laval Tank Equipment A/SBaldershoej 192635 ISHOEJDENMARKPhone (+45 43) 55 86 88Fax (+45 43) 55 86 03E-mail bobb.jensenalfalaval.com

174 EHEDG SubgroupsEHEDG Subgroup “Test Methods”The EHEDG Test Methods Subgroup was one of the rst Subgroups established by EHEDG and isresponsible for publishing test methods, dening validation criteria and providing assessmentsof equipment according to the hygienic design criteria of EHEDG in conjunction with the EHEDGCertication SchemeAndrew Timperley, e-mail: andy.timperley@tesco.netAt the beginning of 2011 the Test Methods Subgroup workwas sub-divided into two divisions under the commondirection of the Authorised EHEDG Test Institutes. Onedivision has since been concentrating its efforts on thedevelopment of a new test method for evaluating ‘openprocessing equipment. This division met in April 2011 anddened various work items to develop this method. Theprimary task was to construct a ‘reference piece in orderto conduct trials on various soiling, cleaning and detectiontechniques. Results of these initial trials have shown thatit is very difcult to obtain repeatable results due to themany variables associated with the uniformity of theapplication of soil and controlling the cleaning procedure.However, work is ongoing in this division to investigateother techniques.Member Companies. The website will continue to beupdated with this additional information and provide morebenets for EHEDG Member companies to showcase theircertied equipment.The Test Institutes efforts have been concentrated on theupdates of the test methods used to evaluate equipment inconjunction with the Certication Scheme and these will bereviewed by the EHEDG Executive Committee for com-mentsbefore publishing. Additionally, the Certication Scheme hasbeen expanded to include a new certication class, Type EL-Class II Aseptic, to enable equipment to be certied for usein Aseptic applications where CIP cleaning is not practicaland the equipment must be dismantled for cleaning. The owchart and testing matrix of the Scheme has been updated onthe EHEDG website and manufacturers are encouraged toliaise with their local Test Institutes in order to co-ordinatecertication activities.In September 2011 the Annual Test Institutes meeting washeld at ADRIA Normandie in France to review progresson becoming an Authorised Test Institute. During thesame Year EHEDG received notication that the DanishTechnological Institute would resign as the AuthorisedInstitute in Denmark and this role is now being taken upby the Danish Technical University. These new Instituteswill provide accessibility to manufacturers for testing andcertication of equipment in these regions and the Groupwill continue to work with these new Institutes to satisfy thecriteria for authorisation.In September 2012, all the Test Institute representativesheld their main Annual meeting at TNO in the Netherlands toreview any specic issues associated with repeatability andreproducibility of the test methods and agree the next ringtrial programme for 2013. During this meeting the updatedtest methods were reviewed and the next reproducibilitytrial for the assessment of in-place cleanability testingwas initiated. Additionally, a new structure for the websitelisting of certied equipment was nalised to include moreinformation about certied equipment produced by EHEDGFigure 1. Testing SchemeAs a result of the day to day testing activities of theInstitutes information is collected to provide equipmentmanufacturers with guidance on the selection of suitablepipe couplings and process connections for hygienicintegration of equipment into processing systems. Thislist was revised in April 2011 and is available to downloadfrom the free documents section of the Guidelines area onthe website. This list will be updated as new informationbecomes available.

EHEDG Subgroups 175Chairman:Andy TimperleyTimperley ConsultingGREAT BRITAINPhone +44 1789 49 00 81Fax +44 1789 49 00 81E-mail andy.timperleytesco.netFigure 2. EHEDG Certication SchemeEHEDG Subgroup “Training and Education”Knuth Lorenzen, e-mail: knuth.lorenzen@ewetel.netBackground to the subjectTo facilitate undertaking worldwide EHEDG training coursesin local languages requires a set of training materials whichcan be used by authorised EHEDG trainers to pass ouruniform message of Hygienic Design on to all participants.Number of participants/meetings in 2012The Training & Education Subgroup has 21 activemembers who come from universities, faculties, institutes,consultancies and companies such as Unilever, Exaris andGivaudan. These members offer their expertise and inputto accomplish the production of ready to use presentationmaterial enabling EHEDG trainers to arrange and executetraining courses worldwide. With the support of the membersof the EHEDG regions this material has been and willcontinue to be translated. This makes lecturing in the locallanguages of the different member countries possible.To produce this training material we create and deliver easyto understand – both good and bad examples of hygienicdesign for the different process applications. We shareour knowledge in our daily work and at our four Subgroupmeetings every year.Proposed presentation material contentsIn visual aids and on DVDs the ready to use presentationmaterial demonstrates the importance of hygienic engineeringand design for improving food process installations andmaintenance in order to comply with all legal requirementsand to achieve safe food.The training modules cover the following topicsLegal requirementsHazards in hygienic processingHygiene design criteria

176 EHEDG SubgroupsFood grade lubricantsMaterialsTest methodsWeldingCleaning and disinfectionPackaging machinesSealsA questionnaire with 47 questions was developed and isused for the participants nal exam.Timescale to publishingWe are condent to have a full set of training materials readyin 2013. This will enable us to run the three day AdvancedCourse in Hygienic Engineering and Design globally.At present, we are offering the EHEDG training course in thefollowing languages and countriesEnglish, German, Spanishin Denmark, Germany, the Netherlands, Spain and theUSA.Segments of the EHEDG training material are used by ourauthorised EHEDG trainers globally at seminars, symposia,workshops or universities where EHEDG is involved.Special serviceAll authorised EHEDG trainers as well as all thoseparticipants who have successfully attended the EHEDGAdvanced Course in Hygienic Engineering and Design arelisted on the EHEDG web page.Chairman:Knuth LorenzenEHEDG PresidentFlurstr. 3721445 WulfsenGermanyE-mail knuth.lorenzenewetel.netPhone (+49 4173) 8364EHEDG Subgroup “alves”Ulf Thießen, e-mail: ulf.thiessen@gea.comSince the formation of the Subgroup in September 2009,the Subgroup saw some member uctuation but meanwhilea consolidation has been achieved. The group has 14regular members with an average of eight participants at themeetings.This manageable size led to a rapid progress of work in thegroup and by the end of 2011 we succeeded to nalize therevision ofDOC 14 Requirements for valves in hygienic andaseptic processes (4th edition, 2011)The Guideline is currently being subedited for use of correctEnglish and will afterwards be translated into variouslanguages.The subsequent task of the Subgroup is now the revision ofDOC 20 Hygienic design and safe use of double-seatmixproof valves (July 2000)This work has already been started in 2012.Due to the complexity of the topic and the long periodbetween its rst release in 2000 and today, we have to bearin mind that many changes both in market structure andtechnology for hygienic and aseptic valves have to be dealtwith.This will lead to a complete restructuring of the Document.Chairman:Ulf ThießenGEA Mechanical EquipmentGEA Tuchenhagen GmbHAm Industriepark 2-10D-21514 BüchenGermanyPhone +49 4155 49 2709Fax +49 4155 49 2423E-Mail ulf.thiessengea.com

EHEDG Subgroups 177EHEDG Subgroup “Welding”Peter Merhof, GEA Tuchenhagen GmbH, e-mail: peter.merhof@gea.comThe Subgroup started in May 2012 to develop the concept forthe new EHEDG guideline “Inspection of Hygienic Welds”.It is very important from both a hygienic and economicalpoint of view that the demands regarding the quality ofwelds will be met in tubing systems used for food processingindustry. This document should help the user to identify theright control method for an efcient and economical testingof the welds.The main target group of this document will be the user/manufacturer in the foot processing industry. Therefor thedocument has to be an easily understandable mixture of textand photos and graphic illustrations.The accepted inspection methods still in use will be describedincluding with their advantages and limitations.Finally the document will give recommendations with thefocus of documentation and shall supply standard operationprocedures.Chairman:Peter MerhofWelding SupervisorGEA Tuchenhagen GmbHGEA Mechanical EquipmentPhone +49 (0) 4155 / 49-22 07,Fax +49 (0) 4155 / 49-26 95Mobile +49 (0) 172 / 45 82 563E-mail peter.merhofgea.comwww.gea.com

The easiest way to apply for EHEDG membership is via the EHEDG website www.ehedg.org. You can apply directly online.

European Hygienic Engineering & Design GroupPublished byEHEDGEuropean Hygienic Engineeringand Design GroupLyoner Str. 1860528 FrankfurtGERMANYISBN978-3-8163-0640-5Publishing House:VDMA Verlag GmbHLyoner Str. 1860528 FrankfurtGERMANYPrinting:Franz Kuthal GmbH & Co. KGJohann-Dahlem-Straße 5463814 MainaschaffGERMANYExecutive EditorJulie BricherQuiddity Communications677 SW Tanglewood CircleMcMinnville 97128UNITED STATES OF AMERICACopyrightCopyright rests with EHEDG. All rights reserved.The copyright of the pictures and illustrations within thearticles belongs to the authors, respectively the companiesor institutes they represent unless otherwise stated.Illustrations:Cover1. Scanjet Systems AB, S- Gothenburg2. Coperion GmbH, D-Weingarten3. Elmar Europe GmbH, D-Neuss4. Ecolab Europe GmbH, CH- Wallisellen5. GEA Westfalia Separator,D-Oelde6. seepex GmbH Food and Beverage, D- Bottrop7. HECHT Technologie GmbH, D-Pfaffenhofen8. VTT Technical Research Centre of Finland, FI- EspooContactEHEDG SecretariatLyoner Str. 1860528 FrankfurtGERMANYPhone (+49 69) 66 03-12 17FAX (+49 69) 66 03-22 17E-mail secretariatehedg.orgWeb www.ehedg.orgCopy EditorJuliane HonischEHEDG SecretariatFrankfurtGERMANYEditorial BoardDr. John Holah, Campden BRI, GREAT BRITAINKnuth Lorenzen, Wulfsen, GERMANYHuub Lelieveld, Bilthoven, NETHERLANDSDirk Nikoleiski, Kraft Foods R&D Inc. Munich, GERMANYEric Partington, Nickel Institute, Cirencester,GREAT BRITAIN