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Keeping hygiene in mind

08 November 2021

Those undertaking automation projects in food production environments should not forget about hygiene, argues Sue Springett. 

Continued labour shortages mean investment in automation is inevitably the way forward for many food producers. However, as with every new approach, automation brings with challenges when it comes to hygiene.  

• Scope it out – get a 360 view: Poor communication can kill a project so it is important when  planning a new automated line, or introducing new equipment to a manufacturing space that all departments communicate openly about what is needed and what the impact of automation could be on the whole business.  Engineering departments that adopt a collaborative approach with other in-house specialists often gain from their experience and insight when it comes to planning an automated installation.

What is the current cost of cleaning, and will automation increase or reduce that?   Will the proposed new project eliminate the hygiene risks that currently exist or generate new problems? How complex is machine access needed to conduct microbe tests?  

By actively seeking the input of every department – such as stores management, production, finance, Health and Safety, Technical and HR – it is possible to fully assess the risks and rewards of the planned investment and generate a robust project plan that addresses the needs of the entire business. 

• Washdown flow: Ineffective washdown flow is not only a major time stealer but can have a dangerous impact on microbe management. Cleaning and washdown flow should always be included from the start of the project plan.  

For example, when using a dedicated wash down area, having a clear route for staff to follow between production and washroom areas can avoid unnecessary cross contamination and time-wasting.  Dirty items left in a corner, ready to be moved to a dedicated cleandown room, can quickly become a contamination risk as microbes multiply unsupervised. Do you log your equipment in and out for cleaning?  Do you tag each item, so it is clearly identifiable as clean or dirty? 

If operating ‘cleaning-in-place’ will you have the right tools and equipment to complement full washdown for that new machinery? Will operators be able to safely access all areas?   

By asking tough questions, and planning and investing up front in smart cleaning processes that actively support a hygienic approach, there is an opportunity to make meaningful savings on your production and cleaning costs.  

• Don’t compromise on kit: It goes without saying that furniture for automated lines need to incorporate the best possible hygienic design.  Just one tiny corner where listeria can hide can cause a whole line to be shut down and potentially lead to an audit.  
Every piece of equipment needs to be able to hold its own, enabling efficient and effective clean downs.  It is vital to select kit that is ‘perfect for purpose’:  by that I mean purposely designed to fit in to automated lines.  For example, has your computer console been designed to prevent water ingress so that it can be easily washed down in an automated environment? 

The equipment incorporated into a line should actively contribute to productivity, without compromising on hygienic standards. 

When evaluating the cost benefits of new equipment, consider that different items will have a different anticipated lifespan.  Based on this, are the expected RoI timescales reasonable?  

•  Don’t miss ‘forgotten’ areas: In an automated environment, mesh is critical for safety.  But poorly manufactured mesh can be a hygienic nightmare; with a plethora of tiny dirt traps that are hard to spot and hard to clean.  But you can minimise the risk by being specific about the mesh products you introduce to your production line.  Ensure you purchase well-designed mesh products which have less opportunities for dirt to sit, and bacteria to thrive.  

Gantries can be easy to forget about.  But even gantry design should incorporate hygienic design.  Is your gantry constructed to withstand high-pressure cleaning and designed to minimize dirt traps?  Even when considering large pieces of equipment, it’s vital to drill down to the detail.  How easy is it for the hygiene team to clean it down?  We’ve seen some gantries that took an extra 30 minutes to deep clean, simply because their parts were harder to access than similar setups.  

Sue Springett is commercial manager at Teknomek.


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