EHEDG

Yearbook 2011/2012

European Hygienic
Engineering & Design Group
EHEDG Yearbook 2011/2012

EHEDG Secretariat Phone +49 69 6603-1217 and -1430

Lyoner Strasse 18 Fax +49 69 6603-2217 and -2430
60528 Frankfurt am Main E-mail secretariat@ehedg.org
Germany Web www.ehedg.org

EHEDG Umschlag.indd 2 01.04.11 08:40

 EHEDG
Yearbook 2011/2012

European Hygienic
Engineering & Design Group

EHEDG_Innenteil.indd 1 01.04.11 08:43

 European Hygienic Engineering & Design Group

Contents

Articles Page

Greeting, Knuth Lorenzen 4

From the Treasurer, Piet Steenaard 5
EHEDG Executive Committee Members 2010 6
EHEDG Member Companies 8
EHEDG Membership 11
EHEDG Website news, Susanne Flenner 12
Hygiene requirements of the EU Directive 2006/42/EC on machinery, by Hans-Werner Bellin 14
A suggested method for assessing the cleanability of flooring materials, Brigitte Carpentier 16
Comparison of materials used in food refrigeration equipment with respect to ease of removal 21
of organic soil, Olivier Firmesse, Danile Chassaing, Anne-Marie Leconte, Brigitte Carpentier
Tank cleaning technology: Innovative application to improve clean-in-place (CIP), 26
Bo Boye Busk Jensen, Jesper Bak Nielsen, Henrik Falster-Hansen, Karl-ge Lindholm
Hygienic seal design, by Christine Riebesell 31
How do you clean a flour silo? by Wolfgang Haucke 35
Hygienic design as a winning choice, by Silvia Grasselli, Michele Madureri, Alessia Ilariuzzi 40
Roughness is not the only issue, by Dr. Georg Henkel 43
Cleanability of equipment: a prerequisite for the validation of cleaning in the food industry, 45
by Dr. Laurence Nicolay, Dr. Rudolf Schmitt
Examining the microbial contamination potential of fabric flat belts, by Dr. Zhinong Yan 49
Potential savings of CIP costs by consistently following hygienic design principles, 53
by Andreas Dorner
Hygienic design inside and out, by Valeska Haux 56
Recent developments in cleaning technology, by Stefan kesson, Anders Gransson 58
How to secure food safety in a production line, by Stefan kesson 60
Food equipment hygienic design philosophy, by Tadeusz Matuszek 62
Validation of aseptic packing machines, by Giampaolo Betta, Roberto Massini 66
Construction materials in contact with food and global food safety regulations, 69
by Stefan kesson, Julie Larson Bricher, Olaf Heide, Huub Lelieveld, Piet Steenaard
Food contact material for baking: a review on associated chemical risks and technological 75
issues, by Alain Le-Bail, Bruno Veyrand, Sophie Durand, Hanane Kadar, Carole Prost, Jolle Grua,
Catherine Simoneau, Annick Perronnet, Guillaume Roelens, Bruno Le Bizec
Hygienic design of enclosure boxes in relation to high pressure cleaning? 89
by Heinz Schmitt, Hans-Robert Koch
A new silicone rubber for demanding applications in the food industry, 91
by Anne-Sofie Ravn-Bering, Lars Linnemann
Hygienic pneumatic components, by Cordula Krause-Widjaja 94
Hygienic compact containment system, by Henri Michiels 97

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 Contents 3

Hygienic design in the life science industry: strict implementation of hygienic design 100
requirements described by way of stainless steel furniture, by Markus Keller
New ultra-hygienic synchronous drum motor drive, by Lorenz G. Koehler 103
Simply simple: hygienic design in filling technology, by Ludwig Clsserath 106
Key to quality, by Andrea Husson, Frank Schimpf, Schnee PR 110
New sensor concepts for the packaging industry, by Christoph Mller 112
EHEDG Regional Sections, Chairmen and contacts 115
EHEDG Armenia, by Karina Grigoryan, Suren Martirosyan 116
EHEDG Denmark, by Jon J. Kold 117
EHEDG France, by Nicolas Chomel 118
EHEDG Germany, by Jrgen Hofmann 119
EHEDG Italy, by Giampaolo Betta 120
EHEDG Japan, by Hiroyuki Omura 123
EHEDG Macedonia, by Vladimir Kakurinov 124
EHEDG Netherlands, by Ernst Paardekooper 125
EHEDG Russia, by Mark Shamtsyan 126
EHEDG Spain, by Rafael Soro 128
EHEDG Switzerland, by Matthias Schfer 129
EHEDG Taiwan, by Bing-Huei Barry Yang 130
EHEDG Thailand, by Navaphattra Nunak 131
EHEDG Ukraine, by Yaroslav Zasyadko 132
EHEDG Guidelines titles available and description 133
EHEDG Subgroup work 141
EHEDG Subgroup Conveyor Systems 143
EHEDG Subgroup Design Principles 144
EHEDG Subgroup Dry Materials Handling 146
EHEDG Subgroup Fish Processing 146
EHEDG Subgroup Mechanical Seals 147
EHEDG Subgroup Pumps, Homogenisers and Dampening Devices 147
EHEDG Subgroup Seals 148
EHEDG Subgroup Separators 148
EHEDG Subgroup Test Methods 149
EHEDG Subgroup Training 141
EHEDG Subgroup Valves 149
Imprint 152

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Greeting
Knuth Lorenzen
President of the European Engineering & Design Group (EHEDG)
E-mail: knuth.lorenzen@ehedg.org
Not only innovation but also tradition is a value of EHEDG;
tradition in the sense that we will keep our brand name
European Hygienic Engineering & Design Group (EHEDG)
although we are acting globally via our different regional
EHEDG sections in connection with EHEDG International.
The EHEDG regional sections are our extended source of
excellence on hygienic engineering and design. Here we
use our global network to disseminate the knowledge of
hygienic engineering & design.
Discovering regions where hygienic engineering & design is
an unknown concept we educate students, manufacturers
of process machinery, equipment and systems and their
users, by arranging training & education via workshops,
seminars, symposia and congresses.
Training and education in hygienic engineering & design is
essential in every country throughout the world, regardless
whether we view a well- or poorly developed country. The
knowledge of hygienic engineering & design is still
incomplete and for most of our students today, who are our
future source of excellence, an unknown topic on their
curriculum.
Every day we consume food which was harvested,
processed, packed and transported to and from and to any
locations on the globe. In addition, we prefer fresh and
convenient food. If there is not enough knowledge in
hygienic engineering & design, how can we expect safe
food throughout the whole supply chain from farm to fork?
Every single day designers, installers, plant managers,
operators, maintenance and cleaning personnel, auditors
and inspectors working for the food chain are forced to
bring innovative as well as traditional skills to their specific
project. If these people are not trained in hygienic
engineering & design, what can we expect?
EHEDG_Innenteil.indd 4
European Hygienic Engineering & Design Group
EHEDG was established with the objective of providing
technical, scientific and economic information on hygienic
design and engineering to the food-processing industry and
to the relevant decision makers in the EU and other
stakeholders.
Our association has been active since 1989 following some
significant food crises resulting from food processing
equipment, process lines and plants that were not
hygienically designed.
Every single day of the year we find ourselves confronted
with hygienic deficiencies which compromise food safety.
These may be flaws in the storage, distribution and retail
chain, in the domestic households or in the food service
sector.
We also discover hygienic failings in the production process
itself and the actual operation of facilities and plants.
Hygienic design very often gets disregarded when
production facilities or parts of them are planned, produced
or assembled.
Even in the areas of development and design for the food
industry we find engineers who in their university studies
never had the opportunity to acquire the necessary hygiene
related skills.
It is therefore hardly remarkable that we are confronted with
hygienic deficiencies each and every day, flaws that find
their origin in the lack of education where food hygiene and
hygienic design are concerned.
It is here that we wish to help. We offer our bulk knowledge
which has been collated and created by experts from the
global hygiene network to industry, trade, schools,
universities and institutes.
Our expertise comprises hygiene related literature, training
courses, workshops, symposia and seminars. Its target is to
close the existing gaps in knowledge and training where
food hygiene and hygienic design is concerned.
This is the only way to guarantee that over the course of time
we shall be able to broaden and spread the knowledge about
food hygiene and hygienic design worldwide so that we can
enjoy safe food each and every day and everywhere.
Yours
President of EHEDG
01.04.11 08:43
 European Hygienic Engineering & Design Group

News from the Treasurer

Piet Steenaard, EHEDG Treasurer
Dr Catzlaan 19 NL 1261 CE Blaricum
E-mail: steenaard@kpnmail.nl

In various disciplines experts shared their knowledge and

created new guidelines or updated existing guidelines. With
the financial income from EHEDG members we could bring
them together and let them do their voluntary work.

The Subgroup Lubricants developed two new guidelines,

Doc. 23 A and B. The Subgroup Chemical Treatment of
Stainless Steel Surfaces is making an update of Doc. 18.
The SG Pumps, Homogenizers and Dampening Devices
started to develop a new guideline. The Subgroup Dry
Materials never slowed down. The Meat Processing Sub-
group will have a guideline available soon. You may expect
a guideline from the Subgroup Open Equipment and from
the Subgroup Seals. The Subgroup Valves is updating of
Documents 14 and 20. The Welding Subgroup will update
Guideline 9. The Subgroup Test Methods created a new
The EHEDG is a non-profit organisation with company
certification scheme and the Subgroup Training and Educa-
members, institute members and individual members. From
tion is continually updating the programme in order to dis-
a financial point of view the years 2009 and 2010 have
seminate know-how following the state of the art. There
been very successful. EHEDG has grown, currently com-
was activity in various other Subgroups like Fish Process-
prising 150 company members (from 105 in 2009) and 42
ing, Cleaning Validation, Chilling and Freezing Equipment,
institutes. All in all the membership has risen from 580 to
Membrane Filtration.
716 active specialists since 2009 (253 of which are individ-
ual members). More are expected to join.
Frequent training courses are organised in the different
countries to train the trainers, engineers and equipment
The day to day business and all the activities from the sub-
designers.
groups and the regions created a workload too high for one
secretary. We welcomed Juliane Honisch in our team to
In October 2010 EHEDG organised an annual conference.
work together with our secretary Susanne Flenner in our
More than twenty topics about hygienic design and engi-
office in Frankfurt.
neering were presented to some 100 delegates. The or-
ganisation was hosted by the EHEDG Regional Section
What have we done with the membership income? EHEDG
Russia in the beautiful city of Saint Petersburg.
continued with the development of EHEDG in the East
European countries. EHEDG regions in Armenia, Russia,
In 2011, the EHEDG World Congress on Hygienic Engi-
Macedonia, Ukraine, and Poland became active. The moti-
neering will be hosted by the EHEDG Regional Section
vation of the people in Eastern Europe to participate in
Macedonia in Ohrid, from September 22- 25.
EHEDG is great. They started to translate the guidelines
and websites to make them available in their local lan-
EHEDG participated in many trade events. Our volunteers
guages. Training courses and workshops closed the gap of
were actively informing hundreds of visitors about the tasks
information about hygienic design and engineering. Gov-
and objectives of EHEDG. Because EHEDG does not re-
ernments showed interest and offered support. We expect
ceive subsidies, companies, institutes and individuals are
regions to start in Bulgaria, Croatia, Romania, Serbia and
invited to join EHEDG as a member. Participate in EHEDG
Slovakia this year. EHEDG is becoming an increasingly
and do not miss essential information! Become part of a
global organisation. Japan, Thailand and Taiwan have
growing number of specialists and share in the ever grow-
started a Regional Section. USA, Canada, India, South
ing knowledge pool!
Africa, and UK will follow soon. We have also seen boom-
ing activities of the subgroups.
Let us keep up the good work!

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 European Hygienic Engineering & Design Group

EHEDG Executive Committee Members

Andrew Batley Juliane Honisch
Nestl Product Technology Center EHEDG Secretariat
NESTEC LTD. GERMANY
SWITZERLAND Phone (+49 69) 66 03-14 30
Phone (+41 31) 7 90 15 86 E-mail: Juliane.Honisch@ehedg.org
E-mail: andrew.batley@rdko.nestle.com
Salwa El Janati
Erwan Billet Lactalis RD
Hydiac FRANCE
FRANCE Phone (+33 24) 3 59 52 18
Phone (+33 61) 2 49 85 84 E-mail: salwa.eljanati@lactalis.fr
E-mail: e.billet@hydiac.com
Ludvig Josefsberg
Professor Olivier Cerf Tetra Pak Processing Systems
Alfort Veterinary School SWEDEN
FRANCE Phone (+46 46) 36 60 01
Phone (+33 1) 43 96 70 34 E-mail: ludvig.josefsberg@tetrapak.com
E-mail: ocerf@vet-alfort.fr
Jacques Kastelein
Susanne Flenner TNO - Quality of Life
EHEDG Secretariat NETHERLANDS
GERMANY Phone (+31 30) 6 94 46 85
Phone (+49 69) 66 03-12 17 E-mail: jacques.kastelein@tno.nl
E-mail: susanne.flenner@ehedg.org
Huub Lelieveld
Dr. Peter Golz NETHERLANDS
VDMA Food Processing and Packaging Machinery Phone (+3130) 2 25 38 96
GERMANY E-mail: huub.lelieveld@inter.nl.net
Phone (+49 69) 66 03-16 56
E-mail: peter.golz@vdma.org Knuth Lorenzen
GERMANY
Richard Groenendijk Phone (+49 4173) 83 64
Stork Food & Dairy Systems B.V. E-mail: knuth.lorenzen@ewetel.net
NETHERLANDS
Phone (+31 20) 6 34 86 48 Dirk Nikoleiski
E-mail: richard.groenendijk@sfds.eu Kraft Foods R&D Inc.
Product Protection & Hygienic Design
Christophe Hermon GERMANY
Conservation des Produits Agricoles Phone (+49 89) 6 27 38 61 14
CTCPA - Centre Technique de la E-mail: dnikoleiski@krafteurope.com
FRANCE
Phone (+33 2) 40 40 47 41 Susanna Norrby
E-mail: chermon@ctcpa.org Alfa Laval Tumba AB
SWEDEN
Dr. Jrgen Hofmann Phone (+46 85) 3 06 56 33
Ingenieurbro Hofmann E-mail: susanna.norrby@alfalaval.com
Hygienic Design Experte
GERMANY Arno Peter
Phone (+49 8161) 8 76 87 99 GEA TDS GmbH
E-mail: jh@hd-experte.de Niederlassung Bchen
GERMANY
Dr. John Holah Phone (+49 4155) 49-24 27
Campden BRI E-mail: arno.peter@geagroup.com
GREAT BRITAIN
Phone (+44 1386) 84 20 41
E-mail: j.holah@campden.co.uk

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 EHEDG Executive Committee Members 7

Satu Salo Dr. Gun Wirtanen

VTT VTT
Industrial Contamination Control FINLAND
FINLAND Phone (+358 20) 7 22 52 22
Phone (+358 20) 7 22 71 21 E-mail: gun.wirtanen@vtt.fi
E-mail: satu.salo@vtt.fi
Patrick Wouters
Tracy Schonrock Unilever Research Laboratory
11302 Alms House Ct. NETHERLANDS
UNITED STATES OF AMERICA Phone (+3110) 4 60 50 28
Phone (+1 703) 5 03 29 71 E-mail: patrick.wouters@unilever.com
E-mail: ftracy1@cox.net
This shows the Executive Committee as listed in 2011.
Piet Steenaard
EHEDG Treasurer
NETHERLANDS
Phone (+31 35) 5 38 36 38
E-mail: steenaard@kpnmail.nl

EHEDG_Innenteil.indd 7 01.04.11 08:43


EHEDG company and institute members
EHEDG thanks its members for their continued support
AFRISO-EURO-INDEX
GmbH, Germany
AGORIA Federation
Multisectorielle de LIndustrie
Technologique, Belgium
AINIA Centro Tecnolgico,
Denmark
Akvatekhavtomatika CJSC,
Austria
Alfa Laval Tumba AB, Sweden
AMEC, Spain
amixon GmbH, Germany
AMMAG GmbH, Austra
Anderol BV, Netherlands
APV Rosista GmbH, Germany
Armaturenbau GmbH,
Germany
Armaturenwerk Htensleben
GmbH, Germany
Arol Spa, Italy
Aseptomag AG, Switzerland
AVK GUMMI A/S, Denmark
AZO GmbH & Co. KG,
Germany
Nordischer Maschinenbau
Rud. Baader GmbH & Co. KG,
Germany
Balluff GmbH, Germany
Bari Samaratsi LLC, Armenia
Robert Bosch Packaging
Technology B.V., Netherlands
Bosch Rexroth Pneumatics
GmbH, Germany
BOSSAR Rovema Ibrica
S.A., Spain
BP Biofuels UK Ltd, United
Kingdom
Brabender Technologie KG,
Germany
Brinox Engineering d.o.o.,
SLO
Burggraaf & Partners B.V.,
Netherlands
European Hygienic Engineering & Design Group
www.afriso.de Campina GmbH CPE Supply www.en.frieslandcampina.com
Chain Germany, Germany
www.agoria.be Cargill, Belgium www.cerestar.com
Cederroth AB, Sweden www.cederroth.com
www.ainia.es CENTA Centre of New Food www.centa.cat
Technologies and Processes,
Spain
www.akvatekh.narod.ru
Central Hygiene Limited, www.central-hygiene.co.uk
United Kingdom
www.alfalaval.com
CFT S.p.a., Italy www.cftrossicatelli.com
www.amec.es
Chronos BTH, Netherlands www.chronosbth.com
www.amixon.de
Ciptec Services, Finland www.ciptec.fi
www.ammag.com
Clyde Materials Handling Ltd, www.clydematerials.com
www.anderol.com United Kindgom
www.apv.com Cocker Consulting Ltd., www.cocker.ie
Ireland
www.armaturenbau.com
Consulting & Training Center
KEY, Macedonia
www.awh.de
Coperion Waeschle www.coperion.com
GmbH & Co. KG, Germany
www.arol.it
John Crane GmbH Gleitring- www.johncrane.de
www.aseptomag.ch dichtungssysteme, Germany
www.avkgummi.dk CSF Inox S.p.A., Italy www.csf.it
www.azo.de Danish Technological www.dti.dk
Institute, Denmark
www.baader.com Defontaine S.A., France www.defontaine.fr
DGL Deutsche Gesellschaft www.dgl-com.de
fr Lebensmittelsicherheit,
www.balluff.com Wasser-und Umwelt,
Germany
Dinnissen BV, Netherlands www.dinnissen.nl
www.boschpackaging.com
Diversey Europe BV EMA www.diversey.com
Headquarters, Netherlands
www.boschrexroth.com
DTU Technical University of www.biocentrum.dtu.dk
Denmark
www.bossar.com
Ecolab Deutschland GmbH, www.ecolab.com
Germany
www.bp.com/biofuels
Elmar Europe GmbH, www.elmarworldwide.com
Germany
www.brabender-technologie.com
Endress + Hauser Japan, www.jp.endress.com
Japan
www.brinox.si
Eurobinox S.A., France www.eurobinox.com
www.burggraaf.cc FAFNIR GmbH, Germany www.fafnir.de
Festo AG & Co. KG www.festo.de

FIRDI Food Industry Research
and Development Institute,
Thailand
Food Masters Ltd.
Engineering & Equipment
Supply, Israel
Foundation Food Micro &
Innovation, Netherlands
Fraunhofer-Anwendungs-
zentrum Verarbeitungsma-
schinen und Verpackungs-
technik, Germany
Fraunhofer Institut fr Produk-
tionstechnik und Automatisie-
rung, Germany
Freudenberg Process Seals
GmbH & Co. KG, Germany
Friesland Campina Nederland
B.V., Netherlands
Funke Wrmeaustauscher
Apparatebau GmbH, Germany
GEA Avapac Ltd.,
New Zealand
GEA TDS GmbH, Germany
GEM Gebr. Mller Appa-
ratebau GmbH & Co. KG,
Germany
Gericke GmbH, Germany
Gram Equipment A/S,
Denmark
Grontmij Industrial Division,
Netherlands
Habasit AG, Switzerland
hwa GmbH & Co. KG, Spain
HECHT Technologie GmbH,
Germany
H.J. Heinz & Co Ltd, United
Kingdom
Hengesbach GmbH & Co. KG,
Germany
HENKEL Lohnpoliertechnik
GmbH, Germany
Herding GmbH Filtertechnik,
Germany
HES-SO University of Applied
Sciences Western Switzer-
land, Switzerland
Hochschule Fulda, Germany
HRS Spiratube S.L., Spain
IDMC Limited, India
EHEDG_Innenteil.indd 9
www.firdi.org.tw
www.foodmast.com
www.foodmicro.nl
www.avv.fraunhofer.de
www.ipa.fraunhofer.de
www.freudenberg.dewww.freude
nberg-process-seals.de
www.frieslandcampina.com
www.funke.de
www.avapac.com
www.gea-tds.com
www.gemue.de
www.gericke.net
www.gram-equipment.com
www.grontmij.nl
www.habasit.com
www.haewa.de
www.hecht.eu
www.hjheinz.ie
www.hengesbach.biz
www.henkel-epol.com
www.herding.de
www.hevs.ch
www.hs-fulda.de
www.hrs-spiratube.com
www.idmc.coop
EHEDG company and institute members 9
Interroll (Schweiz) AG, www.interroll.ch
Switzerland
Intralox L.L.C. Europe Modu- www.intralox.com
lar Plastic Conveyor Belts,
Netherlands
D. Iordanidis S.A, Greece www.iordanidis-pumps.gr
ITDI, S.L., Spain www.itdi.es
JFMA The Japan Food www.fooma.or.jp
Machinery Manufacturers,
Japan
J-TEC Material Handling, www.j-tec.com
Belgium
Kanto Kongoki Industrial Ltd., www.kanto-mixer.co.jp
Japan
KHS GmbH Werk www.khs.com
Bad Kreuznach, Germany
G.A. KIESEL GmbH, www.kiesel-online.de
Germany
Kieselmann GmbH, Germany www.kieselmann.de
Maschinenbau Kitz GmbH, www.maschinenbau-kitz.de
Germany
KNOLL Maschinenbau GmbH, www.knoll-mb.de
Germany
KOBOLD Messring GmbH, www.kobold.com
Germany
Kraft Foods R&D Inc., www.kraftfoods.de
Germany
Krones AG, Germany www.krones.com
LABOM Mess- u. Regel- www.labom.com
technik GmbH, Germany
LECHLER GmbH, Germany www.lechler.de
Jrgen Lhrke GmbH, www.loehrke.com
Germany
Lbbers Anlagen und Umwelt- www.luebbers.org
technik GmbH, Germany
M&S Armaturen GmbH, www.ms-armaturen.de
Germany
Marel Food Systems B.V., www.marel.com
Netherlands
Mettler Toledo AG Process www.mt.com
Analytics, Switzerland
MGT Liquid Process Systems www.mgt.co.il
Industrial Area Maalot, Israel
Microzero Corporation, Japan www.microzero.co.jp
MikroPul GmbH, Germany www.mikropul.de
MST Stainless Steel Sdn. www.minox.biz
Bhd., Malaysia
MULTIVAC Sepp Haggen- www.multivac.de
mller GmbH & Co. KG,
Germany
01.04.11 08:43
10 EHEDG company and institute members
National Institute of R&D
for Machines & Installations
for Agriculture and Food
Industries, Romania
NESTEC Ltd., Switzerland
Nestl S.A., Switzerland
Nocado GmbH & Co. KG,
Germany
Novozymes A/S, Denmark
Nu-Con Ltd, New Zealand
Parker Hannifin Corporation
Pneumatics Div.
Europe/Automation Group,
United Kingdom
Pepperl+Fuchs GmbH
Pneumatic Scale Angelus,
USA
PNR Italia, Italy
POWER Engineers, Inc.,
United Kingdom
Purdue University, USA
Gebr. Rieger GmbH + Co.
KG, Germany
Rittal GmbH & Co. KG,
Germany
Rondotest GmbH & Co. KG,
Germany
RS Roman Seliger Armaturen-
fabrik GmbH, Germany
RULAND Engineering &
Consulting GmbH, Germany
SAMSON REGULATION S.A.,
France
Scanjet Systems AB, Sweden
seepex GmbH, Germany
SEITAL Separatori Italia Srl,
Italy
Serac, France
SEW Food & Process bv,
Netherlands
SGS INSTITUT FRESENIUS
GmbH, Germany
SICK AG, Germany
Simon Ingenieria SL,
SpainSIS Natural LLC
Cannery, Armenia
SISTO Armaturen S.A.,
Luxembourg
www.inma.ro SKF Sverige AB, Sweden www.skf.com
SOLIDS COMPONENTS www.migsa.es
MIGSA, S.L., Spain
www.nestle.com Solids system-technik s.l., www.solids.de
Spain
www.nestle.com
SONTEC Sensorbau GmbH, www.sontec.de
www.nocado.de Germany
SORMAC B.V., Netherlands www.sormac.nl
www.novozymes.com
Gebr. Steimel GmbH & Co. www.steimel.com
www.nucon.com Maschinenfabrik, Germany
www.parkermotion.com/ Stephan Machinery GmbH, www.stephan-machinery.com
pneu/food Germany
Stork Food & Dairy Systems www.fds.storkgroup.com
B.V., Netherlands
www.pepperl-fuchs.com
Stranda Prolog AS, Norway www.stranda.net
www.psangelus.com
Sdmo Components GmbH, www.suedmo.de
Germany
www.pnr.it
system-technik GmbH, www.solids.de
www.powereng.com Germany
Taiwan Filler Tech. Co., Ltd, www.twftc.com
www.purdue.edu Thailand
Tanis Food Tec b.v., www.tanisfoodtec.com
www.rr-rieger.de Netherlands
Technische Universitt www.vat.tu-dresden.de
www.rittal.de Dresden, Germany
Tetra Pak Packaging www.tetrapak.com
www.rondoshop.de Solutions AB, Sweden
TPI Chile S.A., RCH www.tpi.cl
www.rs-seliger.de
Forschungszentrum Weihen- www.blq-weihenstephan.de
stephan fr Brau- und Lebens-
www.rulandec.de mittelqualitt Technische
Universitt Mnchen,
Germany
www.samson.fr
ULMA Packaging www.ulmapackaging.com
Technological Center, Spain
www.scanjetsystems.com
Unilever Research Laboratory www.unilever.com
www.seepex.com Vlaardingen, Netherlands
www.seital.it University of Parma, Italy www.unipr.it
VAK Kimsa, S.A., Spain www.vakkimsa.es
www.serac-group.com
Van Beek, Netherlands www.van-beek.nl
www.seworks.nl
Van Meeuwen Smeertechniek www.vanmeeuwen.nl
B.V., Netherlands
www.institut-fresenius.de
VDMA Fachverband www.vdma.org
Nahrungsmittelmaschinen und
www.sick.de Verpackungsmaschinen,
www.sisnatural.am Germany
Vienna University of Technol- www.vt.tuwien.ac.at
ogy / Institute of Chemical
www.sisto.de Engineering, Austria
Vincas Srl, Italy www.vincas.it

von Rohr Armaturen AG, www.von-rohr.ch
Switzerland
VTT Technical Research www.vtt.fi
Centre of Finland, Finland
Wennekes Welding Support www.weldingsupport.nl
BV, Netherlands
Wenzhou Aomi Fluid Equip- www.wzaomi.com
ment Science & Technology
Co., Ltd., People's Republic of
China
Wire Belt Co Ltd, United www.wirebelt.co.uk
Kingdom
EHEDG membership
EHEDG Membership
The EHEDG network is open to individuals, companies and
institutes and comprises more than 700 persons who are
the representatives of
Companies for the manufacturing of food or of equip-
ment for the production of food, pharmaceuticals and/or
cosmetics
Companies supplying engineering services
Scientific and research organisations
Health authorities.
EHEDG is an "Institution for General Benefit" and donations
may be fully deducted from tax.
Good reasons to become an EHEDG member
EHEDG is aiming to create a central, internationally
recognised source of excellence on hygienic engineer-
ing
EHEDG provides networking on an international level,
opportunities for the establishment of global contacts
and interlinking with its Regional Sections
EHEDG is a platform for the exchange of state-of-the-
art know-how and offers advancement in knowledge
EHEDG provides influence in setting global standards
and rules and has impact on regulatory bodies
EHEDG offers a legal basis by practically demonstrating
how to follow existing requirements and standards
EHEDG guidelines are referenced by international or-
ganisations and provide practical know-how
EHEDG guidelines are created by gathering the expert
know-how of its members who are equipment manufac-
turers of food and packaging machinery as well as food
processing companies, research institutes and health
authorities
EHEDG adds to defence arguments in court cases
when it can be demonstrated that guidelines have been
observed
EHEDG follows up new trends and helps to share, dis-
seminate and channel hygienic design know-how
EHEDG_Innenteil.indd 11
EHEDG company and institute members 11
Zeppelin Reimelt GmbH, www.reimelt.de
Germany
Zrcher Hochschule fr www.lsfm.zhaw.ch
Angewandte Wissenschaften,
Switzerland
EHEDG extends the EHEDG mission to environmental
issues and aims to support food safety and sustainabil-
ity
EHEDG evaluates hygienic design in relation to shelf-
life
EHEDG provides high-level training & education on an
international level and its training material is developed
by recognised experts in the field
EHEDG provides a unique certification scheme and
equipment certification by EHEDG-authorised test insti-
tutes
EHEDG-recognised certification methods are continu-
ously being developed and complemented by new test
methods
EHEDG provides reference publications like the
EHEDG Yearbook and press articles in trade journals
and magazines
EHEDG enhances the good reputation of its member
companies and makes them leaders in Hygienic Design
and Processing
Benefits for Company and Institute Members:
Company / institute members are authorised to use the
EHEDG company member logo under agreed condi-
tions.
Companies and institute memberships award at least
one, and up to four, free individual memberships
Publication of the companys / institute logo and name
on the EHEDG website, conference programmes, bro-
chures, etc.
Hyperlink from the EHEDG website
Whole series of the EHEDG guidelines including up-
dates
Discount or waiver of registration fees for EHEDG spon-
sored conferences
Access to training courses
Discounted or complimentary EHEDG training toolbox
(depending on the annual contribution)
01.04.11 08:43

The EHEDG Website
Susanne Flenner, EHEDG Secretariat
E-mail: susanne.flenner@ehedg.org
Since its relaunch at the end of 2008, the EHEDG Website
www.ehedg.org has undergone comprehensive improve-
ments and features new add-ons. As a first step, the front-
end which is accessible by all visitors had been structured
and re-arranged into the following chapters:
The Home page comprises all the general EHEDG informa-
tion including its objectives and organisational structure,
information on the Regional Sections, EHEDG publications
and recommended literature.
Training & Education informs on the scope of the EHEDG
training course programmes based on the EHEDG guide-
lines, explains the use of the Training Toolbox and the
Facilitator and gives information on upcoming international
and regional hygienic design courses as well as on the
training target groups and the authorized trainers.
The Guidelines section provides information on all pub-
lished EHEDG documents and summarises their contents.
Flow charts and accompanying notes describe the guide-
line review and approval process. EHEDG Company and
Institute Members can download all documents in all lan-
guage versions available directly from the Guidelines sec-
tion after member login while individual and non-members
are referred to the webshop http://www.world-of-
engineering.eu/EHEDG:::390.html for purchasing the
documents.
Certification explains in detail the EHEDG test methods
and the equipment certification scheme and provides in-
formation on the EHEDG test and certification institutes as
well as the contact details. The List of Certified Equipment
is a comprehensive database offering various selection
parameters to assess all equipment which have success-
fully passed the EHEDG certification procedure.
The Subgroups section provides information on the
EHEDG work group clusters and their individual groups
including all documents published by them as well as the
EHEDG_Innenteil.indd 12
European Hygienic Engineering & Design Group
C
contact details of all Chairmen. The section is interlinked M
with the EHEDG Subgroup News providing information on
the current status of work as well as on future meetings and Y
the guideline development status. CM
MY
The News & Events section highlights at a glance all re-
cent and future EHEDG Regional Section events, Sub- CY
group work and meetings, training courses, congresses, CMY
exhibitions as well as publications and other important K
general information.
Membership explains the benefits of an EHEDG individual,
company or institute membership and new members are
welcome to directly register via the online form presented
here. In addition, companies and institutes can download
the annual EHEDG member logo after login and their
names and logos are listed and interlinked.
The heart of the EHEDG website is its Back-end (only
visible after member login). It is the major EHEDG commu-
nication platform and comprises much more information
available to members. Subgroup experts and Regional
Chairmen have access to various file sections according to
their individual needs from where they can download /
upload all relevant subgroup and meeting information, work
documents, guideline drafts, pictures, presentations or
whatever they need for their active work within EHEDG.
Subgroups can add all work documentation to their
download sections and can use them as a platform for
information exchange.
The website contents have been translated into the lan-
guages of most Regional Sections. For the time being,
apart from English, the following languages are available:
Armenian, Danish, Dutch, French, German, Italian, Japa-
nese, Polish and Spanish others will follow. In the near
future, the News & Events Sections will be complemented
by additional information of the Regional Sections in their
own languages.
The EHEDG website is thus the major communication
platform and a multi-level database for the members allow-
ing them to view exactly the contents of interest to them.
Welcome to the network!
Susanne Flenner
EHEDG Secretariat
Lyoner Str. 18
60528 Frankfurt am Main
Germany
Phone: +49 69 6603-1217
Fax: +49 69 6603-2217
E-Mail: secretariat@ehedg.org /
susanne.flenner@ehedg.org
Web: www.ehedg.org
01.04.11 08:43 Anz_EH
 Anz_EHEDG_FZW_gb.pdf 1 10.01.11 12:15

Technische Universitt Mnchen

Research Center Weihenstephan

C
for Brewing and Food Quality
M

Y
STATE-OWNED INDEPENDENT COMPETENT
CM

ANALYSES HYGIENIC DESIGN

MY

CY

CMY
CONSULTING PILOT BREWERY
K

RESEARCH & YEAST CENTER

DEVELOPMENT CERTIFICATION

Our laboratories are accredited according to DIN EN ISO/IEC 17025:2005.

Analytische Qualittssicherung Bayern (AQS). Certificates to TrinkwV 2001.

Alte Akademie 3 D-85354 Freising Phone +49 (0) 8161/ 71- 33 31 blq@wzw.tum.de

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EHEDG_Innenteil.indd 13 1 10.01.11 08:43
01.04.11 12:17

Hygiene requirements of the EU Directive 2006/42/EC
on machinery
The EU Machinery Directive 2006/42/EC establishes the legal framework concerning machinery
safety and hygienic design for all machines brought into the European market. The hygienic
design requirements of the latest revised version of the directive are not only valid for food
pro-cessing machinery, but also for machinery coming in contact with cosmetics and pharma-
ceutical products. The following article describes the main requirements and highlights some
aspects of interest to the food manufacturing industry.
Hans-Werner Bellin, BELLINconsult, Aarbergen, Germany
E-mail: hans-werner.bellin@bellinconsult.de
The revised version of the EU Machinery Directive
2006/42/EC, which came into force at the end of 2009, sets
out the essential requirements for machinery in Europe. All
machines brought to the European market must fulfil these
requirements. The CE mark, which identifies industrial
equipment as in compliance with all the of safety require-
ments established by the European Union must appear on
each unit.
Annex I of the Machinery Directive describes in detail what
has to be taken into consideration to build safe machines.
Of particular interest to the food industry is Chapter 2.1 of
Annex I, entitled Foodstuffs machinery and machinery for
cosmetics or pharmaceutical products. This chapter not
only takes into consideration potentially hazardous situa-
tions for equipment operators and the environment in which
the machine is used, but it is the only chapter in this Direc-
tive that refers to the potential hazards for the consumer of
the product produced on these machines. Essentially, this
means that mistakes caused by neglecting these require-
ments can even have a strong impact on public health.
Requirements for food processing equip-
ment
Under Section 2.1.1, General, the Directive states: "Ma-
chinery intended for use with foodstuffs or with cosmetics
or pharmaceutical products must be designed and con-
structed in such a way as to avoid any risk of infection,
sickness or contagion.
The following requirements must be observed:
a) materials in contact with, or intended to come into
contact with, foodstuffs or cosmetics or pharmaceutical
products must satisfy the conditions set down in the
relevant Directives. The machinery must be designed
and constructed in such a way that these materials can
be cleaned before each use. Where this is not possible
disposable parts must be used;
b) all surfaces in contact with foodstuffs or cosmetics or
pharmaceutical products, other than surfaces of dis-
posable parts, must:
be smooth and have neither ridges nor crevices
which could harbour organic materials. The same
applies to their joinings,
EHEDG_Innenteil.indd 14
European Hygienic Engineering & Design Group
be designed and constructed in such a way as to
reduce the projections, edges and recesses of
assemblies to a minimum,
be easily cleaned and disinfected, where necessary
after removing easily dismantled parts; the inside
surfaces must have curves with a radius sufficient
to allow thorough cleaning;
c) it must be possible for liquids, gases and aerosols
deriving from foodstuffs, cosmetics or pharmaceutical
products as well as from cleaning, disinfecting and
rinsing fluids to be completely discharged from the ma-
chinery (if possible, in a cleaning position);
d) machinery must be designed and constructed in such
a way as to prevent any substances or living creatures,
in particular insects, from entering, or any organic mat-
ter from accumulating in, areas that cannot be cleaned;
e) machinery must be designed and constructed in such
a way that no ancillary substances hazardous to
health, including the lubricants used, can come into
contact with foodstuffs, cosmetics or pharmaceutical
products. Where necessary, machinery must be de-
signed and constructed in such a way that continuing
compliance with this requirement can be checked.
Further, in Section 2.1.2, Instructions, the Directive states:
The instructions for foodstuffs machinery and machinery
for use with cosmetics or pharmaceutical products must
indicate recommended products and methods for cleaning,
disinfecting and rinsing, not only for easily accessible areas
but also for areas to which access is impossible or inadvis-
able."
The Directive does not cover every possible critical point,
but rather, outlines the main issues. For food processing
machines, so-called "C-Standards," are provided in some
detail, however, including how the design of the machine
and e.g. the roughness of the surfaces should be in contact
with specific products. The standards EN ISO 14159,
"Safety of machinery - Hygiene requirements for the design
of machinery (ISO 14159:2002) and EN 1672-2, "Food
processing machinery - Basic concepts - Part 2: Hygiene
requirements" describe the aim of the Directive through
examples. Machinery producers who design their machin-
01.04.11 08:43
 Hygiene requirements of the EU Directive 2006/42/EC on machinery
ery according to these standards are considered to be
fulfilling the Machinery Directive in this area and can de-
clare that their machines are in conformance with the re-
quirements. Both standards show a scheme for conducting
risk assessment to ensure that all relevant hazardous situa-
tions and potential risks are taken into consideration, that
all results of this analysis have been used in the design of
the machinery, and that the appropriate documentation has
been linked to every project.
In addition to those standards the EHEDG Guidelines
Doc. 8 Hygienic equipment design criteria
Doc. 10 Hygienic design of closed equipment for the
processing of liquid food
Doc. 13 Hygienic design of equipment for open process-
ing
offer additional guidance. The content of these two guide-
lines is comparable with the two CEN standards, and in
some cases, the examples used are the same.
HIGH PERFORMANCE
RUBBER COMPONENTS
- for food and healthcare applications with high
demands on hygienic design and traceability
EHEDG_Innenteil.indd 15
15
There are some minor differences in the definition of the
food zone, but the design of the units should be such that
they can be readily cleaned within an appropriate time.
Ultimately, every machine has to be cleaned, and depend-
ing on the overall cleanability of a machine and its compo-
nents, this can be time-consuming. For this reason it is
much cheaper for food processors to invest in machines
that are designed properly with high cleanability rather than
buying cheaper machines with low cleanability, which might
cause product spoilage or contamination triggered by prod-
uct residues and/or cleaning agents left behind.
For machines that do not meet the "easy to clean" require-
ments of the Machinery Directive and the relevant stan-
dards, the CE conformity is not valid. The only question is,
who decides if something is cleanable or not? For this,
EHEDG provides certification for different equipment. This
is a voluntary approval, that the equipment conforms with
the Machinery Directive. EHEDG is working on new certifi-
cation schemes and guidelines to improve the machines for
more efficient cleanability.
www.avkgummi.dk
01.04.11 08:43

A suggested method for assessing the cleanability of
flooring materials
Since bacteria are able to move from floors to food-contact surfaces, it is important to select
hygienic flooring materials that also are slip-resistant and therefore rough. A simple, cost ef-
fective test based on counting undesirable features is suggested as a first screening tool.
Brigitte Carpentier, French Agency for Food, Environmental and Occupational Health Safety,
Maisons-Alfort Laboratory for Food Safety, 23 Avenue du Gnral de Gaulle, FR-94700 MAISONS-ALFORT, France
E-mail: brigitte.carpentier@anses.fr
Floors are not food-contact surfaces, which is probably why
they are not given enough attention. Food processors are
frequently unaware that microorganisms are able to move
from floors to food-contact surfaces, transported by aero-
sols, including those formed during cleaning (Holah, Tim-
perley and Holder, 1990) or by any item deposited on the
floor and subsequently placed on a food-contact surface.
Compared with food-contact materials that have to be du-
rable and sufficiently smooth to be hygienic, flooring mate-
rials must be slip-resistant to avoid falls, which account for
20% of all workplace injuries resulting in lost working days.
To achieve slip-resistance, large aggregates (with size in
the millimetre range) are incorporated in flooring materials,
making them rough and consequently, more difficult to
clean than smooth ones.
By comparing bacterial counts after cleaning and disinfec-
tion of flooring materials that were placed in a food proc-
essing plant for several weeks, it was found that gas bubble
holes, which did not contribute to slip resistance, were
highly undesirable harbourage sites for microorganisms
(Mettler and Carpentier, 1999). Unfortunately, the test
method to assess cleanability (Mettler and Carpentier,
1999; Carpentier, 2005) did not classify the smooth mate-
rial-containing gas bubble holes as the worst, although in
situ it was significantly more contaminated than all the other
flooring materials tested. Also, the use of the Rvk rough-
ness parameter describing the surface texture at the mi-
crometer scale (Mettler and Carpentier, 1999), while inter-
esting, is not suitable for detecting huge harbourage sites.
Consequently, it was decided to look only for undesirable
features that would be visible under a stereomicroscope.
Described here is a variety of undesirable features ob-
served on 37 new flooring materials, 17 ceramic tiles and
samples from 20 resin-based floors, received from manu-
facturers between 2001 and 2010. For some of these floor-
ing materials, new samples were received several times to
monitor their quality over time. All the observed flooring
materials were selected by the French National Health
Insurance Fund for Salaried Workers (Caisse nationale de
l'assurance maladie des travailleurs salaris/CNAMTS) for
satisfactory slip-resistance (Leclercq, Tisserand and Saul-
nier, 1994) and successful application in food premises,
including factory, catering, wholesale and retail premises.
The aim of this paper is to suggest counting the undesir-
able features as a first screening test to assess the hygi-
enic quality of floors. The different types of flooring materi-
EHEDG_Innenteil.indd 16
European Hygienic Engineering & Design Group
als designed for food premises are not described (for a
comprehensive description, see Carpentier, 2005).
How to proceed?
Because a given commercial reference may include floor-
ing materials of different sizes, the dimensions of ceramic
tiles and the thickness of resin-based samples must be
registered. Special attention must be paid to thickness and,
if appropriate, the highest and lowest thickness of the sam-
ple must be registered. Indeed, a decrease in thickness,
which reduces thermal and mechanical resistance, may
also lead to a modification of the surface texture.
It is recommended 100 cm samples are scanned under a
stereomicroscope at x40 magnification with strong double
lighting. For resin-based flooring materials, the samples
edges should not be considered because they are often
damaged by the cutting performed to produce the sample.
Of course, a smaller area can be scanned if the number of
undesirable features is too large so that the flooring mate-
rial can be considered unhygienic at a first glance. Each
undesirable feature must be marked by an ink point with a
felt-tip pen or permanent marker pen in order to avoid
counting it twice. Unfortunately, photographs taken through
a stereomicroscope are not satisfactory, because even with
a high depth of field and strong double lighting, it is quite
difficult to detect the difference between grooves and
peaks. Therefore, it is not recommended that such photo-
graphs are included with the test results. As shown on
Figures 1 to 10, photographs produced by scanning elec-
tron microscopy, which can only be taken with costly
equipment, are probably the best way to illustrate the
shape of texture defects.
Because the result of such a counting test may vary de-
pending on the experience and concentration of the opera-
tor, it should be done by at least two trained persons on two
different samples.
Description of undesirable features observed
on flooring materials
Holes
Gas bubble holes (Figure 1) may form during the hardening
process of resin-based flooring materials. Although several
techniques can be used to eliminate them following their
application to the floor base, they are frequently observed
in polyurethane-based flooring but can be found in all other
01.04.11 08:43
 A suggested method for assessing the cleanability of flooring materials 17

resin-based floors. They may be big enough to be visible to

the naked eye, but 0.1 mm diameter or even smaller gas
bubble holes may need a stereomicroscope to be detected.
Such holes have also been observed in ceramic tiles, albeit
in small number and size (Figure 2). Holes created by the
removal of aggregates (Figure 3) are frequently observed,
particularly in multicoat resin-based systems when the
aggregates are sprinkled on the finish coat of mortar in-
stead of being mixed with all the flooring components prior
to application. Other kinds of holes can be observed, such
as the ones caused by incorrect application of acrylic ce-
mentitious systems (Figure 4) or those seen in a ceramic
tile (Figure 5).

Cracks
Isolated cracks can be observed in ceramic tiles (Figure 6)
and in polyurethane flooring. Cracks around an aggregate
Figure 2. Gas bubble hole in a ceramic tile.
can be observed in ceramic tiles (Figure 7).

Crumbled aggregates
The quality of the aggregates included in flooring material
to increase slip-resistance may be poor, in which case they
may appear crumbled under the microscope (Figure 8).
Such a defect occurred more often in 2009/2010 (seen on 8
out 26 floors) than in 2008 (seen on 2 out 18 floors).

Insufficiently embedded aggregates

Finally, an undesirable feature that was observed on only
one floor for which only one sample was received in 2004 is
that aggregates are not sufficiently embedded in the floor-
ing material (Figure 9).

Figure 3. Hole created by the removal of an aggregate in an epoxy-

based floor.

Figure 1. Gas bubble hole in an epoxy-based floor.

Figure 4. Holes in an incorrectly applied acrylic cementitious sys-

tem.

EHEDG_Innenteil.indd 17 01.04.11 08:43

 18 A suggested method for assessing the cleanability of flooring materials

F
b

Figure 5. Hole in a ceramic tile Figure 8. Crumbled aggregate in an epoxy-based floor

H
w
H
Figure 6. Cracks in a ceramic tile Figure 9. Aggregates insufficiently embedded in a floor
E
B
t

Figure 7. Cracks around an aggregate in a ceramic tile Figure 10. Sponge structure of a polyurethane-based floor

E
P
E
P

EHEDG_Innenteil.indd 18 01.04.11 08:43

 First class hygiene technology
because safety comes first

Hygiene is an integral part of modern production processes in the food and beverage industry as
well as in the pharmaceutical and cosmetics industry.
Hygiene is also at the core of Ecolab's product and service portfolio.
Ecolabs expertise in hygiene and process optimization is recognized throughout the Food and
Beverage industry. This competence coupled with our knowledge of industrial equipment ensures
the highest standards of hygienic design and quality.

food-safe construction materials

smooth, chemical resistant surfaces
easy to maintain
designed with cleaning in mind
EHEDG and CE certified

Cleaner. Safer. Healthier.

Ecolab Europe GmbH Richtistr. 7 8304 Wallisellen Switzerland
Phone +41 44 877 2000 fab-europe@ecolab.com www.ecolab.com
Ecolab Engineering GmbH Raiffeisenstr. 7 83313 Siegsdorf Germany
Phone +49 86 62 610 www.ecolab-engineering.com

2011 Ecolab. All rights reserved.

EHEDG_Innenteil.indd 19 01.04.11 08:43

 20 A suggested method for assessing the cleanability of flooring materials

Observations concerning flooring materials Acknowledgments

When considering the selected 37 new flooring materials,
only seven (of which six were ceramic tiles) did not reveal
any undesirable feature on a 100 cm sample. In order to
monitor the quality of some flooring materials over time,
samples of several references were requested in 2006,
2008 and 2009. Some of these floors improved; for exam-
ple, on one ceramic tile reference we found: 66 undesirable
features per 100 cm in 2006, 25 in 2008 and only five in
2009. Others worsened over time, for example one resin-
based reference had no undesirable features per 100 cm
in 2006, 72 in 2008 and 193 in 2009. A classification of the
26 flooring materials received in 2009 and 2010 is given in
Table 1. It shows that undesirable features are still fre-
quently found, even though manufacturers have been in-
formed since 2006 that such defects are highly undesirable.
Counting those features is suggested as a first step in as-
sessing the hygienic quality of flooring materials.
The author is grateful to Stephan Borensztajn for taking the
scanning electron microscopy photographs, and to Vanina
Viale, Jean-Paul Liot and Henri Saulnier for their long co-
operation in the search for flooring materials that are both
slip-resistant and hygienic. Many thanks also to John Kerr
for the English correction and to Anne-Marie Leconte for
organizational assistance.
References
Carpentier, B. (2005). Improving the design of floors. In Handbook
of Hygiene Control in the Food Industry. Lelieveld, H.L.M., Mostert,
M.A. and Holah, J.T., eds. pp.168-182. Cambridge: Woodhead
Publishing Ltd.
Holah, J.T., Timperley, A.W. and Holder, J.S. (1990). The spread
of Listeria by cleaning systems: Campden Food and Drink Re-
search Association. Technical memorandum No. 590

Leclercq, S., Tisserand, M. and Saulnier, H. (1994). Assessment of

Table 1. Number of flooring materials received in 2009-
the slip resistance of floors in the laboratory and in the field: two
2010 in terms of the number of undesirable features per complementary methods for two applications. International Journal
100 cm (N). of Industrial Ergonomics 13, 297-305.

N5 5  N 30 30  N 70 N > 70 Mettler, E. and Carpentier, B. (1999). Hygienic quality of floors in

relation to surface texture. Transaction of the Institute of Chemical
CT* R** CT* R** CT* R** CT* R**
Engineers 77, 90-95.
7 6 3 3 2 1 3 1
*CT= ceramic tile, ** Resin-based flooring material

Conclusion

There are limitations of such a counting test. Of course,

depending on their size, not all the undesirable features
have the same retention ability with respect to microorgan-
isms. Moreover, conducting the test on new materials does
not give any information about the attachment strength of
the aggregates or about the impact of wear on the surface
texture. It was noticed that aggregates can sometimes be
detached very easily by simply scratching them with a me-
tallic object. Some materials were very soft and easily
scratched by a metallic object. Such materials showed an
undesirable sponge structure at the micrometer scale that
could not be detected under the stereomicroscope (Figure
10). Finally, this test cannot detect whether the use of a
finish coat to fill the gas bubble holes or other defects is
relevant or not. As a consequence, this counting test
should be considered as a first screening tool that has the
advantage of being simple, cost effective and easily carried
out by manufacturers to improve their floors.

Unfortunately, these results do not allow any decision about

how many undesirable features are acceptable. It may
happen that the most hygienic floors in terms of number of
undesirable features are not adapted to the constraints of
some industrial premises. The flooring materials also must
be screened for abrasion, wear and temperature or chemi-
cal resistance characteristics in order that the best trade-off
between slip-resistance, durability and hygienic properties
can be made for each type of constraint encountered in
each type of food premises.

EHEDG_Innenteil.indd 20 01.04.11 08:43

 European Hygienic Engineering & Design Group

Comparison of materials used in food refrigeration

equipment with respect to ease of removal of organic soil
The cleanability test of surface materials presented here includes soiling of 1 cm with an
organic soil, cleaning by swabbing and quantifying the residual soil by epifluorescence
microscopy. This method, very simple to implement, has the advantage of highlighting very
small quantities of a large variety of soils.

Olivier FIRMESSE, Danile CHASSAING, Anne-Marie LECONTE, Brigitte CARPENTIER. French Agency for Food,
Environmental and Occupational Health Safety (ANSES), Maisons-Alfort Laboratory for Food Safety, 23 avenue du
Gnral de Gaulle, FR-94700 Maisons-Alfort, France
E-mail: olivier.firmesse@anses.fr, danielle.chassaing@anses.fr, anne-marie.leconte@anses.fr,
brigitte.carpentier@anses.fr

Introduction cleaned one material at a time in new alkaline detergent

solution 3% (v/v) RBS 35 according to the protocol
The cleanability of materials is an issue that has been the described by Leriche and Carpentier (1995). Water contact
subject of many studies, all based on the quantification of angles were measured by the sessile drop method using a
residual soil after the cleaning of soiled materials (Ridenour goniometer (Krss, Palaiseau, France) on each material
and Armbruster, 1953; Masurovsky and Jordan, 1958; cleaned (10 measurements per material) as described by
Leclercq-Perlat and Lalande, 1994; Boistier-Marquis et al., Carpentier and Midelet (2002). The following roughness
2000; Boyd et al., 2001; Kuisma, 2006; Detry et al., 2007; parameters were measured: arithmetic average (Ra) and
Kuisma et al., 2009). There are a great variety of soils, reduced valley depth (Rvk). Measurements were made on
cleaning methods and methods for quantifying residual cleaned materials using a surface-tracing tool (Perthometer
soils. The choice of a soil is usually determined by the use S3P) equipped with a stylus radius of five micrometers and
for which the materials are intended, and the cleaning cone angle of 90, held by a RWF 750 arm and moved by a
process must be representative of whichever method is SPVK drive unit (Feinprf Perthen GmbH, Gttingen,
likely to be used. Germany) at a cut-off wavelength limit of 0.8 mm as
detailed by Mettler and Carpentier (1999). For each
We aimed at comparing the cleanability of various material 10 measures, five in the longitudinal direction and
construction materials for refrigerated serve-over counters five in the width direction, were carried out.
or display cabinets. Since this type of equipment is used,
amongst others, to sell delicatessen, a soil based on liver
pork pt was chosen. Since in field conditions the Table 1. Tested materials and their uses.
surfaces are cleaned by scrubbing with a cloth soaked in a Abbreviat Thicknes
Materials Use*
ion s (mm)
detergent/disinfectant solution, we performed this by Metal coated with Inner lining of injected
scrubbing with a swab. Epifluorescence microscopy was plastic
PM 0.5 tanks (NFC)
used to quantify the residual soil (i.e., the percentage of a Acrylonitrile
ABS 6
Various parts located
butadiene styrene within tanks (NFC)
field covered by soil). This method, very simple to Polyethylene Separation between or
implement, has the advantage of highlighting very small terephthalate glycol
PETG 3 within shelves (FC)
quantities of soils of varied nature: either food extracts, oils, Stainless steel Z2
Inner lining of injected
CN 18/10 (AISI 304 SS Z2CN 0.5
proteins or carbohydrates (Whitehead, Smith and Verran, 2B)
tanks (NFC)

2010). Polyethylene PE 15 Cutting boards (FC)

Fittings (shelves,

Materials and methods White painted

galvanised metal
WPGM
The organic soil was canned liver pate (Casino brand,
Black painted
France) based on pork fat, meat and liver. Twenty grams of galvanised metal
BPGM
pate were added to 80 mL of distilled water in a sterile
Stomacher bag, the mixture was then homogenized for 1 Stainless steel T.25 SS T25
min using a Stomacher 400 (Chemunex AES, Bruz,
France) and stored at -30C in 1 mL tubes. Prior to testing,
1
sheaths), decorative
sheets (frontons,
facades) (FC)
Fittings (shelves,
sheaths), decorative
1 sheets (frontons,
facades) (FC)
Decorative sheets
0.7 (frontons, facades)
(NFC)
Paint, fittings, decorative

a further 1:5 (v/v) dilution was performed after thawing. Galvanised metal GM 1 1 sheets (frontons,
facades, backing) (NFC)
Preliminary tests on stainless steel (not shown) showed Outer lining of injected
that this dilution was sufficient for the soil to be detectable Galvanised metal GM 0.5 0.5
tanks, outer sheet of
furniture, ballast boxes
while less dilution caused too heavy soiling. Ten new (NFC)
materials received in 2007 and used in the construction of
refrigerated serve-over counters and display cabinets *Within brackets: FC= food-contact surface; NFC= non-food
(Bonnet Nv, Hendaye, France) were used (Table 1) in contact surface.
the form of 2.5 cmu4 cm coupons. The coupons were

EHEDG_Innenteil.indd 21 01.04.11 08:43

 22 Comparison of materials used in food refrigeration equipment with respect to ease of removal of organic soil

On each coupon, a square of 1 cm was drawn with a Results

marker delivering a hydrophobic substance (Dakopen,
Dako, Trappes, France) to delineate the area of deposition The water contact angles and the roughness parameters,
of the organic soil and thus prevent its spread on the Ra and Rvk, are presented in Table 2. It was found that nine
surface. One hundred L of the soil based on liver pate out of 10 materials had Ra less than 0.8 m and that Rvk is
were deposited inside the square. The materials were then always greater than Ra except for the GM 1. The water
placed under a laminar flow hood for 2 h to 2 h 30 min to contact angle ranged from 64 (GM 1) to 81 (BPGM, GM
dryness. The materials were then either stained as 0.5). It is remarkable that these significantly different (P =
described below, or subjected to a cleaning operation using 0.0002) extremes were the two galvanised metals, which at
one of the following solutions: either a 1.5% (w/v) solution first glance only differed by their thickness.
of an alkaline chlorinated product (P3 Topax M95, Ecolab,
Issy-les-Moulineaux, France) (half the concentration
recommended by the manufacturer); or a 0.07% (w/v) Table 2. Roughness parameters Ra (arithmetic average
degreasing and disinfectant solution based on alcohols and roughness) and Rvk (reduced valley depth) of materials and
biguanide (Divosan S5, Johnson-Diversey, Fontenay-sous- water contact angles. Standard deviations (SD) are given in
Bois, France) (1:10 of the concentration recommended by brackets (n=10).
the manufacturer). This product is specifically
recommended for cleaning and disinfecting refrigerated Mean water
Mean Ra (m) Mean Rvk (m)
Materials contact angle
serve-over counters. To achieve this, a swab previously
(SD) (SD)
immersed in a solution was scrubbed horizontally, vertically (SD)
and diagonally on the soiled surface. The same person
always did this swabbing since we have observed (results 0.67 1.30 69
PM
not shown) that the intensity of the swabbing could be (0.38) (1.35) (7)
significantly different from one person to another. After
cleaning, the coupons were placed under a laminar flow 0.34 0.58 68
until visually dry (5 min, approximately). The staining of the ABS
(0.04) (0.19) (4)
soil was made by depositing on the defined area 100 L of
a 0.01% solution of acridine orange in water that was
0.33 0.39 77
previously deionized and filtered through a membrane with PETG
0.22 m pore diameter. After 10 min in the dark, the (0.02) (0.04) (3)
materials were rinsed by pouring 25 mL of filtered
deionized water, and observed under epifluorescence 0.29 0.47 71
SS Z2CN
microscopy (oil immersion, magnification x100, Axioskop, (0.02) (0.10) (5)
Zeiss, France) connected to a CCD camera (Jaim50,
Adersa, Palaiseau, France). The amount of soil was 1.20 3.40 79
assessed by measuring the percentage of a field covered PE
by the stained soil using the image analysis software (0.48) (1.45) (4)
Photofiltre v.6.4.0 (Copyright Antonio Da Cruz). The
experiment was performed twice and for each experiment, 0.22 0.32 80
WPGM
five images were analysed. (0.02) (0.08) (7)

Statistical analyses of surface coverage measurements 0.20 0.35 81

were made by variance analysis using StatGraphics BPGM
(0.02) (0.06) (2)
Centurion software, v.15.2 (Sigmaplus, Levallois-Perret,
France). When all the coverage of the same material 0.28 0.57 72
returned zero, the material was excluded from the analysis SS T25
of variance to retain only the observations where the (0.06) (0.35) (2)
variances were homogeneous as verified by Levene's test
using StatGraphics Centurion v.15.2. In one instance, a 0.76 0.61 64
GM 1
material (uncleaned PETG) showed a very high variance (0.08) (0.17) (9)
and thus had to be excluded from the analysis of variance.
For these excluded data, two means comparisons under 0.53 0.91 81
unequal variances were then conducted with Microsoft GM 0.5
(0.10) (0.32) (7)
Office Excel 2007. Other means were compared by the
post hoc least square difference multiple range test with
StatGraphics Centurion v.15.2. Finally, mean comparisons
were conducted to compare the roughness and the water Representative images of each material are presented in
contact angles of materials, using Microsoft Office Excel Figure 1. The materials differed even before they had been
2007. Statistical significance was accepted at P <0.05. cleaned. One of the 10 materials, the metal coated with
plastic (PM), showed no trace of soil on its surface after
acridine orange staining and rinsing. The percentage
coverage of uncleaned and cleaned materials is shown in
Figure 2. In all cases, the two galvanised metals had the

EHEDG_Innenteil.indd 22 01.04.11 08:44

 Comparison of materials used in food refrigeration equipment with respect to ease of removal of organic soil 23

Discussion and conclusions

The staining that was done to highlight the fouling of the

materials had to be followed by rinsing to remove unfixed
dye. This rinsing removed some of the soil and therefore
provided a ranking of materials before any cleaning had
been completed. The classification of materials after the

A Uncleaned
100
80

% Coverage
60
40 E
DE
20 C CD CDE
BC
0 A A ABC B

B
P3TopaxM95
100
80 *
*
%Coverage

60
*
40
20 * D D
C
A A A BC B A BC
0

C
DivosanS5
P3 Topax M95

Divosan S5
Uncleaned

100
Materials

*
80
*
%Coverage

60
* D
40
C
Figure 1. Photographs
Fig 1. Photographsproduced
producedby byepifluorescence
epifluorescencemicroscopy
microscopy 20 *
showing
showing materials
materials after
after deposition
deposition of of liver
liver pt,
pat staining
staining withwith A A A B A A A A
acridine orange and rinsing (uncleaned) and after the action of 0
acridine orange and rinsing (uncleaned) and after the action of
swabbing with cleaning and disinfection solutions (P3 Topax
swabbing with cleaning and disinfection solutions (P3 Topax M95
M95 or Divosan S5).
or Divosan S5) staining with acridine orange and rinsing.

Figure 2. Percentage coverage of a soil based on pork liver pat

highest percentage coverage (from 55-76 %), which did not
decrease significantly after either of two cleanings. In
contrast, four materials had zero percentage coverage after
cleaning, whether by P3 Topax M 95 (Figure 2B) or
Divosan S5 (Figure 2C). These were: the plastic coated
metal (PM) whose percentage coverage was already zero
before cleaning; ABS which was already weakly fouled
before cleaning; PETG; and the white painted galvanised
metal. Among the four intermediate materials, three, the
black painted galvanised metal, PE and stainless steel T25,
no longer had visible soil after cleaning with Divosan S5
(Figure 2C). For stainless steel Z2CN, which had a low
initial contamination (30% coverage), no decrease could be
observed after cleaning whatever the product applied.
on different materials: the soil was stained with acridine orange
and then rinsed (A); soiled materials were cleaned with a solution
of P3 Topax M95 (B) or Divosan S5 (C) and then stained with
acridine orange and rinsed. Three sets of multiple range tests were
performed for each of the situations A, B or C. The same letter
associated with two values means that the difference between
these values is not significant. An asterisk on a bar means that the
percentage coverage is not significantly different after cleaning.
Error bars represent individual standard deviations (n=10).
staining phase was retained after cleaning whatever the
product used, except for two materials: the white painted
galvanised metal (WPGM) and stainless steel SS Z2CN.
The stainless steel SS Z2CN was slightly soiled but the
fouling was not reduced by cleaning whatever the cleaning

EHEDG_Innenteil.indd 23 01.04.11 08:44

 24 Comparison of materials used in food refrigeration equipment with respect to ease of removal of organic soil
product used. This stainless steel behaved very differently
from the other stainless steel (SS T25) while the two
materials did not differ significantly either in terms of
roughness or in terms of contact angle (P> 0.38). It is
therefore likely that the difference in composition of these
steels (which was not evidenced by the water contact
angle) was responsible for the observed difference.
The materials that held the most soil after cleaning were
the galvanised metals. The GM 0.5 was always more soiled
than the GM 1. This difference could be explained by a
larger Rvk of GM 0.5 (mean significantly different, P = 0.02),
while Ra values were significantly different (P <0.001), but
in reverse order. Indeed, Rvk is an indicator of the ability of
materials to retain oils (Sander, 1992), depending on the
depth of the inwardly directed portion of the surface profile
(i.e., of grooves extending below the core profile). This
parameter has already proved useful for characterizing the
hygienic quality of flooring materials (Mettler and
Carpentier, 1999). In addition, the galvanised metal GM 0.5
also was more hydrophobic, which may explain a higher
affinity with the fat soil used. It turns out that these two
galvanised metals also were the only two materials that had
antibacterial activity: A culture of Pseudomonas fluorescens
5
on these materials did not exceed 10 CFU/cm, whereas
on the other materials it achieved, under the same
7
conditions, densities of 10 CFU/cm (results not shown). If
these materials are not thoroughly cleaned, it can be
hypothesized that the presence of residual soil could shield
the bacteria from direct contact with the material and
thereby cause a reduction in its antimicrobial effect.
Three of the four plastic materials in the study had the
lowest coverage percentage: PM, ABS and PETG. The
advantage of these plastic materials, or of the plastic that
coats the metal, is relative however, because plastics are
less resistant to wear than stainless steels (Holah and
Thorpe, 1990; EHEDG, 2005) and also are materials
known to be easily disinfected (Boulang-Petermann,
1996). The fourth plastic material, PE, is clearly
distinguishable from the others by its roughness. Its Ra was
the highest of all materials used and its Rvk was 2.6 times
higher than the material that had the next highest Rvk. In
addition, this was the only material that did not have Ra d
0.8 m as recommended by EHEDG (2004).
Comparing the results obtained with the two
detergent/disinfectants showed the efficiency of the
degreaser, Divosan S5, at 1:10 of the concentration
recommended by the manufacturer, while the P3 Topax 95,
a chlorinated alkaline was used at one-half of the
recommended concentration. The greater efficiency of
Divosan S5, which is specifically recommended for
cleaning and disinfecting serve-over counters, can be
explained by a higher detergent power than the chlorinated
alkaline with respect to the high fat content of the soil used.
It therefore appears that the test used could also be
employed to compare the effectiveness of cleaning
products.
EHEDG_Innenteil.indd 24
In conclusion, the proposed test gave sufficiently
reproducible results for the materials to be clearly
classified. It was noted in particular that three of the four
plastics retained less of the pork liver pt based soil than
the metallic materials, whether they were painted or not.
Swabbing to clean is therefore quite acceptable if
performed by the same person. This test has the
advantage of being simple to implement and applicable to a
wide range of soils after fixing the optimal concentration.
Finally, these results again showed the advantage of the
Rvk roughness parameter for assessing the cleanability of
materials, although this parameter alone is not sufficient to
explain all the differences observed.
Acknowledgment
This study is part of the SIMPFRI project (Safety,
Innovation and Energy Management in Refrigeration
Processes and Equipment) funded by the French National
Research Agency within the framework of the PNRA
program (ANR-05-PNRA-015). The author is grateful to
John Kerr for the English correction.
References
Boistier-Marquis, E., Oulahal-Lagsir, N. and Larpent, J.P. (2000).
Methodology for a comparative evaluation of sensitivity to fouling
and cleanability of floor materials used in the food industry.
Biofouling 14, 279-286.
Boulang-Petermann, L. (1996). Processes of Bioadhsion on
stainless steel surfaces and cleanability: a review with special
reference to the food industry. Biofouling 10, 275-300.
Boyd, R.D., Cole, D., Rowe, D., Verran, J., Paul, A.J. and West,
R.H. (2001). Cleanability of soiled stainless steel as studied by
atomic force microscopy and time of flight secondary ion mass
spectrometry. Journal of Food Protection 64, 87-93.
Detry, J.G., Rouxhet, P.G., Boulang-Petermann, L., Deroanne, C.
and Sindic, M. (2007). Cleanability assessment of model solid
surfaces with a radial-flow cell. Colloids and Surfaces A:
Physicochemical and Engineering Aspects 302, 540-548.
EHEDG ed. (2004). Hygienic equipment design criteria: Campden
& Chorleywood Food Research Association Group.
EHEDG ed. (2005). Materials of construction for equipment in
contact with food: Campden & Chorleywood Food Research
Association Group.
Holah, J.T. and Thorpe, R.H. (1990). Cleanability in relation to
bacterial retention on unused and abraded domestic sink materials.
Journal of Applied Bacteriology 69, 599-608.
Kuisma, R. (2006). Physical characterization of plastic surfaces in
wearing and cleanability research, Academic Dissertation,
University of Helsinki.
Kuisma, R., Kymlinen, H.R. and Sjberg, A.M. (2009).
Determination of cleanability and wearing of plastic flooring
surfaces in field and laboratory conditions. Construction and
Building Materials 23, 1093-1101.
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 Comparison of materials used in food refrigeration equipment with respect to ease of removal of organic soil 25

Leclercq-Perlat, M.N. and Lalande, M. (1994). Cleanability in
relation to surface chemical composition and surface finishing of
some materials commonly used in food industries. Journal of Food
Engineering 23, 501-517.
Leriche, V.and Carpentier, B. (1995). Viable but non culturable
Salmonella typhimurium within single and binary species biofilms in
response to chlorine treatment. Journal of Food Protection 58,
1186-1191.
Masurovsky, E.B. and Jordan, W.K. (1958). Studies on the relative
bacterial cleanability of milk-contact surfaces. Journal of Dairy
Science 41, 1342-1358.
Mettler, E. and Carpentier, B. (1999). Hygienic quality of floors in
relation to surface texture. Transaction of the Institute of Chemical
Engineers 77, 90-95.
Midelet, G. and Carpentier, B. (2002). Transfer of microorganisms,
including Listeria monocytogenes, from various materials to beef.
Appl Environ Microbiol 68, 4015-4024.
Ridenour, G.M. and Armbruster, E.H. (1953). Bacterial cleanability
of various types of eating surfaces. American Journal of Public
Health 43, 138.
Sander, M. ed. (1992). A practical guide to the assessment of
surface texture. Gttingen, Germany: Feinprf Perthen GmbH.
Whitehead, K.A., Smith, L.A. and Verran, J. (2010). The detection
and influence of food soils on microorganisms on stainless steel
using scanning electron microscopy and epifluorescence
microscopy. International Journal of Food Microbiology 141, S125-
S133.

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EHEDG_Innenteil.indd 25 01.04.11 08:44

 European Hygienic Engineering & Design Group

Tank cleaning technology: Innovative application to

improve clean-in-place (CIP)
Tank cleaning technology helps solve the challenge of clean-in-place (CIP) cleaning in difficult-
to-clean areas such as closed equipment for liquid processing. Recent innovations in tank
cleaning technology illustrate how and why a dynamic and targeted flow significantly improves
cleaning efficiency. Implementing tank cleaning technology in other types of equiment can
solve cleaning challenges.

Bo Boye Busk Jensen, R&D Engineer, Tank Equipment, Alfa Laval, Jesper Bak Nielsen, R&D Engineer, Valves,
Alfa Laval, Henrik Falster-Hansen, R&D Manager, Tank Equipment, Alfa Laval, Karl-ge Lindholm, R&D Manager,
Valves, Alfa Laval
E-mail: Bobb.jensen@alfalaval.com

In 2010, the first European Hygienic Engineering & Design
Group (EHEDG)-certified rotating spray head for tank
cleaning, the patent-pending Alfa Laval SaniMidget SB,
was introduced into the marketplace. In early 2011, Alfa
Laval will introduce a patent-pending Pasteurized Milk
Ordinance (PMO) mix proof double seat tank outlet valve
that also utilizes the principle of the hygienically designed
spray device. This merger of technologies has helped solve
a problematic cleaning task: cleaning of the vent cavity in a
PMO mix proof double seat tank outlet valve. Similar
cleaning problems often occur inside medium-sized pieces
of equipment. A large compartment needs to be
continuously flushed, and to achieve adequate cleaning, it
must be completely filled with cleaning liquid. A large flow
rate of detergent/water is needed to completely fill the large
volume inside the equipment during clean-in-place (CIP), or
as in the case of the PMO mix proof valve, pressure on the
gaskets is not allowed (i.e., the vent cavity of a mix proof
valve cannot be filled with circulating water).
The solution to the challenge of cleaning medium-sized
processing equipment with as little water as possible (i.e.,
without needing to fill the equipment completely) is actually
straightforward using tank cleaning technology. Remember,
cleaning is done at the wall. There is really no need to have
a large bulk of liquid that never touches the walls running
through the equipment. This is often seen in medium-sized
equipment and pipes. To explain the philosophy behind this
innovative use of tank cleaning technology, this article
describes the progress made in tank cleaning over the
years using the tank cleaning technology ladder schematic
(Figure 1) and presents a detailed look at the patent
pending solution inside the Alfa Laval mix proof double seat
tank outlet valve.
The tank cleaning ladder: steps of progress
Historically, the tank cleaning process utilised simple fill-
and-dump principles, where the entire tank was filled with
detergent, allowed to soak for a period of time, and then the
detergent was dumped to drain. However, this proved to be
a very time-, water- and detergent-consuming process that
relies on the action of the chemistry and temperature.
The first step up the technology ladder for tank cleaning
was the introduction of static spray balls, where each ball
has a number of drilled holes to form a shower (Figure 1).
Here, liquid is sprayed from a number of holes in a pre-
defined static pattern onto the tank wall. Cleaning is
achieved mainly by the liquid that hits the wall and forms a
free-falling film down the tank wall. Cleaning is primarily
accomplished through soaking and a small amount of force
from the falling liquid. The force (wall shear stress) is of the
same magnitude as that present in a pipe, in which liquid is
pumped through at a flow rate corresponding to average
velocity of 1.5 m/s (3-5 Pa). As for the fill-and-dump
cleaning method, time is also an important factor; however,
the amount of water used is reduced as water is
recirculated and only a thin, turbulent, free-falling film on
the wall is needed to perform the cleaning (e.g., the rule of
3
thumb is approximately 2 m /h per m circumference of the
tank). Hence, all of the water that was previously in the bulk
of the tank during a fill-and-dump is no longer needed;
detergent is supplied to where it performs the actual
cleaning.
The second step up the ladder is rotating spray head
technology, which utilises a ball with holes or slots that can
rotate around an axis (typically, the axis of the supply line)
during cleaning (Figure 1). The rotation comes from water
being supplied by a supply pipe and into a spray head. The
spray head rotates on ball bearings or slide bearings. The
rotation comes from the force generated when water is
ejected from the slots or holes in the rotating spray head.
The cleaning principle is related to that of a static spray
ball: free-falling film cleaning with a stronger impact than
the static spray ball. The increased impact is due to the fact
that the water circulated is focused into only a number of
slots or holes, and thereby a higher velocity at the jets is
generated at the same flow rate. The main difference is that
the water is sprayed onto the tank wall in a dynamic
pattern. Hence, the coverage is approximately 100%,
whereas the static spray ball does not achieve 100%
coverage. The tank wall with direct hit from the jets/fans will
experience relatively high-impact cleaning. The boundary
layer on the walls will build up and be disrupted again to
increase the mass and heat transfer to the soil because the
walls are continuously hit by incoming liquid.

EHEDG_Innenteil.indd 26 01.04.11 08:44

 Tank cleaning technology: Innovative application to improve clean-in-place (CIP)
Figure 1. Tank cleaning technology ladder.
The third step up the tank cleaning technology ladder is
rotating jet head technology. This technology involves a
number of nozzles, mounted in a nozzle head that rotates
around a horizontal axis, while the nozzle head is mounted
in a body that rotates around a vertical axis. The motion is
driven by pumping the cleaning liquid through a turbine and
a gearing system. The two-axis rotation of the machine
generates a dynamic impact pattern from the jets and
allows for complete coverage if installed and operated
correctly. The cleaning principle is very different from that of
the other tank cleaning technologies because the flow rate
used is concentrated in a number of nozzles. Focusing the
flow rate allows for local cleaning conditions that are
extreme. Compared with other technologies, the
mechanical action is much higher. Wall shear stresses in
3
the footprint of the impinging jet start at a magnitude of 10
Pa and are reduced to around 50 Pa at a diameter of
approximately 100 mm, depending on flow rate and nozzle
configuration. Impact force and high wall shear stress in the
footprint of the jet that hits the wall means that cleaning is
done mainly by force and only a little by the detergent and
temperature. On top of the impact cleaning, some soaking
takes place as the incoming liquid forms a free-falling film
on the wall after the jet has passed an area.
Cleaning time, cleaning liquid and detergent levels can be
reduced significantly by focusing flow and running the
cleaning in a dynamic fashion. There is no static flow field,
which means that boundary layers build up quickly and are
disrupted again as the next jet passes through that area.
Also, the impact pattern and number of nozzles means that
EHEDG_Innenteil.indd 27
27
the soil to be removed is affected by the impact and
footprint region several times during the cleaning process.
From the progress achieved in tank cleaning technology
over the years, it should be learned that a piece of
equipment or a process line does not necessarily have to
be cleaned by pressurising the system, such as pumping
pipes full of detergent with recirculation. All the detergent in
the centre of the equipment that does not touch the wall
does not contribute to the cleaning of the walls. Hence, if
the process line/equipment is drainable, the cleaning could
be done by spraying detergent onto the walls in a dynamic
pattern instead (i.e., as seen with tank cleaning using
rotating spray heads or rotating jet heads). Focusing the
flow rate available for cleaning into a limited number of jets
increases local cleaning conditions where the jets hit the
wall. Having these favourable cleaning conditions move
around in the process line/equipment ensures a dynamic
system of cleaning conditions and full coverage. The larger
the equipment or diameter of the pipes, the easier it will be
to mount such devices in the equipment/process line.
Today this is done in some duct systems and very large
processing equipment (e.g., centrifuges and separators),
where a static spray ball or a standard rotating spray head
is mounted using separate solution supply pipes coming
through the walls of the equipment.
01.04.11 08:44
 28 Tank cleaning technology: Innovative application to improve clean-in-place (CIP)
SaniMidget SB principle
The SaniMidget SB was designed to fulfil the 3-A Sanitary
Standard (3-A SSI) on spray cleaning devices and has
successfully met the objectives of the 3-A Third Party
Evaluation program. In the design process, the EHEDG
Test Method Doc. 2 was applied in order to provide
evidence for the self cleanability of this device and a
certificate was obtained.
Figure 2. SaniMidget SB, Alfa Laval.
The SaniMidget SB works in principle by attaching the
device to a solution supply tube (Figure 2). The connector
holds the stator with the pin-connection that also attaches
the device to the supply pipe. Between the connector and
stator a rotating element is mounted. This rotating element
Figure 3. PMO mix proof valve for horizontal tank outlet: (1) sealing element, (2) liquid supply line for cleaning liquid and (3) rotating element.
EHEDG_Innenteil.indd 28
rotates between two slide bearing surfaces generated by
water flowing between one end of the connector and the
rotor and between the stator and the rotor. The rotor is
open at both ends where it meets the connector and stator.
The rotor has a number of slots that generate the rotation
and also distribute the liquid onto the tank wall as it rotates.
The detergent comes through the downpipe, into the
connector, and passes through a number of holes into the
rotor from which it flows through the bearing area and the
slots in the rotor. The design is extremely simple, can be
fully dismantled without tools and is fully inspectable.
Cleaning the vent cavity in a PMO tank outlet
mix proof valve
As mentioned above, a new mix proof valve for vertical and
horizontal tank outlets will be introduced by Alfa Laval in
2011 (Figure 3). The valve is designed according to PMO
standards, for which special rules apply for the design and
cleaning of the vent cavity.
For large mix proof double seat tank outlet valves, cleaning
of the vent cavity is a challenge. The compartment has a
relatively large volume that must have a cross-sectional
area equal to or larger than the cross-sectional area of the
product pipe line. Also, according to the PMO (3-A SSI
Standard 85-01), the vent cavity is not allowed to be
pressurised during cleaning and impingement on the
gaskets is not allowed. This limits the cleaning methods
that can be chosen.
Conventionally, the cleaning of the vent cavity in mix proof
double seat tank outlet valves is done by flowing liquid
through the annulus between the spindle and the valve
stem. This liquid then flows out and runs along the curved
surface of the valve plug and back down the inside of the
second valve stem, further down past the sealing element
(shown as (1) in Figure 3), along the inside walls of the vent
01.04.11 08:44
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EHEDG_Innenteil.indd 29 01.04.11 08:44

 30 Tank cleaning technology: Innovative application to improve clean-in-place (CIP)

cavity, and finally, out to drain. The PMO regulation does
not allow pressurisation of the vent cavity. Thus, filling the
cavity and recirculating is not an option in this case. The
conventional method of cleaning the vent cavity can be
problematic, especially around the sealing element (1) and
the wall just after the sealing element. The sealing element
creates a shadow zone and a corner that is almost
impossible to clean with the liquid coming from the curved
surface of the valve plug. In addition, the wall in the vent
cavity on the opposite site of the pipe to drain is a
problematic location to clean because the liquid will go
towards the pipe to drain due to gravity instead of flowing
along the walls opposite and next to this pipe to drain.
Another option for cleaning could be to use one or several
static or rotating spray device(s) that can clean the surfaces
of the vent cavity. The external connection would then be
placed through the valve body. This would require
additional piping for supplying these spray devices and
there would be shadow zones generated by the valve stem
and also the supply lines themselves.
Conclusion
The synergy of joining state-of-the-art tank cleaning
equipment and cleaning philosophy with novel valve
technology has allowed a unique solution for easier
cleaning of large compartments in processing equipment.
Previously, it was only possible to clean by pressurising
equipment with water at a high flow rate to perform the
cleaning. In the case of the PMO mix proof valve, it is even
more crucial as the compartment to be cleaned cannot
become pressurised. The insertion of a rotating spray head
on a cylindrical shape that allows cleaning liquid to flow
through and into the rotating spray head has proven to be
an effective cleaning method for cleaning larger
compartments without installing numerous spray devices to
compensate for shadow areas. Further, a dynamic cleaning
effect from the rotating spray device also improves the
cleaning mechanisms by increased coverage, increased
impact cleaning and increased heat and mass transfer from
the non-stationary liquid film generated on the surface to be
cleaned.

Experimental cleaning trials with the valve proved that there

were areas that were almost impossible to clean with
traditional methods (around the sealing element (1) and the
walls after it). Also, using stationary spray devices did not
create impact on all of the surfaces to be cleaned. Hence,
alternative methods are needed to produce effective
cleaning using minimum water.

The straightforward alternative to this is to adapt tank

cleaning technology, as the drain area can in fact be seen
as a small tank. As shown in Figure 3, the design of this
new mix proof double seat tank outlet valves already has a
detergent supply from the outside (2) and through the
clearance between the stem and the spindle for cleaning
the curved part of the valve plug that faces the vent cavity.
By exploiting this together with the principle of the
SaniMidget SB, it was possible to put a rotating spray head
(3) around the spindle. The rotating head is fed with liquid
from a number of holes in the spindle, and bearing surfaces
are created on the spindle, as well. As liquid is pressed
through the bearing surfaces and slots in the rotating
element, rotation is created and liquid is distributed
throughout the entire vent cavity with no shadowing effect
from the spindle (stem) as would have been the case if
spray devices were mounted on separate supply lines
through the valve body.

This patent-pending design has allowed an extremely

efficient cleaning of the vent cavity at a low flow rate. The
entire vent cavity can now be cleaned at approximately the
same time, since all surfaces are exposed to impacting
water from the rotating element. There are no areas
significantly more difficult to clean than others.

EHEDG_Innenteil.indd 30 01.04.11 08:44

 European Hygienic Engineering & Design Group

Hygienic seal design

Christine Riebesell, Freudenberg Process Seals GmbH & Co. KG, D-69469 Weinheim, Germany
E-mail: fps@freudenberg-ds.com; www.freudenberg-process-seals.com

Every plant operator seeks to take all measures necessary

in order to promote and preserve public health. Every food
item, pharmaceutical or cosmetic product should be
shipped in perfect condition (i.e., safe for humans and ani-
mals). Neither toxic substances nor microorganisms can be
present in levels that could influence product quality or
longevity, putting consumer health at risk.

As such, facilities must be constructed so as to satisfy all

applicable hygienic requirements, especially during running
operations. They must be designed for easy and reliable
cleaning, especially in those areas where automatic clean-
in-place (CIP) and sterilisation-in-place (SIP) processes are
utilised and where visual inspections cannot be made.

In this regard, seals are of special importance: first, in terms

of the chemical degradation of their materials, and second,
in terms of their use as static or dynamic seals at all con-
necting points in the facility.
Figure 1. Standard seal for dairy pipe couplings.
Seals for dairy couplings and conventional
clamp connections are inadequate for hygi-
enic requirements

Seals for food couplings (Figure 1) and clamp connections

(Figure 2) are standardised products with which pipes for
liquid media can be easily connected and sealed. Seals for
food fittings have been standardized in accordance with
DIN 11851 regulations. Their extraordinarily fast and un-
complicated installation, thanks to the ease of separating
them from the flange, has made them an extremely popular
choice. Clamp connections, manufactured in keeping with
International Standards Organisation (ISO) 2852 (for inch
measurements) and Deutsches Institut fr Normung (DIN)
32676 (for metric measurements), are another easy-to-
install solution. Both options are highly economical and
easy to acquire.

However, as seals for food couplings have been designed

without metallic stops, seal compression can fluctuate once
the seal is installed and gaps of differing widths can appear
and with them, dead spaces. A similar problem arises with
clamp connections, which also fail to produce consistent
compression. Further, field experience has shown that
major stresses can affect the seal landings, which can lead
sealing material to shear off, contaminating the product.
Figure 2. Conventional clamp connection with Type A seal.
Aseptic clamp connection satisfies the
requirements of hygienic design
A good example of a standardized solution is the aseptic
clamp connection in keeping with DIN EN 11864 Part 3.
The European Hygienic Engineering & Design Group
(EHEDG) contributed its expertise so as to avoid the prob-
lems associated with previous connections and develop a
reliably hygienic design. The result: two seals, one an O-
ring that has already proven its effectiveness in practice
(Figure 3), and one a moulded part for effectively connect-
ing pipes with operating pressures of up to 40 bar.

EHEDG_Innenteil.indd 31 01.04.11 08:44

 32 Hygienic seal design

The metallic stop provides the seal with consistent com-
pression and a sufficient gap is created between the seal
and the product space to facilitate rinsing in cleaning proc-
esses. This gap also serves as an expansion space that
can accommodate volume expansions in the material as a
result of heat or the influence of media without producing
forces that can result in shearing. To the left and right, the
sealing surfaces are directly on the product space, prevent-
ing product leakage and the attendant risk of contamina-
tion.
merous valve failures. This made it necessary to take a
closer look at the double seat valves disk seal. The O-ring
on the lower valve disk from one of these applications
showed clear signs of material wear; the seal truly looked
chewed up. Detailed examinations revealed that the
round O-ring groove had been overfilled at room tempera-
ture; when the temperature was raised to a maximum of
120C, major stresses in the material were created. The
motion of the valve disk led to a shearing off of parts of the
elastomer and the previously described damage.

The valve manufacturer wanted to keep the same seal, so

the only viable solution was to redesign the groove. With
the help of FEM analysis, the O-rings expansion (given the
-4
use of EPDM with a coefficient of expansion of 1.6 x 10
1/K, friction-free) due to increased temperature and swell-
ing was calculated. The resultant maximum principal de-
formations in the material are represented in Figures 4 and
5. The critical point for the material used is at roughly 60%
expansion; however, this is only an approximate value, as
strains such as temperature are further factors that are
anything but negligible. In this case, in both graphs even
the green sections should be considered critical.

Figure 3. Aseptic clamp connection with O-ring seal.

Special considerations in designing sealing

locations

Design engineers often do not have the luxury of being able

to use standardised solutions, and must instead design
seals to match the components involved. In this regard,
particular attention should be paid to the operating parame-
ters and their effects on the actual situation at the sealing
location. Elastomers can have coefficients of expansion
that are up to 15 times that of steel. Furthermore, elastom- Figure 4. Maximum principal deformation in the material in the
ers are incompressible and require enough space to allow installation situation, temperature: 136C.
their changes in volume without compromising product
quality. Cleaning processes and sealing function should
remain unaffected, ensuring that the product leaves the
facility in perfect, undamaged form.

To achieve this is by no means a trivial goal, and thus the

Finite Element Method (FEM) can be extremely helpful. The
following examples, which illustrate the hygiene-friendly
design of sealing locations, were prepared in cooperation
with Freudenberg Research Services CAE Department.

Example 1: New groove design for an O-ring

in a double seat valve

The valve design used by a mid-sized company for years

began to reach its limits in the face of the plant operators
growing expectations and more extreme processing pa-
rameters. In certain applications, this led to increasingly Figure 5. Maximum principal deformation in the material in the
frequent problems, with short product life cycles and nu- installation situation with 3% swelling due to the influence of media.

EHEDG_Innenteil.indd 32 01.04.11 08:44

 Hygienic seal design 33

The results are plain to see: The seal needs more expan-
sion space. Once this has been provided, the new clear-
ance should be carefully measured and analyzed. At the
lower extreme, the seal must be able to perform reliably
despite the low level of compression; at the upper, the
forces at work should not become so high as to pose a risk
of damage.

First, the lower threshold is considered, which is done by

calculating the normal stresses that work on the following
assumptions:
x The groove is large, but within the acceptable tolerance
x The O-ring cross-section thickness is at the lower toler-
ance limit
x Pressurization: 10 bar
Figure 7. View of the maximum strains at work in the elastomer.
x Room temperature
x No swelling due to contact with media
In the new, optimised groove the sealing locations are
directly on the product space. At a temperature of 136C
Figure 6 clearly shows the results of the functional testing:
and simultaneous 3% swelling due to contact with media,
The problems of leakage and subsequent contamination
the elongation reaches 70%. As this strain arises in only a
can be readily seen. As shown in the lower right-hand sec-
small area and several stress factors must be taken into
tion of the graphic, the effects of the operating pressure
consideration at the same time, the expansion value is
cause the seal to lift out of the groove. This allows the
acceptable.
product (and potentially, microorganisms) to collect in the
space created. To avoid this problem, the sealing location
must always be directly on the product space. Example 2: New sealing geometry for a dead
space-free valve
It is equally important to simulate the upper extreme, where
the most important question is: can the seal hold up? Fig- The second example also involves a disk seal for a double
ure 7 shows the results for the following parameters: seat valve. In this case, the task is to design a seal geome-
x The groove is small, but within the acceptable tolerance try that remains free of dead space under the full range of
x The O-ring cross-section thickness is at the upper operating conditions.
tolerance limit
x No pressurization In this particular application the operating pressure can
x Temperature: 136C vary, but the temperature remains constant. The situation is
x Swelling due to contact with media: 3% analysed for the seal on the closed valve as depicted in
Figure 8 (minimum pressure: 0 bar) and Figure 9 (maxi-
mum pressure: 40 bar). In these illustrations, one can
clearly see the influence of the changing pressure. On the
side closest to the media, the pressure forces the seal
away from the groove, creating a gap that can produce
unsterile conditions. On the side farthest from the media
the elastomer is driven into a crack, which can result in
sealing material shearing off.

Figure 6. View of the sealing locations with the improved geometry

with expansion space. (Note: This is not the actual solution be-
cause of a gap opening during product pressure.)

Figure 8. Situation with the current seal, valve closed, at 23C and
0 bar.

EHEDG_Innenteil.indd 33 01.04.11 08:44

 34 Hygienic seal design
Figure 9. Situation with the current seal, valve closed, at 23C and
40 bar.
After modifying the seal geometry, the closed valve is ex-
amined once again (Figures 10 and 11). The sealing posi-
tion is now directly on the operating space, and even under
pressure no gaps form. There is also sufficient clearance
on the opposite side, and the stresses that are produced
there are within the elastomers tolerance range.
Figure 10. Situation with the new seal geometry, valve closed, at
23C and 0 bar.
As a final step, a functional test is performed on the new
seal. For the purposes of FEM analysis, 35 points on the
seals outer contour are identified and numbered; then the
contact potential is calculated for each point at a certain
process pressure.
EHEDG_Innenteil.indd 34
Figure 11. Situation with the new seal geometry, valve closed, at
23C and 40 bar.
Figure 12 shows the contact potential progression for three
different pressure levels. For each level, the contact poten-
tial is higher than the fluid pressure for a sufficiently large
area. As such, the valve remains sealed and functions
dependably under all operating conditions.
Figure 12. Contact potential progression on the outer contour of
the seal at fluid pressures of 0, 10 and 14 bar.
Summary
When selecting a seal for applications in the food and bev-
erage, cosmetics and pharmaceutical industries, it is not
enough to use a pure and approved material (e.g. Drinking
Water, U.S. Food and Drug Administration, EC 1935/2004,
etc.). Nor does it suffice to choose a material that is resis-
tant to process media and cleansers. Reliable hygienic
process conditions can only be ensured when a design has
been found that remains dead space-free and precludes
gap extrusion under the full range of operating parameters.
01.04.11 08:44
 European Hygienic Engineering & Design Group

How do you clean a flour silo?

In this practical example, the development of an effective cleaning technology for a flour silo
involved applying the different available cleaners and cleaning methods to ensure optimised
hygiene.

Wolfgang Haucke, Sales Engineer/Cleaning Technology, GEA Tuchenhagen GmbH

E-mail: wolfgang.haucke@geagroup.com

About 7 billion people are currently living in this world, and
by 2050, it is estimated that this number will rise to 9 billion.
About 50% of the people who will populate Earth in 2050
are already living today. This has become possible
because modern production technologies make it easier for
all people to live better and healthier lives. In particular,
advances in food manufacturing technology have
contributed significantly to improvements in the quality,
functionality and safety of food.
know-how. The comprehensive process expertise of
engineers today must therefore be in sync with the food
processing industrys need to ensure that products are
produced with the highest level of efficiency, hygiene and
safety.
Optimising cleaning processes in a processing plant is one
important way to accomplish these goals. As an example,
GEA Tuchenhagen engineers worked closely with a well-
known manufacturer of bakery products to find effective
solutions to the challenges of cleaning the operations flour
silos.

)LJXUH2XWVLGHWDQNVLORIDUPZLWKILOOLQJOLQHV


While dramatic technological advances offer vast
Figure 2. Component to be cleaned: an aluminium flour silo, 3.5 m
opportunities, they also present enormous challenges. The
in diameter, 33 m in height.
efficient and cost-effective production of high-quality food
products, which new processing technologies foster, is
necessary to meet the needs of a burgeoning global
Flour Silos: A Cleaning Challenge
population. However, production efficiencies and cost-
The bakery manufacturers products are made to the
effectiveness cannot come at the expense of meeting the
highest quality standards and are in compliance with
most stringent of cleanliness and safety requirements for
extensive ecological and economic requirements. The
food manufacturing and handling. Ensuring that all of these
hygiene requirements placed on the process plant make it
needs are met requires a very detailed yet broad process

EHEDG_Innenteil.indd 35 01.04.11 08:44

 36 How do you clean a flour silo?
necessary to clean all systems and machine components
used for this type of production to a level at which no
residues remain. For these cyclically repeated production
processes, the customers quality assurance staff was
looking for an advanced cleaning system for the perfect
interior cleaning of their flour storage silos (Figure 1). The
cylindrical flour silos, approximately 3.5 m in diameter and
33 m in height, which were presented to engineers for
examination and advice on cleaning do not have any
internal structures. The silo walls are made of uninsulated
aluminium and each has a conical outlet and a flat silo top
with an eccentric manhole (Figures 2 and 3). Located
outside near the production building, the storage towers are
arranged in a silo farm.
The flour is discharged from the silo by gravity onto a
conveyor worm, and compressed air is used for further
conveyance downstream. Production runs 24 hours a day
all year long, and as such, each silo is periodically
completely filled with flour and is then emptied continuously
or intermittently, depending on process requirements. As a
result, the inside of the tank is irregularly contaminated with
product residue deposits (Figure 4). These contaminants
build up at various points and various levels; in particular,
lumps of flour form at all heights of the silo wall, which, after
the level has risen to a certain point, tend to drop down
uncontrollably and cause recurring blockages with
subsequent standstill of the downstream flour conveying
and production plants. This results in cost-intensive
production downtimes for remedying the damage. The type
and thickness as well as the adhesion behaviour of the
contamination is largely determined by the quality of the
flour; the flowing and emptying properties of the flour,
depending on the discharge rate; the air humidity in the
suppliers transport silos and in the storage silo itself; and
the seasonal fluctuations in temperature and other
parameters.
The previous cleaning process was such that hired
cleaning workers/industrial climbers, equipped with manual
lifting gear and watched by a safety supervisor, entered the
silos in order to clean them. Flour residues, which vary from
light dust to heavily encrusted or sticky residues, were then
removed either using brushes or brooms for light
contamination or with spatulas and scrapers, in miner's
fashion, for stubborn residues. The main drawback of this
solution not only was that the mental and physical strain for
the workers, who had to be provided with breathable air,
was extremely high, but cleaning also took several hours or
even an entire day.
Additionally, the cleaning efficiency and results varied from
cleaner to cleaner and the result was not repeatable. Due
to the eccentric manhole, positioning of the personal safety
and lifting gear for the cleaning workers was complicated
and time-consuming. In order to minimise the time and
effort described above as much as possible and to remedy
existing problems, the company sought an improved
cleaning process based on water with reliably repeatable
results. An essential prerequisite was unreserved
compliance with all customer requirements with regard to
food hygiene regulations.
EHEDG_Innenteil.indd 36
Cost-effectiveness, minimisation of cleaning times, cleaning
media, utilities and auxiliary materials, and system
sustainability also were of foremost importance to the
bakery product manufacturer. An inventory of requirements,
technical details and on-site conditions were recorded
during a personal visit to the site. These initial engineering
considerations were subsequently translated into a
cleaning concept, which was then put to a practical test
(i.e., basic engineering).

Figure 3.Open top manhole cover of the flour silo with
contaminated attachments and internals, prior to cleaning.
A key initial step in the preparatory considerations was to
clarify the basic approach; namely whether a low-, medium-
or high-pressure cleaning method should be used. The
following methods were assessed:
Low-pressure cleaning is based on the effect of the
chemical composition of the cleaning agent, the
temperature and the volume flow rate of the cleaning
medium, and the resulting cleaning velocity. This is an ideal
application for spray balls and rotating jet cleaners.
Medium-pressure cleaning is based on the effect of the
chemical composition of the cleaning agent, the
temperature and the reduced volume flow rate of the
cleaning medium at an increased cleaning pressure, and
the resulting cleaning velocity. This is an ideal application
for rotating nozzles and rotating jet cleaners.
High-pressure cleaning is based on a mechanical
cleaning effect that is achieved by an intensive, direct
cleaning jet. This is the typical field of application for orbital
cleaners.
As a next step, a suitable nozzle and cleaning pattern for
the selected pressure cleaning method was chosen from
the following nozzle systems, in accordance with the type
of contamination:
Static cleaners for the cleaning of vessels, tanks and
containers, such as storage tank and clean-in-place (CIP)
tanks, are designed to work with low pressure. A fixed
spray head sprays the cleaning medium onto the surface to
be cleaned. Cleaning is achieved by rinsing or impingement
01.04.11 08:44
 How do you clean a flour silo? 37

Separating solutions from GEA Westfalia Separator

of the tank walls. By adding appropriate cleaning agents,
the cleaning effect can be enhanced while cleaning times
3
are reduced. The flow rate ranges between 2.4-42 m /h, at
a pressure difference of 1 bar. The cleaning diameter is
Liquids to Value
0.8-8.0 m.

Rotating cleaners are used for the cleaning of tanks,

vessels and containers with heavy product encrustations
(e.g. larger storage tanks, fermentation tanks, tanks with
internal agitators). These cleaners are designed to work
with low pressure; a flow gear unit generates a fan-shaped
jet, which slowly rotates in one plane, thereby wetting the
entire surface. The flow rate ranges between 7.1 and
3
28 m /h, at a supply pressure of 2.3-4.3 bar.

The cleaning diameter is 2 to 10 m. Depending on the

material, operating temperatures in the range between
80C and 100C are possible.

Milk, basic and luxury foodstuffs, bever-

ages and medicines, energy, transport,
logistics, water and waste water treatment
for almost 7 billion people?

Unthinkable without the use of centrifugal

separation technology!

The gigantic flow of materials and mixtures

 centrifuges worldwide, contains value
Figure 4. Interior surface of a storage silo, heavily contaminated
with flour.
Orbital cleaners, for the cleaning of tanks, vessels and
containers that require special mechanical treatment of the
inner surfaces by a concentrated jet (e.g. road tankers,
product tanks and kegs), are designed to work with low,
medium or high pressure. A flow gear unit generates a
highly concentrated cleaning jet that rotates in two planes.
The ideal jet geometry is produced by specially shaped
round-jet nozzles and bevel gears that produce a dense
orbital cleaning pattern which covers the entire surface to
3
be cleaned. The flow rate ranges between 1.8 and 27 m /h,
at a supply pressure of 4.5-80 bar. The cleaning diameter is
2 to 14 m.
of materials, which flows through our
which we need for daily life: food, health,
comfort and mobility. Our separators
and decanters ensure that this value is
harnessed efficiently, profitably and
eco-friendly.
Liquids to Value with this promise, we
are supporting our customers in the food
and beverage industry, the chemical and
pharmaceutical industry, energy and
environmental technology.

Liquids to Value
GEA Mechanical Equipment

GEA Westfalia Separator Group

WSG-1-10-006

Werner-Habig-Strae 1 59302 Oelde (Germany)

Phone +49 2522 77-0 Fax +49 2522 77-2488
www.westfalia-separator.com

EHEDG_Innenteil.indd 37 01.04.11 08:44

 38 How do you clean a flour silo?
Figure 5. Orbital cleaner type Tempest with four wide-range
nozzles.
When the engineering considerations for the method to be
selected were finally aligned with the customers
requirements, the relatively low-priced spray balls were
excluded right from the start due to the degree of
contamination, which can be very high at times. The
rotating jet cleaner would have worked in the upper section
of the silo, but it would not have been possible to
implement the optimum cleaning line near the bottom of a
33-m high silo. To avoid an additional investment on the
customers part for the necessary pumps, considerations
with regard to medium- and high-pressure cleaning were
not pursued.
Due to on-site conditions, the type of contamination and the
silo geometry, a low-pressure method was selected for
optimised water-based cleaning, which typically works with
a pump capacity of 8-9 bar, cold water. As no external
utilities were available on the silo dome, a turbine-powered
cleaner was selected for testing. For cost reasons, cleaning
chemicals and thermal support for the cleaning process
were not to be used.
Considering an installation height of more than 33 m, an
orbital cleaner with four nozzles of 7 mm each was
3
selected, which discharges approximately 12 m /h cleaning
water at a working pressure at the cleaner of approximately
5 bar (Figure 5). The engineers expected short cycle times
for cleaning when the cleaning result was first assessed, so
it was decided to discharge the cleaning water into the on-
site wastewater system.
To test the selected orbital cleaner under the given
conditions, the cleaner was connected via a pressure hose
to a centrifugal pump placed on the bottom of the silo and
then introduced eccentrically into the silo and positioned at
an immersion depth of 2500 mm and at a lateral distance
from the wall of 500 mm (Figure 6). After positioning the
cleaner, the cleaning process was started and monitored.
When the process was stopped after three minutes, a large
part of the adhering, even critical, contamination had
already been removed from those silo surfaces that were
EHEDG_Innenteil.indd 38
covered by the strong cleaning jets. This cleaning result,
achieved just after a few minutes, confirmed that the
selected path was correct. After an overall cleaning
duration of just 15 minutes, all contamination, especially
stubborn flour encrustations, were removed (Figure 7).
Despite the cleaners eccentric position, it worked without
any oscillating movement in the silo, while generating a jet
pattern that covered the entire surface of the silo, even in
the deeper zones.
Figure 6. The flour silo with contaminated attachments and
internals, prior to cleaning.
After completion of a water-based cleaning of the silo
another point to consider was drying, as this is an
indispensable step from a process engineering point of
view.
Due to the seasonally ideal conditions for the cleaning
process described and as the silos are installed outdoors, it
was decided to remove residual moisture by convection.
Direct sunlight on the surface of the silo ensured sufficient
drying from a technical and economical viewpoint. To allow
any residual water to evaporate easily, the upper manhole
and the connection in the bottom section of the silo outlet
cone were opened to enable optimum venting and
discharging of moisture.
In similar applications where it is not possible to dry the
silos by solar radiation, using hot water as a cleaning
medium lends itself as a supplementary solution. The hot
water heats up the silo walls during cleaning and
afterwards dries off the inside surface of the silo by
convection.
If hot water is not available for cleaning, another feasible
solution for the reliable drying of the silo contact surfaces is
blowing filtrated hot air into the tank via the openings at the
top and bottom. Attention must be paid here that sufficient
air flow rates are selected.
Approximately 3,000 litres of cold water were consumed to
achieve the cleaning result, which were discharged into the
factory wastewater system together with the removed flour.
01.04.11 08:44
 How do you clean a flour silo? 39

The final laboratory analysis of the silo surface samples

confirmed that the desired and expected results had been
achieved. The water-based cleaning process selected and
described in this article is repeatable under the conditions
determined and achieves the desired result efficiently and
effectively. In addition, the process defined allows for
intermediate cleaning at any time in the event that
contamination increases. Expensive external cleaning Reliable. Powerful. Efficient.
specialists are no longer required as water-based cleaning
can easily be carried out by the customer's own staff and VARIPURE orbital cleaners
without any expensive production downtimes.
get tanks cleaned up.

Figure 7. The silo after the cleaning operation with an orbital Thanks to their intelligent geometry and
cleaner.
surface quality, our orbital cleaners meet
the highest demands in terms of hygiene
suitable for tank diameters of up to 27 meters
and for flow rates from 1 to 34 m. Achieving
working pressures between 4 and 90 bars,
they cover the entire interior surface in
narrow circles.

All models offer these surpassing advantages:

hygienic design
economical application
strong mechanical cleaning effect

VARIPURE orbital cleaners highly

recommended for complete cleaning.

Liquids to Value
GEA Mechanical Equipment

GEA Tuchenhagen GmbH

Am Industriepark 210 21514 Bchen Germany
Phone +49 4155 49-0 Fax +49 4155 49-2423
sales.geatuchenhagen@geagroup.com www.tuchenhagen.com

GEA_TUC_Varipure_84x245_engl_RZ.indd 1 06.10.2010 17:13:23 Uhr

EHEDG_Innenteil.indd 39 01.04.11 08:44


Hygienic design as a winning choice
Silvia Grasselli, Michele Madureri and Alessia Ilariuzzi, GEA Niro Soavi, Parma, ITALY
E-mail: silvia.grasselli@geagroup.com, alessia.ilariuzzi@geagroup.com, michele.madureri@geagroup.com
Today, food, pharmaceutical and even chemical manufac-
turers are demanding better hygienic design to optimise the
cleanability of high-pressure homogeniser equipment. Al-
though each of these industry sectors has specific opera-
tional requirements that may differ from one another, they
have similar requirements with regard to homogenisers:
The equipment must be capable of operating at very high
temperatures, withstand fatigue stress, operate with a high
safety level, and be comprised of reliable and long-lasting
components. Homogenisers that meet the fundamental
requirements of hygienic design, coupled with high opera-
tional quality, are a winning choice for companies across
industry sectors.
Homogenisation: how does it work?
The benefits of homogenisation are well known within the
food and dairy industry. High-pressure homogenisation is
the process of reducing and standardising particle size of
fluid products, such as fruit juices, beverages, flavours and
sauces, in order to make them more stable and to achieve
better texture and taste. Specifically, homogenisation util-
izes pressure energy to subdivide particles or droplets that
are present in fluids to reduce them to the smallest possible
)LJXUH3URGXFWIORZVDFURVVWKHKRPRJHQLVLQJYDOYH
EHEDG_Innenteil.indd 40
European Hygienic Engineering & Design Group
size (under one micron). This process creates a stable
dispersion in a finished product or provides a starting point
for further production processes. The fluid passes through
a specially designed valve (i.e., the homogenising valve)
under high-pressure conditions and through a high energy
density field that is able to downsize dispersed particles to
the order of magnitude of micrometres and nanometres
(Figure 1).
Dynamic high-pressure homogenisers are made of a sin-
gle-acting reciprocating multi-plunger pump with a specific
adjustable valve designed to create the required pressure
to micronise various fluid products. Dynamic high pressure
can be applied under continuous flow conditions in order to
process fluids such as emulsions and dispersions for a
large variety of applications, viscosities and physical prop-
erties.
Hygienic design regulations and guidelines
for homogenisers
All homogenisers must comply with the European Union
(EU) Machinery Directive 2006/42/EC, which covers not
only all safety-related aspects of machinery, but also de-
fines specific requisites for all equipment used in food,
cosmetic and pharmaceutical applications. The hygienic
design requirements outlined in this directive are comple-
mented by other rules, standards and certifications that
vary according to country of installation and sector of appli-
cation of the hygienic design of the machinery (i.e., food,
pharmaceutical, chemical or other industries). Among the
most significant of the hygienic design guidelines used for
homogenisers are those issued by the European Hygienic
Engineering & Design Group (EHEDG), in particular Doc.
17, Hygienic design of pumps, homogenisers and dampen-
ing devices; as well as 3-A Sanitary Standards, such as No,
04-04, Sanitary standards for homogenisers and reciprocat-
ing pumps.
When selecting a suitable homogeniser, the end-user will
not only need to ensure that the machine is specifically
designed for the particular application, but that it is also
validated to achieve the necessary certifications. In the
demanding pharmaceutical industry, for example, the ho-
mogeniser must be able to achieve the required Current
Good Manufacturing Practices (cGMP) certification. In
addition to supplying a customized high pressure homogen-
iser that satisfies the specific production requirements of
the customer (i.e., pressure range, controls and manage-
ment), the equipment supplier should also be able to pro-
vide accompanying traceability documents, surface rough-
ness measurement data for all product-contact materials
and documentation that all of the machine validation steps
have been conducted, including FAT/SAT/IQ/OQ.
01.04.11 08:44
 Hygienic design as a winning choice 41

GEA Niro Soavi

homogenizers,
a natural choice

Figure 2. GEA Niro Soavi homogeniser Ariete NS5355. Our Homogenizers are optimized
to get the best homogenization
with lowest possible energy
Advances in the hygienic design of consumption.
homogenisers Typically, the same degree of
homogenization can be achieved
All of these requirements have led the Parma company, at lower pressure thanks to the
part of the GEA Group AG, to develop homogenising equip- high efficiency design of our
ment that meet the various hygienic design criteria as a homogenizing valves.
standardised solution, while at the same time designing GEA Niro Soavi machines are
some flexibility into the equipment to allow for the unique characterized by low RPM , low
applications of the various industry sectors. GEA Niro Suavi operating noise and long lasting
has developed machines are suitable for sanitary and reliability, for dramatically reduced
aseptic applications and are resistant to ultra-high pressure total cost of ownership.
(up to 1500 bar) (Figure 3) whilst remaining demonstrably
cleanable.

Figure 3. Ultra high pressure compression head hygienic design..

One area of this patent focuses on the configuration of

gaskets (O-rings). The GEA Niro Soavi O-ring grooves for
very high pressure meet the spirit of EHEDG guidelines,
while taking into consideration the wear-and-tear impact on
machines working at high pressures under pulsating stress
conditions.
Liquids to Value
In some cases, certain protocols in various guidelines and GEA Mechanical Equipment
regulations differ from each other; therefore, in order to
standardize the design of specific parts, it is necessary to GEA Niro Soavi
Via da Erba Edoari, 29 43123 Parma (Italy)
Phone +39 0521 965411 Fax +39 0521 242819
Info.GeaNiroSoavi@GeaGroup.com
www.niro-soavi.com

EHEDG_Innenteil.indd 41 05.04.11 10:59

 42 Hygienic design as a winning choice

develop a compromise solution between different require-

ments. For example, 3-A Sanitary Standards and EHEDG
guidelines take different approaches to addressing dead
areas inside the machine. According to EHEDG guidelines
(Doc 17, 7.1), Due considerations shall be taken in the
design of the equipment to avoid dead areas wherever
possible. According to 3-A Sanitary Standards (Doc. 04-
04, D4.1.1), Ports for instrumentation and pressure relief
devices on high pressure pumps and homogenisers de-
signed to operate at over 250 psig (1724 kPa) may have
dead end passages of 10 port diameters or less but not to
exceed 5 in. (127 mm) when assembled provided the pas-
sages are readily accessible for manual cleaning and in-
spection when disassembled. In order to comply with both
the EHEDG and 3-A Sanitary Standards requirements,
GEA Niro Soavi designed a special optional configuration
with regard to the high pressure gauge and safety valve Figure 5. The compression head standard configuration presents
ports. The hygienic design involves placing the pressure spacer cage and pumping valves with springs that are extremely
gauge and the safety valve in a separate block, closer to critical for solids, fibres and agglomerates processing.
the main flow (Figure 4). This special configuration allows
both direct cleaning-flow passage and reduces the lengths To solve these problems, GEA Niro Soavi has developed a
of dead legs for good cleanability results. new compression block which can be installed on a stan-
dard transmission system, and which allows the product
flow to remain constant through the homogenising valve.
OpenXFLOW: A winning example of clean The compression block enables the operator to pump a
design driven by the chemical industry fluid product with agglomerate fibres and solids, which then
flows to the homogenising valve without any accumulation
or obstructions (Figure 6). This configuration, designed to
solve a specific cleanability issue in chemical manufactur-
ing, is also suitable for processing foods with high-fibre
contents or foods that contain big particles.

Figure 4. In the GEA Niro Soavi special hygienic design, the pres-
sure gauge and the safety valve are placed in a separate block
more close to the main flow.
Figure 6. The patented liquid end configuration of the OpenX-
FLO optimises the products flow and cleanability, avoiding the
Today, there is increasing demand from the chemical and agglomeration of solid pieces dispersed into the liquid phase.
pharmaceutical industries for hygienically designed equip-
ment. For these sectors it has become critically important to
carry out multi-product productions without the risk of cross-
contamination that might occur due to inadequate cleaning
of machinery. In the case of the chemical sector, for exam-
ple, the manufacturing production cycle is often interrupted
in the presence of hard to process products, such as latex
and polymeric nanodispersions, wastewater sludge, polym-
erising fluids, products with a high content of fibres and
solids. These materials are subject to product clots that are
deposited inside homogenisers during the manufacturing
process.

EHEDG_Innenteil.indd 42 05.04.11 10:59


Roughness is not the only issue
Three criteria provide a reliable assessment of functional stainless steel surfaces.
Dr. Georg Henkel, Benedikt Henkel, HENKEL Lohnpoliertechnik GmbH, Neustadt-Glewe, Germany
E-mail: b.henkel@henkel-epol.com
Surfaces of stainless steel equipment components and
tube systems must fulfil the important functions of being
resistant to corrosion, neutral to the medium and easy to
clean, especially when they are in contact with the medium.
These aspects must be taken into account when the mate-
rial is specified and selected by the planner in order to meet
the demands of food production companies as exactly as
possible.
Electropolished tanks, material 1.4435/316L.
Even if it is assumed that the demands of the user have
been correctly translated into a material specification, a
technologically empty space often remains with regard to
the surface assessment of the components. Due to the
given control techniques, however, this is less than satisfy-
ing. Along with visual assessments (unaided eye) and
comparisons with standards that are often subjective, sur-
face roughness measurements generally provide a fast and
cheap method when used with one of the commercially
available test or stepwise processes, such as Hommel or
Perthen. These simple methods generally give a two-
dimensional geometrical index whose interpretation, how-
ever, in comparison to the fairly complicated condition of
the surface with regard to its operative behaviour, is prob-
lematic and requires further observation and classification.
EHEDG_Innenteil.indd 43
European Hygienic Engineering & Design Group
Topography, morphology and level of energy
For a reliable assessment of the facts it is necessary to
define three interrelated areas:
x Topography
x Morphology
x Level of energy
At the same time, the surface treatment process (non-
cutting and/or chemical or electrochemical) must be con-
sidered conclusively and classified.
The topography describes the three-dimensional geomet-
rical structure of the surface (i.e., the accessible micro-
cavities near the surface) where the formation of a flowing
boundary layer and diffusion behaviour may be considered
in the interpretation, depending on the state of the process
(static, dynamic). Basing assessments solely on the topog-
raphy of a surface is nearly impossible, or only possible to
a limited extent, using the abovementioned roughness
measurements. Isolated topographical information on
roughness is therefore a criterion that is of little help. Impor-
tant supplementary information on the geometrical structure
is needed, for example, localised elution of a suitably pre-
pared surface, since the diffusion mechanisms in both the
fluid and gas ranges can be examined and assessed.
The morphology of the surface (i.e. the layer near the
surface) shows whether the surface treatment process has
left traces that have significantly altered the originally pure
and clean austenitic structure to its detriment. The distur-
bances can be detected easily with a probe analysis up to a
depth of 30 Pm, ensuring that a surface in contact with the
media is represented by a material structure that is not
exactly defined.
Foreign matter pressed into the surface (e.g., abrasive grit)
may be found as alterations in the structure (ferrite parts) or
grain deformation. In addition to the problems of particle
generation, a weakening of the surfaces corrosion resis-
tance is expected.
The energy level of a surface is a thermodynamical state-
ment and can be divided into the fundamental alloy rate
and into stored external energy. This storage is caused by
the introduction of foreign matter (see morphology) and,
above all, the plastic deformation of the grain respective to
the crystals (entropy-mainly, energy-elasticity) via the cut-
ting and non-cutting formation of the surface and the diffu-
sion in thermal processes (welding, etc.). The alteration of
the energy level to a higher value alters all the other factors
of behaviour, such as corrosion resistance, adhesion be-
haviour and catalytic behaviour, which result in less favour-
able conditions for cleanability of a surface.
01.04.11 08:45
 44 Roughness is not the only issue
It should be pointed out that the abovementioned division of
criteria leads to the conclusion, arguably, that the morphol-
ogy influences both the topography and the energy level,
and vice versa. These perceptions allow the conclusion that
roughness values are only meaningful or of informative
value when combined with further information (e.g., the
traceability of the history of the surface via specification and
certification). Within the framework of further quality control,
a number of supplementary testing processes should be
standardised and implemented if the needs of the user are
to be fulfilled exactly and safely.
EHEDG_Innenteil.indd 44
References:
[1] G. Henkel, F. Stieneker, M. Wesch, Lexikon der Pharma-
Technologie - Werkstoffe und Verfahren, 1. Aufl., Editio Cantor
Verlag, Aulendorf 2006
[2] G. Henkel, J. Rau, B. Henkel, Topographie und Morphologie
funktionaler Edelstahloberflchen, Kontakt & Studium, Band 691,
Expert Verlag, Renningen 2008
01.04.11 08:45
 European Hygienic Engineering & Design Group

Cleanability of equipment: a prerequisite for the validation

of cleaning in the food industry
Cleaning is the most important process to prevent contamination in food production. Testing
cleanability of equipment is the first step before new machinery is integrated into a production
line. The validation for a cleaning procedure includes different qualification tests and is rele-
vant only for an integral production line.

Dr. Laurence Nicolay and Dr. Rudolf Schmitt, HES-SO Valais, CH-1951 Sion
E-mail: laurence.nicolay@hevs.ch, rudolf.schmitt@hevs.ch

Over the centuries, the evolution of techniques for produc-
tion, storage and preparation of food has been driven by
the demand for safe, nutritious and high-quality foods. Of
these, the assurance of food safety has first priority and is
not negotiable.
The frequency and the severity of foodborne illness out-
breaks throughout the world demonstrate a lack of hygiene
during food handling, from primary production to prepara-
tion by consumers. More to the point, equipment designed
without cleanability in mind and/or the use of inappropriate
cleaning procedures can be responsible for the advent of
dramatic diseases. In one famous example involving a
dairy plant in 1985, changes and extensions of the opera-
tions production capacity led to severe errors in the design
of the production lines. A cross-contamination occurred due
to seal defects in a cross-connecting pipe between raw and
processed milk, resulting in 16,284 foodborne illness cases
and five deaths.
Cleanability of a powder mixer prototype
In the first case, the development of a new powder mixer
for the pharmaceutical and food industries required the
validation of the mixing effectiveness in blending powders
with different particle sizes, shapes, densities and flowing
properties. The hygienic design of the equipment was ad-
dressed and integrated in the first steps of the mixers de-
velopment.
For the evaluation of the powder mixers cleanability, a 100-
L prototype was used (PTS-Batchmixer, Dec Group). The
procedure was designed according to the general validation
process (Figure 1). In this case, the focus was on the de-
sign qualification. Risk analysis identified the critical zones
and components that could not be sufficiently cleaned dur-
ing a standard cleaning procedure (CIP), based on the
general overview of the prototype plan and the visual check
of the prototype itself.

The hygienic design of processes and equipment, as well

as clean-in-place (CIP) procedures, is crucial to avoid con-
tamination and to produce safe food. Many companies are
confronted with inadequate cleaning results, and signifi-
cantly, the increased use of closed equipment systems may
lead to a false sense of confidence as to the faultless per-
formance of any given production and the level of hygiene
attained following cleaning. Equipment cleanability and
cleaning procedures are often considered as loss of time
and pure costs for companies that opt to start production
without any pre-production qualification and validation of
control measures. This is in full opposition to the under-
standing of Codex Alimentarius Commission guidelines,
which state: Validation is performed at the time a control
measure or a food safety control system is designed, or
when changes indicate the need for re-validation. Valida-
tion of control measures is, whenever possible, performed
before their full implementation. (CAC/GL 69 - 2008) (Ta-
ble 1).

Through two case studies, this paper illustrates an effective

method by which to design the validation for a cleaning
procedure. The first case study deals with the qualification
of the cleanability of a powder mixer. The second example Figure 1. General process for qualification and validation of equip-
extends the method to the validation of a powder filling ment.
machine.

EHEDG_Innenteil.indd 45 01.04.11 08:45

 46 Cleanability of equipment: a prerequisite for the validation of cleaning in the food industry
For design qualification, a cleaning procedure was de-
signed to simulate a CIP process under industrial condi-
tions. The design of the cleaning loop (Figure 2) included
the following materials: a) one tank for cleaning and sanitiz-
ing solutions and one tank to prime the circulating pump;
b) a centrifugal pump; c) a tubular heat exchanger; d) two
spray nozzles installed in the main compartments of the
mixer; and e) a flow meter, thermometers, a manometer
)LJXUH&,3ORRSWRWHVWWKHFOHDQDELOLW\RIGLIIHUHQWHTXLSPHQWFRPSRQHQWVDQGGHDG]RQHV.
The mixer was soiled using 50 kg of a mixture of cocoa
powder in wheat flour contaminated with Saccharomyces
6
cerevisiae (10 cfu/g). The mixture was processed for 5
minutes in the pneumatic mixer before emptying. The
cleaning protocol comprised rinsing at 75C, cleaning with
an alkaline solution, rinsing with cold water, and finally,
disinfection with an appropriate chemical at 60C, based on
a standard operating procedure (SOP). After disassem-
bling, visual observation of residues was performed, fol-
lowed by swab sampling at 12 points for microbiological
analysis.
EHEDG_Innenteil.indd 46
and a universal datalogger. Next, the target values were
defined, which included:
a. Verification of the spray nozzles efficiency using the
riboflavin-test with ultraviolet (UV) detection: all surfaces
are humidified
b. No soil residue can be observed
c. Absence of Saccharomyces at each sampling point
The results of the cleaning experiments and microbial ana-
lyses confirmed that the zones previously assumed to be
critical were, in reality, not cleanable in place. The methods
used allowed the industrial manufacturer to improve the
cleanability of the entire piece of equipment by modifying
the design of some parts and replacing some components
with those of hygienic design.
01.04.11 08:45 LL-10-0
 Cleanability of equipment: a prerequisite for the validation of cleaning in the food industry
Validation of a cleaning process in a dairy
plant producing infant foods
A validation of cleaning was performed on a new filling
machine in a dairy plant producing milk powder, powdered
infant formula (PIF) and specialty products for babies, such
as soy-based powder, hypoallergenic formulae and lactose
free products. The new equipment is intended to be used
on a variety of process lines and for the production of a
diverse range of products. The supplier made certain that
the basic needs for cleanability were satisfied through the
use of food-grade construction materials and the certifica-
tion of some of the filling machines components. A proce-
dure (SOP) was created for the cleaning and disinfection of
the new equipment.
First, a validation plan was created, which included:
a. A description of the equipment and the objective of the
validation
b. Identification of the hazards intended to be controlled:
Salmonella spp., Cronobacter spp. (for PIF), and aller-
gens for all powders without milk as ingredient
c. Identification of an acceptable level of cleaning: Ab-
sence of Enterobacteriaceae and beta-lactoglobulin at
each critical sampling spot. Serratia marcescens and
beta-lactoglobulin were used as surrogates for the iden-
tified hazards.
LEWA EcoFeed
The metering pump for
precise filling tasks
LEWA GmbH Ulmer Str. 10 71229 Leonberg / Germany lewa@lewa.de Phone +49 7152 14 - 0
LL-10-041_ AZ_EcoFeed_EN_V3.indd
EHEDG_Innenteil.indd 47 1 18.10.2010 12:21:54
47
d. Reference to the sampling and the validated testing
methods for the Enterobacteriaceae (enrichment in en-
teric enrichment (EE) broth and isolation on nutrient
agar; commercial enzyme-linked immunosorbent assay
(ELISA# test kit) and specifying the limits of detection
e. Reference to the cleaning and disinfection procedure
(SOP): manual dry cleaning
f. Description of the detailed validation protocol: soiling,
identification of sampling spots, cleaning, testing, and
frequency
g. Assignment of responsibilities for performing the valida-
tion study, for sampling and testing, and for approving
the results
h. Determination of corrective measures that must be
taken if the results proved that the objectives were not
met
Next, the validation protocol was implemented. Sampling
spots were identified by processing using 100 kg of PIF
containing cocoa powder, followed by dry cleaning, disas-
sembly of the machine, and visual inspection for cocoa
residues. The process resulted in the identification of 24
sampling points (Figure 3).
Solves all your filling tasks accurately,
securely and reliably:
one pump - various package sizes (5 ml - 1.000 ml)
innovative system solutions with LEWA intellidrive
self-cleaning capability (CIP)
Find out more about LEWA EcoFeed:
www.lewa.com/en_ecofeed
www.lewa.com
01.04.11 Uhr
08:45
 48 Cleanability of equipment: a prerequisite for the validation of cleaning in the food industry
Figure 3. Powder filling machine disassembled for visual inspection
and sampling.
Soiling was achieved using 50 kg of PIF contaminated with
5
10 Serratia marcescens per gram, processed and filled in
250 g bags. Dry cleaning was then followed by disinfection
as described in the SOP. Sampling was performed with
swabs following both cleaning and disinfection at the 24
identified sampling spots. Microbiological testing was con-
ducted for Serratia marcescens, and allergen testing (i.e.,
ELISA for beta-lactoglobulin) was also performed by apply-
ing an allergen-free powder to the filling machine after
cleaning and then sampling with swabs at one spot. Three
independent validation runs were completed following the
established protocol.
Microbiological analyses showed that dry cleaning alone
was not sufficient to reduce the test organism to an accept-
able level (16 of 24 points were positive). Test results
showed that only after disinfection was the acceptable level
achieved at all tested points. Allergen testing showed that
for all samples, the presence of beta-lactoglobulin was not
detectable.
In this case, validation was successful. The cleaning and
disinfection procedures were found to be effective to control
the identified hazards. It was found that verification proce-
dures for testing the effectiveness of the cleaning and disin-
fection could be created and implemented based on the
results of the validation. Results indicated that re-validation
will be necessary whenever there is a significant change in
the equipment or the cleaning and disinfection methods
used. In the event there are no changes to either the
equipment or the cleaning processes, re-validation should
occur, at a minimum of every five years.
EHEDG_Innenteil.indd 48
Conclusion
Effective cleaning procedures are of the highest importance
to prevent contamination at any step of food production.
This demands an integration of hygienically designed
equipment with appropriate chemicals and suitable clean-
ing methods for the specified production parameters. Ulti-
mately, the scientific data of the validation process must
show that the system produces a result that consistently
meets predetermined specifications. Interplay between
equipment and chemical suppliers and the users of the
equipment and chemicals is necessary to reach this goal.
It is impossible for equipment suppliers to provide set in-
structions for cleaning, especially when the equipment is
used to process a variety of different food products. How-
ever, suppliers can make sure that basic requirements for
cleanability are fulfilled. Particular attention should be paid
to using European Hygienic Engineering & Design Group
(EHEDG) certified components as an important element to
improving the cleanability of machinery.
In addition, by working in collaboration with chemical sup-
pliers, the equipment user can more effectively choose the
appropriate cleaning procedure that suits the type of resi-
dues that must be removed. Perhaps the most important
step is to validate equipment cleaning so there is docu-
mented evidence of the procedures effectiveness. Ulti-
mately, the owner of the food processing company is re-
sponsible for the application of effective cleaning proce-
dures. The proof of cleanability of all components of the
processing lines represents an important prerequisite to
meet this responsibility.
Control Measure: Any action and activity that can be
used to prevent or eliminate a food safety hazard or
reduce it to an acceptable level.
Validation: Obtaining evidence that a control measure
or combination of control measures, if properly imple-
mented, is capable of controlling the hazard to a speci-
fied outcome.
Verification: The application of methods, procedures,
tests, and other evaluations, in addition to monitoring,
to determine whether a control measure is or has been
operating as intended.
Table 1. Definitions extracted from the Codex Alimentarius Com-
missions Guidelines for the Validation of Food Safety Control
Measures (CAC/GL 69-2008).
Acknowledgements
Claudia Fricker-Feer (Hochdorf Nutritec Ltd., Hochdorf,
Switzerland) and Frdric Dietrich (DEC Group, Ecublens,
Switzerland) are acknowledged for their assistance in these
case studies. The Innovation Promotion Agency CTI (Swit-
zerland) is acknowledged for its financial support.
01.04.11 08:45

Examining the microbial contamination potential of fabric
flat belts
Hygienic and sanitary design of conveyor belts is critical in reducing microbial contamination
to assure food safety and quality. A conventional fabric flat belt was investigated using a food-
borne bacterial pathogen and animal blood as an indicator to determine its potential risk for
food product contamination. The results demonstrate that the fabric materials used in these
belts cannot be sufficiently cleaned.
Dr. Zhinong Yan, Senior Food Safety Scientist, Intralox
E-mail: zhinong.yan@intralox.com
Conveyor belts are an extremely important component of
food processing. Conveyor belts that directly contact food
products have been frequently targeted as contamination
sources in food processing facilities (Tompkin, 2002; Sui-
hko, et al., 2002). Correct application of hygienic and sani-
tary conveyor belts for food processing is critical in reduc-
ing the incidence of product contamination by foodborne
pathogens and spoilage microorganisms in order to ensure
food safety and quality. The three most widely used con-
veyor belt types in food industries today are fabric flat belts,
modular plastic belts, and continuous, smooth plastic belts
with positive-drive operation.
Conventional fabric flat belts, which are composed of layers
of fabric and covered with rubber or plastic materials, have
been used in the food industry for decades and continue to
be used today in many countries in many food processing
areas. Although these belts provide lower costs and flexibil-
ity in fabrication, they pose significant operational disadvan-
tages: mistracking, fraying, moisture absorption, stretching,
and most importantly, risk of product contamination.
The risk of product contamination in food processing appli-
cations is increased simply by using fabric flat belts due to
their design: 1) the frayed fibres of fabric flat belts absorb
moisture and adhere to food debris, providing favourable
conditions for bacterial growth and resulting in obvious food
safety risks; 2) the reverse side of fabric flat belts are com-
posed of weaves of fibres, containing pores that have
proven to be ideal harbourage sites for bacteria (Bremer et
al., 2002); 3) although the surface of a flat belt may appear
clean, it can harbour bacteria in the cracks (Scheffler,
2009); and 4) when the surface of a fabric flat belt is dam-
aged by tools or sharp food components during production,
bacteria can penetrate into the fabric layers, grow, and
eventually transfer to food.
Thus far, the contamination risk of flat belts in food produc-
tion has not been thoroughly investigated. The objective of
this study was to examine the cleanability of fabric flat belts
using routine sanitation procedures during normal opera-
tions and to assess the potential contamination risks
through belt surface damage.
EHEDG_Innenteil.indd 49
European Hygienic Engineering & Design Group
Examination of the cleanability of fabric flat
belting during normal operation
One thousand grams of deli turkey meat without preserva-
tives were autoclaved and homogenized in 9000 mL of
sterile distilled water to yield 10% meat slurry to simulate
the predominant organic matter found on conveyor belts
during ready-to-eat meat processing. Six strains of Listeria
monocytogenes (LM, ready-to-eat meat isolates) were
grown individually for two consecutive days, equally com-
7
bined, and added in turkey slurries to contain 10 CFU/mL
of LM. A polyurethane (PU) reinforced fabric flat belt (7.9 m
x 152 mm) was used, which was laced with 48 hinged
pieces (152 mm x 102 mm) capable of being removed for
microbial analysis. Three lines (3.175 mm wide each) of PU
surface were removed to expose fabric on each belt piece,
simulating surface damage on the belt during operation.
The belt was then inoculated by passing it through five
revolutions in the meat slurry with LM in a removable
trough. After removing the meat slurry, the belt was air-
dried for 30 min, allowing meat debris and bacteria to ad-
here to the belt. LM populations on the fabric flat belt were
then monitored for three consecutive days to simulate pro-
duction operations.
At day one, the LM populations were monitored at 2 h in-
tervals. Each removed belt piece was transferred into a
Whirl-Pak bag containing 150 mL of neutralizing buffer.
The samples were treated in an ultra-sonic water bath for 5
min. Appropriate dilutes or filtered membranes were plated
onto modified Oxford medium (MOX) overlaid with trypti-
case soy agar containing 6% yeast extract (TSAYE) to
o
recover the LM and incubated for 48 h at 37 C. At the end
of the day (after eight hours of operation), the belt was
cleaned and sanitized following a standard cleaning proto-
col, which included pre-rinsing the belt both inside and
outside, spraying it with detergents (Soil-Off, Ecolab), rins-
ing the belt with water, and sanitizing the belt with 200 ppm
chlorine-based products (XY-12, Ecolab). After sanitation,
LM populations were monitored. Thereafter, the belt was
kept under ambient conditions overnight.
01.04.11 08:45
 50 Examining the microbial contamination potential of fabric flat belts
At day two and day three, the belt was run through fresh
meat slurry without LM to add organic load as described
above. The belt continued to run for eight hours and was
sanitized, with LM populations analyzed every two hours.
LM population changes on the fabric flat belt during normal
operation over the weekend were studied using the same
materials and methods as described above.
Listeria population dynamics measured on
fabric flat belting during normal operation
As shown in Figure 1, at day one, LM inoculated onto fabric
6
flat belting yielded 10 CFU/piece and declined slightly dur-
ing eight hours of operation. The populations of LM were
2
then reduced to 10 CFU/piece after cleaning and sanitation
by the end of the day. LM continued to grow overnight at
room temperature to reach 103CFU/piece in the morning of
day two. After fresh meat debris without bacteria was
5
added, LM continued to grow to reach 10 CFU/piece during
operation. LM populations were then reduced to
3
10 CFU/piece after sanitation. The same growth trend of
LM populations on the belting was seen at day three.
Figure 1. Listeria monocytogenes populations on fabric flat belting.
Day 1, inoculation of bacteria through meat slurry; days 2 and 3,
adding fresh organic load through meat slurry without bacteria.
The LM population changes on the fabric flat belting during
discontinuous operation over the weekend were the same
as the three days of consecutive operation (Figure 2).
Figure 2. Listeria monocytogenes population dynamics on fabric
flat belting. Day 1, inoculation of LM via meat slurry; days 2 and 3,
fabric flat belting was kept under ambient conditions in the plant
without operation; days 4, 5, and 6, belting was loaded with organic
meat debris by running it through meat slurry without bacteria and
cleaned eight hours after operation.
EHEDG_Innenteil.indd 50
Observation of possible microbial
contamination through surface damage on
fabric flat belting
Contamination of food products can occur as a result of
bacteria harboured inside of fabric flat belting through areas
of damage on the belts surface (although very few studies
can be found to prove it). To demonstrate that bacteria can
migrate internally in flat belts, pig blood was used as an
indicator of aliquot organic matters to visualize the diffusion
patterns inside of the belt. The top polyurethane surface of
both new and used fabric flat belting was cut or peeled to
expose the fibre plies to simulate surface damage during
normal food-processing operations. One drop (100 L) of
fresh pig blood was then pipetted onto either the cut lines
or the peeled-off belt surface and held for two minutes,
allowing the blood to thoroughly diffuse. The patterns of
blood diffusion were then made visible by light transmission
from the backside of the belt. Meanwhile, the diffusion rates
(mm/min) on both the new and used fabric flat belts were
also measured from the warp and weft directions.
Blood diffusion on damaged fabric
flat belting
As demonstrated in Figures 3 and 4, animal blood was able
to penetrate and diffuse inside both new and used fabric
flat belting, respectively, through any surface damage.
Figure 5 indicates the diffusion rate (mm/min) of animal
blood inside both new and used PU fabric flat belts. It dem-
onstrates that diffusion was significantly faster in used
fabric flat belts than in new fabric flat belts, and that diffu-
sion was quicker along the warp direction than the weft
direction.
Figure 3. Diffusion of pig blood inside of a new PU fabric flat belt.
Top: surface cut; bottom: surface peel.
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 52 Examining the microbial contamination potential of fabric flat belts

Acknowledgment

Special thanks to Dr. Bradley Marks, Dr. Elliot Ryser, and

Mr. Michael James at Michigan State University for allowing
the author to use the pilot plant facility and providing the
bacterial strains used in testing.

References
Bremer, P.J., I. Monk, and R. Butler. (2002). Inactivation of Listeria
monocytogenes/Flavobacterium spp. Biofilms using chlorine:
impact of substrate, pH, time, and concentration. Letters in Applied
Microbiology 35:321-326.
Scheffler, R. (2009). Maximizing sanitation efforts in food process-
ing: the importance of conveyor hygiene. Trends in Food Science
Figure 4. Diffusion of pig blood inside of a used PU fabric flat belt. & Technology 20:S40-S43.
Top: surface cut; bottom: surface peel.
Stocki, S.L., C.B. Annett, C.D. Sibley, M. McLaws, S.L. Checkley,
Singh, M.G. Scruette, and A.P. White. (2007). Persistence of
25 Salmonella on egg conveyor belts is dependent on the belt type
but not on the rdar morphotype. Poultry Science 86:2375-2383.
20
Diffusion rate (mm/min.)

Warp Weft
Suihko, M-L., S. Salo, O. Niclasen, B. Gudbjrnsdttir, G. Torkels-
15 son, S. Bredholt, A.-M. Sjberg and P. Gustavsson. (2002). Char-
acterization of Listeria monocytogenes isolates from the meat,
10 poultry and seafood industries by automated ribotyping. Interna-
tional Journal of Food Microbiology 72:137-146.
5
Tompkin, B. (2002). Control of Listeria monocytogenes in the food-
0 processing environment. Journal of Food Protection 65:709-725.
Used belt New belt

Figure 5. Diffusion rate through a surface cut on both new and

used PU fabric flat belts.

Analysis of Testing

The results from the analysis of microbial tests and animal

blood diffusion observations on fabric flat belting demon-
strate that this type of conventional conveyor belt cannot be
sufficiently cleaned and sanitized with routine cleaning
practices in meat and poultry processing facilities. This is in
agreement with the report by Stocki et al. (2007) that clean-
ing and sanitation (using water and Virkon sanitizer) cannot
completely remove Salmonella Enteritidis on four types of
egg conveyor belts made of fabric materials and other
plastic materials. Blood as food fluids can carry bacteria,
and it diffuses inside of fabric flat belts through any damage
or wear. Niches between the top surface of the belt and the
fabric layers hold moisture and nutrients in food-processing
environments, providing favourable conditions for bacteria
growth.

In addition, the underside of a fabric flat belt, which is po-

rous due to its woven design, harbours bacteria and is hard
to clean and sanitize (Bremer et al., 2002). The numerous
niches on the fabric flat belt will provide some protection for
bacteria against sanitizers. Food residues containing fat
and protein that are buried in damaged areas of the belt
can prevent sanitizer from effectively contacting with bacte-
ria or inactivate sanitizers. The weaves can also absorb
sanitizers, reducing their efficacy (Bremer et al., 2002).

EHEDG_Innenteil.indd 52 01.04.11 08:45

 European Hygienic Engineering & Design Group

Potential savings of CIP costs by consistently following

hygienic design principles
Even today, the food industry avoids investing in hygienically designed equipment, although
the overall life cycle costs of such processing machinery can be much less than those of poor
design and lower capital investment.

Dipl.-Ing. Andreas Dorner, Kraft Foods sterreich, Bludenz, Austria

E-mail: ADorner@krafteurope.com

In order to meet the increasing expectations of consumers

with respect to demand for longer shelf life and higher qual-
ity products, food processing companies must diligently
maintain high levels of hygiene in the production environ-
ment. Regulatory requirements, such as EC Directive
2006/42 on machinery and EC Directive 178/2002 on food
safety, must be followed. To ensure that all requirements
Figure 1. Changing colour of the cleaning agent dependent on the
are met, the food processing plant must implement hygienic
organic load from purple (no organic freight) to yellow (heavy
principles in all aspects of food production and handling. organic freight).

One factor that is becoming increasingly relevant to achiev-

ing compliance with regulatory mandates and industry best
practices is the use of easy-to-clean equipment and com-
ponents. However, there is a prevalent misconception in
the food industry that the higher capital costs of purchasing
and installing hygienically designed equipment, as opposed
to lower-cost equipment of poor hygienic design, do not
offer a return on investment in cost savings. This view is
narrow and typically excludes life cycle costs from
cost/benefit analyses. While investing in a machine that is
designed to hygienic principles typically does result in
higher acquisition costs, it is also possible that such a piece
of equipment will offer cost-savings during its life cycle that
low budget machinery cannot.
The goal of this thesis is to investigate the effect of hygienic
design on cost savings in clean-in-place (CIP) procedures
and on overall costs, as well as to provide a strong argu-
ment for project engineers and decision guidance for ap-
proving managers.
Materials and methods
Cleaning experiments were carried out in a pilot plant lo-
cated at the Technische Universitt Mnchen. Different
pipe equipment, valves and pumps were used in standard-
ised soiling and CIP procedures. The soil used in these
experiments was common household sugar (saccharose)
that was dissolved in water and adjusted to a constant
concentration. This oversaturated fluid was applied to the
inner surface of the test equipment and dried for 24 h using
oil-free pressurised air. This application resulted in a crack-
free and even coating that was repetitive and standardised.
An alkaline cleaning agent from Thonhauser, Austria, was
used, which consists of a redox-indicator that changes its
colour according to the load of organics contained in the
fluid (Figure 1).
Figure 2. Optical detection system: Photo-Eye from Thonhauser,
Austria
The progress of cleaning is indicated via a chemical com-
pound in the cleaning agent that changes colour dependent
on the dissolved organic soil. An optical device is used to
measure the colour of the cleanser after equipment clean-
ing (Figure 2). The optical results give an impression of the
cleaning progress and cleaning time since the cleaning
agent returns to its original colour due to oxidation.
The colour turns from purple through green to yellow when
organic compounds in the fluid are present. In a non-
circulated CIP procedure, the cleaning agent will dissipate,
and therefore, its colour will change from purple through
green to yellow and back to purple again if all the organic
soil has been cleaned from the test object. This indicates
the time needed for a thorough cleaning.
In addition to these experiments, financial data from several
anonymous dairy plants were accessed and the cleaning
costs analyzed. With this cost-basis, savings due to lower
cleaning time could be evaluated.
Experimental results and calculation of
saving potential
Comparing different single pipe accessories with the same
purpose, hygienically designed equipment showed signifi-
cantly lower cleaning times than ones with corners and
dead ends (Figure 3).

EHEDG_Innenteil.indd 53 01.04.11 08:45

 54 Potential savings of CIP costs by consistently following hygienic design principles
Figure 3. Cleaning times of sensor mountings.
Figure 3 shows that the hygienic device (Varinline spherical
body housing) could be cleaned up to twice as fast as its
comparable standard part (T-shaped pipe sensor housing),
the latter of which is predominantly used in the food indus-
try. Figure 3 also shows the cleaning times of different
types of sensor housings (e.g., 2d means that the length of
the dead end is double the diameter of the pipe) compared
to a straight pipe.
Figure 4. Sensor assembly according to good hygienic design
principles.
Comparing more complex assembled groups of equipment
constructed in a hygienic manner (Figure 4) to those of
much worse design (Figure 5) results in noticeably greater
advantages of hygienic design.
Figure 5. Sensor assembly according poor hygienic design princi-
ples.
EHEDG_Innenteil.indd 54
Companies can shorten their CIP programs to one-quarter
of the time and save money through water, cleaning agent,
energy, time, etc. Figure 6 illustrates that a group of sensor
housings constructed with a sound hygienic design results
in a cleaning time that is four times faster than a construc-
tion with common T-shaped dead-end pipes.
Figure 6. Cleaning time of a complex group: good hygienic design
compared to poor design.
The experimental outcomes combined with the financial
data of the dairy plants produced calculated payback times,
which are essential for approval of any project. Depending
on the type of installation, new or replacement equipment,
this study showed that amortization can occur in less than a
week in the cases of these dairy plants.
Conclusion
Taking the low overall life cycle costs into account is essen-
tial for decision making in favour of hygienically designed
equipment. Reducing change over time is an obvious target
in continuous improvement programmes. Implementing
equipment and machinery designed according to hygienic
design principles can dramatically shorten CIP time and
leverage savings while increasing the level of hygiene in
the food processing environment.
Acknowledgments
This topic was covered by a diploma thesis at the Lehrstuhl
fr Verfahrenstechnik disperser Systeme (former Lehrstuhl
fr Maschinen- und Apparatekunde) at the Technische
Universitt Mnchen in Weihenstephan, Freising, and was
supervised by Prof. Dr.-Ing. K. Sommer and Dr.-Ing. J.
Hofmann. This study was honoured with the Hygienic Study
Award 2010 during the HygieniCon in Karlsruhe and the
young academics sponsorship award 2010 from the GDL
e.V. (Gesellschaft Deutscher Lebensmitteltechnologen).
01.04.11 08:45 304-108
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01.04.11 Uhr
08:45

Hygienic design inside and out
For manufacturers who produce protein- and fat-containing products like meat, fish or dairy,
there is hardly another factor of such importance as hygiene. A new generation of hygienically
designed thermoform packaging machines are helping these food producers to ensure cleanli-
ness on both the external and internal components of production equipment.
Valeska Haux, Multivac Sepp Haggenmller GmbH & Co. KG, D-87787 Wolfertschwenden
E-mail: valeska.haux@multivac.de
It is particularly important to take hygiene into consideration
when constructing the exposed areas of the machine. This
includes both the food processing areas (i.e., the areas that
come into direct contact with the product or that can have a
direct effect on the product) and the splash zone (i.e., the
areas that can become contaminated with the product dur-
ing the packaging process without having any direct effect
on the product itself).
Taking a closer look at these critical zones, it is clear that
the hygienic optimisation of equipment design cannot be
restricted to the outside of any given machine, because
many critical internal components are located within the
splash zone, such as the transport chain (including the
brackets), the chain guide rail, the side frames and the
pumps. Due to their construction, these components typi-
cally are difficult to clean, and sometimes require time-
consuming disassembly.
Frame of the thermoforming machine built according to Hygienic
Design Guidelines
Supported by independent experts, the designers at Multi-
vac have developed a new generation of thermoform pack-
aging machines. One of the overarching goals was to sim-
plify and speed up the cleaning of the machines and to
support it technically to the extent possible, in order to
enable hygienic perfection in an economic way. To this
end, the machine design has also been completely re-
worked, both with respect to the exterior and the internal
components.
EHEDG_Innenteil.indd 56
European Hygienic Engineering & Design Group
Hygienic design certified to DIN 1672
The new hygienic design doesnt just conform with the EC
machinery guidelines, but is also certified by the German
Association for Food and Gastronomy (Die deutsche
Berufsgenossenschaft Nahrungsmittel und Gaststtten/
BGN) in accordance with the strict requirements of the
standard EN 1672-2. The materials used and the composi-
tion of the surfaces, the construction of the connections, the
ease with which liquid flows off the machines and the ac-
cessibility for cleaning were all examined. The machines
are also evaluated and certified by the United States De-
partment of Agriculture (USDA) in accordance with the
requirements of ANSI/NSF/3A 14159.
The outside of the machine is characterized by smooth,
sloping services on the front section and the covers for
external components, so that cleaning water and dirt resi-
dues can run off easily. Dead space and inaccessible
niches are avoided consistently, even in details such as the
height-adjustable feet, which are without an external
thread, or the closed form deflexion pulleys. The hinged
side parts enable quick access to the internal components
for maintenance and cleaning purposes.
The hygienic design of the essential internal components
also follows the principle of quick and comprehensive
cleaning. New developments include a transport chain with
open spring windings and an open chain guide rail to avoid
creating dead spaces. The design enables contaminants to
be rinsed away, leaving behind no residues, without the
need to remove the chain. This makes thorough cleaning
considerably easier. Throughout the interior, the cables and
pumps are fed along spacers, which prevents contaminants
from collecting within interior surfaces. For the same rea-
son, smooth-cased motors without fans and a direct drive
mechanism without a drive belt are used as part of the
hygienic design.
Automatic chemical cleaning of the interior
To make the cleaning process easier and more economi-
cal, an optional clean-in-place system (CIP) is available for
machine types R 535 and R 245 and represents a major
innovation for thermoform packaging machines. CIP pro-
vides fully automated chemical cleaning of the internal
components, the transport chain and the chain guide rail as
01.04.11 08:45
 Hygienic design inside and out 57

a complete package or partial packages for individual com-

ponents. By a system of nozzles and pipes, cleaning fluids
and disinfectants get directly to the components and re-
move fats, proteins and other organic materials, as well as
lime. The standardised, fully automated procedure is car-
ried out from the machine control and is precisely proto-
colled. This ensures adherence to specified cleaning cycles
or quantities and compositions of cleaning chemicals.

Real-world use of the system, which is in use in several

manufacturing plants in Europe, confirms that the cleaning
process can be repeated in exactly the same way each
time, enabling a higher level of security that all necessary
steps regarding consumer protection have been performed.
The machines can be washed down externally and internally
The effects of the automated cleaning process were also
investigated in a scientific research study. In several tests,
the internal components of the machine were contaminated actually able to reach the areas in question. Results
with a mix of meat juices, milk and crme fraiche (i.e., with showed that all substances could be removed by the CIP
fats and protein), and were sprayed with a fluorescent sub- system, and on a microbiological level, it was possible, in
stance to test exactly how well water and detergents were part, to reduce the number of bacteria below any detectable
level.

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EHEDG_Innenteil.indd 57 05.04.11 13:57


Recent developments in cleaning technology
It is important to consider the clean-in-place (CIP) operation as part of the whole, rather than as
an isolated event. Using guidelines and structured procedures is an important aid in the daily
work of a food processing plant. New tools, methods and cleaning agents change the way
cleaning technology can be used and improve cleaning results.
Stefan kesson, Manager Food Safety & Equipment Safety, Tetra Pak, Lund, Sweden
E-mail: stefan.akesson@tetrapak.com
Anders Gransson, Key Technology Manager Cleaning & Performance, Tetra Pak, Lund, Sweden
E-mail: anders.goransson@tetrapak.com
Cleaning is a must in food industry sectors, and an essen-
tial prerequisite to secure food safety and product quality.
Many producers focus on cleaning, because this has a
major impact on the length of production runs, which in turn
contributes to the producer's performance including the
ability to reduce energy, utility and detergent costs.
Three major trends related to cleaning technology have
emerged in recent years:
A holistic view and structured approach to cleaning as
part of production
Development of new tools, cleaning methods and clean-
ing agents
Structured validation of cleaning results
Cleaning: part of production
It is important to consider the process as a whole rather
than focusing on the clean-in-place (CIP) operation as an
isolated element. This approach helps ensure that the
product recovery step preceding CIP is performed in an
intelligent way. CIP is, to a large extent, an optimisation
issue. Food producers do not want to clean any longer than
necessary, but at the same time, all soils must be removed
to secure food safety. CIP activities should be planned so
that they intrude as little as possible on production time,
because no production equals no profit.
The required CIP time correlates to the specific object to be
cleaned; thus, it is of vital importance to identify the charac-
teristics of every single part of a line when optimising the
CIP program. In many ultra high temperature (UHT) appli-
cations production starts immediately after the pre-
sterilisation step, and thus sterilisation of the processing
equipment must also be considered as part of the cleaning
cycle.
One way to improve cleaning is to use guidelines (i.e.,
structured procedures) as an important aid in the daily work
of a food processing plant. Another way is to implement
production-adapted cleaning. Advanced automation sys-
tems that incorporate recipe handling, production monitor-
ing and production analysis assist food producers in ac-
cessing information about the ongoing cleaning sequence
through CIP sensors and automatically adapt the cleaning
procedure, depending on the information received and
analyzed.
EHEDG_Innenteil.indd 58
European Hygienic Engineering & Design Group
New cleaning methods and cleaning agents
The type of product being processed affects equipment
cleanability in different ways. Components with good clean-
ing result when running with low-viscous products, such as
white milk might not be suitable for high-viscous products,
or products containing fibres, seeds, salts and other addi-
tives. In addition, rapid development of new products puts
new demands on cleaning methods. Fortified juices, health
drinks and mineral additives are examples of products that
present new particles and substances that can influence
the equipment material in new ways.
To improve cleanability and disinfection, new methods such
as ozone and electrolysed water are being developed.
Using electrolyzed water is not a completely new concept,
but its use in a CIP system is novel. Electrolysed water is
produced by the electrolysis of water containing sodium
chloride. The electrolysis produces a solution of sodium
hypochlorite, which is the most common ingredient in
bleach. Improved commercial applications have made this
method more interesting for the food industry. Ozone oxi-
dises any bacteria with which it comes into contact, and
then converts back into oxygen without any environmental
side effects. Ozone has long been used for water treat-
ment, in medical therapies and as a surface treatment due
to its anti-viral and anti-fungal properties, and new devel-
opments in CIP technology have made this an interesting
alternative for the food industry.
Controlling CIP parameters
The Sinner circle is still valid. Four main process parame-
ters can be controlled during CIP: temperature, time, flow
and concentration of cleaning detergent. It is difficult to say
which of these parameters has the most significant impact
on cleaning due to combination effects. If the flow velocity
is too low, the detergent concentration, cleaning time and
temperature must be adjusted to retain cleaning efficiency.
With a fully working CIP flow, the mass transport of deter-
gent solution to the fouled surface will work satisfactorily.
The fouled surface is also exposed to mechanical forces
through the fluid flow, which helps remove fouling.
01.04.11 08:46

Traditionally, the cleaning temperature in the liquid food
industry has been high, up to 140C for some applications.
Recent research has found indications that it is not neces-
sary to use these high temperatures for all production sce-
narios. Testing has shown that the same cleaning effect
can be achieved at lower temperatures, which benefits both
the environment and the producers heating bill. Optimisa-
tion is the key.
Tetra Alcip, a flexible extendable CIP module for liquid food
The solution to a cleaning problem might require more than
merely increasing the detergent concentration. Many inves-
tigations show that an optimum detergent concentration
exists and that increasing the concentration beyond it will
lead to a less effective cleaning result. Furthermore, new
types of cleaning agents adversely affect materials tradi-
tionally used in the food industry. For example, several
types of rubber normally suitable for foodstuffs may be
sensitive to these new types of cleaning agents. It is essen-
tial to carefully select the correct detergent in relation to the
material in food contact, otherwise chemical migration can
occur and rubber particles from the seals may end up in the
product.
EHEDG_Innenteil.indd 59
Recent developments in cleaning technology 59
Hygienic design
In the development of machines, production lines and en-
tire plants, food safety starts on the drawing board with
hygienic design. The idea is to ensure everything that will
come into contact with foodfrom components to connec-
tions, welds, etc.is built for cleanability, using materials
approved for food contact. Moreover, hygienic risk assess-
ment of equipment during the development and engineer-
ing phases analyses and evaluates any hazards to reduce
or eliminate hygienic risks, such as microbiological and
chemical contamination and foreign bodies originating from
machinery or other sources. Such complete analysis en-
ables verification of entire production systems. Cleaning is
not a way to correct improper hygienic design.
Structured validation of cleaning results
Tradition is strong in the food industry. Producers have
done things in a certain way for a long time. Even if a
method works well, by challenging traditional methods,
current methods can be scientifically secured or better
procedures can be developed.
To make sure CIP cycles work effectively, it is vital to vali-
date CIP procedures. Tetra Pak has developed a structured
method for validating CIP that includes all the necessary
steps: design qualification, installation qualification, opera-
tional qualification and finally performance qualification.
With the correct CIP function, product quality and through-
put can be increased, while food safety and sustainability
are ensured.
01.04.11 08:46

How to secure food safety in a production line
A holistic view on the entire, integrated production is necessary to secure food safety. Hygi-
enic design ensures that everything that will ever come in contact with food is built for
cleanability, using approved materials, taking into account the entire production solution.
Automation on plant level controls the production process from intake to distribution and se-
cures traceability.
Stefan kesson, Manager Food Safety & Equipment Safety, Tetra Pak, Lund, Sweden
E-mail: stefan.akesson@tetrapak.com
To the consumer, food safety simply means being able to
rely on the food you eat. To the producer it means so much
more it means being in full control of all production pa-
rameters at all times to secure quality and production
throughput. What is the cost of maintaining high food safety
standards? And what is the cost of neglecting to uphold
those standards?
Food safety, according to the World Health Organization
(WHO) Codex Alimentarius, is defined as: Assurance that
food will not cause harm to consumers when it is prepared
and/or eaten according to its intended use. Most countries
have precautionary principles and legislation covering pro-
duction, handling and sales of foods and beverages. All
parties in the food chain share the responsibility: the pri-
mary producer, the processing and packaging industries,
wholesalers and retailers, and last but not least, consum-
ers. Products can be bacteriologically safe and of high
quality at the point of sale, but incorrect storage or handling
by the consumer can turn food into a health risk.
Integrated production solutions from intake
to distribution
The demands for traceability, production planning and
performance for entire plants drive development. In addi-
tion, fierce competition in the food processing industry is
speeding up the need to reduce costs. Integrated process-
ing and packaging solutions makes it easier for food pro-
ducers to reach their objectives of efficient operations.
Integration between processing and packaging lies not in
any particular hardware, but in the way producers can run a
plant.
Integration means a number of things, such as making old
and new equipment work together, including third-party
equipment, in the customers total operations. Integration
also demands and effective flow of information. Also, hav-
ing one supplier with total responsibility for the complete
operation of a plant from intake to distribution secures
delivery times, production stability and performance.
With an integrated processing and packaging solution built
on a common software platform, customers can enjoy sim-
plified operations and decision making. They need only a
single control room where all processing and packaging
activities can be managed and monitored. In this way, all
the equipment speaks the same language.
EHEDG_Innenteil.indd 60
European Hygienic Engineering & Design Group
Tools of the trade
Food safety charts, performance and quality analysis, and
automated traceability are examples of different tools that
support food producers' efforts to comply with food safety
regulations and consumer demands. Food safety charts
identify critical control points and set limitation values for
monitoring and monitoring intervals, so action can be taken
if the set point values are out of range.
Food safety charts are an important aid when implementing
a HACCP program or a food safety management system
such as ISO 22000:2005 including prerequisite program
PAS220:2008.
Hygienic design
When machines, production lines and entire plants are
developed, food safety has to start right on the drawing
board, with hygienic design. Everything that will ever come
into contact with the product has to be built for cleanability,
using approved materials. Hygienic design also takes into
account how all these components are put together into a
production solution where the flow system and control sys-
tem collaborate to achieve a correct function.
Hazards must be analysed and evaluated in advance to
reduce or eliminate hygienic risks. These might be microbi-
ological and chemical contamination or foreign bodies
originating from machinery or other sources A complete
hygienic risk assessment of equipment during the devel-
opment and engineering.
Ongoing research tries to find new surface treatments and
materials that will minimise fouling and facilitate cleaning
operations. When developing new production technologies
it is essential for equipment and solutions producers to
incorporate a food safety perspective and standards for
hygienic design. Also important is that these efforts are
promoted by independent organizations such as the Euro-
pean Hygienic Equipment Design Group (EHEDG).
Integrated automation solutions
Advanced, integrated automated solutions should control
the plant, to secure every step, from intake to distribution. A
real-time automation application on the factory floor can
communicate in seconds via databases that send and re-
ceive information.
01.04.11 08:46

Business systems and enterprise resource planning (ERP)
systems, also connected to the real-time automation appli-
cations, can manage planning, raw material handling, in-
ventories, production analysis and reporting, which are
crucial for a safe and effective production result.
View of a control room in a Chinese dairy plant
Automation solutions should be modular and based on
open architecture platform and open industry standards, as
well as production know-how. They should cover the entire
production chain from intake to distribution, and provide full
reporting and traceability, including unit history, batch con-
trol and a review of all actions, and should interface with
other equipment and systems, including packaging lines.
Accumulated data can be used to improve the tracking
possibilities, ensuring better food safety. These functions
enable continuous improvements and reduce the risk of
human error. The design on the operator interface is also
important. It has to be is easy to understand, with safe-
guards against incorrect operation to further minimise the
risk for human error.
Traceability secures food safety
The globalisation of food production, together with in-
creased demands from consumers for absolutely guaran-
teed food safety, has led to legislative demands on the food
producers. In recent years. traceability has become highly
important and is now mandatory in many countries around
the world, including in the European Union, United States
and China. The general principles of food law now apply to
every stage of the supply chain and the new regulations
state that every step in the production chain, every product
batch and its history, must be traceable.
Traceability can be achieved in many ways, but a manual
system has many disadvantages compared with an auto-
matic one. Automatic systems offer production parameter
logging, ingredient control, traceability and quicker access
times.
EHEDG_Innenteil.indd 61
How to secure food safety in a production line 61
It must be possible for the producer to trace the movement
of materials throughout production: what recipes, material
amounts, equipment and process parameters were used;
timing data for a batch, clean-in-place (CIP) routines; and
even the names of operating personnel. This increases the
total transparency of the entire value chain.
It is also important that quality assurance data, for example,
are linked to databases such as a laboratory information
management system (LIMS), and continuous online moni-
toring of materials, processing and production builds up a
valuable bank of information. Analysis of this data is used
for food quality and food safety management, production
planning strategies, and for generating key performance
indicators, facilitating implementation of ISO 22000.
Traceability codes
There are a number of methods to make products trace-
able, such as bar codes, radio frequency identification
(RFID) tags and printed labels, etc. The common factor is
that the code on each package is unique. Traceability is
made transparent to retailers and consumers via the code
on the product, which can be traced all the way back to the
raw material. For instance, the dairy producer can set up an
internet portal where the consumer can key in the traceabil-
ity code from their package to open up a web page display-
ing all relevant information, including a Google map where
each collection point/farmer is pinpointed, displaying where
the raw milk is sourced. Furthermore, an application in-
stalled in the Apple iPhone allows consumers access to the
same websites from their mobile phones.
Control systems including tracking and traceability lead to
higher security in production and better quality, and for the
economically minded, also to improved production through-
put, lower production losses and better cost-efficiency.
They minimise the size of a structured recalls. It is impor-
tant to recognise that when applying a control system in the
food industry it is not only about automation, but also about
knowledge of the food to be produced. A holistic view is
essential.
01.04.11 08:46
 European Hygienic Engineering & Design Group

Food equipment hygienic design philosophy

Today, the food industry is changing more quickly and more radically than ever before. The
global market demands new food products, each developed to ever-increasing levels of so-
phistication that use novel methods and technologies, from cooking engineering and tailored
food diets, to nanotechnology. No matter what technology is used, the fundamental require-
ment for any food product is that it is safe to consume. By following a food equipment hygienic
design philosophy at each step of food production, food safety and quality can be significantly
enhanced for the benefit of all consumers.

Dr. Tadeusz Matuszek, Gdansk University of Technology, c/o EHEDG Regional Section Poland
E-mail: tmatusze@pg.gda.pl

The term food quality is very difficult to define, in large
part because the number of desired product attributes and
functions are as varied and numerous as the number of
individuals consuming these myriad products. The multi-
tude and scope of consumer preferences related to food
quality from taste, mouthfeel, flavour and colour, to nutri-
tional values and functionality, to cultural and religious
factors can be nearly impossible to uniformly quantify.
Yet, there is one factor with which most consumers agree:
The safety of food means that the products they consume
are of the highest possible food quality. In other words, if
the food is not considered safe, it is not considered a qual-
ity product.
ards and flow of raw materials and product; movement and
control of people; design and installation of the process
equipment; design and installation of air, water, steam,
electric services and utilities; and ease of equipment and
component maintenance. In other words, in order to ac-
complish food production quality through hygienic design,
there must not only be engineering of specific equipment
functions for precisely defined tasks but also engineering of
various preventive features to reduce or eliminate any haz-
ards that could act against the desired function. Once the
appropriate variables of the desired functions are identified,
the relevant instrumentation and procedures can be se-
lected with a higher level of confidence.

Food processing equipment designers play an important
role in ensuring high-quality (i.e., safe) products by incorpo-
rating the principles of hygienic design into every machine
and component that will be used in the production environ-
ment. Before beginning any design process, hygienic food
equipment designers also must consider what, why and
how to arrange required actions on many fronts to achieve
a common way of thinking about food quality and how food
contributes to quality of life for all consumers.
Hygienic design philosophy
Ultimately, the quality of food products depends on the
strength of each link in the food production and supply
system, from farm to fork; i.e., from the place where the
raw materials are harvested or produced to the processing
plant and through various food engineering processes,
through distribution and storage systems, and finally, to the
consumer's plate. By implementing the principles of food
equipment hygienic design philosophy at all points (or links)
in the food processing and production environment, de-
signers and engineers are able to create the unique fea-
tures required by each processing plant, along with ex-
pected reduction in contamination by biological, physical
and chemical hazards at any point in the processing opera-
tions.
The twin goals of hygienic design are to minimise risks of
contamination and to make easier the challenges of clean-
ing and maintaining the plant and equipment. Design con-
siderations should cover the following: factory location and
construction; design of the building structure; selection of
surface finishes; segregation of work areas to control haz-
Challenges of food production environments
and facilities
There are several challenges to the realisation of hygienic
design philosophy principles in real-world production set-
tings. For example, the food engineering process and indi-
vidual food product recipes interact in a very complex way,
making it difficult for designers to find the right combination
of these various interactions without performing hundreds
of experiments. Although product quality is described by
numerous measurements (i.e., sensory, microbiological,
instrumental, etc.), the equally numerous results of such
measurements require product developers and equipment
designers to interpret them in a meaningful way that will
help increase food safety in the product and in the produc-
tion system. As the demand for data on food safety, origin,
traceability and environmental and ethical impacts in-
creases, more knowledge will also need to be generated in
the areas of hygiene, food contamination pathways and risk
evaluation, requiring new strategies and refined analytical
methods.
Meeting different needs related to food production lines
also poses challenges for equipment designers and engi-
neers in the food industry.
Different facilities have different operating needs and objec-
tives; some food production line facilities require a higher
degree of flexibility than others, some may need to operate
more cost-effectively than others, and some must be able
to increase automation and product variation with short set-
up time between product runs. Various hygienic and envi-
ronmental demands that characterise the development of

EHEDG_Innenteil.indd 62 01.04.11 08:46

 Food equipment hygienic design philosophy 63

new food production systems can be determined through
two types of evaluations: Life Cycle Assessment (LCA) and
environmental impact assessment (EIA).
These assessments require equipment designers to con-
sider a number of production line factors when designing
machinery: a) hygienic design of buildings; b) new process-
ing equipment together with cleaning and disinfection sys-
tems; c) methods of risk evaluation and validation of risk
levels; d) processes for inactivation and elimination of mi-
croorganisms; e) risk related to packaging and food trans-
portation vehicles; and f) quality assurance systems.

Raw materials x Freshness, density and structure

x Sensory attributes (i.e., colour, shape, texture)
x Microbial content
x Pesticides, manure or fertiliser used
x Concentration of microstructure components
x Temperature/pressure resistance
x Microbial growth niches or harbourage points
x Transportation and storage of raw materials
x Genetically modified organisms (GMO) or natural product claims
Human Beings x General human food consumption and handling behaviours
(Needs and preferences) x General human needs and preferences (i.e., value-added functional foods with
antioxidant characteristics, non-GMO or gluten-free foods, tastiness, etc.)
x Quality and level of education of consumers
x Psychological
x Physiological (i.e., food allergies, immunocompromised individuals)
x Sociological factors (i.e., cultural, ethnic/traditional, or religious requirements)
Air x Temperature
x Pressure
x Velocity
x Transparency
x Moisture and dust content
x Cleanliness

Water x Temperature
x Pressure
x Sources
x Velocity and volume
x Cleanliness
x Recovery possibilities
x Limited content of heavy metals and other chemicals (i.e., Fe, Mg)
Facilities x Food production equipment and facility surface materials are corrosion and
micro-corrosion resistant
x Equipment components and parts designed for hygienic connections
x Mechanical strength and durability of materials used
x Surface cleanliness (i.e., disinfection, sterilisation and aseptic process objectives can
be achieved)
x Surface roughness
x Exploitation of maintenance (i.e., both repair and upkeep of equipment and
components and sanitation tasks)
x Adhesive adherence and cohesive disposed
x Surface reaction resistance to the raw material components
Packaging x Preserves food content freshness, colour stability, and other quality attributes
x Acts as barrier to microorganisms
x Durable, easy to open
x Light and radiation resistance, yet transparent
x No interaction between the product and packaging materials
x Suitable for pasteurisation, sterilisation and aseptic filling processes
x Stable shape, forming feature
x Hermetic closure

Table 1. The six design factors of the design-driven approach.

EHEDG_Innenteil.indd 63 01.04.11 08:46

 64 Food equipment hygienic design philosophy
Approaches to machinery design
Machinery design is an interdisciplinary process, influenced
by basic knowledge of mathematics, physics, mechanics
and thermodynamics. Good machinery design also takes
into account the business side of manufacturing, including
material engineering, economics and cost ratios, together
with marketing and distribution strategies. At its core, how-
ever, the discipline of machinery design is focused on the
technical side, in which technical systems are developed
and described by streams of energy, materials and informa-
tion, as well as by the structural and functional relationships
between parts of the machinery.
In general there are two approaches to building technical
systems: the science-driven and the design-driven. In the
science-driven approach, the decisions made with respect
to the design, materials and functionality of the technical
system is derived from scientific knowledge of what and
how the elements of machinery work together to efficiently
operate. In other words, the engineering of the system
begins with objective data, such as the atomic level struc-
ture, crystallography, defect structure, thermodynamics and
kinetics, microstructure, material properties, and mechani-
cal, thermal, electrical and optical properties. These data
drive the design such that the machine functions properly
and efficiently with respect to its purpose.
The design-driven approach incorporates the same techni-
cal elements as the science-driven approach but has one
significant difference: The desired outcomes of the design
are considered first, not last. Six major factors strongly
influence food equipment design from a safety, hygiene
and food quality point of view: raw materials, humans, air,
water, facilities and packaging (Table 1). As shown in the
table, each of the six factors contains both a number of
technical considerations governed by function (i.e., packag-
ing should be designed such that it is suitable for pasteuri-
sation, sterilisation and aseptic filling processes) and out-
come-based considerations (i.e., packaging should pre-
serve freshness, colour and other quality attributes of the
food). Thus, the design-driven approach weds the logic of
engineering design processes with the creative thinking
needed for innovation to enhance the production of safe,
high-quality food.
Designing for safety
The design factors also support the principles of the food
equipment design philosophy. The designing process re-
quires the designer to incorporate adequate actions that
have to be taken to prevent the harbourage, growth and
survival of harmful microorganisms, bacteria, fungi and
yeast at every single surface of the designed equipment.
Among the actions that need to be considered at the stage
of equipment design, the following can play crucial roles in
ensuring hygiene:
x Identification of food structure and its potential for
microbial growth
x Microbial adaptation and survival to define safety
margin for more natural foods
EHEDG_Innenteil.indd 64
x Detection of hygiene on surfaces in food processing
equipment through the microbial assessment methods
used in cleaning efficiency evaluation
x Determination of sampling methods to be used, espe-
cially the basis for the number of samples and the fre-
quency for the detection of attached microbes and
biofilms on that surfaces
x Development of optimal cleaning and disinfection sys-
tems, such as clean-in-place (CIP), clean-out-of-place
(COP), CIS, and those that enhance the general cleanli-
ness of the food production areas
x Methods for detection and evaluation of air and water
contamination
x Risk assessment and risk communication
x Safety of gene technology
x Material engineering research conducted to improve the
manufacturing of water and air material filters that re-
duce particle and contamination level to the lowest pos-
sible level
x Methods for increasing the durability and life cycle of
equipment through improved food grade lubricants that
can be used at every joint part of the machine (i.e., at
the point of horizontal, vertical or rotational movement)
x Better methods for visualisation and monitoring every
operational parameter changes at each stage of the
food manufacturing processes
Of course, food equipment designers also take into account
the rules provided in EU Directive 852/2004 on the hygiene
of foodstuffs in the design process, including but not limited
to the following:
x Materials should be cleaned before each use
x All surfaces, including joining areas, must be smooth,
with neither ridges nor crevices that could harbour or-
ganic materials
x Reduce edges and recesses to a minimum
x Easily cleaned and disinfected; easily dismantled
x Bends in components of a radius sufficient to allow
thorough cleaning
x Liquid deriving from foodstuffs or cleaning, disinfecting
and rinsing agents should be discharged from the ma-
chine and must not be harmful to the environment
x Machinery must be designed and constructed to pre-
vent any liquids or living creatures, in particular insects,
entering, or any organic matter from accumulating in ar-
eas that cannot be cleaned
x Equipment should be designed and constructed to pre-
vent entry of any ancillary substances before they come
into contact with foods.
The European Hygienic Engineering & Design Group
(EHEDG) Doc 39 guidelines (currently undergoing editing)
also reflect the need for high standards in hygiene that
emphasise the arrangement of processing facilities, con-
struction and maintenance, presenting a variety of ways in
which this can be done to fulfil the best hygiene require-
ments for safe food production.
01.04.11 08:46

Conclusion
By applying the principles of a food equipment hygienic
design philosophy at all food production links, machinery
designers are better able to create the unique functional-
ities of machinery required by each processing plant, along
with the expected reduction of contamination by biological,
physical and chemical hazards at any point in the process-
ing operations. For example, food equipment designers
must always pay special attention to the theoretical and
practical issues of diagnosis and monitoring of food produc-
tion processes, primarily with regard to modelling microbial
growth in specific process engineering conditions. Respec-
tive food quality assurance programmes should be set up
EHEDG_Innenteil.indd 65
Food equipment hygienic design philosophy 65
for diagnosis and monitoring of all food engineering opera-
tions, and in the light of that, food quality should be con-
tinuously interpreted and monitored. Through hygienic
equipment design, computerised control system applica-
tions, could result in flexible configurations of periodic sam-
pling and control signal updating with a significant effect on
food quality control. Effective implementation of any food
quality control diagnosis and monitoring programme goes
directly to the food company's bottom line, increasing prod-
uct quality, yield, consistency and profitability. Thus, by
utilising the principles of food equipment hygienic design
philosophy, machinery and component designers can have
a positive effect on the ultimate consumer preference: safe
foods.
01.04.11 08:46

Validation of aseptic packing machines
A test method for the assessment of decontamination by hydrogen peroxide of wrapping
material, based on a critical literature survey
Giampaolo Betta and Roberto Massini, Universit degli Studi di Parma, Dipartimento di Ingegneria Industriale
E-mail: giampaolo.betta@unipr.it
Recontamination is responsible for a large percentage of
the spoilage of canned products (Stersky, et al., 1980). In
addition, it is now recognized that, in practise, microbial
recontamination of food products is likely one of the most
frequent and important causes of foodborne disease
outbreaks (Reij and Den Aantrekker, 2004). The potential
for recontamination makes the wrapping of food a complex
operation, particularly in cases in which sterilised product is
aseptically wrapped into a decontaminated, sealed
container to ensure that the final product is commercially
sterile.
Adequate cleanability and sterilisability of the filler and the
filling area, decontamination of the packing material and
bacterial tightness of the packing machine are some of the
necessary conditions for safe aseptic wrapping of food.
Unfortunately, there are few publications available in the
literature that address experimental validation of
cleanability, sterilisability and bacterial tightness of food
processing equipment.
The European Hygienic Engineering & Design Group
(EHEDG) has, however, provided some guidance relevant
to these areas by developing the following six test methods
(EHEDG Docs. 2,4,5,7,15,19) and guidance document
(EHEDG Doc. 21):
EHEDG Doc 2: A method for assessing the in-place
cleanability of food processing equipment.
EHEDG Doc 4: A method for the assessment of in-line
pasteurisation of food processing equipment.
EHEDG Doc 5: A method for the assessment of in-line
sterilisability of food processing equipment.
EHEDG Doc 7: A method for the assessment of bacteria-
tightness of food processing equipment.
EHEDG Doc 15: A method for the assessment of in-place
cleanability of moderately sized food processing
equipment.
EHEDG Doc 19: A method for assessing the bacterial
impermeability of hydrophobic membrane filters.
EHEDG Doc 21: Challenge tests for the evaluation of the
hygienic characteristics of packing machines for
liquid and semi-liquid products (2001).
Decontamination of packing materials in aseptic systems
could be a matter of concern. Due to the various chemicals
used and technological solutions adopted, it is not possible
to use a single validation method for every application, and
generally, the test procedure must be developed on a case-
by-case basis. In this paper, a test method for the
assessment of decontamination of the external surfaces of
internally pre-sterilised spout-less pouches is described.
EHEDG_Innenteil.indd 66
European Hygienic Engineering & Design Group
The real case
The advantages of aseptic processing in terms of reduced
processing time, longer shelf life and improved quality are
widely known. The conventional bag-in-boxaseptic
technology is currently limited to liquid product applications,
due to the small one-inch spout aperture. (Borgese, 2009)
The elimination of the spout allows wrapping of particulate
foods and also allows significant savings in the use of
plastic packaging materials and reduces environmental
impact.
In developing a test method for assessing the
decontamination of wrapping material by hydrogen
peroxide (H2O2), a packing machine with the following
features was used:
A chamber for spraying of H2O2/water solution on the
external surfaces of internally -ray pre-sterilised spout-
less sealed pouches
A chamber in which activation of the H2O2/water
solution occurs by means of warm air, and hence, the
external surfaces of the sealed pouches are
decontaminated
A chamber for pouch-cutting, filling and sealing
The last chamber is sterilized by means of steam, and the
bacteria-tightness is ensured by overpressure of sterile air.
The test-method described below is one part of a holistic
validation procedure that includes cleanability, sterilisability
and bacteria tightness of the machine. The procedure also
includes a preliminary compliance check of the packing
machine with the applicable regulations, standards and
guidelines (i.e., materials, hygienic design, monitoring and
control), which is based on a specifically developed
checklist.
Literature survey
Following a survey of the scientific literature pertaining to
sterilisation by hydrogen peroxide, the use the following
Bacillus strain spores was proposed:
Bacillus subtilis var. globigii (NCIB 8058, ATCC 9372,
NCA 7552). In 30% H2O2/water solution at 30C, this
Bacillus strain is much more resistant compared with other
Bacilli (Ito, et al., 1973). In 25.8% H2O2/water solution, its
decimal reduction time (D-value) is equal to 2 min at 24C ,
0.92 min at 40C, and based on Z-value (thermal
resistance constant) calculated at 30C, 5.5 seconds at
80C (Toledo, et al. , 1973). According to the Elopak
method (No. 644, 95-08-11, Filler sterility test [EHEDG,
2001]), 5 decimal reductions (5-D) are acceptable as a
minimum.
01.04.11 08:46

Bacillus subtilis SA22 (NCA 72-52; DSM ATCC 4181). In
25.8% H2O2/water solution at 24C, D=7.3 min, compared
with 2 min of B. subtilis var. globigii and 1.5 min for B.
stearothermophilus (Toledo, et al., 1973). In 29.5%
H2O2/water solution at 65C, D=0.05 min (Leaper, 1984).
The method proposed by Cerny (1992) and recommended
by the EHEDG Doc. 21 (EHEDG, 2001) for validation of the
sterilisability of the inner surface of packing material,
considers acceptable the application of at least 4-D. The
German Engineering Federation (VDMA) 2006/N.14
(VDMA, 2006), which pertains to external sterilisation of
containers by H2O2, considers acceptable the application of
at least 3-D; whereas the VDMA 2003/N. 8 (VDMA, 2003),
which pertains to sterilisability of the sterile zone in
machine interior, considers the application of at least 4-D in
all critical areas acceptable.
Bacillus subtilis A. This strain is recommended for
treatment with H2O2 and ultraviolet (UV) light (Reidmiller, et
al., 2003) and also for mixtures of H2O2 and peracetic acid
(Blakistone, et al., 1999). In the BOSCH Machine Pre-
sterilisation procedures (EHEDG, 2001), samples
inoculated with 104, 105 and 106 spores are used and the
application of at least 5-D is required).
Geobacillus stearothermophilus (ATCC 7953/12980;
NCTC 10003/10007; DSM 494/22/5934; CIP 52.81). In
30% H2O2/water solution at 30C this strain is much less
resistant compared with B. subtilis var. globigii and B.
subtilis A, whereas at 87.8C its resistance is slightly less
than that of B. subtilis var. globigii, and greater than that of
B. subtilis A (Ito, et al., 1973). In 28.5% H2O2/water solution
at 24C, its resistance is lower than that of B. subtilis SA22
and scarcely lower than that of B. subtilis var. globigii
(Toledo, et al., 1973). In Oxonia Active (an alternative
sterilant to hydrogen peroxide) at room temperature, the
strain has lower heat resistance than B. subtilis A and
about the same resistance of B. subtilis var. globigii
(Blakistone, et al., 1999). In H2O2 vapour, however, it has
the highest resistance (McDonnell, et al., 2002).
There are no Bacilli spores used as biological indicators
with a certificate of resistance to treatment with H2O2. Their
resistance depends on the varying operating conditions
(i.e., dip or fill, spray, spray and condensation, at different
concentrations and temperatures, followed by sterile rinse
or treatment with hot air at different temperature, etc.), as
well as depending upon the strain used. The available data
on resistance to treatment with H2O2 of C. botulinum spores
is very poor and focuses primarily on dipping treatment at
room temperature. The only research study on post-
treatment with hot air that allows direct comparison with C.
botulinum reports that G. stearothermophilus spores are at
least 3.3 times more resistant than those of the more
resistant strain of C. botulinum (Ito, et al., 1973). Using
sporicidal H2O2+air (55C-85C), 4-D reduction of G.
stearothermophilus spores could be considered as equal to
more than 12-D for the most resistant spores of C.
botulinum. In cold Oxonia (dipping), the spores of G.
stearothermophilus have resistance at least 4.5 times
greater compared with the more resistant spores of C.
botulinum (Blakistone, et al., 1999). Moreover, currently the
spores of G. stearothermophilus are used as a biological
EHEDG_Innenteil.indd 67
Validation of aseptic packing machines 67
indicator to validate the sterilising effect of H2O2 in the
vapour phase (Kokubo, et al.,1998). It is preferable to use
spores of G. stearothermophilus, rather than other Bacilli,
since its thermophilic character allows the inoculation and
manipulation of samples without the need for nominally
aseptic conditions.
The test method
Guided by the literature survey, the following procedure
was developed:
1. Locate four critical areas of the pouches, depending on
the H2O2 and hot air fluxes. Identify the areas where
rectangular strips (5x70 mm) of plastic laminate will be
applied and their positions codifed with letters.
2. Cut a sufficient number of strips [approximately 50]
from the pouch samples. Apply double-sided tape to a
face of the strips. With indelible pen, divide the untaped
side of the samples with vertical marks so as to have,
starting from the left, a 5x10 mm area to be used for
manipulation and three adjacent 5x20 mm areas.
3. Using a micropipette (Eppendorf), inoculate three 20
mm areas of 42 samples with 0.1 mL of a
hydroalcoholic suspension (ethanol, 40-70%) at three
different dilutions, approximately 104, 105 and 106
cfu/mL spores of Geobacillus stearothermophilus
(ATCC 7953 = NCA 1518 = DSM 5934).
4. Allow the inoculated samples to dry completely and
store them in open Petri plates in a dryer for at least 16
hours before use. Extract the samples to be used and
close and codify their plates.
5. Arrange 150 sterile tubes with a suitable nutrient
containing 200 cfu/mL of catalase.
6. With tape, attach the inoculated strips on the four
critical spots of 10 numbered pouches, taking care not
to touch the inoculated surfaces. Start the H2O2
spraying and hot air cycle. Take the samples, taking
care not to touch the inoculatums, and cut the three
parts with different inoculation and insert each one in a
tube encoded with the number of the pouch, the letter
of the critical point and the level of inoculation.
7. Repeat the previous step for two pouches without the
inoculated strips.
8. In the remaining six tubes, insert the six parts of the
two strips not subjected to sterilisation).
9. Incubate the tubes at 55C for 3 days (72 h).
10. Express the results as the maximum completely
inactivated inoculum for each critical point of each
pouch. The result can be considered acceptable if in all
the inoculated samples there is, at minimum, a
complete inactivation of 104 cfu. The results of the
uninoculated and treated samples should be negative,
whereas those inoculated and untreated should be
positive.
The whole procedure should be repeated at least twice
(with more repetitions in the event of inconsistent results).
01.04.11 08:46
 68 Validation of aseptic packing machines

Conclusion McDonnell, G., Grignol, G. and Antloga, K. (2002). Vapour phase

Reliable test methods are necessary to evaluate and
validate cleaning, pre-sterilisation and decontamination
processes of aseptic packing machines and packaging
materials.
The proposed method allows convenient and reliable
assessment of effectiveness of a decontamination process
based on the synergistic effect of hydrogen peroxide and
hot air.
References
hydrogen peroxide decontamination of food contact surfaces.
Dairy Food Environ. Sanit., 22:868-873.
Reidmiller, J., Baldeck, J., Rutherford, G. and Marquis, R. (2003).
Characterization of UV-peroxide killing of bacterial spores.
J. Food Prot., 66(7):1233-1240.
Reij, M.W., and Den Aantrekker, E.D. (2004). Recontamination as
a source of pathogens in processed foods. International Journal of
Food Microbiology, 91:1-11.
Stersky, A., Todd E. and Pivnick, H.. (1980). Food poisoning
associated with post-process leakage (PPL) in canned foods.
J. Food Prot. 43:465476.

Anon (2001). Feb. 27, 2001. Proposed rules. Federal Register,
Vol. 66, No. 39.
Anon (2005). Clostridium spp. in foodstuffs. The EFSA Journal,
199:1-65.
Bernard, D.T., Gavin, A., Scott, V.N., Chandarana, D.I., Arndt, G.
and Shafer, B. (1993). Establishing the aseptic processing and
packaging operation. In: Principles of Aseptic Processing and
Packaging, 2nd ed. The Food Processors Institute. Washington,
DC, USA.
Blakistone, B., Chuyate, R., Kautter, D.J., Charbonneau, J. and
Suit, K. (1999). Efficacy of Oxonia Active against selected spore
formers. J. Food Prot., 62(3):262-267.
Toledo, R., Escher, F. and Ayres, J. (1973). Sporicidal properties
of hydrogen peroxide against food spoilage organisms.
Appl. Microbiol., 26:592597.
VDMA (German Engineering Federation). (2003). Food processing
machinery and packaging machinery. Document No. 8: Code of
practice. Testing aseptic plants: sterilizing the sterile zone in
machine interior. (English edition: March 2004).
VDMA (German Engineering Federation). (2006). Food processing
machinery and packaging machinery. Document No. 14: Code of
practice. Testing hygienic filling machines of VDMA Class V
(aseptic filling machines): external sterilization of packaging
materials. (English revised edition: July 2007).

Borgese, R. (2009). Ricerca e innovazione tecnologica nella

progettazione di linee di lavorazione per vegetali. PhD thesis.
Universit digli Studi di Parma.

Cerny, G. (1992). Testing of aseptic machines for efficiency of

sterilization of packaging materials by means of hydrogen
peroxide. Packaging Technology and Science, 5:77-81.

EHEDG (1993). A method for the assessment of bacteria tightness

of food processing equipment. Trends in Food Science &
Technology, 4:190-192.

EHEDG (2001). Challenge tests for the evaluation of hygienic

characteristics of packing machines for liquid and semi-liquid
products. Trends in Food Science & Technology, 12:244-248.
Ito, K. and Stevenson, K. (1984). Sterilization of packaging
materials using aseptic systems. Food Technology, 38(3):60-62.

Ito, K., Denny, C., Brown, C., Yao, M. and Seeger, M. (1973).
Resistance of bacterial spores to hydrogen peroxide. Food
Technology, 27(11):58-66.

Kokubo, M., Inoue, T. and Akers, J. (1998). Resistance of common

environmental spores of the genus Bacillus to vapor hydrogen
peroxide. J. Pharm. Sci. Technol., 52:228-231.

Leaper, S. (1984). Comparison of the resistance to hydrogen

peroxide of wet and dry spores of Bacillus subtilis sa22.
International Journal of Food Science & Technology, 19(6):695-
702.

EHEDG_Innenteil.indd 68 01.04.11 08:46

 European Hygienic Engineering & Design Group

Construction materials in contact with food and

global food safety regulations
All materials that come into contact with food, including the machinery and components used
to process food, must not in any way render the food unsafe for human consumption. This
article provides an overview of the regulations for food contact materials, examples illustrating
how regulations can influence the choice of essential construction materials that come into
contact with food, and the need for harmonisation of global regulations pertaining to food
contact materials.

Huub Lelieveld, Global Harmonization Initiative; Stefan kesson,Tetra Pak, Lund, Sweden, Olaf Heide, Habasit,
Reinach-Basel, Switzerland, Piet Steenaard, EHEDG, and Julie Larson Bricher, Global Harmonization Initiative
E-mail: huub.lelieveld@globalharmonization.net, Stefan.Akesson@tetrapak.com, olaf.heide@habasit.com,
steenaard@kpnmail.nl, julie@quidditycommunications.com

Any material that comes into contact with food interacts
with that food. Therefore, manufacturers of equipment that
will come in contact with food must be aware of potential
food safety risks resulting from that contact. This includes
all machinery, including pumps, piping, measuring devices
and valves. Although food production machinery is
constructed, in large part, from stainless steel, many small
components, such as gaskets, mechanical seals and slide
bearings are made from a wide variety of materials,
including many types of polymers and elastomers. For
example, conveyor belts may be made from steel,
polymers, elastomers and glass, but they also contain
minor components, such as softeners (plasticisers)
catalysts, stabilisers, fillers and pigments that are needed
to obtain required properties or functionalities of the
equipment. Machinery and conveyor belts usually need
lubricants that may contain oils, antimicrobials,
antioxidants, rust inhibitors, anti-foam agents and viscosity
extenders. While in many cases lubricants are not intended
to be in contact with food and may do so only rarely, in
some cases, lubricants are needed between the food
product and solid food contact surfaces.
Where there is contact between construction materials and
food, there is a risk of contamination of the food, (e.g., by
leaching, wear and electrochemistry). Self-evidently,
contact of food with food contact surfaces should never
result in a finished food product that is contaminated or
presents a health risk. Before applying food contact
materials, it must be known in what way that material might
contaminate the food, what the acceptable concentration in
the food is to prevent health risks, and how to ascertain that
the acceptable level will not be exceeded. For most
chemicals used in the construction of equipment
components that may come into contact with food, there
are food safety regulations, although they may differ
between countries. If new materials of construction are
developed that require the use of other chemicals in the
design of food processing equipment, the safe
concentration of these chemicals in food must be
established.
These considerations are paramount in a number of
regulations pertaining to food contact materials that exist
throughout the world. However, differing regulations
between countries or regulatory authorities can create a
difficult maze for equipment designers and manufacturers
who must select essential but low-risk materials for
construction of machinery used in food production
environments. Organisations such as the European
Hygienic Engineering & Design Group (EHEDG), which has
published a guideline on food contact materials (Doc 32,
Materials of construction for equipment in contact with food)
and a guideline on lubricants (Doc 23, under revision), help
manufacturers successfully navigate this maze, but more is
needed. To illustrate the need for global harmonisation of
food contact materials legislation, this article provides an
overview of relevant European food safety regulations,
gives examples that show how global regulations impact
the choice of materials, and suggests the formation of a
scientific working group to address the challenges that
result from differing food contact material regulations.
European regulations for food contact
materials
In Europe, there is a framework regulation, EC 1935/2004,
regulating the use of materials and articles intended for
food contact that states that food contact materials shall be
safe. According to the EU regulation, materials and articles,
including active and intelligent materials and articles, shall
be manufactured in compliance with good manufacturing
practices (GMPs) so that, under normal or foreseeable
conditions of use, they do not transfer their constituents to
food in quantities which could endanger human health or
bring about an unacceptable change in the composition of
the food. All material and parts in food contact should be
accompanied by a written declaration stating that they
comply with the rules applicable to them. Furthermore,
appropriate documentation shall be available to
demonstrate such compliance. That documentation shall be
made available to the competent authorities on demand.
In addition, EC 1935/2004 states that the traceability of
materials and articles shall be ensured at all stages in order
to facilitate control, the recall of defective products,
consumer information and the attribution of responsibility.
All involved in the supply chain shall have in place systems

EHEDG_Innenteil.indd 69 01.04.11 08:46

 70 Construction materials in contact with food and global food safety regulations
and procedures to allow identification of the businesses
from which and to which materials or articles and, where
appropriate, substances or products and its implementing
measures used in their manufacture are supplied. That
information shall be made available to the competent
authorities on demand. There are also specific demands on
labelling of materials and articles, which are not yet in
contact with food when placed on the market.
The regulation also includes procedures to be followed for
authorisation of new substances or new materials to be
used in the construction of food-contact equipment. The
evaluation of such materials is made by the European Food
Safety Authority (EFSA), for which the most important
requirement is that evidence (if provided) shows that the
material in the quantities that might migrate to the food, or
interact with the food in any other way, cannot make the
product unsafe for consumption. For new or novel
substances that have never been tested, this includes
testing using animals.
Other legislation related to food contact materials that
impact the design of food machinery and the construction
materials selected for manufacture include the following:
x Plastic materials. There also is legislation pertaining to
specific materials such as plastic materials and articles
in food contact (2008/39/EC). There is a Community list
of additives that may be used for the manufacture of
plastic materials and articles, together with restrictions
and/or specifications on their use. This is a "positive
list," meaning only listed substances are allowed. The
list of substances also contains information about
allowable migration. There are also directives laying
down basic rules necessary for testing of migration,
including procedures and simulants to be used. A new
legislation, no 10/2011/EU, on plastic materials
intended to come in to food contact, will be
implemented in Europe during 2011.
x Elastomers. There is no specific legislation for
elastomers (e.g., rubber) in Europe, and because of
this, equipment manufacturers often refer to the US
regulation Code of Federal Regulations (CFR) Title 21
177.2600 to show legal compliance for food contact
material. However, some substances allowed in the US,
such as phthalates (plasticisers allowed up to 30 weight
percent) are prohibited in Europe and in some other
countries such as Japan. It is important to secure and
use ingredients that appear on the positive list.
Migration has to be calculated according to the Council
of Europe guidance, or manufacturers must conduct
migration tests using simulants.
x Good manufacturing practices. Regulation EC
2023/2006 on good manufacturing practices for
materials and articles intended to come into contact with
food is another important regulation. The GMP
regulation states that the business operator shall
establish, implement and ensure adherence to an
effective and documented quality assurance system
and take account of the adequacy of personnel, their
knowledge and skills, and the organisation of the
EHEDG_Innenteil.indd 70
premises and equipment such as is necessary to
ensure that finished materials and articles comply with
the rules applicable to them. The operations shall be
carried out in accordance with pre-established
instructions and procedures.
In addition, EC 2023/2006 states that the quality control
system shall include monitoring of the implementation and
achievement of GMP and identify measures to correct any
failure to achieve GMP. Such corrective measures shall be
implemented without delay and made available to the
competent authorities for inspections. The business
operator also must establish and maintain appropriate
documentation in paper or electronic format with respect to
specifications, manufacturing formulae and processing that
are relevant to compliance and safety of the finished
material or article.
The impact of regulations on materials
selection
Life would be easy if the equipment and component
designer could simply select materials that do not contain
any additives and are not corrosive under any
circumstances. The problem is that every construction
material selected has a desired function and the designer
may find that he or she has little choice between essential
materials, even materials that may pose a contamination
risk, to achieve the target function. An example is a belt
that transports product from one place to another, for
further processing or to be packed. Other examples are
moulds use for baking, where the product is in contact with
the mould at a high temperature for a long time and
lubricants that have to ensure that moving parts keep
moving under a variety of circumstances. In all cases, the
materials do not only have to meet the requirements for the
function under operation conditions, but must also be able
to cope with the conditions during cleaning and disinfection
or sterilisation.
Conveyor belts, baking moulds and antistick fluids, and
food machinery lubricants are examples illustrating the
influence of regulations on the choice of equipment
construction materials that will come into contact with food
but that may also pose a food safety risk. However,
differing regulations between countries and/or lack of such
regulations altogether give rise to a number of challenges
for the equipment manufacturer as follows:
Conveyor belts
Conveyor belts that transport unpacked product may
present a food safety risk. First, constituents of the belt
material may migrate to the product, but secondly,
microorganisms may grow on the surface of the belt and
these may be pathogenic or toxigenic. If such microbes are
allowed to grow (e.g. in dead corners, where the residence
time of the product can be extreme, even as long as the
entire production run), their numbers can be huge and so
can be the amount of toxin produced. Consequently, it is
not only the belting material itself that plays a role, but also
the way the conveyor system has been designed.
01.04.11 08:46
 Construction materials in contact with food and global food safety regulations
Often, conveyor belts are reinforced by fibres (from
polyester, aramide or others). The ways in which these
belts have been made determine whether or not the sides
of the belts are prone to ingress of moisture and product,
thereby creating a breeding opportunity for microbes. Belts
with open sides should not be used for food contact
applications. In the EU, their use is illegal, because the
design is not hygienic. The principle of a correct design is
shown on the right-hand side of Figure 1 and an industrial
execution is shown in Figure 2. Care must be taken that the
product side of the belt will not be cut or damaged in such a
way such that the reinforcing fabric is exposed, which can
allow microbes and their metabolites to contaminate the
food it carries.Regulation (EC) No 852/2004 of the
European Parliament and of the Council of 29 April 2004,
On the Hygiene of Foodstuffs, Annex II, General hygiene
requirements for all food business operators, Chapter IV,
"Transport" reads: "Conveyances and/or containers used
for transporting foodstuffs are to be kept clean and
maintained in good repair and condition to protect
foodstuffs from contamination and are, where necessary, to
be designed and constructed to permit adequate cleaning
and/or disinfection ...". It would be good if such
requirements would apply globally.
If used for frozen products, it is essential that the product
has enough friction to be moved by the belt (i.e., the
product should never be frozen to the belt). To achieve this,
special materials, special coatings or lubricants are used.
Obviously, these coatings and/or lubricants should be safe
when ingested, because they will certainly come into
contact with the food conveyed.
Manufacturers and suppliers of conveyor and processing
belts must be fully aware of their responsibilities in the
production chain. They therefore must care that raw
materials and the final products comply with the various
EU, US and other applicable regulations, with regard to any
restrictions or bans on the use of certain potentially
dangerous substances and preparations. This is especially
important for food conveyor belts, which come in direct
contact with unwrapped foods. Here, irrespective of
regulations, other vital aspects such as an understanding of
hygienic equipment design, effective cleaning methods and
knowing how to integrate these aspects into the process
lines all play a key role in the development of effective and
safe systems.
Companies should be able to issue certificates to declare
the food contact compliance status for a conveyor. Some
companies have been doing this long before food
processors, to comply with legislation, started to demand
such certification documentation. Some of the important
regulations relevant for belting products that come into
direct contact with food are listed below and raw material
suppliers must provide respective documentation:
EHEDG_Innenteil.indd 71
71
x US Food and Drug Administration (FDA) compliance
statement regarding direct food contact application
(repeated use). Manufacturers must specify for which
food types and conditions of use they are valid
according to 21 CFR 176.170 Tables 1 and 2. All raw
materials used for their product or their product itself
must be listed in 21 CFR parts 170 199 or have
another respective approval and be accepted for the
intended use.
x EU compliance statement regarding direct food contact
application according to EU Regulation 1935/2004 and
EU Directive 2002/72 and the amendments in their
latest versions. Confirmation must be provided for all
monomers, stating substances and additives for which
restrictions are specified (e.g., specific migration limit,
SML, or a maximum permitted quantity, QM) and those
substances that are not yet EU-wide harmonised (i.e.,
listed in the EU Synoptic Documents or in national lists).
For so-called dual use additives (substances also
authorised as direct food additives), disclosure to the
customer is compulsory.
x In many cases, overall and specific migration tests of
the belt must be performed according to Directives
82/711/EEC and 85/572/EEC and their amendments.
Based on this, companies should issue Declarations of
Compliance (DoC) for their food belts. When needed,
products should be tested and certified according to the
NSF/3-A/ANSI 14159-3 Meat & Poultry standard and/or 3-A
Sanitary Standards for Multiple-Use Plastic Materials
Number 20-xx Dairy classifications. In addition, the EHEDG
Subgroup Conveyor Systems is developing a new guideline
covering the issues discussed here, as well as various
other relevant issues, which will help industry better
achieve the twin goals of selecting functional yet food-safe
construction materials.
Bakeries, heat-resistant coatings and antistick fluids
As discussed elsewhere in this edition of the EHEDG
Yearbook by Le Bail, et al., selecting materials for contact
with food at baking temperatures (up to 350C) may
present difficulties. What distinguishes high-temperature
contact materials is that at high temperatures safe
constituents may react with each other or with the food to
produce toxic materials. In many cases, these newly
formed reaction products have not been considered in
existing regulations and have been ignored for a long time.
In water and pancakes that have been in contact with
perfluorinated antistick coatings, 13 different perfluorinated
compounds have been found. Which compounds are
formed and in what quantities, depends on temperature, pH
and composition of the food product. Because these
compounds are potentially genotoxic, the industry is looking
for other materials. There are no regulations in place for
these materials, other than the general food laws, which
state that the producer has to be certain that the product
produced is safe. The supplier of the equipment, however,
has to provide data to the food processor about what may
be the consequence of the use of the equipment in contact
with the food product.
01.04.11 08:46
 72 Construction materials in contact with food and global food safety regulations
Apart from antistick coatings, antistick fluids are used. Self-
evidently, these materials end up in the product. Because,
however, they are seen as technical agents, they are not
considered part of the recipe of the product. Again, there
are no specific regulations and there is very little
information about their safety. It would be prudent to collect
sound scientific information in currently applied and
proposed food contact compounds, which then may be a
basis for sensible food safety regulations that can be
harmonised for use by every country.
Lubricants
Where food handling equipment has moving parts, in most
cases, the use of lubricants is essential. Where such
equipment comes in contact with food, there is a risk of
contamination of that food. Typical examples are pumps,
homogenisers, conveyors, valves, mixers, packing
equipment, bearings, closed and open gears, hydraulic
installations, chains, sliding surfaces, air compressors and
blowers.
In the case of baking equipment, newly formed compounds
are of primary concern and generally, microbial
contamination does not play a role, because of the baking
temperatures take care of microbes. However, lubricants
used at low or moderate temperatures may give rise to a
microbial problem, since lubricants are in place for long
periods of time and may become contaminated with water.
The microorganisms can break down the lubricant
components, rendering the lubricant ineffective. In addition
these microorganisms may contaminate the food with
which they come into contact. Therefore, manufacturers
look for additions that prevent the growth of
microorganisms in the lubricant. Self-evidently, these
antimicrobial substances should not present an
unacceptable risk of contamination of the food product.
Consequently, the preservatives allowed differ from those
used for lubricants for non-food applications, which may
present a serious toxicological risk if ingested in small
quantities.
In the past, the US Department of Agriculture (USDA)
authorised the use of lubricants that may incidentally
contaminate food products, if they complied with the
Guidelines for Obtaining Authorization of Compounds to
be Used in Meat and Poultry Plants. In 1999, after the
USDA ended this programme, NSF International closed the
gap by introducing a similar programme, which is
recognised by most countries.* It is a voluntary programme,
but if a lubricant is certified by NSF for incidental contact
with food, it complies with the US CFR Title 21, Food and
Drugs, Section 178.3570 and is considered safe by the US
authorities and authorities in many other countries, which
lack appropriate regulations. The list is regularly updated
and might be the basis of global regulations on lubricant
incidental food contact.
EHEDG_Innenteil.indd 72
The importance of harmonisation
the China example
China is becoming an important player in the global food
market, due to its significant economic growth in recent
years, and it provides a useful example of the importance
of global regulatory harmonisation for purposes of this
discussion. Several food safety issues have hit the Chinese
food industry during the past few years, some of which
have had significant international impact such as the
discovery of melamine in milk powder, pet food, and other
food products. These food contamination outbreaks
resulted in the development and promulgation in June 2009
of tougher Chinese legislation, standards and inspections
of food manufacturing premises. To support the legislation,
a number of standards were developed, some mandatory,
which often contain a mix of EU and US requirements. One
such standard is GB 16798, Requirements of safety and
sanitation for food machinery, which features some
sections pertaining to food contact materials, such as:
x Material in food contact must not contain harmful matter
or any harmful matter should not be above the limitation
specified in food sanitation standard. Interactions
between products and materials are not allowed to
transfer unhealthy matters to the product or to exceed
given limitations in standards.
x Materials are not allowed to pollute or change the
colour, lustre or quality of the product. Neither is it
allowed that the product affects the equipment during
production.
Another example is the new Chinese standard GB 9685,
Hygienic standard for use of additives in food containers
and packages, which was updated in 2008. The preface to
the standard clearly references the US FDA CFR Title 21
170-189 and EU Directive 2002/72 for plastic materials
and articles intended to come into contact with foodstuffs.
In this standard, there is a positive list of substances, CAS
number, allowed migration limits, etc.; however, the
drawback is that several substances that are allowable in
the US and EU are missing from the Chinese list. In this
case, it is clear that such discrepancies may ultimately
have a negative impact on equipment manufacturers in
using construction materials that are in compliance with all
potential global market regulatory and legislative
requirements.
As one can see in the above example, harmonisation of the
Chinese legislation and standards with EU and US
regulations will be an important factor in facilitating the
export of food and the acceptance of the machinery used to
produce food across markets. Similar legislative gaps exist
in other nations as well, including emerging global food
industry power players such as India and Latin America.
While it is a general requirement that food contact materials
should not make the food product with which it comes into
contact unsafe for consumption, international regulations
on food contact materials are at best incomplete, or at
worst, do not exist at all. Where food contact material-
related regulations do exist, differences in those regulations
01.04.11 08:46
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EHEDG_Innenteil.indd 73 01.04.11 08:46

 74 Construction materials in contact with food and global food safety regulations

between countries may reduce industry's ability to

effectively reduce food contamination risk while achieving
the high functionality from equipment required in the
process of food manufacture.

Therefore, it is suggested that a scientific working group is

formed to collect and evaluate international regulations and
standards pertaining to food contact materials, in particular
machinery construction materials, which may be used as
the basis of a global consensus document of the Global
Harmonization Initiative (GHI).** Founded in 2004 as a joint
activity of the US-based Institute of Food Technologists Figure 1. Cross-sections of wrong (left) and correct (right) design of
(IFT) International Division and the European Federation of fabric-reinforced conveyor belts.
Food Science and Technology (EFFoST), the Global
Harmonization Initiative (GHI) is a non-profit, independent 
network of scientific organisations and individual scientists
working together to promote harmonisation of global food
safety regulations and legislation. EHEDG is a leading
supporter of the organisation, which facilitates global
discussion about the scientific issues that will better support
informed, objective decisions made by national
governments and international regulatory bodies through:

1) providing the foundation for sound, sensible, science-

based regulations;
2) creating a forum for scientists and technologists to
interact with regulatory authorities, globally; and
3) giving industry, regulators and consumers an inde-
pendent, authoritative information resource.

As part of its efforts to provide tools and science-based

guidance for promoting harmonisation of food safety laws
and regulations, GHIs Working Groups continually collect Figure 2. Conveyor belt with sealed edges, avoiding ingress of
and evaluate available data to produce consensus moisture and product.
proposals or statements related to controversies and issues
in science and regulations of food. With support and
participation of its individual members and member * NSF International, 789 N. Dixboro Road, Ann Arbor, MI
organisations, GHI has formulated approaches to critically 48105 (www.nsf.org)
evaluate the scientific evidence used to support existing ** GHI-Association, c/o BOKU, Department of Food
global regulations in the areas of product composition, Science and Technology, Muthgasse 18, A-1190
processing operations, and technologies or measures Vienna, Austria (www.globalharmonization.net)
designed to prevent foodborne illness. EHEDG members
are encouraged to visit GHIs website
(www.globalharmonization.net) to find out more about the
working group process and establishing a new Food
Contact Materials Working Group within the association's
structure. A united effort by scientists and engineers within
the framework of GHI will help advance successful
harmonisation of global standards for food contact
materials that will better ensure food safety for all
consumers worldwide and streamline global trade of food
processing machinery and packaged food products.

EHEDG_Innenteil.indd 74 01.04.11 08:46

 European Hygienic Engineering & Design Group

Food contact material for baking: a review on associated

chemical risks and technological issues
Alain Le-Bail (1.3.5),* Bruno Veyrand (2,4,5), Sophie Durand (2,4,5), Hanane Kadar (2,4,5), Carole Prost (1,3,5),
Jolle Grua (1,3,5), Catherine Simoneau (6), Annick Perronnet (7), Guillaume Roelens (8) and Bruno Le Bizec (2,4,5)

(1) ONIRIS, UMR 6144 GEPEA CNRS, Nantes, F-44307, France

(2) ONIRIS, USC 2013 LABERCA INRA, Nantes, F-44307, France
(3) CNRS, Nantes, F-44307, France
(4) INRA, Nantes, F-44307, France
(5) L'UNAM, L'Universit Nantes Angers Le-Mans, France
(6) European Commission DG Joint Research Centre Institute for Health and Consumer Protection Chemical
Assessment and Testing Unit I-21020 Ispra, Italy
(7) LUNAM Universit, Universit de Nantes - Centrale Nantes , GeM - UMR CNRS 6183 Institut de Recherche en
Gnie Civil et Mcanique, 37 Bd de l'Universit, BP 406, 44602 Saint-Nazaire, France
(8) Universit de Nantes CRTT UMR GEPEA CNRS 6144 UNAM - 37, Bd de l'Universit
BP406 44602 St-Nazaire cedex

* Corresponding author: alain.lebail@oniris-nantes.fr

Abstract result in the formation of neoformed contaminants. The

This article presents an overview on product contact sur-
faces (PCS) used for baking supports, with a focus on
associated neoformed and exogenous contaminants re-
lated to these PCSs in the case of baking. Exogenous
contaminants are usually brought into the product from the
surface contact material of the baking support, and in par-
ticular, from antistick coatings (ASC). Due to multiple ther-
mal treatments, the performance of ASCs evolve during
ageing, resulting in sticking problems. In addition, there is
no European regulation in force to track associated chemi-
cal risks.
Two main types of ASC material are used: perfluorinated
and silicone based ASC. Sticking of bakery products during
baking is linked to various aspects such as recipe, baking
temperature, the use (or not) of antistick fluids, etc. For
instance, silicone coatings are preferred to perfluorinated
coatings for yellow dough. Some products, such as bis-
cuits, can be baked directly on steel. A limited amount of
literature exists on the risk of chemical transfer from either
fluorinated or silicone based coatings to the food. Highly
sensitive measurement methods based on liquid chroma-
tograpy coupled to tandem mass spectometry (LC-MS/MS)
and/or liquid chromatography-high resolution mass spec-
trometry (LC-HRMS) have been used for the determination
of 13 perfluorinated compounds (including perfluorooctane
sulfonate anion (PFOS) and perfluorooctanoic acid (PFOA)
in water and pancakes cooked in contact with ASC. Pre-
liminary results (not shown) indicated that contamination
was below the regulation threshold when using new cook-
ware equipment (frying pan). Two other PCSs used in bak-
ing, aluminium and baking paper, and their associated
case of the Maillard reaction compounds (MRCs) and of the
3-chloro-1,2-propanediol (3-MCPD) esters and the impact
of the pH on those contaminants is discussed. Finally, the
technological problem of sticking seems to be closely linked
to the condition of the product contact surface, and thus
indirectly linked to a higher risk of transfer of exogenous
contaminants into the product. Therefore, it appears advis-
ible to develop tools and protocols to assess the condition
of baking support undergoing multiple thermal cycles for
the benefit of the industry and of the health of consumers.
1 - Introduction
There is a growing demand for the identification and better
control of the effect of chemical contaminants on food and
their impact on human health as addressed by the Euro-
1
pean regulation on Food Contact material . Much research
recently has been devoted to these topics, including studies
of neoformed contaminants from inoffensive precursors,
such as acrylamide or 3-MCPD esters. Among the industry
sectors concerned by these chemical hazards is bakery.
Bakery products are considered staple foods the world
over, as indicated by its huge market size: according to one
well-known market research firm, bread-viennoiserie-
patisserie (BVP) products represented 38.7 million tons of
consumed products in Europe in 2006 (83% of which was
bread). Bakery products not only are manufactured using a
number of raw materials and ingredients known to generate
neoformed contaminants, but are also processed at some
of the highest temperatures in food production, which can
lead to a significant risk of the presence of these contami-
nants. Further, other types of contaminants, such as those
that may arise from baking supports, are under scrutiny
2,3

chemical risks are discussed. such as PFOS and PFOA . 4

Neoformed contaminants are usually due to reactions be-
tween inoffensive precursors, which result from the interac-
tion between these precursors and the matrix. The impact
of the thermal treatment combined with the evolution of
other physical parameters (e.g., moisture, pH, etc.) may
Contaminants present in BVP products can be classified as
either neoformed contaminants (NFC) or exogenous con-
taminants (EC). A flowchart illustrating the two main
classes of contaminants is proposed in Figure 1.

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 76 Food contact material for baking: a review on associated chemical risks and technological issues

PASTRY Silicone coating is more fragile than PFC and therefore,

NFC: NEOFORMED CONTAMINANTS
- MRC less durable. Oligomers (linear and cyclic) may be re-
NFC - ALDEHYDES (from recipe oils) leased in the bakery product. Antistick fluids are very of-
- MCPD
ten used to solve the sticking problem. It is estimated
that silicone coatings are washed once a day or once
EC EC: EXOGENOUS CONTAMINANTS per week in around 80% of bakery production facilities;
ASF - OLIGOMERS sometimes they are cleaned by air jet or brushed.
- PFC
- ALUMINIUM
COATING - DIVALENT IONS(Fe2+ - Catalysis)
- ALDEHYDES (from anti-stick fluid)
Perfluorinated coating may generate perfluorinated
PAN contaminants, especially PFOA and PFOS, which are
under regulatory and media scrutiny. Perfluorinated
OVEN
coating is sensitive to scratches; nevertheless, 90% of
users brush this coating between each baking produc-
Acronym Key: ASF: Antistick Fluid; NFC: Neoformed Contami- tion process. Perfluorinated coating is more expensive
nants; MRC: Maillard Reaction Compounds; PFC: Perfluorinated than silicone and is more difficult to refurbish because
Compounds of environmental concerns.

Figure 1.The two main classes of food contaminants in bakery
products.
Neoformed contaminants (NFC) can be formed in three
ways:
Through Maillard reaction at the crust (MRC): Of the
Maillard reaction contaminants, acrylamide (ACR) is the
best known NFC, but others also can be identified, in-
cluding pyrazines (PYZ) and furfurales (FUR).
From the technological treatment of oils: For example,
3-chloropropane-1,2-diol is formed during the process-
ing of different lipids, in particular vegetable oils treated
for deodorisation and whitening that are used in the
5-8
baking sector. Several toxicological studies have
shown that 3-MCPD induces infertility in rats and
causes tumours in rats when administered in high
2
doses.
As a result of the oxidation of the lipid used in the recipe
(aldehydes): Oxidized lipidic aldehydes (in particular,
nonsaturated ones like nonenal or nonadienal that are
genotoxic) can be formed when oil is used in the recipe.
Metal traces may act as a catalyst when metallic baking
supports are used.
Other conventional baking supports (mainly aluminium
and steel) also are used, generating a risk of metallic
contaminants, which in turn may act as catalysers in
lipid oxidation reactions. Also, aluminium, a nanoscale
3
contaminant, is often left in contact with the food during
the storage (weeks or months) until consumption.
Finally, contact may also occur with a baking parchment
paper in which silicone or PFC are often used as plasti-
cisers and/or as a moisture repellant.
The level of contamination due to these baking support
coatings is dependent on their lifetime, the kick-off and end
of life phases being the more risky. As a consequence, the
decision to repair (refurbish) or replace a batch of baking
moulds is of crucial importance in controlling the amount of
contaminants (NFC and EC) in the final products. However,
with no regulation currently in place, this decision is wholly
taken by industry within a good manufacturing practices
(GMP) framework, and sometimes the decision is taken
only when an extreme condition is reached (Figure 2).

Exogenous contaminants (EC) originate either from the

coating of the baking support or from a greasing agent at
the interface with the dough. The addition of a greasing
agent (or antistick fluid) is used to solve the problem of
decapsuling the product at the end of baking. But such a
lipophilic agent may boost the risk of transfer of lipophilic
contaminants from support coating. Also, greasing agents Figure 2. Example of a silicone-coated baking support at the end
of its life cycle (note the peeling of the coating).
can be trapped, along with sugar and biopolymers, in the
ASC, which sometimes can be porous. In such cases, EC
No objective methods or protocols are available and no
may be released to the crust of the pastry after multiple
European regulation is able to give clear indications on
baking cycles. Finally, a direct contact of the greasing
when to stop using a baking mould when its ASC is in an
agent with a metallic baking support (aluminium or steel)
unacceptable condition. Data are still missing to improve
may facilitate the lipidic aldehyde oxidation.
the coverage of the European regulations and secure the
control of process-induced contaminants. Among the miss-
There are two major ASCs used in the industry: those
ing data, one can cite aluminium and silicone, which are left
manufactured using perfluorinated substances and those
under the control of each member state in Europe. In par-
with silicone. The market ratio between them is around
ticular, the cross-contamination related to the use of sili-
60:40 in Europe. Each substance has its pros and cons:
cone, or even the consideration of silicone as FCM in a

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 Food contact material for baking: a review on associated chemical risks and technological issues 77

more general way, remain missing bricks in the European
FCM regulations. Data pertaining to PFOS and PFOA are
also coming under scrutiny by the European regulatory
authorities and the Scientific Committee on Health and
4.5
Environmental Risks (SCHER).
undergoing ageing is not well defined. Furthermore, it is not
clear which testing mode should be used according to the
type of materials used or in relation to any specific bakery
product food matrix, since these materials are not neces-
sarily regulated at the harmonised EU level.

The existing legislation has been developed mainly for
packaging materials. The application of migration tests by
enforcement laboratories and consequent alerts appearing
in the Rapid Alert System have shown discrepancies in the
interpretation of the legislation with regard to test conditions
for kitchenware and bakeware. Another gap consists in
harmonised test conditions for compliance testing for spe-
cific migration in dry foods. Risk assessment studies are
based on the worst foreseeable contamination. However,
the worst foreseeable contamination in the case of a FCM
The most significant challenge in developing meaningful
legislation and regulation to control such food contaminants
is two-fold. On the one hand, the missing data necessary to
formulate optimal regulations must be generated, and on
the other, the industrial tools necessary to implement such
regulations and testing methods must be developed and
made available to the food industry. Table 1 summarises
some of the existing or currently known regulations, health
risk and mitigation strategies associated with NFC and EC.

Table 1. Neoformed and exogenous contaminants observed in the baking sector. Associated regulations, health risks and possible
mitigation strategies.

CHEMICAL REGULATIONS ASSOCIATED HEALTH POSSIBLE MITIGATION STRATEGIES (MS)

RISKS
6 Tolerable daily intake
3-MCPD Fertility in rats Control of the baking temperature
(TDI) of 2 g/kg bw for In vitro genotoxic Increasing the pH can reduce 3-MCPD, but a balance
3-MCPD activity must be found because acrylamide can form where
production is accelerated at higher pH
Impact of processing condition and of antistick fluid
6 Large family of different
MCR Acrylamide: Formulation: Use low level of reducing sugars,
(Acrylamide, neoformed compounds. Chromosomal breaks control the fermentation
pyrazine, Several families of NFC Gene mutations Lower the pH but also take into account reduction of the
furfurale, concerned. Genotoxic (mutagenic, browning, sensorial aspects and increased risk of 3-MCPD
etc.) increased cancer in rats esters due to lower pH
at doses of 1-2 mg/kg Control of the baking temperature
bw)
6 Nonsaturated
ALDE- aldehydes Genotoxic (mutagenic) Control of the baking temperature.
HYDES (nonenal, nonadienal) Assessment of the impact of traces of divalent ions
2+
(e.g., metal ion life Fe ), which may act as a catalyst
(pro-oxidation effect)
ALUMINIUM JECFA/EFSA 2006:
1,7-8 Affects reproductive Data on impact of aluminium quality on migration in
7
TWI 1 mg Al/kg bw/week and developing bakery/migration risks to upgrade the EU Directive of
nervous systems in Sept. 1996, Best Available Techniques for Surface -
FAO/WHO 1989: experimental animals Treatment of Metals and Plastics, as developed for use.
PTWI: 0-7 mg Al/kg Better control of quality and set in operation (first use) of
bw/week (JEFCA report - aluminium moulds
see below) Food additives with aluminium: listing plus information for
the industry
9,10
SILICONE Resolution of the Release of silicone- Providing of data and migration risks to upgrade the EU
7
Council of Europe: cyclic and linear Directive of Sept. 1996
Overall migration limit of polydimethylsiloxane Better control of quality and set in operation (first use) of
10 mg/dm oligomers moulds with silicone
Evaporation of volatile Effectiveness of risk and migration tests for silicone
organic contaminants Migration tests to be developed for European regulation
Thermal oxidation of Specific antistick fluid developed
trapped elements Testing equipment: detection of coating end of life
4
PFC EU Directive of 2006: Chromosomal breaks Providing of data and migration risks to upgrade the
7
(PFOS- PFOS: < 0.005% by mass (in vivo and in vitro) Directive of Sept. 1996
PFOA) Coated materials: < 1 Genotoxic (mutagenic) Better control of quality and set in operation (first use) of
g/m Increased incidence of moulds with silicone
cancer in rats Effectiveness of risk and adapted migration tests for PFC
11
Also: EFSA 2005; Migration tests for European regulation
12
Germany 2006; Specific antistick fluid developed
and AFSSA 2009 Testing equipment: detection of coating end of life
(Saisine n 2007-SA-0391)
Acronym key: FAO: Food and Agriculture Organization; JECFA: Joint World Health Organization Expert Committee on Food Additives;
TWI : Tolerable Weekly Intake; PTWI: Provisional Tolerable Weekly Intake; Kg bw: kilogram body weight
JEFCA Report: JECFA (1989). Evaluation of certain food additives and contaminants. Thirty-third report of the Joint FAO/WHO Expert
Committee on Food Additives. World Health Organization, Technical Report Series 776.

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 78 Food contact material for baking: a review on associated chemical risks and technological issues
2 Neoformed contaminants in baking
The bread and pastry manufacturing process as a whole
encompasses several unit operations: mixing, shaping,
fermentation, baking, packaging and storage. The forma-
tion of NFC is usually associated with formulation and in-
teraction occurring within the processing conditions. Mail-
lard reaction compounds, 3-MCPD and the impact of pH on
these contaminants will be discussed. The following section
will present a brief review of state-of-the-art approaches
related to these different aspects.
2-1 Neoformed contaminants: the Maillard reaction
In many cooking processes, the Maillard cascade is the
predominant chemical process determining colour, flavour
and texture of cooked foods, based on highly complex
reactions between amino acids and sugars (i.e., common
nutrients present in all relevant foods). The cooking proc-
ess, as well as the combination of temperature and heating
time to which the product is subjected, are of crucial impor-
tance. The Maillard reaction (MR) occurs in systems allow-
ing reaction between reducing sugars and proteins. The
reactions may be retarded below pH 6.
Variables such as composition and processing influence
13
Maillard reaction rates. Such variables include the con-
centrations of reducing sugars, amino acids, oxygen, oxida-
tive metal ions, MR inhibitors, time-temperature combina-
tion used during processing, water activity (aw), pH and the
structure of the food. Among the leavening agents, one
study has shown that ammonium bicarbonate is the most
14
effective for the progress of MR during baking. There is a
strong correlation between acrylamide formation and the
15,16
baking temperature and time. The amount of acryla-
mide formed in the crust increases with increased baking
temperature, and typically no acrylamide is found in the
17
bread crumb. Concentration reaching 100-230 g/kg-1
and below 2 g/kg-1 have been observed in crust and
crumb, respectively.17. However, sampling is some times
very challenging as shown in Figures 3 & 4.
Figure 3. Caramelised debris on a baguette that may contain
aldehydes, MRC, or that may be contained in some pieces of ASC.
EHEDG_Innenteil.indd 78
Figure 4. Brownish deposit on the flank of a small brioche.
Sampling is crucial to properly quantify the MRC.
Acrylamides are toxic compounds that appear during bak-
ing of bakery products due to asparagine and glu-
cose/fructose reactions in low moisture and in the presence
18
of ammonium bicarbonate. The formation of acrylamides
can be reduced by shorter time-temperature, reducing
asparagine levels by using asparaginase enzyme, using
low levels of reducing sugars, and by replacing ammonium
bicarbonate with sodium hydrogen carbonate. Specific
strategies can be used to reduce acrylamides, such as
controlling the moisture in the oven or through the use of
19-21
asparaginase. The tracks to reduce acrylamides are
always more or less the same, based on formulation and
processing parameters. However, for all existing literature
related to baking, the information given on the control of the
baking conditions are often very vague.
Slight differences in product composition and process con-
ditions, and even the location within the temperature range
of one specific production line, may lead to major differ-
ences in acrylamide concentration, often of several multi-
tudes between samples derived from the same product
22
recipe made on the same production line. Irrespective of
the formulation, there is evidence that a reduction of the
baking temperature results in a reduction of the amount of
acrylamide in the same food.
2-2 MCPD esters
Like acrylamide, 3-chloropropane-1,2-diol (3-MCPD) be-
longs to a group of contaminants that are formed during the
processing of different foodstuffs. Recent studies have
identified high levels of 3-MCPD esters in refined edible
fats, such as margarine and oils, and in fat-containing
foods. Other related ester compounds such as 2-MCPD
esters and glycidol esters also are expected to occur. Sev-
eral toxicological studies have shown that MCPD induces
infertility in rats and causes tumours in rats when adminis-
2
tered in high doses. Its in vitro genotoxic activity, however,
is not confirmed in vivo.23 Bread and cereals contribute
25-28
significantly to intake of MCPD present in these foods.
MCPD esters also are widespread in toasted bread, bread
crust, donuts, salty crackers, roasted barley and in fer-
24-26
mented foods. One study showed that yeast-derived
glycerol accounts for a major part of 3-MCPD. Reported
levels were between 0.2 and 6.6 mg/kg in most of the ana-
lysed foodstuffs and the levels of esterified 3-MCPD were
27
much higher than the levels of free 3-MCPD.
At a recent congress, held in February 2009, warning mes-
sages were sent regarding 3-MCPD esters, which have
27
been found in all refined vegetable oils studied. The low-
est levels of these esters were observed in refined rape-
seed oil (0.3-1.5 mg/kg) and the highest levels were found
01.04.11 08:46
 Food contact material for baking: a review on associated chemical risks and technological issues
in refined palm oil (4.5-13 mg/kg), which are temperature
resistant and may be used for mould greasing and in dough
formulation. It appears that MCPD is linked, in particular, to
food production in which a deodorisation process has been
27
used. In the EU, maximum levels of 0.02 mg/kg for free 3-
MCPD in hydrolysed vegetable proteins and soy sauce
were established in 2001. A maximum tolerable daily intake
-1
(TDI) of 2 mg kg body weight has been established by the
Scientific Committee for Food (SCF). In the European Un-
ion, a maximum level of 20 mg/kg-1 3-MCPD has been set
for soy sauce and hydrolysed vegetable proteins; maximum
levels for other foods are currently under discussion. The
maximum TDI level 2 g/kg bw for 3-MCPD, mandated
since April 2002, is integrated into the Commission Regula-
6
tion (EC) 1881/2006. These limits were not designed to
account for 3-MCPD esters. EC No. 1881/2006 invites EU
member states to examine other foodstuffs for the occur-
rence of 3-MCPD in order to consider the need to set
maximum levels for additional foodstuffs.
2-3 Impact of pH on neoformed contaminants
During the baking of dough (e.g., bread, butter sponge
cake, pie, quiche), heat and mass transfer occurs at the
interface between the product contact surface (PCS) and
the product. The heat transfer interface is the point at which
most of the hazards associated with the risk of presence of
chemicals in the product occurs. The different substances
present at the interface, such as water, proteins, polysac-
charides and lipids, develop complex reactions that evolve
during the temperature rise associated with the progress of
the baking and with the apparition of crust. Due to the high
baking temperature and to the presence of proteins, carbo-
hydrates and fats, these components break down structur-
ally to influence the quality of heat transfer and the quality
of the bakery products. Interfacial properties of the dough
components must be considered, in particular the composi-
tion and properties of the dough liquor (i.e., the water-
soluable phase of the dough), which represents the liquid
film that comes into contact with the PCS. Hydrophobic-
hydrophilic properties of the PCS and the contact angle
play a role on adhesion energy. Another risk arises in the
use of lipids applied in the mould to reduce the stickiness.
These lipids may modify the biochemical reactions occur-
ring at the interface between the dough and the PCS. PCS
chemical composition, surface roughness and working
temperature are key parameters to consider. In this con-
text, the condition of the PCS (in particular, its roughness
and porosity) is important with respect to the interaction
between that surface and the product.
The CIAA Acrylamide Tool Box guide indicates that ex-
periments with an intermediate product (semisweet biscuit)
have shown that reducing pH by addition of citric acid can
lead to a 20-30% reduction of MRC in the intermediate
22
product. However, reducing the pH can also result in
reduced browning, reduced expansion during baking, and
an adverse impact on the organoleptic properties of the
final product. Other undesired neoformed contaminants
also may arise, such as 3-MCPD, which has been ob-
served in certain bakery products produced with lower pH
in combination with fermentation.
EHEDG_Innenteil.indd 79
79
Among the chemical leavening agents, "baking powder," or
sodium bicarbonate (NaHCO3), is a common ingredient in
the formulation of sponge cake or butter sponge cake. A
review on this topic is proposed in the thesis of Bellido.28 As
shown in another study, the pH of the batter may increase
29
during baking. Above 70C, sodium bicarbonate gradually
decomposes into sodium carbonate, water and carbon
dioxide, resulting in the expansion of the batter. The asso-
ciated reaction is as follows: 2 NaHCO3 Na2CO3 + H2O +
CO2. The hydrogen ion reacts with the bicarbonate ion,
resulting in the production of water and carbon dioxide. The
carbon dioxide migrates to gas nuclei in the batter and
expands as it is heated, increasing the volume of the bak-
ing product. According to the following reaction (HCO3- +
H+ CO2 + H2O), when baking starts, H+ concentration
decreases in the batter (pH increasing factor), producing
CO2 for volume expansion. At the same time, the H+ con-
centration can increase due to the water loss (pH decreas-
ing factor). In the range of pK1 (6.34) of bicarbonate solu-
tion, pH can move from a basic region to an acid region
30
due to its concentration. In the earlier part of baking, the
change in pH is the most important and is followed by a
decrease in pH. Baik, et al. showed that there is a relation-
29
ship between pH gradients and moisture gradients. After
baking, the pH of the product generally falls in a neutral
range (6.5 to 7.5). The evolution of pH during baking and
the final pH is known to play a role on the kinetics of Mail-
lard reaction and also on the possible chemical reaction
between the surface and the dough. Ammonium bicarbon-
ate also is used as baking powder; it poses the same prob-
lems as mentioned above. The aqueous solutions of all the
carbonates undergo decomposition during baking with
production of carbon dioxide, water and ammonia:
NH4HCO3 NH3 + H2O + CO2
Baking powder (type, concentration) interacts with dough
pH and thus may interact with acrylamide formation. In-
deed, the pH gradient seems to be linked to the moisture
gradient, suggesting that the pH is related to the moisture
29
content. The baking powder also interferes with the kinet-
ics of crust formation and possibly with the release of ex-
ogenous contaminants from the chemicals in the PCS.
3 Exogenous contaminants in baking
Exogenous contaminants (EC) are contaminants related to
the PCS supporting the product during baking. The associ-
ated risk results from two key points: the nature of the PCS
and the interaction between the formulation and the baking
conditions (time-temperature history). The following section
presents a review on the most common PCSs.
3-1 Product contact surface and antistick coatings
perfluorinated coating
Perfluorinated coatings (PFCs) have been used since the
1970s and are well adapted for the coating of surfaces
used in bread production; in particular, mould" or "tin"
bread (i.e., sandwich bread in square slices), which repre-
sents a large part of industrial breads (Figure 5). Perfluori-
nated based coatings are used in a number of diverse
applications, such as stain-resistant coatings, paper coat-
01.04.11 08:46
 80 Food contact material for baking: a review on associated chemical risks and technological issues

ings and baking parchment paper). PFC compounds are

typically derived from perfluorooctanesulfonyl fluoride
(FPFOS).

An independent science review panel in the US has rec-

ommended that perfluorooctanoic acid (PFOA) and its salts
to be considered 'likely to be carcinogenic' based on labora-
tory studies in rats. The US Environmental Protection
Agency (EPA) also has determined that PFOA is 'likely' to
cause cancer in rats. PFOS and PFOA are accumulating in
the natural environment and the use of these compounds is
under the scrutiny of the media and of the EU Commis-
31 Figure 6. Damaged PFC coating. Pieces of coating may be
sion. PFOS and PFOA are persistent organic pollutants
released (m to mm scale).
(POPs), according to the Scientific Committee on Health
and Environmental Risks (SCHER). EU Directive
2006/122/EC states that the marketing and use of PFOS
4
should be restricted. PFOS has a half-life of four years
and accumulates in blood and tissues. Several documents
propose an apocalyptic view of the potentially hazardous
32
nature of PFC. However, although these chemical com-
pounds may give rise to specific health risks, a scientific
approach should be taken to objectively assess the level of
risk.

There is a controversy about the transfer of PFC to bakery

products, although it is clear that the condition of the coat-
ing, and therefore its functionality, degrades over time with
use. Powley, et al. showed that no transfer was 'detectable'
33
using a mould and food simulant. The fact remains that
bakery product manufacturers must recoat the moulds
approximately every 12 months (after ca. 2000 baking
cycles). Thus, there is evidence that the ASC detaches
from its support during its life cycle and that it is partially
captured by the bakery products and ultimately, is eaten by
consumers (Figures 5-7).
PFC coating is much more resistant than silicone, but in
terms of antistick properties it does not perform as well as
silicone (at least when silicone is new). Greasing is often
used once the coating loses its antistick performance. Ap-
plication of PFC coating on a metallic surface is done with
at least three to four different layers. The first coat (primer)
helps to fix the subsequent coats. Two to three coats are
applied as paint and dried between each coat. A powder
layer may be used to provide a given roughness of the
surface. Each coat may have a different composition. PFC
coating is sensitive to scratches and notches; the antistick
property is frequently lost on a notch because of the con-
tact with the undercoats.
Figure 5. New steel mould with PFC coating.
Figure 7. SEM picture of a new PFC coated baking mould. Free
particules are visible (circle) and may leave the support during the
first use.
Tests have been done by LABERCA-ONIRIS (Nantes,
France) using water and pancakes as model foods. New
30-cm diameter frying pans coated with PFC were used. In
the case of water, the pan was filled with 500 mL distilled
water, covered with a stainless steel cover and allowed to
boil for 30 min. The remaining water was collected after
cooling and distilled water was added to reach an initial
volume of 500 mL. For pancakes, an oil dose (rapeseed oil)
was sprayed onto the pan and 75 mL of pancake dough
was disposed in the pan. The pancake was cooled for 5
min on the first side, flipped over and cooked for an addi-
tional 3 min. The pancake was cooled and then frozen.
PFOS and PFOA were determined using a liquid chro-
matograph coupled to tandem mass spectrometry (LC-
13
MS/MS). C internal standards were used for the quantifi-
cation (isotopic dilution approach). For pancakes, the ex-
traction of PFCs was done using organic solvent. The ex-
tracts were purified by solid phase extraction (SPE) (co-
polymeric stationary phase, Oasis HLB). The detection
threshold was 0.1 ppt of PFC. Results obtained with water
indicated that the presence of PFOA decreases with the
number of uses (up to five successive uses were performed
starting with a new, unused frying pan), whereas the pres-
ence of PFOS was detected irrespective of the number of
uses. Traces of PFOA were detected for nine out of 11
tested frying pans. More PFOA was always observed dur-
ing the first heating process. Detected amounts seem to
decrease for the second heating process. However, the
PFOS and PFOA concentration were below the threshold
imposed by the European regulation.

EHEDG_Innenteil.indd 80 01.04.11 08:46

 Food contact material for baking: a review on associated chemical risks and technological issues
Additional tests were done with pancake as a model food.
The pancake was baked in a new frying pan, similar to the
one used for the water tests. The PFOA concentration
-8
reached up to 0.25 g/kg of fresh matter (i.e., 2.5 10 % in
mass), representing an amount of 18.7 mg per pancake or
2
0.117 g/m of pancake (considering the total surface of
the pancakes, both sides). According to EU Directive
-3
2006/122, the PFOS concentration should be below 5.10
% (50 g/kg) in mass or below 1 g/m. Therefore, the respectively). Migration tests using food simulants differed
observed transfer of PFOA was below the current limit fixed
by European regulations.
Based on these results, it is clear that PFC coating mi-
grates into food, possibly at trace level during a given pe-
riod of use. After a certain period of use, the coating de-
grades faster, resulting in possible migration of more sig-
nificant quantities of coating in the food. The existing Euro-
pean regulations neither consider the ageing of the coating
nor address the changes in the amount of contaminant as
a function of the ageing of the product contact surface.
3-2 Product contact surface and antistick coatings
silicone coating
Silicone elastomers, which have been used since the
1960s, are made from cross-linked polydimethylsiloxanes.
Thermal degradation of silicone has been described in
34-37
many studies. Three stages have been identified for the
decomposition of the polymers: 1) evaporation of volatile
components; 2) thermal decomposition; and 3) thermal
oxidation. Stages 2 and 3 often overlap. Additives and
initial thermal treatment (postcuring) may permit the re-
moval of volatiles and increase the stability of the coating.
The degradation products primarily consist of cyclic polydi-
methylsiloxane (Cn) and linear polydimethylsiloxane (Ln)
oligomers. It is assumed that linear polydimethylsiloxanes
are methyl terminated linear chain, without excluding the
38,39
fact that some chains are hydroxyl terminated. The
migrating substances primarily consist of siloxane oli-
gomers of molar mass between 500 and 2100 Dalton. They
correspond to oligomers with 7 to 28 Si(CH3)2O groups.
The residue of the global migration can be detected using
40
gas chromatography-mass spectrometry (GC-MS).
Modified polyphenylene oxide (MPPO) is an accepted
simulant for dry foods in the measurement of overall migra-
tion for high temperature applications (EN 1186-13:2002
Part 13: Test methods for overall migration at high tem-
peratures). MPPO is a porous polymer with a high molecu-
lar weight (500000 to 1000000), a very high temperature
stability (Tmax = 350C), a high surface area and a low spe-
cific mass (0.23 g/cm-3). The substance is commercially
known as Tenax. The pore size range is important and
the reference used is 60 to 80 mesh.
In two studies by Meuwly, et al, different silicone baking
10,41 1
moulds (37 samples) were investigated. H-NMR, RP-
HPLC-UV/ELSD and GC techniques have been used to
assess migration of silicone in food. It was observed that, in
all cases, cyclic organosiloxane oligomers were found (for-
mula [Si(CH3)2-O]n with n = 650). In 13 of the tests,
linear, partly hydroxyl-terminated organosiloxanes were
identified (HO-[Si(CH3)2-O]n-H with n = 7 20). It was
concluded that the migrants mainly consist of organopolysi-
EHEDG_Innenteil.indd 81
81
loxanes. Various food models were considered for the
migration tests, such as food simulants (olive oil, isooctane,
ethanol [95%], Tenax) and also various cakes. Successive
migration tests have been done showing that until the tenth
experiment with cake, siloxane migration only slightly de-
creased. A significant dependence on fat content was ob-
-1
served. Migration level was below 21 mg kg and was thus
-1 -2,
below the migration limit of 60 mg kg (3 and 10 mg dm
from the results obtained with cake. Thus, there is a need
to harmonise the migration tests used for silicone in
Europe. Research also is needed to better understand the
impact of lipids on migration tests that consider both lipids
from the batter and from the antistick fluids.
Silicone elastomers can be considered inert up to 100C
and start to degrade at around 150C. Therefore, the limit
2
of 10 mg/dm proposed by the Resolution of the Council of
Europe is often reached.9 Above 150C, linear and cyclic
oligomers of polysiloxanes (molecular mass between 500
and 2100 Da) can be found in food in concentrations higher
than what is permitted by the European regulation (10
mg/dm). Modified polyphenylene oxide (Tenax) generally
overestimates the contamination of the foods from packag-
42
ing. The release of volatiles, which is sometimes consid-
ered as a migration test, is high during the first use and
41
then decreases rapidly. Therefore, neither the determina-
tion of the overall migration nor that of the volatiles can give
a clear response to the thermal stability of silicone as a
food contact material.
Studies in the literature do not necessarily agree with re-
gard to the temperature level reached during processing
and silicone resistance. Silcone coating migration tests
show a certain variability in results, and hazards associated
with use of silicone cookware are not fully clarified.
Silicone is less expensive than PFC but is not very durable
(~1000 to 2000 baking cycles). Greasing often is used in
the baking industry after a short number of cycles. The
operation of a baking support is often stopped when the
support sloughs off pieces of coating onto the bakery prod-
ucts. One of the ignored risks related to silicone is, depend-
ing on the methodology used to apply the coating, the sili-
cone coating may have some porosity (Figures 8-11).
When small bubbles in a coating are exposed to high inter-
nal pressure in baking conditions, the bubbles (Figure 9)
may rupture (Figure 10-11) and come into contact with the
food. In the case of bakery products, different compounds
can be trapped in the open porosity (e.g., lipids and bio-
polymers). Around 80% of the industry washes the baking
moulds once following each day of production; however,
the risk of oil burning, aldehyde formation and MRC pro-
duction is high.
01.04.11 08:47
 82 Food contact material for baking: a review on associated chemical risks and technological issues
Figure 8. SEM image of a silicone-coated baking mould (new).
Open porosity at the surface of the coating is shown (black circle).
Figure 9. SEM image of a silicone coated baking mould (new).
Bubbles are visible in the coating; silicone is quite often porous.
Figure 10. SEM image of a used silicone coating. Open porosity is
visible. The antistick property is lost; mould greasing is necessary.
Figure 11. SEM image of a used silicone coating. Open porosity is
visible. At this stage, the antistick property is lost; mould greasing
is necessary.
EHEDG_Innenteil.indd 82
3-3 Aluminium in baking
Aluminium (ALU) is a lightweight, malleable metal that is a
good heat conductor and is fairly inexpensive, making it a
popular material choice for manufacturers of cookware.43
Daily intake of ALU by humans is approximately 10 mg,
which comes primarily from consuming food. ALU pots and
moulds contribute about 1 or 2 mg of the estimated total
intake. However, ALU is under pressure and has been
banned in the list of authorised FCM in some countries.
31
ALU has been associated with Alzheimer's disease . In
2006, the Joint Food and Agriculture Organization/WHO
Expert Committee on Food Additives (JECFA) reevaluated
44
the safety of ALU . It was decided to lower the Provisional
Tolerable Weekly Intake (PTWI) by seven-fold, to 1 mg/kg
body weight (bw) for ALU (including additives). This deci-
sion was based on animal tests showing that the reproduc-
tive and developing nervous system was affected at doses
lower than those used in establishing the previous PTWI. In
one study, it was observed that levels of up to 100-320
45
mg/kg were found in bakery products. This was attributed
to ALU-containing food additives. The reduction of the use
of food additives containing ALU (for example, those found
in some leavening mixes) should thus be recommended.
These authors concluded that the potential health risk of
aluminium to consumers cannot be ruled out."
The anodization of aluminium consists in placing aluminium
in an acid solution and exposing it to an electric current.
This results in the deposit of a layer of aluminium. This
layer is harder than simple aluminium, as well as non-
sticking, which makes it scratch-resistant and more durable.
As a consequence, anodization reduces leaching of alumin-
ium from cookware into foods, particularly acidic foods.
Aluminium absorption is a complex network of biochemical
reactions which are influenced by several parameters. The
absorption can vary up to 50-fold, depending on the chemi-
cal form of aluminium. It is known that aluminium absorp-
tion is increased by low pH. The presence of citrate in-
creases aluminium absorption from aluminium compounds
with low solubility. This is very important because the
human diet contains considerable amounts of citric acid
(average of 4 g as citrate in the daily diet). Elevated expo-
sure of aluminium may produce accumulation of systemic
aluminium and cause toxicity of the respiratory, central
nervous, skeletal and hematopoietic systems.
A new EFSA regulation that calls for reduced aluminium
intake suggests a reconsideration of the allowance and use
of aluminium-containing food additives. Indeed, it appears
that these additives are a significant aluminium source in
some foods. Anodization also can help in reducing the
transfer of aluminium to food. Figures 12-16 present scan-
ning electron microscope (SEM) images that show the
condition of the surface of different aluminium surfaces.
Figures 15 and 16 show that even though an aluminium
surface can appear very shiny, it may host some miniature
particles that can be transferred to the food.
01.04.11 08:47
 Food contact material for baking: a review on associated chemical risks and technological issues
Figure 12. Used aluminium baking tray on which caramelised
starch and lipids are visible (brownish stains).
Figure 13. Aluminium baking tray NEW trashable used in
industry and for domestic bakeware (pie, sponge cake, ready-to-
eat meals).
Figure 14. SEM picture of a new aluminium support.
Zoom: Particles of aluminium.
Figure 15. SEM of domestic cookware. Particles of aluminium are
visible and seem ready to leave the mould.
Figure 16. SEM picture of a used, reusable aluminium mould
(Figure 12). Caramelised coating (top left) and aluminium in the
back.
EHEDG_Innenteil.indd 83
83
3-4 Baking parchment paper
Baking parchment paper is a cellulose-based paper that is
used as a disposable non-stick surface intended for use in
baking. It is commonly used to eliminate the need to grease
moulds. However, this paper is brittle and thus it is fre-
quently treated with a plasticising agent, usually silicone,
glycerin, paraffin or glucose. PFOS and PFOA are consid-
ered residual impurities in some food-contact paper coat-
ings, increasing strongly when thermal treatment is applied
(i.e., PFOA from a microwave popcorn bag paper has been
-1 48
measured at amounts as high as 300 g kg ). Some-
times, polytetramethylene terephtalate (PET) is used for
baking parchment paper. PET resist to 170C with a melt-
ing point of approximately 280C.
Backing parchment paper often is used in aluminium and
steel moulds. The paper creates an air layer between the
mould and the paper, resulting in a temperature rise and
therefore, results in an insulating effect. The presence of
silicone as plasticiser may result in a hazard, however,
exposing the consumer to the release of silicone and other
toxic substances, depending on the technology used.
3-5 European regulations; food contact materials and
food simulants
The European regulation of FCM considers four basic food
simulants (FS): A = water, B = acetic solution, C =
ethanol solution and D = olive oil. Olive oil tends to de-
grade the structure of the coating, and in particular, silicone
based coatings. This is taken into consideration at the mo-
ment by the CEN on FCM, which is working on changing
simulant D and investigating the use of other FSs. MPPO
is an accepted FS for dry foods in the measurement of
overall migration for high temperature applications (EN
1186-13:2002 Part 13). However, it appears that this FS is
not always fully adapted to the case of polymer coating.
There is thus a need for progress in this area of research
as it pertains to modifying the existing European regulation
for food contact material, especially in the case of coatings
that undergo multiple baking cycles.
3-6 Antistick fluids
Greasing agents are often applied to baking surfaces, in
particular at the end of the shelf life of a mould when se-
vere sticking problems arise. Antisticking fluids that can be
applied include emulsion (oil in water), hydrogenated fatty
acids, or oil-starch mixes. Saturated fats often are used
because of their resistance to high temperatures. Antistick
fluids are technical ingredients and do not have to be
shown in product recipes. In the case of small products
(such as miniature bakery products), the surface-to-mass
ratio can be large and the antistick fluid may ultimately
represent a substantial source of lipid that is omitted in the
recipe of the product. The objective of mould greasing is to
obtain an hydrophobic film with a high viscosity resulting in
47-
a reduction of the stickiness of the product during baking
49
. The objective of this film applied before the filling of the
mould (with spraying systems) is to act as a barrier to
aqueous phase, and in particular, to the free sugars that
are present in the aqueous phase of the dough. Different
fluids have been developed for different applications and
products. The measurement of the wetting angle as pre-
01.04.11 08:47
 84 Food contact material for baking: a review on associated chemical risks and technological issues

sented by Ranft often is used to characterise the perform- Figure 19, larger wetting angles are achieved than on a
47
ance of an antistick fluid with respect to a given surface. strictly flat surface shown in in Figure 18. The presence of
lipid (in particular antistick fluids) may modify the surface
However, the risk of transfer of the antisticking fluid is real tension forces and interact with the final crust structure.
48
as quoted in Coordes, et al. The smoke point or the acid-
ity is often used to select the antisticking lipid. Butter, for
example, cannot be used above 130C, whereas margarine
designed for cooking can be used up to 135C. Oil tem-
perature tolerance (180-220C) depends on the non-
saturation of their fatty acids. In fact, at 60C saturated fatty
acids are not exposed to oxidation opposite to polyunsatu-
rated fatty acids. So, hydrogenation of oils often is used to Figure 17. Crust on a crispy roll (left) and of a butter sponge cake
increase this temperature tolerance; however, this process (right). Ghosts of steam bubbles are visible in the crust. Rough-
results in the development of trans fatty acids which are ness of the coating and surface tension properties rule the crust
structure and in turn, the capability of the crust to remove the
unhealthy substances, resulting in cardiovascular dis-
49-51 moisture out of the crust zone. This influences (i) the pan tempera-
ease. From 100C and in the presence of oxygen, the
ture and formation of NFC, and (ii) rate of ageing of the coating.
formation of free radicals and of hydroperoxydesis is accel-
erated. Above 160C, a large amount of monomers and
52
volatiles is released. These transformations have impor-
tant impacts on several food attributes, such as nutrition,
organoleptic quality and physico-chemical composition. The
French regulation considers fatty acids unsafe for food use
fatty acids when after a given thermal treatment they show
the apparition of more than 25% of new chemical species
(representing a non-adduct forming [NAF] of 7.5%). Fresh
oil has a NAF of 0.1 and 0.3%. This can be increased to Figure 18. Example of a surface tension test.
5% with a viscosity increased by a 30 factor. Oxidation The wetting angle is .
reactions also are linked to several other factors, such as
water activity and presence of metallic ions. In the case of
metallic support, divalent ions like Fe2+ may act as cata-
lysts to lipid oxidation and will promote the formation of
nonsaturated aldehydes like 2-nonenal and nonadienal,
which are genotoxic.

4 Technical issue impact of the baking

surface on the crust structure
The structure of the crust is closely related to the baking
temperature and to the structure and interfacial properties
of the product contact surface in contact with the dough.
During baking, the dough temperature rises, resulting in an
expansion of the dough due to (i) increasing yeast or bak-
ing powder activity, which produces CO2; (ii) vaporisation of
the CO2 solubilised in the dough; and (iii) vaporisation of
the water. This expansion results in a compression of the
dough against the surface of the baking mould. The com-
pression is effective until the viscous forces of the matrix
(dough/crumb and then dough/crust transition) overcome
the pressure forces. In parallel, the crumb setting is ac-
companied by the rupture of the walls of the fermented
dough, which becomes porous. The onset of crust forma-
tion starts with the boiling of the dough, which corresponds
to the apparition of steam bubbles in the dough in the vicin-
ity of the interface between the dough and mould (product
contact surface). The heat flux and the surface tension of
the liquid film at the mould-dough interface will control the
ebullition phenomenon and therefore the final structure and
porosity of the crust. This ultimately influences the structure
of the crust and its ability to remove the moisture to form
the crust (Figure 17). In the case of a product contact sur-
face with notches, steam bubbles will appear preferentially
in the notches or inside crevasses. Indeed, as shown in
G
Figure 19. Notch (roughness) on a surface affecting the affinity of
a fluid with the surface.
Each substance of a dough has a given affinity toward the
two main solvents present in the system: water (hydrophilic
substances) and lipids (lipophilic subtances). The principle
of an antistick coating is to reduce the surface tension to-
ward both lipophilic and hydrophilic substances. The sur-
face tension can be measured with specific technique such
as the wetting angle test (see Fig. 18). In order to attract a
molecule from the interior to an interface at the surface, the
net force acting inward (surface tension) needs to be over-
come. Lowering the specific interfacial energy would de-
crease the total energy needed to achieve the new system
with the larger interfacial area, and it will be more stable.
Temperature also has a significant effect on surface ten-
sion (specific interfacial energy). Most antistick coatings are
lipophylic. It is very likely that the risk of transfer of coating
substances to the product will be promoted when using an
antistick oil that is not adapted. This condition also corre-
sponds to the case of a pan reaching its end of life phase
for which the risk of transfer of chemicals is high and in the
range of particles (m to mm scale). In the case of cara-

EHEDG_Innenteil.indd 84 01.04.11 08:47

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EHEDG_Innenteil.indd 85 01.04.11 08:47

 86 Food contact material for baking: a review on associated chemical risks and technological issues
melised biopolymers, the viscosity significantly increases,
resulting in a possible higher affinity of caramelised bio-
polymers with the coating. Notches also may help to fix the
caramelised compounds. The risk of sticking and the risk of
transfer of exogenous contaminants from the product con-
tact surface toward the product are thus closely related to
the condition of the product contact surface. Developing
technologies to control the ageing of product contact sur-
faces in the case of baking is thus of importance to mitigate
sticking problems and chemical risks for both exogenous
and neoformed contaminants.
Conclusion
This paper presented an overview on different aspects
related to product contact surfaces used in the baking in-
dustry. The objective of this overview was to assess the
known risks and to compare them with the existing regula-
tion on ASC and antistick fluids. Further research is clearly
needed to improve the existing situation, particularly in the
case of silicone based coatings for which regulations re-
main unharmonised within Europe. Regarding the risk of
transfer of EC to the product, although the level of contami-
nation appears to be very low, there is room for improve-
ment in reducing contamination risk, both in terms of newly
coated moulds and in the detection of the end of life of the
product contact surface. In between these two periods of
the life cycle of a coating, a reasonable level of contamina-
tion (traces) may be acceptable. Alternative product contact
surfaces that are in development by the industry will need
to be in compliance with existing regulations.
The use of antistick fluids and the chemical reactions taking
place at the interface between the product contact surface
and the product is a challenging problem. Antistick fluids
are widely used in the industry to decapsulate the products,
in particular when the antistick coating loses its efficiency.
Depending on the structure of the antistick coating, uncon-
trolled reactions may take place and result in the presence
of neoformed contaminants on the products. The antistick
fluids are not considered in the recipe of a given products,
since they are technical agents. Regulations should evolve
to improve the situation.
Acknowledgments
This research project has been co funded by the Rgion
Pays De Loire within the AISQAL project (2007-2010). This
presentation is done within the frame of the AGRI-
FOODRESULTS European project (FP7- Grant Agreement
226927) aiming at communicating the results of European
projects to the food industry. It does not necessarily reflect
the views of the European Commission and in no way an-
ticipates the Commissions future policy in this area.
EHEDG_Innenteil.indd 86
Glossary
ACR: Acrylamide
AFSSA: French agency for food safety
ALD: Aldehydes (linked to lipid oxidation)
ARP: Amadori rearrangement products
ASC : Antistick coating
BVP: Bread, viennoiseries, patisseries
CR: Caramelisation
EC: Exogenous contaminants
EFSA: European Food Safety Agency
EHEDG: European Hygienic Engineering & Design Group
FCM: Food contact material
FEP: Perfluorethylenepropylene is limited to application to
205C; posesses excellent antistick properties
FPFOS: perfluorooctanesulfonyl fluoride
FUR: Furfurale
HL: Hydrogenated lipids
IMI: Imidazine
LPB: Low pressure baking
MCPD: Monochloropropanediol (also called 3-MCPD
(3-chloropropane-1,2-diol)
MPPO: Modified polyphenylene oxide (known as Tenax );
accepted simulant for dry foods in the measurement of
overall migration for high temperature applications.
(EN 1186-13:2002, Part 13)
MR: Maillard Reaction
MRC: Maillard Reaction compounds
NFC: Neoformed contaminants
PCS: Product contact surface
PFA: Perfluoralkoxy
PFC: Perfluorinated compounds, such as PFOS and PFOA
PFOS: Perfluorooctane sulfonate
PFOA: Perfluorooctanoic acid
PTFE: Polytetrafluoroethylene
PYZ: Pyrazines
QMA: Maximum permitted quantity of the residual
substance in the finished material or article expressed as
mg per 6 dm of the surface in contact with foodstuffs.
(See Reference 1)
SCHER: Scientific Committee on Health and Environmental
Risks
SILO: Silicone oligomers
SML: Specific migration limit
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EHEDG_Innenteil.indd 88 01.04.11 08:47

 European Hygienic Engineering & Design Group

Hygienic design of enclosure boxes in relation to

high pressure cleaning?
High-pressure cleaning has long been employed in the food and beverage industry. Food resi-
dues are removed from the soiled machinery and plant enclosures by mobile high-pressure
cleaners working at up to 120 bar, using water and detergents. This report outlines the disad-
vantages that may still arise when using high-pressure cleaning equipment, and describes
what alternative cleaning solutions look like in conjunction with hygienic design enclosures.

Heinz Schmitt, Head of the Food and Luxury Consumables Sector Management Service, and Hans-Robert Koch,
Public Relations, Rittal,
E-mail: schmitt.h@rittal.de, koch.hr@rittal.de

The degrees of protection of enclosures from water are
regulated in the European standard EN 60 529 (Protection
Classes Provided by Enclosures). Point 6 (Protection from
Water Jets) states that water directed at the enclosure in
powerful jets from all directions must have no harmful ef-
fects. Compact enclosures with IP69K protection (water
with high-pressure/steam-jet cleaning), in accordance with
DIN 40 050, Part 9 (Road vehicles, IP Protection Catego-
ries, Protection against Foreign Bodies, Water and Contact;
Electrical Equipment) are now also available. When water
is directed against these enclosures from every direction
under very high pressure, it must not have any adverse
effects.
is forming that can lead to a micro-contamination and that
dirt is spread to the adjacent, otherwise uncontaminated
surroundings. The fact that liquid also can penetrate into
the enclosure when using high-pressure liquid cleaners has
to be tolerated to a certain extent. It thus remains the deci-
sion of the plant manufacturer to define the protected area
in the enclosure. If neither buttons nor signal lamps have
been installed in the enclosure door, and the manufacturer
has restricted the size of the protected interior, water may
be allowed to drop within the enclosure, behind the door.
However, it must be ensured that that this has no adverse
effect on the electrical equipment.
In terms of hygiene, however, the penetration of liquid into
the enclosure is a very serious business (Figure 1). Where
the slightest amount of moisture enters the enclosure, mi-
croorganisms such as bacteria, yeasts or moulds also may
find their way inside. The heat dissipated from the controls,
and so on, also substantially increases the risk of contami-
nation within the enclosure. When opening the door for
maintenance work or to alter a control function, the envi-
ronment and the production area may easily become con-
taminated. Enclosure gaskets damaged by aggressive
cleaning also can increase the risk of contamination of
conventional enclosures. The penetration of fluids into the
enclosures used in the food industry production environ-
ment must be avoided in all circumstances. The risks of
contamination cannot be easily reduced through the use of
high-pressure cleaners, as they are unable to prevent the
harmful effects on electrical equipment defined by the EN
60 529 and DIN 40 050 standards.

If any parts do have to be cleaned by high-pressure meth-

Figure 1. Hygienic design is a necessity for easy-to-clean produc-
tion systems in hygiene-critical processes in the food industry.
The risks of high-pressure cleaning
ods in the food production plant, enclosures are available
that ensure adherence to protection class IP69K. This can
be done by attaching removable parts by multiple screws or
by using a labyrinth seal in front of the gasket. With multiple
screw joints, there is a risk that not all the screws will be
tightened sufficiently during later service work and so the
intended level of protection will no longer be ensured.

Even though the use of high-pressure cleaning is recom-
mended for cleaning road vehicles or machinery, as in the
automobile industry, it is not necessarily of benefit to the
food industry. Although it is perfectly possible to clean the
equipment with that procedure, the risk is that either spray
Dead spaces must be avoided
The labyrinth, a tortuous construction, protects the gasket
from the sharp jet of water. However, the labyrinth gives
rise to dead spaces, which have to be avoided at all costs.

EHEDG_Innenteil.indd 89 01.04.11 08:47

 90 Hygienic design of enclosure boxes in relation to high pressure cleaning?
DIN EN 1672-2 (General Design Principles and Guidelines
for Hygienic Food Production Machinery, Part 2, Hygiene
Requirements) demands the elimination of these dead
spaces, except where it is technically impossible. The DIN
EN ISO 14159 standard (Machine Safety Hygiene Re-
quirements Pertaining to the Design of Machinery) makes
an even clearer demand: dead spaces must be avoided. In
its Document 13 (Hygienic Design of Apparatus for Open
Processes), the European Hygienic Engineering & Design
Group (EHEDG) provides a great deal of unambiguous
information on avoiding hollows, gaps and dead spaces.
Special gaskets make it possible
Today, effective cleaning can be accomplished with lower
pressures, at 25 bar, for example. Thus, the penetration of
water into the enclosure can be avoided by choosing the
adequate IP66 protection class and by employing special
gaskets, as well as by using a minimum number of lock or
hinge points.
What is necessary is that suitable gaskets not only with-
stand pressure, but that they also remain stable over a long
period in the face of cleaning agents and disinfectants.
Practical experience shows that, over the long term, no
gasket can stand up to alkalis and acids, which are highly
aggressive in some cases. As a minimum, it should thus be
easy to replace gaskets in the event of damage.
Figure 2. A special silicone seal assures a gap-free sealing of the
enclosure that produces higher resistance to acids, alkaline solu-
tions, detergents and disinfectants.
The original protection category guarantee must not be
reduced by inserting the new gasket improperly. Welded
gaskets are useful here. Unlike rolls of seals that are avail-
able by the metre, they avoid having the sealing strip being
pulled during assembly, so causing subsequent gaps at the
ends.
EHEDG_Innenteil.indd 90
Cleaning hygienic design enclosures
Rittal's hygienically designed series of enclosures have
sealing frames. Silicone is used in the seal, instead of poly-
urethane, as it is more is resistant to all kinds of detergents
and disinfectants (Figure 2). Hygienic gaskets are coloured
blue, so that they are immediately noticed in food produc-
tion applications, important in the case of foreign bodies,
which stand out and are thus are easily detected. The eas-
ily replaceable, outer silicone gasket ensures a gap-free
seal. The sloping roof of the enclosure, which has a 30-
degree gradient, also allows the water and detergents to
drain off completely (Figure 3). With their residue-free
cleaning, confirmed as effective by the Fraunhofer Institute
following extensive comparative tests, the Rittal enclosures,
designed for very high levels of cleanliness, make an active
contribution to safety. They are effective in minimising the
risk of cross-contamination in highly sensitive food produc-
tion applications.
Figure 3. A chamfered edge fold prevents liquids from accumulat-
ing. The hinges are located inside the enclosure.
Conclusion
Easy-to-perform cleaning and disinfection procedures at
low pressures and hygiene-friendly production systems
offer major advantages over high-pressure cleaning. This
allows the processors of meat or poultry, fish and delica-
tessen products, frozen and convenience meals, bakery
products and confectionery, as well as the bottling and
beverage industry in coordination with the health regula-
tors to achieve top results and meet demanding quality
and environmental requirements.
01.04.11 08:47
 European Hygienic Engineering & Design Group

A new silicone rubber for demanding applications in the

food industry
A number of rubber types are applied as materials in the construction of numerous equipment
components used in the food industry. These materials must meet a variety of temperature,
chemical resistance and mechanical property requirements, depending on the use and
operational environment in which they are applied. A new silicone rubber has been developed
that meets these myriad requirements.

Anne-Sofie Ravn Bering and Lars Linnemann, AVK GUMMI A/S, Mosegaardsvej 1, DK-8670 Laasby, Denmark
E-mail: avk@avkgummi.dk

Silicone rubber is a good choice of material for the

construction of gaskets and diaphragms used in many food
industry applications. In the past, however, it has been
necessary to compromise on tear strength and friction in
order to achieve a material with an excellent compression
set (i.e., low permanent set after compression). For
instance, in the case of traditional butterfly valve gaskets, it
has been necessary to balance wear-and-tear resistance of
the shaft hole with the lowest possible permanent
deformation. With the new QCF-70 silicone rubber material
(developed by AVK GUMMI A/S, Denmark), excellent
mechanical/dynamic properties together with an optimum
compression set are now possible.

QCF-70 has been designed to complement the traditional

silicone grades on the market today and is based on new
alternative compounding principles. The material has been
developed according to the U.S. Food and Drug
Administration (FDA) 21 CFR 177.2600 and complies with
the extraction specification for both aqueous and fatty
foods. Furthermore, QCF-70 is approved as a Class I (high
fat) compound according to 3-A Sanitary Standards (18-
03). The approval process according to USP Class VI has
been initiated.
Gaskets for butterfly valves produced in QCF-70 have the
best properties with respect to durability of the shaft holes,
as well as very little permanent deformation. Permanent
deformation marks on a butterfly valve gasket are shown in
Figure 1. The explanation for such marks can be found in a
bad compression set. The effect is a risk of leakage in the
butterfly valve in the long term.
Figure 1. Permanent deformation marks on butterfly valve gasket.
Mechanical properties and lifetime testing
data
In Table 1, data is presented showing the mechanical
properties of the new QCF-70 in comparison with the well-
known silicones QPF-70 and QRB-70. It is worth noticing
that the friction is lowest in the case of QCF-70. This results
in a low open/closing torque for the disc in the butterfly
valve and a lower load on the gasket, which minimises the
risk of rubber being torn off the gasket. A high modulus
ensures that gaskets produced in QCF-70 will significantly
reduce the risk of having the gasket torn out of the housing,
even with a high media flow rate.

Table 1. Mechanical
properties and lifetime test.

EHEDG_Innenteil.indd 91 01.04.11 08:48

 92 A new silicone rubber for demanding applications in the food industry

Also shown in Table 1 are the results of the lifetime Material selection
(durability) tests for QCF-70, QPF-70 and QRB-70. At AVK
GUMMI A/S lifetime tests have been applied for many Mechanical properties and compression set cannot stand
years in connection with new development projects. During alone and in any choice of material, various factors must be
a lifetime test, gaskets are mounted in butterfly valves and considered. Figure 2 illustrates important factors for a
tested in 90C demineralised water. Open/closing cycles material selection: mechanical properties, chemical
run continuously, and the closing torque is measured. resistance, temperature resistance, lifetime and approvals.
Furthermore, the system is checked for any leakages. The
test is terminated when the sealing pressure reduces to a
predetermined level. As shown in the data, an additional
advantage of QCF-70 is a low permanent set that will have
a long-term effect when working in the field.

Cold flexibility and high temperature

compression

In Table 2, the compression set is compared for QCF-70,

QPF-70 and QRB-70 at a high temperature and the
momentary compression set is compared at a low
temperature. The momentary compression set expresses
cold flexibility and is defined as the ability of a rubber
material to remain flexible during sudden temperature
changes. In real-world applications, the momentary Figure 2. Material selection must be based on various factors.
compression set is important (e.g., when handling cold
media and subsequently exposing the rubber gasket to
steam sterilisation or vice versa). QCF-70 shows excellent
results for both momentary compression set and high
temperature compression set.

Table 2. Compression set.

Figure 3. Volume change after swelling

(144 h) in selected food media.

EHEDG_Innenteil.indd 92 01.04.11 08:48

 A new silicone rubber for demanding applications in the food industry 93

Temperature and chemical resistance
As with other silicones, QCF-70 is serviceable over a wide
temperature range. The chemical resistance of QCF-70 has
been tested in comparison with QPF-70 and QRB-70 in
selected media within foods and cleaning agents. The
results shown in Figure 3 are volume changes after a 144 h
exposure at 80C. QCF-70 shows good chemical
resistance in acetic acid, olive oil, butter fat and 96%
ethanol (23C).
For validation of chemical resistance towards cleaning
agents, the following chemicals (2% solutions) have been
selected as representative: nitric acid, phosphoric acid and
sodium hydroxide. The swelling was performed at 80C for
144 h. Furthermore, the resistance against demineralised
water at 150C has also been validated. The conclusion is
that the volume swell is very low, as shown in Figure 4.

Figure 4. Volume change after swelling (144 h) in selected cleaning agents.

EHEDG_Innenteil.indd 93 01.04.11 08:48

 European Hygienic Engineering & Design Group

Hygienic pneumatic components

Food manufacturers and packaging specialists rely on strict hygienic standards, easy-to-
operate machinery and leading-edge packaging to optimise cleaning processes and assure
food safety and quality. The development of hygienically designed pneumatic components is
especially important because direct contact with acidic, alkaline or highly adhesive
compositions in the wet areas of a system places stress on all component materials, reducing
equipment cleanability and production efficiencies. The use of materials such as corrosion-
resistant or acid-proof steel, anodised aluminium or high-performance plastics in the
manufacture of pneumatic components enhance their ability to withstand these stresses in the
long term.

Cordula Krause-Widjaja, Bosch Rexroth AG, Ulmer Str. 4, 30880 Laatzen, Germany
E-mail: cordula.krause-widjaja@boschrexroth.de

The food and beverage industry is an especially demanding
sector with strict requirements for machinery equipment.
Original equipment manufacturers (OEMs) and end-users
need the best possible components in their systems in
order to optimise the cleaning processes. In addition to
becoming the first pneumatics manufacturer to join the
European Hygienic Engineering & Design Group (EHEDG),
Rexroth has presented its first EHEDG-certified product.
Valves in IP69K
withstand cleaning at both high pressures and
temperatures, which means the system can be used in
areas where direct contact with food products is an issue.
The CL03 valve terminal system is the only valve system
available that fulfils IP69K requirements, eliminating the
need for a protective cabinet. This enables a significant
reduction in tubing lengths by allowing it to be placed near
the actuators in the food & beverage industry, something
that is not normally possible due to high-pressure cleaning
requirements.

Stainless cylinder

Another essential part of the hygienic design of pneumatic

components is the ISO Clean Stainless (ICS) cylinder
(fig. 2), which offers corrosion protection. The ICS cylinder,
with a piston diameter of 32 to 100 mm and a maximum

CLP02_FP_EN_1009
stroke length of 1500 mm, is ideally suited for food and
packaging applications. Its smooth surfaces and
interlocking seals and cushioning screws help prevent dirt
pockets, making the cylinder easy to clean.

)LJXUH9DOYH7HUPLQDO6\VWHP&/LQK\JLHQLFGHVLJQ )LJXUH7KHVWDLQOHVV,62&\OLQGHU

The CL03 Series Valve Terminal System is a successful
example of hygienic design in pneumatic components
(Rexroth, Laatzen, Germany). The overall design and
special materials used in the construction of the CL03 have
been tested for use with chemicals and to determine ease
of cleaning (fig. 1). In development, for example, it was
important that the plastic cover had a hygienic design, free
of seams or crevices to eliminate the possibility of dirt
deposits. The valve terminal system, designed in
accordance with protection class IP69K, has been shown to
In addition, the stainless steel cylinder offers sufficient
corrosion protection to enable its application from the
production process through to the food packaging step. The C
ICS is available in two basic versions: The ICS-D2 is made
W
of stainless steel and offers standard corrosion protection.
The ICS-D1, made of acid-proof steel, is recommended for g
food applications where food comes into or may come into B
direct contact with acidic components.
B
w

EHEDG_Innenteil.indd 94 01.04.11 08:48 Rexroth

 Drives and controls

Pneumatics

Linear technology
CLP02_FP_EN_1009

Assembly technology

The Goal: The Means:

The Best Technology Objective Consultation
for Your Processes from Rexroth

Comprehensive know-how for the food and packaging industry

We make your automation processes more effective using our cross-technology expertise. Fewer interfaces,
greater flexibility, increased productivity. All components for drive, control, and motion from a single source.
Bosch Rexroth. The Drive & Control Company

Bosch Rexroth AG packaging@boschrexroth.de

www.boschrexroth.com/packaging

Rexroth_Anz_DINA4_CLP02_EN_EHEDG.indd
EHEDG_Innenteil.indd 95 1 23.09.2010 9:39:0808:48
01.04.11 Uhr
 96 Hygienic pneumatic components

Guide cylinders for filling liquid products

Material handling in the food and packaging industry has

further stipulations: for example, a precise adjustment of
the end position for the receipt of a work piece. The GPC
Clean pneumatic cylinder, a guide unit for applications in
wash-down environments, is designed for this purpose
(fig 3). Its housing is made of anodised aluminium, which
stands up to extremely harsh cleaning processes. The front
plate and screws are manufactured from stainless steel.
Figure 4. ISO Clean Cylinder for applications with corrosive
The smooth surface is free of grooves and holes where environment
residue from cleaning agents or food products could
accumulate.
The ISO/VDMA Clean Line has a practical and corrosion-
resistant sensor mountings and is easy to clean and
maintain. The hygienic and corrosion protected surface
makes it suitable for applications with corrosive
environment, dry and wet splash zones. The NSF-H1 or
H2 certified lubricant is another advantage in surroundings
such as primary and secondary packaging.

Figure 3. The GPC Clean cylinder is characterised by its easy-to-

clean surface.

Rexroth developed the GPC Clean guide cylinder in close

cooperation with Ecolean, a leading Swedish company
specialising in packaging for liquid products that uses the
cylinders as part of its innovative production line concept
which extends from newly developed packaging material to
an automatic filling station. Dairy companies make up the
largest portion of the company's customers, and as such,
require components that withstand specific environmental
conditionscold, humidity and liquid product splashing.

The hygienic pneumatic components in the system

contribute to the end customer's assurance that the
packaging used to contain food and beverage products are
produced to the highest hygienic standards.

Corrosion protection:
the ISO/VDMA Standard Cylinder ICL
As corrosion-protection is one of the main subjects in
hygienic design, Rexroth offers another pneumatic cylinder
especially for this industry sector: the ISO Clean Line (ICL)
series. This corrosion-protected ICL pneumatic cylinder
(fig. 4) is fully compliant with the strict hygienic
requirements of the food and packaging industries. Its
Aluminium covers and tube ends are anodised. All screws
are made of stainless steel and the scrapers are available
in PEE or PTFE.

EHEDG_Innenteil.indd 96 01.04.11 08:48

 European Hygienic Engineering & Design Group

Hygienic compact containment system

Compact equipment design of a new processing system provides manufacturers with the
ability to work hygienically, safely and efficiently in environments with specific cleanliness
requirements, potential explosion hazards, or potential emissions of toxic substances.

Henri Michiels, Technical Commercial Director, Dinnissen BV

E-mail: h.michiels@dinnissen.nl

The ability to quickly and thoroughly clean production

processes is becoming increasingly crucial, as more
producers choose to invest in single process lines for the
production of several products. For companies in the feed,
food, pharmaceutical and chemical sectors that specialise
in the processing of powders, particles and granulates, the
ability to implement effective cleaning also is critical. In
many of these environments, it is essential to work
hygienically, safely and efficiently due to specific
cleanliness requirements, risk of explosion hazards or the
potential emission of toxic or sensitising substances. To
address these needs, the Hygienic Compact Containment
system (Dinnissen Process Technology, Sevenum,
Netherlands) has been developed, which provides effective
containment of even the finest particles in a compact
design that also ensures that all of the processing
equipment is easily accessible for cleaning purposes Figure 2. Pegasus mixing system.
(Figure 1).
In the past, achieving the flexibility to handle such a wide
range of products whilst remaining easy to clean quickly
and frequently has only been possible with quite bulky
machinery. Now, precision instrumentation has led the way
to significant improvements in both versatility and
cleanability.

The compact design and construction of the Hygienic

Figure 1. Flow diagram of the Hygienic Compact Containment
concept.
Compact construction for fast cleaning
Hygienic Compact Containment has been developed for
use in manufacturing operations that involve product intake,
mixing, grinding, sifting and packaging. In many of these
types of production environments, raw materials are
processed for the production of products ranging from
probiotics, vitamins, baby food, meat, dried herbs, graphite,
toner, additives and nitrates, to other fine particles,
sensitising substances, and/or substances associated with
explosion risk. In these facilities, hygienic equipment is key
to meeting high standards of cleanliness while gaining
production efficiencies.
Compact Containment system relies upon the use of very
accurate flow meters and weighing systems, and dosage
components. As a result, the variants of the system can
quickly and accurately dose various ingredients and
process a large number of batches per hour. This makes it
possible to achieve a high mixing capacity in spite of the
compact design of the processing equipment. High mixing
capacity is possible even at coarse dosage/fine dosage
ratios of 1:500. In practice, these systems allow coarse
dosage rates of 20 tons per hour and fine dosage rates of
40 kg/h (11 g/sec).
The compact design of the processing equipment is very
important in enabling production processes to be cleaned
quickly and thoroughly. The systems mixing and grinding
installations are fitted with oversized inspection hatches
and easily removable mixing shafts. As a result, all of the
interior parts of the machines are optimally accessible.

EHEDG_Innenteil.indd 97 01.04.11 08:48

 98 Hygienic compact containment system
Cleaning of mixing and transport systems
using compressed air
Fully automated dry clean-in-place (CIP) technology, based
on the use of compressed air, is included in the system to
increase the effectiveness of cleaning. The dry CIP
technology cleans mixing systems via powerful blasts of
compressed air and an interval switch. Specifically, the
system employs tanks of compressed air and special
nozzles installed at critical locations in the mixing system.
Figure 3. Pegasus continuous mixing system with two feeders.
The equipment is blown clean on a step-by-step basis with
the help of an interval switch that ensures that the cleaning
operation proceeds as programmed. The blow-cleaning
process starts from the weighing bunker and proceeds,
from front to back (or from top to bottom), to clean every
component of the mixer and storage bunker with the help of
blasts of compressed air. After each compartment has
been cleaned, it is automatically sealed off by special
valves to prevent any raw material particles from moving
backwards to previous parts of the chain. An efficient
suction system removes all particles and dirt and transports
them to a hermetically sealed section.
This new technology blows weighing bunkers, mixers and
storage bunkers clean and empty at efficiencies of 99.9%.
Since the entire cleaning process is conducted with dry air,
caking, clumping and the growth of bacteria and moulds
are also effectively prevented. After removal, expensive
raw materials remain undamaged and can be reused. For
companies that need the very highest level of hygiene, the
dry CIP system can be fitted with extra options such as
electrolytically polished surfaces.
EHEDG_Innenteil.indd 98
Hermetic sealing prevents particle entry
across process applications
As noted, the entry of fine particles and microorganisms is
a threat to the hygienic production of foodstuffs, particularly
for companies operating in the food sector. In addition, the
emission of toxic and sensitising substances can pose a
threat to worker safety, particularly in the chemical and
pharmaceutical sectors. The Hygienic Compact
Containment concept is capable of hermetically sealing off
production processes, preventing particles from coming in
from or going out to the environment.
The concept is based on a combination of three
functionalities. First, underpressure is established at all
points at which ingredients are introduced into the system.
The resulting pressure exerted from outside the system
prevents any hazardous substances from escaping from
connections, seams or joints. In addition, inflatable seals
and air-seals with air pressure are used throughout the
system. The end result is a hermetically sealed system,
whereby dirt and microorganisms are not able to enter and
hazardous substances are not able to escape. The use of
underpressure and inflatable seals makes it possible to limit
3
particle emission to less than 0.1 mg per m of air. The
Hygienic Compact Containment system is even effective
against extremely fine particles (down to 10 nm). In
situations that call for the very strictest standards of
hygiene and safety, the system can be fitted with a
controlled airflow facility (Figure 4). In such cases, a
conditioned flow of clean (or even sterile) air is created that
flows in a safe direction, while potentially contaminated air
is removed and transported elsewhere.
Figure 4. Pegasus Mixer with CIP cleaning by air
01.04.11 08:48
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EHEDG_Innenteil.indd 99 01.04.11 08:49

 European Hygienic Engineering & Design Group

Hygienic design in the life science industry:

strict implementation of hygienic design requirements
described by way of stainless steel furniture
A hygienic manufacturing environment is a prerequisite in life science and food & nutrition
industries in order to maintain product sterility and minimise reject rates due to contamination.
Product quality is primarily impaired by microorganisms, but also by other forms of
contamination such as particles and chemical residues. To minimise the risk of product
contamination during the manufacture, operating utilities used in the production environment
should not represent a source of contamination. The hygienic design of equipment and the
types of materials used for housings, shelves and joints require special consideration. The
EHEDG design recommendations as well as other guidelines for hygienically designed utilities
used in the food industry can be directly applied to the life science industry and are being
implemented more frequently. The fundamentals of the recommendations are described in
detail in this paper based on a qualification and optimisation tested device project on a
stainless steel utility.

Markus Keller, Department Ultraclean Technology and Micromanufacturing, Fraunhofer Institute for Manufacturing
Engineering and Automation IPA
E-mail: markus.keller@ipa.fraunhofer.de

In order for equipment materials to be suitable for use in life the manufacture and construction of equipment that
science, they must be resistant to the chemical cleaning operate in a wide variety of manufacturing sectors,
and sterilising agents implemented. Materials used in the including the food and beverage, pharmaceutical and
construction of equipment or utilities used in sensitive cosmetics, and life science industries, as well as in plants
production environments may not allow microorganisms to that make chemical apparatus, household objects and
colonise, present a food source for bacteria, or allow appliances, surgical instruments, and bar and kitchen
substances to migrate from materials into products. It must equipment.
be possible to optimally clean material surfaces.

In general, well-known materials that have been tested and

declared to be food-compatible, such as stainless steel and
a range of elastomers, plastics and lubricants, are used in
the construction of equipment used in the food production
environment. Appropriately qualified new materials will
significantly increase the current range of materials
available to manufacturing operations. The selection of
materials for manufacturing facilities with regard to minimal
contamination is a highly relevant industrial issue, but for
which there has been little research information available.
The European Hygienic Engineering & Design Group
(EHEDG) design Document 8 (Doc. 8) recommendations,
as well as other guidelines for hygienically designed utilities
used in the food industry, can be used to guide decisions
about material selection and can be directly applied to the Figure 1. Hygienically designed sink unit.
life science industry. The fundamentals of these
recommendations are described in detail in this paper using
Design details
an example of a qualification and optimisation tested
device project on a stainless steel utility. The main material
used in the example, a hygienically designed sink unit A. Doors and hinges
(Figure 1), is stainless steel-grade 1.4301 (USA AISI Type The implementation described fulfils the requirement that a
304; Japan JIS SUS 305). It is an austenitic, acid-resistant utility must be completely emptied, as stated in EHEDG
18/10 Cr-Ni-steel that is sufficiently resistant to atmospheric Doc. 8, and "to avoid the collection of liquids, as stated in
corrosion. The steel is highly polishable and can be easily DIN EN ISO 14159-1. The doors are made of double-
shaped through deep-drawing, bending, roll-forming, etc. It walled, seamlessly-welded stainless steel elements, with
is resistant to water, water vapour, humidity, food acids and sloping edges angled at 45 at the top and bottom (Figure
weak organic and inorganic acids. This material is used in 2). This enables any liquid present to drain away entirely.

EHEDG_Innenteil.indd 100 01.04.11 08:49

 Hygienic design in the life science industry 101

The three-dimensional adjustable door hinges are of

special interest: By integrating the slope as a feature into
the hinge and minimising it to a small movable pin inserted
into a bushing open at the base, liquids are able to drain
away completely and cannot collect in the hinge. Each
hinge is attached seamlessly to the door and sealed
appropriately, thus preventing liquid from penetrating the
connecting gap of the hinge. Therefore, the hinges do not
represent a contamination risk. The sealing itself is also
made of a U.S. Food and Drug Administration (FDA)-
approved silicone sealant.

Figure 3. Push2Open concept.

D. Design of the interior

The interior of the hygienic utility is constructed without any
seams (Figure 4). All rounded areas have a radius of r = 15
mm, equating to the hygienic class H3 (DIN 18865-9) and
enabling all surfaces to be easily cleaned.

Figure 2. A close-up view of the sink unit's door and hinges shows
how hinges are seamlessly attached to prevent liquid from
penetrating the connecting gap of the hinge.

B. Sink and plughole

The sink is rounded with a radius of r >3 mm and thus fulfils
EHEDG Doc 8 requirements. The plughole has been
lasered directly into the sink to avoid any seams. The
Figure 4. Design of the sink unit's interior allows construction
edges of the sink also are appropriately sloped to enable
without seams
liquids to drain directly into the sink, minimising the amount
of horizontal surface area. This fulfils the EHEDG Doc. 8
hygienic design requirement regarding the ability to empty
a utility completely.

C. Opening and closing the doors

The novel Push2Open concept needs further improvement
as the tiny gap between the cylinder and the housing walls
is very difficult to clean (Figure 3). The markings drawn by
electrolysis in the doors are completely planar and have a
surface roughness of <0.8 m, facilitating cleaning
throughout the unit. When pressed lightly on the marked
"push" area, the doors open gently. The Push2Open fitting
also serves as a lock when the doors are closed. Avoiding
the movement of the cylinder and using a fixed magnetic
connection will improve cleanability extensively.

EHEDG_Innenteil.indd 101 01.04.11 08:49

 102 Hygienic design in the life science industry
E. Hygienically designed canopy
Hygienic cupboards generally have a slanted canopy or
protruding edge with a 30 slope. Particles and liquids are
unable to collect on it. A drip edge prevents liquids from
penetrating into the interior.
Figure 5. A sloped canopy helps prevent particles and liquids from
collecting on the surface.
F. Shelves
The shelves of the sink unit are also double-walled and
seamlessly welded. The welded seams have been
subsequently polished to ensure a uniform surface quality.
Bearing pins are inserted into cut-outs in the shelves and
have a rounding radius of >3 mm, thus fulfilling EHEDG
Doc. 8 requirements (Figures 6 and 7). The stainless steel
pins can be thoroughly cleaned, and because they can be
unscrewed easily if required, the surface to which the pins
are attached also are accessible for cleaning.
Figure 6. Cut-outs in the shelves fulfil EHEDG Doc. 8
requirements.
EHEDG_Innenteil.indd 102
G. Glazing
As standard configuration, the stainless steel doors are not
fitted with glazing; however, for better control of the interior,
glazing can be realised using safety glass. These optional
safety glass elements are planar with the surface and are
sealed all the way round with an FDA-approved sealant
material.
Figure 7. Glazing utilises safety glass elements that are planar,
thus enhancing cleanability of the sink unit
Summary
As a result of these construction features, the stainless
steel utility has been declared suitable for use in clean and
hygienic manufacturing areas by Fraunhofer IPA. The
assessment is based on a high-level ability to effectively
clean and disinfect the representative stainless steel sink
unit, which is reported in the corresponding tested device
documentation.
Acknowledgement
This tested device project was supported by
Friedrich Sailer GmbH, Neu-Ulm
01.04.11 08:49
 European Hygienic Engineering & Design Group

New ultra-hygienic synchronous drum motor drive

In September 2010, Interroll launched the worlds first-ever synchronous drum motor conveyor
belt drive using sensor-less control technology and designed according to EHEDG
recommendations for the food processing industry.

Lorenz G. Koehler, Interroll Corporate Marketing

E-mail: l.koehler@interroll.com

Interroll produces up to approximately 150,000 drum Therefore, all external surfaces such as the shell, end
motors per year for the material handling sector, a large housings and shafts had to be machined to very fine
proportion of which are designed for use in the food tolerances with smooth and rounded edges, without any
processing industry. The new SN062D conveyor belt drive crevices or catchment areas where trapped water could
offers engineers and conveyor manufacturers, food breed harmful microorganisms such as Salmonella or
processing equipment producers and end users with a high Listeria. For the same reasons, no metal-to-metal contact
torque, eco-friendly energy saving drive solution for food was allowed between any of the external components.
processing, packaging, dynamic weighing and logistics.
The result, a Synchronous Drum Motor, is a compact,
Hygienic design as ultimate aim single-component, easy-to-install drive solution for food
processing conveyors and equipment. It requires no
Before the new drum motor project even began, Interroll maintenance and meets the most stringent hygiene and
invited EHEDG consultant engineers to help with the basic material handling demands being totally enclosed and
design concept of the SN062D thus making sure the final easily fitted inside the conveyor frame.
product would be exactly what is needed for hygienic
production. For food processing and pharmaceutical applications, the
Synchronous Drum Motor was designed not only in
The new hygienic design specified that water, debris and accordance with European Hygienic Engineering & Design
soiling should be able to fall away efficiently during running Group (EHEDG) recommendations, it also only uses
operation and that the drum motor should 26.10.10
be easy 13:12
to clean materials approved by EC regulation 1935/2004, the U.S.
DM_HYGIENE_EHEDG_176x117.6mm_en_- Seite 1
using accepted cleaning and disinfection methods.

100 % hygiene
and cleanability
for safe food processing
Drum Motor
conveyor belt drives

l 30 % quicker cleaning cycles

l IP66 sealing protection
I NT E R ROLL l EC1935/2004, FDA, ECOLAB
F R DE RTEC H N I K GM B H l Zero maintenance
+49 2193 23 0
DE.SALES@INTERROLL.COM INTERROLL.COM

EHEDG_Innenteil.indd 103 01.04.11 08:49

 104 New ultra-hygienic synchronous drum motor drive
Food and Drug Administration (FDA) and NSF
International, and which could be cleaned and disinfected
according to ECOLAB recommendations.
Synchronous Drum Motor from Interroll
The shaft sealing system also came under scrutiny. In the
past, as a protection against high-pressure water cleaning,
external labyrinth seals were used. However, this type of
seal can retain minute amounts of soiled water and this can
become a source of contamination. If re-greasable seals
were to be used, the grease itself would become
contaminated, so a completely new sealing system had to
be developed.
This resulted in a new, IP69k open and easy-to-clean
sealing system which ensures the new Synchronous Drum
Motor is unaffected by dust, water, steam or high-pressure
cleaning.
EHEDG_Innenteil.indd 104
Optimised performance for food processing
In addition to the benefits of hygienic design, the
engineering of the Synchronous Drum Motor offers energy
savings of at least 30% and efficiencies to end users in the
food processing sector. The drive operates at a precise
velocity even at extremely high or ultra low speeds. It has a
consistent torque and a sensor-less controlled speed range
from 0.0015 to 4.4 m/s.
The low speed range is ideal for products in a slow-moving
conveyor process, such as foods that are manually
handled, cut, trimmed, de-boned, glazed, blanched,
defrosted, baked or frozen. The fast-speed range is perfect
for conveying materials with high throughputs in automated
packaging, dynamic weighing, high-speed food processing,
logistics and distribution centres.
Synchronous Drum Motor with hexagonal shell and plastic
sprockets
The power loss of the Synchronous Drum Motor is
extremely low (only 9%). The effect of this is that the
motors operate with a maximum shell temperature of 45C,
even at full rated power. With these new motors; chocolate
coatings, dairy and egg products and other perishable
goods like meat or fish can be transported at much lower
temperatures, thus reducing the possibility of proteins
sticking to the drum surface.
A
av
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01.04.11 08:49
 New ultra-hygienic synchronous drum motor drive 105

Universal torque transmission and sensor- The new Synchronous Drum Motor can also be supplied
less control technology support hygienic with an absolute encoder, resolver or other feedback
system to provide servo-drive operation. The feedback
operations system provides fully automated and accurate control over
torque, speed, acceleration and precise positioning, and is
Since the trend in material handling control systems today
suitable for applications requiring intermittent movements
is towards decentralisation, the SN062D is designed with a
on conveyor systems for pick and place, filling, cutting, and
new sensor-less frequency converter with ASi interface that
discharge operations.
is mounted close to the drum motor. It provides full control
of material throughputs, regardless of the load and without
the need of a feedback system.

Decentralised control allows individual motor controllers to

be set up and easily isolated, enabling smaller zones and
equipment to be maintained and serviced without shutting
down the whole system.

A complete selection of the finest seals ...

available from Trelleborg Sealing Solutions your one-stop shop.
Trelleborg Sealing Solutions offers an outstandingly comprehensive sealing portfolio for static and dynamic seals, scrapers and bearings providing the
best in elastomer, thermoplastic, PTFE and composite technologies, compliance with Reg (EC) 1935/2004, FDA, USP, 3-A or ISO 10993-5; our solutions
are featured in virtually every application conceivable within the pharmaceutical and food industry.

Your Partner for Sealing Technology

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EHEDG_Innenteil.indd 105 01.04.11 08:49

 European Hygienic Engineering & Design Group

Simply simple: hygienic design in filling technology

Hygiene is the top priority in the food and beverage industries. Anything related to product
processing must meet best practice requirements in hygienic design and the best solutions
generally tend to be simple rather than complicated.

Ludwig Clsserath, KHS GmbH, Planiger Strasse 139-147, 55543 Bad Kreuznach, Germany
E-mail: ludwig.cluesserath@khs.com

Figure 1. Filler carousel in hygienic design

Common sense, market requirements, legislation and in-
dustrial regulations demand that great emphasis is placed
on best hygiene practices in the production and processing
of food and beverages. This particularly applies to all im-
plemented machines, systems and components. They must
be designed in such a way that contaminants and microor-
ganisms cannot accumulate or can be easily removed from
the surfaces of such devices. This is the fundamental prin-
ciple of hygienic design, the main goal of which is optimum
food safety for final product consumers .
It goes without saying that producer competitiveness is also
important. From the economic perspective, hygienic design
not only pays off because microbiological risks are either
eliminated or significantly reduced, but also because it
means machines and their components can be cleaned
quickly and easily. Short cleaning cycles mean longer pro-
duction times and increased efficiencies of line equipment,
which in turn means less cleaning media and lower energy
consumption.
Right from the start development engineers should take all
of these aspects into account when designing new ma-
chines. A firm rule is that, without a holistic approach, there
can be no such thing as an optimum hygienic design. When
developing a product, it is necessary to ensure at each
stage that machine functions are designed in accordance
with the principles of hygienic design and do not allow har-
bourage of microorganisms. It must be possible to sanitise
and sterilise all surfaces quickly. The modern, computer-
controlled filling systems on the market today satisfy these
very high requirements. Typically, they feature smooth,
fairly simple surfaces, aseptic sealing, easy access for
cleaning and disinfecting procedures, and an unobstructed
runoff of liquids.
From mechanical to computer-controlled
filling systems
A few developmental stages in the history of filling technol-
ogy were needed to achieve the optimum hygienic design

EHEDG_Innenteil.indd 106 01.04.11 08:49

 Simply simple: hygienic design in filling technology 107

of today. For example, in the purely mechanical filling sys- area). Ideally, pneumatic pilot valves also should be placed
tems of previous decades, the entire filling process was outside the hygienic area in closed, easy-to-clean stainless
regulated by mechanical elements, such as switch levers, steel housings.
switch plungers, cams and controllers that were actuated
by machine rotation. High complexity thus prevailed in the
immediate vicinity of the products themselves (critical zone
A, see box Hygienic design: a European standard, p. 00),
with crevices and niches where beverage residues and
microorganisms could accumulate. Consequently, time-
consuming and costly manual cleaning procedures had to
be carried out, even to the point of dismantling individual
components.

In first-generation pneumatic filling systems, the switch

levers and plungers were replaced by pneumatic cylinders.
Membranes and expansion joints transferred the force from
the cylinders to the product area. As a result, components
could no longer move from the outside into the product
area. However, there were still some filling valve compo-
nents, springs and guide parts in the beverage passages,
which meant that.critical areas requiring more thorough
cleaning also existed. Modern, entirely computer-controlled
filling systems provide the optimum hygienic design solu-
tion, not only inside where the filling valves are located, but
also externally. An excellent example of this is the com-
puter controlled KHS Innofill DRV volumetric filling system,
which can process the entire range of plastic bottle shapes
and sizes from 0.1 L to 5 L. In essence, there are three
design concepts realised in this system that optimise the
hygienic aspects of its operation:
1. Tubular ring bowl with no corners and crevices.
The filling system has a tubular ring bowl with filling valves
flanged to a separate valve support system outside. The
advantages are that there are no corners and crevices, and
liquids always flow to the deepest point, which is ideal for
clean-in-place (CIP) and sterilisation-in-place (SIP) proc-
esses. Another benefit includes lower costs since less
energy is required during the heating and cooling phases
thanks to the comparatively smaller amount of material
used versus the thick-walled rectangular container. Finally,
the lightweight construction of the tubular ring bowl lessens
the drive forces necessary, which in turn reduces energy
consumption and the cost of maintenance.
Figure 2. The membrane (right) simultaneously performs four
sealing functions of the conventional rod seals in the gas cylinders
(left).
3. Filling valve designed to improve product runoff.
The filling valve has open rod guides for the neck ring
holder and smooth external surfaces and sloping surfaces
on the gas cylinders, specifically designed to aid product
runoff. All internal sealing systems are aseptic. There are
no springs or guide parts inside the beverage passages. A
single seated seal opens and closes the filling valve (Figure
2). The advantages are that there are no spaces in which
deposits can accumulate; cleaning and sterilisation are kept
simple. All passages through the filling valve are short,
which means that very few parts and only small surfaces
are exposed to the product (Figure 3). Swirlers are used to
fill the product. The filling principle is that once the filling
valve opens, the liquid flows down the walls into the plastic
bottle. The benefit is that there are no radiating elements
protruding into the bottle.

2. Control concept with few switching elements.

The control concept has been kept simple and operates
with only a few switching elements. For example, only two
pneumatically controlled functions per filling valve are
needed for the traditional method of filling carbonated soft
drinks. They control the entire filling process, including the
pressing stroke and sealing the bottle mouth against the
filling valve. It is possible to use very few control functions
and dispense with a lifting element because the energy
resulting from pre-pressurising and from the filling pressure
is transmitted directly to the neck ring holder by expansion Figure 3. The use of fewer components helps reduce the risk
posed by gaps and carryover into the product area (colored blue)
joints designed in accordance with aseptic design criteria.
through sliding seats.
This means that there is no need for bottle-lifting elements
nor the associated components and controllers for supply-
ing air and lubricants. The general principle is that the
fewer the pneumatically actuated membrane cylinders
used, the fewer mechanical elements and hose connec-
tions required (i.e., always located outside the hygienic

EHEDG_Innenteil.indd 107 01.04.11 08:49

 108 Simply simple: hygienic design in filling technology
Figure 4. Many hygienic design components are combined in the
KHS Innofill DRV filling system.
The gas passages are equally simple in their design. Gas
cylinders with gapless sealing systems control the filling
process. The targeted cleaning of the process passages is
also computer controlled.
Example innovations
The key to enhancing the hygienic quality of food process-
ing equipment means taking a common-sense approach to
innovative engineering. The Innofill DRV filling machine is a
good example of these types of innovation while at the
same time adhering to the classic principles of hygienic
design.
Expansion joints
The individual elements integrated into the filling system
must be re-evaluated time and again to achieve the most
optimum hygienic design possible. An example of a new
development further enhancing the hygiene of the Innofill
DRV is the aseptically designed expansion joints. This
means the lifting elements and associated peripheral ele-
ments can be completely eliminated since the expansion
joints transmit the pressure through an aseptic passage
inside the filling valve to the bottle pressing mechanism.
The principle here is that the expansion joints are made of
polytetrafluoroethylene (PTFE), a special durable material
which is highly resistant to hot temperatures, fully resistant
to cleaning media and disinfectants, and has a dirt-repelling
surface structure. Cleaning agents flow through the expan-
sion joints tangentially during CIP cleaning, thereby ensur-
ing optimum dirt removal and discharge. This is verified
both in practice and in numerous laboratory experiments
based on European Hygienic Engineering & Design Group
(EHEDG) specifications and simulating extreme contamina-
tion after applying, for example, beer concentrate or carrot
puree to expansion joints and then allowing it to dry.
EHEDG_Innenteil.indd 108
Hygienic design in brief
According to the definition of the German Society for
Hygiene and Microbiology, hygiene is the doctrine of
disease prevention and the maintenance and promotion
of health. The concept of hygiene originally comes from
Greek and goes back to Hygeia, the goddess of health.
Nowadays, in issues concerning the highest standards
of hygiene, the prime focus is on the food production
industry. Practical application of these standards chiefly
entails implementing hygienic design in machine and
plant engineering. The main principles are
- simple design rules,
- easy access to all machine surfaces for cleaning,
disinfection, and inspection,
- dispensing with machine surfaces wherever possible,
- eliminating hidden areas where deposits and biofilms
can accumulate, and
- the unobstructed runoff of liquids.
New probe solution
Another example of a single development that now ensures
even greater hygiene is a new probe inside the KHS Innofill
DRS filling system. Previously, complex elements and seals
were needed for the necessary separation of the electric
plus and minus poles of a control signal. Now a stainless
steel rod is implemented that separates the poles by means
of a permanently attached insulation coating, making these
areas completely gap-free.
No machine front table
Another highly important factor in terms of enhanced hy-
giene is that, today, filling can be done entirely without the
traditional machine front table (Figure 4). This is thanks to
servo technology with individual drives, which dispenses
with the need for gearboxes, large gear wheels and joint
shafts.
Seals with no gaps
Seals or membranes are necessary everywhere: in filling
valve connections, connections for pipe flanges and fittings,
and in tanks. Although normal O-rings act as seals, when
they are inserted into traditional grooves, they often leave
gaps, creating the perfect niche for product residue and
microbes. This problem is solved by designing O-ring
grooves in such a way that the O-rings slot straight into the
grooves. There are then no more gaps.
Design principles
Smooth welding of pipes and sheet metal structures is a
must. Any uneven surface or misalignment conceals the
risk of contamination. An equally simple hygienic design
solution for the filling area is to slope surfaces, allowing
liquids to drain away. This prevents sumps and deposits
forming in the first place.
01.04.11 08:49
 Simply simple: hygienic design in filling technology 109

From rinsing sleeves to switchover

Humans are a source of contamination and persistent dan-
ger, and automation is key to reducing risk. For example,
instead of inserting rinsing sleeves manually before clean-
Aseptic Safety
ing, the rinsing caps are now positioned automatically in
plastic bottle filling systems. Conversion to a new filling Aseptomag AG specializes in aseptic and hygienic
method, for example, from normal pressure filling to coun- process engineering. In cooperation with our
terpressure filling, now takes place automatically; switching
clients, we develop specific and innovative solutions
between bottles with different mouth shapes can be done at
the push of a button. All of these measures not only result for the food, beverage, pharmaceutical and
in maximum hygiene and optimised hygienic design, they cosmetics industries. Our goal is the complete
also allow for increased system accessibility assistance and support of our clients before, during,
and after the initial installation and operation of
a plant. Thereby our clients may benefit from our
Hygienic design: a European standard
4 main areas of expertise:
European standard DIN EN 1672-2 (hygiene require-
ments for food processing machinery) identifies different
hygiene areas for machines and systems that are ex-
posed to food. Technical solutions must be based on
these standards. Most importantly, hygienic design must Valve Technology
be consistently implemented in zones A and B.
Zone A: Concerns the foods themselves, from where
contaminated products could get back into
the product mainstream. In the beverage in-
dustry zone A could include piping and tanks,
in which products flow, or the area around
the filling valves in the immediate vicinity of
Module Building
open bottles or cans.
Zone B: The spraying area, from where products can
no longer get back into the product main-
stream via a direct route. However, since
product sprays can also stimulate the growth
of microbes, there is a danger that germs will
Engineering
enter zone A. Zone B includes, for example,
machine cladding and star shafts.
Zone C: This is the non-food zone outside danger
zones A and B. It includes, for example, the
outer area of the filler housing, and also the
bottle conveyors located in front of it. Service & Support

Effective hygienic design saves time and

money

Above all, hygienic design means one thing: implementing

simple solutions, which generally lead to a cut in costs. As
a rule, the consistent, practical application of hygienic de-
sign makes systems more efficient. On the one hand, this is
thanks to cleaning processes that can be carried out more Aseptomag AG
simply and quickly; on the other, this is thanks to less com- Industrie Neuhof 28
plex technical solutions, and therefore, minimal use of wear CH-3422 Kirchberg
parts. Ultimately, these numerous benefits give the food Tel. +41(0)34 426 29 29
and beverage industries a clear competitive advantage. Fax +41(0)34 426 29 28
This is a victory for common sense. info@aseptomag.ch

EHEDG_Innenteil.indd 109 01.04.11 08:49

 European Hygienic Engineering & Design Group

Key to quality
Orbital welding technology for the highest quality standards

Schnee PR, Polysoude Press Relations, Frank Schimpf, Krones AG, Flensburg
E-mail: a.husson@polysoude.com

seam roots end flush with the internal pipe wall and there is
minimal heat input with the lowest levels of oxidation, which
can be removed easily by etching if necessary.

The open welding heads of the MU type are very compact

and are used for tube/tube welding of medium wall thick-
nesses. Closed welding heads of the MW type also are
used for tube/tube welding with high duty cycles, and the
TS welding heads join tube to tube-sheet. In order to obtain
and maintain optimum quality results, these welding proce-
dures comply with the European Hygienic Engineering &
Design Group (EHEDG) guidelines, as well as with several
national and international rules.

A perfect result

When compared with conventional machines, the logging

process and its significance prove to be considerably better
and X-ray, as well as destruction tests, show that documen-
tation and reality go hand in hand. Even with more than
100,000 welds per year, there has not been a single com-
plaint, and customers value the possibilities offered by this
new P4 Power source for documenting the joining process.

For the full story on the Polysoude and Krones partnership,

please visit the online edition of Stainless Steel Focus at
www.stainless-steel-focus.com, and view the October 2010
Polysoude closed chamber welding head type MW.
article, Modern orbital welding technology for the highest
quality standards.
Systems for the filling and packaging industry in food, bev-
erage and pharmaceutical production are successful and
powerful machines if they are built to comply with the high-
est quality criteria. This includes procedures and compo-
nents that ensure hygienic design.

Continual investment in the latest welding technology is

one of the key factors for quality, for instance as used by
Krones. Everything that is produced here has to be welded
and it has to be extremely high quality complying with the
companys high purity standard. Special attention is paid
to the stainless steel parts of the system that touch the
product to maintain cleanability. The proportion of auto-
mated tungsten inert gas (TIG) orbital welding has in-
creased steadily. For this, Krones and other manufacturers,
rely on orbital welding technology.

In order to get away from traditional manual TIG welding,

the welding process, for tube assembly in particular, is
being increasingly automated by orbital welding systems.
Only in this way can the quality be repeatedly produced
while at the same time ensuring high levels of efficiency.
The systems from Polysoude have a significant impact on
quality, and only automated orbital welding delivers the
smooth weld seams required for adequate cleaning. The

EHEDG_Innenteil.indd 110 01.04.11 08:49

 THE ART OF WELDING

"Polysoude, the specialist in orbital welding technologies"

User friendly - A perfect weld every time

Hire fleet - Hire from our extensive range, ready for immediate delivery

www.polysoude.com
EHEDG_Innenteil.indd 111 01.04.11 08:50

New sensor concepts for the packaging industry
Christoph Mller, Business Unit Manager, SICK AG, Waldkirch, Germany
E-mail: christoph.mueller@sick.de
The major trading chains ever-increasing demand for
longer use-by dates for packaged foods is one of the food
industrys greatest challenges. The microbiological load of
packaged foods must be reduced in order to achieve longer
shelf life, which in turn, has a direct effect on packaging
and cleaning processes, as well as on the design of
machinery. At the same time, the constant pressure on
food and beverage producers to realise cost savings
through production efficiencies requires considerably
quicker machinery setting up times when switching
between types or sizes of packaging, as well as higher
packaging plant cycle speeds.
Figure 1. Hygienic sensor portfolio for filling and packaging
machines level sensors LFP and LFV200, hygienic pressure
transmitter PHT
Food producers can meet both challenges simultaneously
by using coordinated modern sensors that meet hygiene
standards, possess robust electronics and offer more
efficient communication functionalities. The W4S-3 Inox
family of photoelectric switches and the LFP filling level
sensor are good examples of these optimised, hygienically
sound sensor technologies.
Coordinated modern sensors combine the classic
requirements of factory and process automation to gain the
advantages of both. Process automation requires the use
of robust materials in the sensors construction (such as
stainless steel, which meets the high demands of harsh
environments); the ability of the device to generate output
signals via a single binary signal, and good cleanability in
order to achieve the accepted hygiene certificates for the
process side (such as those issued by the European
Hygienic Engineering & Design Group [EHEDG]).
Factory automation provides benefits such as miniaturised
housings, easy device selection, simple commissioning and
operation, rapid sensor reaction times, and remote
parameterisation, along with the ability to meet housing
cleaning standards and IP69K rating tightness levels. By
combining these requirements in sensor technologies,
EHEDG_Innenteil.indd 112
European Hygienic Engineering & Design Group
synergystic potentials can be better exploited in the
construction, commission and daily operation of filling
plants and packaging machines and microbial safety can
be better assured.
Good sensor construction and better
communication helps reduce microbial loads
Reduction of microbiological loads in packaged food
products to extend shelf life and provide greater assurance
that final products are safe to consume can be achieved
through the use of appropriately constructed sensors. The
shortening of commissioning processes, cycle and
equipping times can be further enhanced when the sensors
are coordinated with comprehensive operating, connection
and communication concepts from a single source.
In the case of the W4S-3 Inox family of photoelectric
switches, 316L stainless steel housings are used and all
external surfaces are extremely smooth due to production
using metal injection moulding (MIM). These switches also
exploit several innovations to ensure enclosure ratings of
IP69K and durable optimum cleaning, even with aggressive
detergents. The user element, for example, is a flexible
laser-welded stainless steel membrane that essentially
melts into the stainless steel housing, which ensures a
high level of cleanability. In addition, the sensors front
screen is equipped with a special quartz coating and can
be precisely adapted to the housing. The coating, as well
as the special gluing of the front screen, provides
resistance against cleaning agents containing up to 30%
hydrogen peroxide. The sensor also sets new standards in
the detection of transparent objects, increasing the
availability of filling and packaging machines through
efficient teach-in capability and automatic switching
threshold adjustment. Some sensors have the accepted
hygiene and cleaning certificates issued by industry
organisations such as EHEDG, ECOLAB and Johnson
Diversey.
Figure 2. IMF Inductive sensors: Robust and powerful
01.04.11 08:50 10263_P
 www.marschner-kuehn.de

Robust. Hygienic. Flexible.

LFP the clean solution for level monitoring

Lowers costs and delivers new ideas

The innovative hygienic LFP level sensor opens new horizons in the food, pharmaceutical and
packaging industries. According to the principle of guided radar, the LFP functions almost inde-
pendently of the properties associated with the liquid to be measured. The intelligent mount-
ing concept offers maximum flexibility. The LFP comes with a high enclosure rating of IP 69K
and fulfills the requirements specified in current hygiene certification such as that provided by
EHEDG.

SICK AG | Waldkirch | Germany | www.sick.com

EHEDG_Innenteil.indd 113
10263_Produktanzeige_LFP_210x297_EN_wf.indd 1 01.04.11
21.01.2011 08:50
14:19:52
 114 New sensor concepts for the packaging industry

The hygienic design benefits of combining factory and

automation process parameters in coordinated sensor
technology also can be seen with the LFP hygienic filling
level sensor. With a housing diameter of just 54 mm, the
LFP sensor works on the principle of guided radar (time
domain reflectometry), which makes it nearly independent
of the properties of the liquid to be measured, and thus
requiring no re-parameterisation when a liquid is changed.
The sensor has one analogue output signal and two
switching points, allowing more efficient control concepts to
be achieved with a lower number of sensors and thus Figure 3. MH15V Photoelectric Sensor Series for Food & Beverage
with reduced cleaning effort. The LFP also has an IO-Link, 100 % stainless steel in shortest housing
a simple producer-independent communication protocol
that provides remote parameterisation and diagnosis of
errors. As is the case for the W4S-3, the sensor is designed
in 316L stainless steel and has an enclosure rating of
IP69K as well as the common hygiene certification. Use of
a state-of-the-art measurement process allows standarddi-
sation to one device family and reduces limitations
regarding mounting requirements.

The current challenges for packaging and filling processes

can thus be met using a new generation of sensors that
take a comprehensive technical approach. In this way, the
classic advantages of both factory and process automation
Figure 4. W4S-3 Inox Hygiene Miniature Photoelectric Sensor
are combined, corresponding to the hybrid nature and Family Applications in Food and Beverage with high hygienic
needs of the packaging industrys applications. requirements
AP Be?cot AnnoncePresseA5 GB:Plaquette AP Bcot06-A 8/09/10 16:15 Page 1

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Equation Impression - Angers - Illustrations D. Benoist - september 2010

Parc dactivits - CS 20012 - Rue du Chne Vert

49184 St-Barthlemy d'Anjou - Tel. 02 41 43 60 20
Fax 02 41 43 05 99 - E-mail: anjoupompes@anjoupompes.fr
www.anjoupompes.fr

EHEDG_Innenteil.indd 114 01.04.11 08:50

 European Hygienic Engineering & Design Group

EHEDG Regional Sections

Chairmen and contacts

The Regional Sections are a local extension of the EHEDG JAPAN

and are created to promote hygienic manufacturing of food x Takashi Hayashi Kanto Kongoki Industrial Ltd.
through regional activities. EHEDG has established Phone: (+81 3) 39 66-86 51
Regional Sections in various countries in Europe and E-mail: hayashi@kanto-mixer.co.jp
overseas. These groups organise local meetings, courses
x Hiroyuki Ohmura
and workshops.
JFMA The Japan Food Machinery Manufacturers'
Association
ARMENIA
Phone: (+81 3) 54 84-09 81
x Professor Dr. Karina Badalyan
E-mail: ohmura@fooma.or.jp
Armenian Society of Food Science and Technology
(ASFoST)
MACEDONIA
Phone: (+374 10) 55 05 26
x Professor Dr. Vladimir Kakurinov
E-mail: foodlab@inbox.ru
Food Institute, Faculty of Agricultural Sciences and
x Dr. Suren Martirosyan Food
Armenian Society of Food Science and Technology Phone: (+389 070) 688-652
(ASFoST) E-mail: kakurinov.vladimir@gmail.com
Phone: (+374 10) 56 40 29
E-mail: surmar.3137@gmail.com NETHERLANDS
x Jacques Kastelein
DENMARK TNO Kwaliteit van Leven
x Jon Kold Phone: (+31 30) 6 94 46 85
Stlcentrum Denmark E-mail: jacques.kastelein@tno.nl
Phone: (+45 88) 70 75 15
x Wouter Burggraaf (Interim Chairman)
E-mail: jon.kold@staalcentrum.dk
Burggraaf & Partners B.V.
Phone: (+31 578) 5 76 99 9
FRANCE
E-mail: wna.burggraaf@burggraaf.cc
x Nicolas Chomel Laval Mayenne Technopole
Phone: (+33 243) 49 75 24
NORDIC (FI, N, S)
E-mail: chomel@laval-technopole.fr
x Dr. Gun Wirtanen
x Erwan Billet Hydiac VTT Technical Research Centre of Finland
Phone: (+33 61) 2 49 85 84 Phone: (+358 20) 7 22-1 11
E-mail: erw.billet@infonie.fr E-mail: gun.wirtanen@vtt.fi
x Salwa El Janati Lactalis RD x Salo Satu VTT Technical Research Centre
Phone: (+33 243) 59 52 18 Phone: (+358 20) 7 22 71 21
E-mail: salwa.eljanati@lactalis.fr E-mail: satu.salo@vtt.fi

GERMANY POLAND
x Hans-Werner Bellin x Dr. Matuszek, Tadeusz Gdansk University
BELLIN Consult Phone: (+48 58) 3 47 16 74
(+49 6120) 37 73 E-mail: tmatusze@pg.gda.pl
hans-werner.bellin@bellinconsult.de
RUSSIA
x Dr. Jrgen Hofmann
x Professor Dr. Mark Shamtsyan
TU Mnchen / Wissenschaftszentrum Weihenstephan
St. Petersburg State Institute of Technology, Russia
Phone: (+49 8161) 8 76 87 99
Equation Impression - Angers - Illustrations D. Benoist - september 2010

Phone: (+7 960) 2 72 81 68

E-mail: jh@hd-experte.de
E-mail: shamtsyan@yahoo.com
ITALY
SPAIN
x Dr. Giampaolo Betta University of Parma
x Andrs Pascual AINIA Centro Tecnolgico
Phone: (+39) 5 21 90 62 34
Phone: (+34 96) 13 66 09 0
E-mail: giampaolo.betta@nemo.unipr.it
E-mail: apascual@ainia.es
x Irene Llorca / Rafael Soro AINIA
E-mail: illorca@ainia.es / rsoro@ainia.es

EHEDG_Innenteil.indd 115 01.04.11 08:50

 116 EHEDG Regional Sections

SWITZERLAND More EHEDG Regional Sections are in the process of

x Matthias Schfer being formed. These are:
GEA Tuchenhagen GmbH Switzerland x Belgium
Phone: (+41 61) 9 36 37 40 x Bulgaria
E-mail: matthias.schaefer@geagroup.com
x Canada
x Croatia
TAIWAN
x Dr. Binghuei Barry Yang* x Lithuania
FIRDI Food Industry Research and Development. x Portugal
Phone: (+886 6) 3 84 73 01 x Romania
E-mail: bby@firdi.org.tw x Serbia
x Slovakia
THAILAND x South Africa
x Dr. Navaphattra Nunak x Turkey
King Mongkut's Institute of Technology, Bangkok x USA
Phone: (+66 2) 7 39 23 48
E-mail: kbnavaph2@yahoo.com

UKRAINE
x Professor Yaroslav Zasyadko
National University of Food Technologies, Kyiv
Phone: +38 044-287 96 40
E-mail: yaroslav@usuft.kiev.ua
x Professor Sergey Fedosov
Odessa National Academy
Phone: (+38 48) 7 12 40 17
E-mail: fedosov@optima.com.ua

EHEDG Armenia
Karina 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 Environmental Protection,
State Engineering University of Armenia, Teryan 105, Yerevan 25009 Armenia, (phone: 3741054742; Fax: 37410587284;
e-mail: surmar.3137@gmail.com)

EHEDG-Armenia was created in 2010 within the framework

of Armenian Society of Food Science and Technology
(ASoFST). In October of 2009 EHEDG Conference;
Hygienic design and operation of food factories was held
in Armenia attended by 45 participants from 5 countries.
The most important task for EHEDG-Armenia was and is
the establishment of relations with relevant authorities to
promote the idea of hygienic design as a primary way to
increase food safety and the translation of EHEDG
Guidelines into Armenian.
At the moment, committee members have already
translated fifteen guidelines. In its own part, ASoFST, which
was created as an independent research organisation,
publicized its objectives through newsletters, promulgated
via the internet and transferred directly to food companies
and research centres. The EHEDG-Armenia section was Figure 1. Meeting in Yerevan State University
actively engaged in the governmental program of
aquaculture products export from Armenia to the EU. Last Regular laboratory analyses were undertaken to verify
year, EHEDG Armenia carried out several activities to help good hygienic practices and, occasionally, to identify bad
local companies to produce food in a hygienic manner. hygienic conditions in food processing factories. For

EHEDG_Innenteil.indd 116 01.04.11 08:50


instance, microbiological tests have been carried out for
several Armenian EHEDG member companies, to
demonstrate the impact of the hygienic condition of the
surfaces of equipment in contact with food on the quality of
final product.
Workshops were organised for dry food, aquaculture, juice
and meat producing companies. In addition, seminars were
held at the Armenian branch of the UNIDO Office and at
the Food Safety Authority with the participation of food
production companies.
Figure 2. After signing the Protocols
EHEDG Denmark success from the very beginning
The Danish section of EHEDG was established in 2009. After an intensive media campaign
EHEDG Denmark is now focussing on disseminating knowledge on EHEDG and converting
Danish guidelines on hygienic design to EHEDG guidelines.
Jon J. Kold, regional chairman EHEDG, general manager Stlcentrum
E-mail: jon.kold@ehedg.dk
EHEDG Denmark was established just a little more than a
year ago on June 11th 2009. Yet the Danish chapter has
already has achieved tremendous success as a regional
section of EHEDG with a growing number of members. 43
persons / companies and research institutes had joined
EHEDG Denmark by September 2010 and more are surely
to follow.
There are several reasons why this success is no big
surprise to us in Denmark.
First, food processing and agriculture are Danish industrial
strongholds comprising and Denmark is a world leader in
dairy and meat processing industry. Secondly, this
important industrial sector is supported by a large number
of companies developing and producing state-of-the-art
technology, equipment and processing plants.
EHEDG_Innenteil.indd 117
EHEDG Regional Sections 117
EHEDG Armenia keeps close ties with Armenian govern-
mental and NGOs concerned with food manufacturing and
processing (meeting and corresponding with key players,
etc.).
Eight organisations and laboratories from research
institutes and universities became members of ASoFST.
In August of 2010, EHEDG-Armenia was included in a risk
estimation group under the auspices of a governmental
science committee. Activities to establish a consortium of
Armenian researchers in the field of food science and
technology within the ASoFST are already underway.
Articles on the objectives and tasks of EHEDG Armenia
were published in the local journals SPAROGH and
PLANETA. Our organisation will be represented at the
PRODEXPO exhibition to be held in October, 2010.
For more information: asofst@gmail.com
A number of leading research laboratories and industrial
networks related to food production should be added to this
scenario, which is witnessed by the fact, that high Danish
food quality standards have made the hygienic design of
food processing equipment a hot issue in Denmark for
several years.
Communication and media
During the first year EHEDG Denmark successfully
established good media relations leading to articles in
professional papers and magazines.
The next step in strengthening EHEDG Denmark will be an
intensive media campaign to persuade food manufactures
to join EHEDG and work together with industry on hygienic
01.04.11 08:50
 118 EHEDG Regional Sections
design issues for new equipment. The campaign will also
strengthen the knowledge of EHEDG and EHEDG
Denmark amongst Danish professionals.
In the future EHEDG Denmark will continue its focus on
media relations as well as contributing to seminars and
conferences. Recent activities included two seminars at the
trade fair FoodPharmaTech 10, which was held in the
biggest centre for fairs and exhibitions in Scandinavia,
MCH Messecenter Herning, Denmark from November 2nd
to November 4th 2010.
The seminars were hosted in collaboration with the
association Staalcentrum, Processing Equipment for the
Food Industry.
The themes are:
x Test methods for hygienic design
x Efficiency by Hygienic design
An upcoming activity is translating the EHEDG website into
Danish to facilitate contact with the many small and
medium-sized companies in Denmark.
Six Danish guidelines
The main driving force in establishing EHEDG Denmark
was the industrial association Stlcentrum, which in 2006
published six guidelines on different aspects of hygienic
design.
EHEDG Denmark is now in the process of identifying
Danish companies to participate in converting these Danish
guidelines into official EHEDG guidelines beginning with
Guideline no. 1 on cabling and Guideline no. 3 on
conveyors.
EHEDG France has turned a new page in 2010
Nicolas Chomel, Secrtaire EHEDG France, www.ehedg.fr
E-mail: chomel@laval-technopole.fr
For its fifth year of existence, the French branch of EHEDG
renewed its Board of Directors and officers: Jean-Pierre
Descamps, consultant and trainer in hygienic design, who
chaired the launch of EHEDG France in 2006, and its
anchor in the French food industry, has yielded the
presidency to Erwan Billet, consultant and trainer in food
hygiene and member since the beginning of the original
founder group of the French association. Another
prominent figure of EHEDG France, Pascale Guerin,
Deputy Quality Director of the dairy group Lactalis, has also
ceded her seat of vice-President to her colleague Salwa El
Janati. Christophe Hermon, Director CTCPA West, was
EHEDG_Innenteil.indd 118
The Danish guidelines are:
x Guideline no. 1: Cabling and electrical cabinets
with focus on hygiene
x Guideline no. 2: Check list for purchase/sale of
production equipment with focus on hygiene
x Guideline no. 3: Conveyors with focus on hygiene
x Guideline no. 4: Stainless steel in the food industry
an introduction
x Guideline no. 5: Design of piping systems for the food
processing industry with focus on hygiene
x Guideline no. 6: Installation of components in closed
processing plants for the food processing industry
with focus on hygiene
All the guidelines may be downloaded in Danish or English
free of charge from www.staalcentrum.dk.
The Danish EHEDG Committee
Chairman
Jon J. Kold, Staalcentrum
Secretary
Henrik Classen, Danish Technological Institute
Treasurer
Bjarne Darr, GEA Liquid A/S
Members
Thomas Dring, Chr. Hansen A/S
Ulla Stadil, Novozymes A/S
Niels Fielse Pedersen, Grundfos A/S
Peter Uttrup, Interroll A/S
Kjeld Bagge, AVS Denmark ApS
Bo Boje Busk Jensen, Alfa Laval A/S
Per Vggemose Nielsen, IPU / DTU
elected second vice president. Nicolas Chomel (Laval
Mayenne Technopole) retains his position as Secretary of
the association and Olivier Dagoreau (Exaris) the role of
Treasurer.
In 2010, the new president wanted to include the
recognition by French food companies in the ongoing
consolidation of the EHEDG. A meeting was held in early
July with the ANIA (National Association of food industry) in
order to consider closer collaboration.
01.04.11 08:50

Figure 1. The new board of EHEDG France: from left to right
Top: Erwan Billet (Hydiac, president), Christophe Hermon (CTCPA,
Vice-president), Bottom: Olivier Dagoreau (Exaris, treasurer),
Salwa El Janati (Lactalis, Vice-President) and Nicolas Chomel
(Laval Mayenne Technopole, Secretary).
EHEDG France continued its work, including dissemination
of technical information. Almost the entire collection of
EHEDG Guidelines has been translated in French, and
more than 70 documents have been sold (mainly as PDFs)
during the year. The diffusion of information also occured
through conferences organized by the association.
Three periods are now becoming scheduled rendezvous:
x In mid March, at the occasion of the CFIA (the Agri-
Food Industry Suppliers Meeting-place) in Rennes,
x At the end of March, with the annual meeting of EHEDG
France members in Laval,
x In November with the EHEDG France autumn
conferences in the Laval University of Technology.
EHEDG Germany
Dr. Jrgen Hofmann, Hygienic Design Weihenstephan, Postfach 1311, D-85313 Freising, Germany
Phone +49(0)8161-8768799, E-mail: jh@hd-experte.de and
Hans-Werner Bellin, BELLINconsult, Heidestr. 3, D-65326 Aarbergen,
mobile Phone: +49 (0)151/42415256, E-mail: Info@BELLINconsult.de
EHEDG Germany is the Regional Section with the largest
number of members. Together with its Austrian members,
Germany has almost 60 member companies and institutes
and more than 150 Individual members, which generates
more than 40 % of the total income of the EHEDG.
The ideals of hygienic design in Germany go back to the
beginnings of the EHEDG in 1989. Since this time, a lot of
work has been done by Dr. Gerhard Hauser of the
Lehrstuhl fr Maschinen- und Apparatekunde, Technische
EHEDG_Innenteil.indd 119
EHEDG Regional Sections 119
th
Figure 2. EHEDG France autumn conference on November 25
Finally, EHEDG has initiated working groups for writing new
documents. The first one deals with the design of CIP
stations, and this document already available in French.
The document has been translated into English to be
submitted to international EHEDG experts. The second
document is entitled Considering the level of hygienic
design in open surfaces for the definition of cleaning
methods. It is compiling information regarding open
surfaces already available in the EHEDG guidelines.
Continuing this work, the French group will then collaborate
closely with the international subgroup.
Particular attention will be paid this year to the French
contribution to the international work of EHEDG: Subgroups
and ExCo meetings. Last but not least, EHEDG France will
be closely associated to the preparation of Food Factory
2012, the 6th international conference on the food factory
for the future, organised by Laval Mayenne Technopole
and SIK (Gothenburg) which will be held in Laval in July 4,
5 and 6.
Universitt Mnchen (Dept. for Machinery and
Components, Technical University Munich) and the EHEDG
showed its appreciation for his efforts over the last 20 years
by presenting him with a small gift (Figure 1). The
development of the German Group has been very much
influenced by his expertise and by the work of the institute
for whom he worked.
The Institute in Weihenstephan, famous for its research
projects in materials cleanability and the hygienic design for
machines in contact with dry materials, has been offering
01.04.11 08:50
 120 EHEDG Regional Sections
Hygienic Design courses ever since the early 1980s, and
up to 1000 Persons have been trained. The contents of
these courses are part of the EHEDG Training Toolbox,
which are now given by EHEDG Trainers all over the world,
and have greatly influenced the design of machinery used
for food processing in Germany.
Figure 1. Susanne Flenner, EHEDG Secretary honours Gerhard
Hauser for his work within the last 20 years during the HygieniCon
2010 in Karlsruhe.
The Weihenstephan institute is also an authorised EHEDG
test laboratory. With approximately 40 EHEDG components
tests giving a lot of optimisation guidance to the design and
with 20 EHEDG certificates granted in 2010 it is one of the
most active test labs for EHEDG testing.
EHEDG Italy
Italian Regional Section on the rise
Giampaolo Betta, Roberto Massini, Universit degli Studi di Parma, Dipartimento di Ingegneria Industriale
E-mail: giampaolo.betta@unipr.it
The Italian food industry, along with agriculture, related
activities and distribution, is the primary economic sector in
the country. It buys and processes about 70% of domestic
raw materials. It is also the ambassador of Made in Italy
in the world, since 76% of the food exports consists of
industrial branded products. The Italian food industry has a
turnover of 120 billion Euros, with 6,400 companies (with
EHEDG_Innenteil.indd 120
Last years highlight was the cleanability test of a diverter
valve for pneumatic conveying. This kind of equipment is
normally not cleaned unless it is dry after being
disassembled. Nowadays, however, the industry demands
CIP cleaning of pipes in powder conveying. Therefore the
equipment has to be designed in a completely different
fashion. The new innovative construction of this diverter
valve passed the cleaning in place test.
With the expansion of EHEDG certification it has been
possible to certify a conveyor gear motor including its
frequency converter. Both are often mounted directly on the
conveyor and are placed right beside the foodstuff.
Therefore these surfaces must be easily cleanable because
they need to be cleaned regularly.
The experience gained during these tests is used for the
benefit of all via further hygienic design training courses
and seminars.
Figure 2. Workshop at the meeting of the German Group during
the HygieniCon 2010
The German Section has an annual meeting, which is
linked to the HygieniCon in Karlsruhe
(www.hygienicon.com). At this meeting, the members get
the latest news about what has happened during the last
year within EHEDG and discuss new strategies.
The EHEDG website has been translated into German and
is now online. Most of the Guidelines are now available in
German and will be sold by the EHEDG webshop.
In the future, the German group. The Hygienic Design
Weihenstephan Akademie will begin additional training
which will communicate the ideals of the EHEDG mainly to
non EHEDG members. More details about courses and
their schedules are available from http://www.hygienic-
design-akademie.de/.
more than 9 employees) and with a total of 386,000
employees. Exports amounted to 19.84 billion Euros (Data
2008).
61% of total turnover is achieved in the Lombardy, Emilia
Romagna, Veneto and Piedmont regions, making this area
the most important food valley of Europe. Within this area,
the Province of Parma distinguishes itself as 23% of all
01.04.11 08:50
 Sensitive bottling
needs sensible care.

Efficiency is in our nature.

Modern food & beverage production plants need the most
up-to-date solutions for automatic cleaning to ensure consistent
production standards and optimum hygiene safety, significantly
reducing costs and the risk of contaminations. Diversey applies its
engineering expertise to the design and implementation of Bottle
Treatment, External File Cleaning (EFC) and Track Treatment,
customised to the individual requirements of every plant and
every hygiene level.

www.diversey.com

EHEDG_Innenteil.indd 121 01.04.11 08:50

 122 EHEDG Regional Sections

employees of the food industry of the entire region Emilia Translation

Romagna work in that province. The province of Parma is
home to historically consolidated food productions, such as
Prosciutto di Parma PDO, Formaggio Parmigiano
Reggiano PDO and tomato products. Parma is at the
present time the site of many well known food
manufacturers and food-equipment manufacturers groups.
In addition Parma is the headquarters of the Stazione
Sperimentale Industria Conserve Alimentari (SSICA), an
institute of research and experimentation founded in 1922.
Finally Parma is home to the European Agency for Food
Safety Authority (EFSA) and, as such, is often the
privileged site of meeting of working groups, seminars and
conferences involving top European experts.
Since 2007 Parma has also been the site of the Italian
Section of the European Hygienic Engineering and Design
Group.
Italian Regional Section
Established in 2007, the Italian Section is an initiative of
EHEDG and the Food Technology Unit of the Industrial
Engineering Department of Parma University. The Italian
Section officially started on 17 October 2007, the date of
the Hygiene Requirements and Standards for Foodstuffs
Machinery Conference, which took place at Parma at the
time of the CIBUSTEC2007 Exhibition.
Italy supports EHEDG with 5 company members (Table 1),
16 individuals and 7 members of Subgroups (Table 2).
Italian Company Members (2010)
CFT S.p.A.
CSF Inox S.p.A.
PNR Italia S.p.A.
Seital Separatori S.r.l.
Vincas S.r.l.
Table 1: EHEDG Italian Company Members in 2010
Company Subgroup
CFT S.p.A. Seals and Valves
CSF Inox S.p.A. Pumps, Homogenisers,
Dampening Devices
At the present time (September 2010) Documents 2, 8, 10,
14, 17, 34 have been translated and are hence available in
Italian language; Italian titles are shown in Table 3.
Documents 13, 20, 25 and 32 are under revision.
Doc. Title
2 Metodo di prova della pulibilit in loco (C.I.P.) delle
apparecchiature per il trattamento degli alimenti
8 Criteri per la progettazione igienica delle
apparecchiature
10 Progettazione igienica di un apparecchiatura
chiusa per la lavorazione di alimenti allo stato
liquido
14 Requisiti di igiene relativi alle valvole per la
lavorazione degli alimenti
17 Progettazione igienica di pompe,
omogeneizzatori e dispositivi di smorzamento
34 Integrazione di sistemi igienici e asettici
Table 3: titles of guidelines available in Italian language
A frequently updated list of the translated documents is
available in the web-page www.ehedg.unipr.it
Guidelines. Many companies and institutes joined the
translation working groups of the Italian Section. The list is
shown in Table 4. The translation of the EHEDG website is
also under revision. So, the EHEDG website
www.ehedg.org will be soon available in Italian language.
Regional news and information will be also included in a
specific areas of the EHEDG website.
For the time being, please still refer to the website
www.ehedg.unipr.it for Italian information and news.
Company / Institute Documents
Bardiani valvole S.p.A. 14,20,
Centro Inox Milano 32
CFT S.p.A. 2,8,10
Csf Inox S.p.A. 14,17,20,25
GEA-Niro Soavi S.p.A. 17
GEA-Procomac 8

GEA Niro Soavi S.p.A. Pumps, Homogenisers, IVG Colbachini S.p.A. 32

Dampening Devices Omac Pompe S.r.l. 17
Sanovo Engineering S.r.l. Chemical treatments of Parmalat S.p.A. 8,34
steel
Roten S.r.l. 25
Seital Separatori S.r.l. Separators
Sidel S.p.A 2,8,10,34
Table 2: Italian companies in Subgroups
Stazione Sperimentale per l'Industria 8
delle Conserve Alimentari
University of Parma 2,8,10,13,14,17,
20, 25, 32,34
Table 4: translation working groups

EHEDG_Innenteil.indd 122 01.04.11 08:50

 EHEDG Regional Sections 123

EHEDG Italy Seminar 2010 The Seminar was very well attended by about 100 people
who showed great interest in the various hygienic design
The 2010 Seminar of the Italian Section, Hygienic Design
topics presented.
delle apparecchiature alimentary (Hygienic Design of food
processing equipment) took place on 11 June 2010 at The lectures and the video of the seminar are now
Centro Sant' Elisabetta Campus Universitario di Parma. available for download from www.ehedg.unipr.it eventi.
The Seminar was jointly organized by the Order of
Engineers of the Province of Parma, University of Parma,
the Chamber of Commerce of Parma and the Italian
Contact
Section of the European Hygienic Engineering and Design For more information and if interested in the activities of
Group (EHEDG). The agenda of the seminar is shown in EHEDG Italy, please contact
Table 5. Dr. Giampaolo Betta,
E-mail: ehedg@unipr.it
Phone: +39 0521 90 62 34 or the EHEDG Secretariat.
Topic of the presentation Speaker
Hygienic Design and biofilm University of Parma
Machinery Directive D.E.C.a. System
Sanitary surveillance Italian Health Ministry
EHEDG Principles EHEDG,
University of Parma
Hygienic Homogenisers GEA Niro Soavi
Hygienic Joints and Seals GEA-Procomac,
University of Parma
Hygienic Valves University of Parma
EHEDG Certification Bardiani Valvole
Simulation for Hygiene University of Parma
Hygienic Pumps CSF Inox
Table 5: topics presented at the Italian EHEDG Seminar

Activities of EHEDG Japan

Hiroyuki Omura, The Japan Food Machinery Manufacturers Association
E-mail: ohmura@fooma.or.jp

Overview of EHEDG Japan Seminars and PR activities conducted in

EHEDG Japan, whose secretariat is based in the Japan
Food Machinery Manufacturers Association (JFMA),
implemented, with full cooperation from the JFMA, the
following projects in 2010
x Translation of the EHEDG website into Japanese.
x Holding of seminars at the FOOMA JAPAN,
a comprehensive exhibition of food processing
machinery, to publicize the EHEDG and its Guidelines.
x Translation of EHEDG Guidelines into Japanese.
x Cooperation with the development of the Japanese
Industrial Standards (JIS) for food machinery that are
consistent with the ISO/IEC standards.
2010
The JFMA hosts the FOOMA JAPAN (area of the venue:
51,300m; visitors: 102,700 (in 2010)) in Tokyo in June
every year. In the FOOMA JAPAN held from June 8 to 11,
2010, the JFMA implemented the following:
x Setting up of a PR booth for the EHEDG (See Fig. 1)
x At the booth, activities of the EHEDG and the
procedures for joining the EHEDG were introduced to
visitors during the exhibition period.
x Holding of a seminar for the EHEDG Guidelines (See
Fig. 2)

EHEDG_Innenteil.indd 123 01.04.11 08:51

 124 EHEDG Regional Sections
x Following last year, the JFMA provided the second
seminar at 10:30 a.m. to 0:30 p.m. on June 9, inviting
EHEDG President Knuth Lorenzen as a lecturer.
President Lorenzen introduced the outline of the
hygienic design of open equipment stipulated in the
EHEDG Doc. 13. This seminar attracted over 400
people, mainly engineers of food and machinery
manufacturers.
Figure1. The EHEDG Japan booth
Translation of the Guidelines
As for the hygienic-design terms used in the EHEDG
Guidelines, Japanese food and machinery industries and
manufacturers have so far used their respective terms.
Hence, it took much time to unify many related terms
before translating the Guidelines. The unified terms were
compiled and publicised in the industries in autumn 2010.
EHEDG Macedonia
News from a new Regional Section
Prof. Dr. Vladimir Kakurinov, Veterinary Faculty, Bitola, Macedonia
E-mail: vladimir.kakurinov@key.com.mk
The EHEDG Regional Section for Macedonia has had a
very busy year.
Translation of EHEDG Guidelines
One of the activities for 2010 was translation of 12 EHEDG
Guidelines, one per month. The following 12 Guidelines
were translated:
1. Doc. 8 Hygienic equipment design criteria.
2. Doc. 10 Hygienic design of closed equipment for the
processing of liquid food.
3. Doc. 13 Hygienic design of equipment for open processing.
4. Doc. 18 Passivation of stainless steel.
5. Doc. 22 General hygienic design criteria for the safe
processing of dry particulate materials.
6. Doc. 23 Production and use of food-grade lubricants, Part 1
Use of H1 registered lubricants
EHEDG_Innenteil.indd 124
We have established the Subgroup 1, consisting of nine
members, which meet about once a month to finalise the
Japanese-language version of Doc. 8. Translators have
already finished provisional translation of 36 guidelines.
However, it is difficult to translate original terms into the
Japanese language so that Japanese readers can
understand the contents. Consequently, this translation
work is taking more time than expected.
EHEDG Japan is considering training specialists, capable
of explaining the EHEDG Guidelines, with the aim of
spreading the use of the Guidelines among many Japanese
companies. We also intend to provide designer training
courses on our own in the future.
Figure 2. EHEDG Guidelines seminar
7. Doc. 23, Part 2 Production of H1 registered lubricants
8. Doc. 24 The prevention and control of Legionella spp. (incl.
legionnaires disease) in food factories
9. Doc. 27 Safe storage and distribution of water in food
factories.
10. Doc. 32 Materials of construction for equipment in contact
with food.
11. Doc. 34 Integration of hygienic and aseptic systems.
12. Doc. 35 Hygienic welding of stainless steel tubing in the
food processing industry.
For the purposes of correct and accurate translation, each
translated guideline was submitted for proofreading to
experts in particular field/s for the topic matter.
01.04.11 08:51

In-country informative workshops
Info Days
Since 2010, the first year of the EHEDG Macedonian
Regional Section, one of the primary goals was to increase
the awareness in the Republic of Macedonia about EHEDG
goals and objectives, among the business, academic and
research communities, as well as the general public.
In order to complete this goal it was suggested to plan four
EHEDG Info Days on a quarterly basis.
These EHEDG Info-Days were planned in the following
regions cities:
1. Skopje region Skopje
2. Eastern region tip
3. Polog region Tetovo and
4. Vardar Sveti Nikole
All the planned EHEDG Info-Days for 2010 were
successfully completed. A fifth Info-Day took place in
December.
5. North-eastern region Kumanovo
Special attention was given to the media coverage of the
events. For each EHEDG Info-Day media invitations and
press releases were prepared and sent to: electronic (TV
and radio) and printed (newspapers) media, both on a
national and local level. Some Info-days were covered by
specialised TV and radio broadcasts, as well as weekly and
monthly printed media.
For 2011, an additional 3 EHEDG Info-Days are planned
between January 2011 and March 2011.
1. South-western Kievo
2. Pelagonia Bitola and
3. South-eastern Strumica region.
These Info-Days will be organized on a monthly basis due
to the importance of promoting the forthcoming EHEDG
World Congress which will be organized in the Republic of
Macedonia from 21st to 25th of September 2011.
EHEDG Netherlands
Activities in 2010
E.J.C. Paardekooper, EHEDG Netherlands
E-mail: e.paardekooper@planet.nl
Translation of Guidelines
At this moment 32 guidelines have been translated into
Dutch of which 22 are available as print-versions. Eight of
the 32 versions are still waiting for final approval.
EHEDG_Innenteil.indd 125
EHEDG Regional Sections 125
Printing/translation work
In order to increase the awareness of the EHEDG work,
membership, activities and visibility, the EHEDG
Macedonian Regional Section developed 3 different types
of information materials:
1. EHEDG brochure
The EHEDG brochure was translated into the Macedonian
language. 300 copies were made and distributed at
EHEDG info meetings and to interested companies,
institutes and individuals.
For 2011the translation and publication of the EHEDG
brochure in the Albanian language is also planned.
2. EHEDG Webpage
One of the EHEDG Macedonian Regional Section activities
has been the translation of the EHEDG International web
page into the Macedonian language.
Before this endeavour was completed, the Consulting and
Training Centre KEY had developed a special section for
the EHEDG on its own web site www.key.com.mk that
gave information on the subject of the EHEDG and a link to
EHEDG International web page.
3. EHEDG Macedonian Regional Section banner
Table flags were created to enhance visibility and visual
effect of EHEDG Macedonia. They are always raised at
Info Days and other events connected with the EHEDG.
EHEDG World Congress on Hygienic
Engineering and Design 2011 Macedonia
The Macedonian EHEDG Regional Section will be the host
of the forthcoming EHEDG World Congress on Hygienic
Engineering and Design 2011 Macedonia, which will take
a place in Ohrid (UNESCO World Heritage Site ), Republic
st th
of Macedonia from 21 25 of September 2011 (more
info on the following web page: www.ehedg.mk)
Combined actions Belgium and the
Netherlands
A number of events have been organised between Belgium
and the Netherlands to gain synergistic effects e.g. for the
production of handouts in the Dutch language.
01.04.11 08:51
 126 EHEDG Regional Sections

The Dutch Society for Food Entrepreneurs (OSV): Joint activities with other associations
x EHEDG Netherlands was present at the SVO EVENT EHEDG Netherlands participates in the Network Education
March 18th, 2010 in Velp. and Learning Hygiene and Contamination Control for
x On April 16th, 2010 in Velp a seminar was held with the Design and Construction:
following topic: Innovation: now and tomorrow. The networks aim is to provide a broad training hygienic
design, construction, and contamination control to the
Several experts from different disciplines of the Food following industry sectors:
Industry, VWA (Dutch Food Safety Authority), Machine and x Healthcare
Packing Companies, and Knowledge Institutions presented x Pharmacy & Biotechnology
their vision on unique Process- and Food Design. The
x Beverage
focus was on Cost Savings through Hygienic production
x Dairy
and Design.
x Meat
x Processed food
Workshop VCCN x Food service
EHEDG Netherlands will continue the alliance with VCCN x Trade channels
(clean room) to promote their knowledge to a broader x Nursing homes
public. A workshop is already planned. x Hotels

Training
Training and education materials remain the main topic to
promote hygiene awareness and understanding among
staff/personnel involved in the food chain, from farm to
fork.
Knowledge dissemination
Other channels of spreading knowledge are magazines and
online publications targeted here were Dutch media such
as Voedingsindustrie/ Vers en Vers and VMT.
Several in-house training sessions were organised for food
companies as well as for equipment suppliers.
The starting point for this endeavour was FHEALINC, the
cooperation of the Jeroen Bosch Hospital, the City of
's-Hertogenbosch, HAS" and Avans institutions of higher
education and the ZLTO. As a network FHEALINC provides
the opportunity for training and research in the areas of
Care Safety (hospices), food safety, food industry and large
kitchens), cGMP (pharmaceuticals and cosmetics), hazard
analysis (machine-building) and devices.

Russian section of EHEDG in 2010

Mark Shamtsyan, Chair of Russian section of EHEDG, St. Petersburg State Institute of Technology,
(Technical University)
E-mail: shamtsyan@yahoo.com

In May 2010, the EHEDG Bylaws were signed and the

EHEDG Russian section was established. Planning for the
1st EHEDG Hygienic Engineering and Design Conference
for Food Factories to be held in St. Petersburg was started
in June. The conference, held in October 2010 in the
conference hall of the Holiday Inn Moskovskiye Vorota
Hotel gathered some 100 participants from 23 countries,
namely from Armenia, Belarus, Belgium, Denmark, Finland,
France, Germany, Great Britain, Hungary, Iran, Ireland,
Italy, Japan, Kazakhstan, Latvia, Macedonia, The
Netherlands, Poland, Romania, Russia, Sweden, Taiwan
and Ukraine.
Figure 1. Participants at the Conference

EHEDG_Innenteil.indd 126 01.04.11 08:51

 Complementing
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EHEDG_Innenteil.indd 127 01.04.11 08:51

 128 EHEDG Regional Sections

Two days of the Conference were filled with high quality

presentations covering various aspects of hygienic design,
such as liquid processing, hygienic design of valves,
construction materials, lubricants, seal materials, air
handling, aseptic processing and packaging systems and
many others, which were of great interest for the
participants.
EHEDG Russia have started the translation of the EHEDG
web-site into the Russian language and will be completed
soon.
In 2011 it is planned to launch the Russian version of
EHEDG web-site and start the translation of guidelines.
Also the first EHEDG training course in Russia and EHEDG
seminar are scheduled for the spring and autumn,
respectively. Figure 2. Mr Lorenzen, EHEDG President, giving his presentation

EHEDG Spain
Different initiatives have been developed during these last years with the main aim of
promoting hygienic design and EHEDG activities among Spanish companies

Rafael Soro. AINIA Technological Centre. Valencia Spain

E-mail: rsoro@ainia.es

Background Recent activities

The first EHEDG event in Spain was in 2001, when the
11th International Conference was, for the first time,
combined with a Training Workshop on hygienic
engineering that was held in Valencia. The 3-day
conference Food in Europe: Building in Safety was
organised by AINIA, and attracted more than 200 attendees
from European food companies and food equipment
manufacturers.
Four years later, in 2005, the Spanish Regional Section
was created under the initiative of AINIA Technological
Centre. In the following years the Spanish Regional section
carried out several activities to spread the requirements of
hygienic design and EHEDG among Spanish companies.
Seminars and advanced courses have been organised and
held in Valencia and Barcelona. In 2006, the translation of
the EHEDG published guidelines was initiated.
A relationship was established with AMEC (Spanish Food
Equipment Manufacturers Association) aiming to
disseminate EHEDG activities in Spain. A Spanish EHEDG
website was created. Ainia has also published several
newsletters about EHEDG and hygienic design that have
been distributed among most of the Spanish food industries
and many food equipment manufacturers.
Being aware that training is one of the most effective ways
of spreading EHEDG hygienic design criteria, last April
2010 the second edition of the Advanced Course on
Hygienic Design was held at Ainia in April. More than 20
people from companies attended the 3-day course. The
course was presented from a very practical viewpoint,
relating the theoretical fundamentals of the different
subjects to practice by means of examples on video,
pictures, samples and the EHEDG Toolbox. The course
included some case studies that were developed in a pilot
plant and was given by experts from the EHEDG Training &
Education Subgroup. The course was given in English and
Spanish, with simultaneous translation.
The process of guideline translation has continued since its
beginning in 2006. To date, twenty six guidelines have
been translated into Spanish. Not all of them are already
available from the EHEDG website. For some, review is still
pending or the original guideline is being updated.
More recently, the translation of the EHEDG website into
Spanish has been completed. These translation activities
are considered crucial for the Regional Section since it is a
very effective way of spreading EHEDG and hygienic
design issues not only in Spain but also in other Spanish
speaking countries.

EHEDG_Innenteil.indd 128 01.04.11 08:51


Figure 1. Advanced Course on Hygienic Design. April 2010
Spanish first authorised institute for EHEDG
certification
After a period of several years of hard work and
investments, the Spanish Technological Centre AINIA has
become the sixth authorised institute to conduct the test
needed for the certification of equipment under the EHEDG
scheme. The process has involved, among others, the
construction of a CIP test rig, training of personnel, and
achievement of the ISO 17025 accreditation, audited and
provided by the Spanish National Accreditation body ENAC
in December 2009.
EHEDG Regional Section Switzerland
Two years of EHEDG Switzerland: An incredible success!
Matthias Schfer, EHEDG Regional Secretary, GEA Tuchenhagen GmbH
E-mail: matthias.schaefer@geagroup.com
The EHEDG Regional section (RS) in Switzerland was
founded as a formal organisation according to the Swiss
civil code in November 2008 at the University of Applied
Sciences Western Switzerland (HES SO) in Sion VS. The
group is headed by Dr. Rudolf Schmitt (Professor for Food
Microbiology) at the HES SO.
Starting with only 5 persons at the foundation meeting and
with a total of 20 members in Switzerland the group is
constantly growing in its activities. Although the first general
assembly was only attended by the 5 members of the
Regional Committee (RC), the groups first activity became
a success. A seminar with the title Hygienic Design of
Process Plants... which was held in November 2009 in
Sion VS at the HES SO was visited by more than 60 people
from different companies.
EHEDG_Innenteil.indd 129
EHEDG Regional Sections 129
Figure 2. Hygiene Experimental Plant CIP test rig
Future plans of the Regional Section are focused on
increasing the awareness of the Spanish equipment
manufacturers and food industries about EHEDG and
hygienic design topics, increasing the number of Spanish
members, making information about EHEDG more
accessible to Spanish companies (guideline translation,
EHEDG-Spain website, etc.), and reinforcing the Spanish
EHEDG members network.
The Spanish regional section is coordinated by Rafael
Soro. More information: rsoro@ainia.es
Mainly suppliers to the food industries were attending this
seminar although advertising was undertaken in all
important Swiss food industry journals. As a result of this
2009 seminar the number of Swiss members grew to about
30 and the general assembly in 2010 at the
Feldschlsschen Brewery in Rheinfelden (Switzerland) was
attended by 13 EHEDG members.
Both the University of Applied Sciences Western
Switzerland (HES SO) and the Zurich University of Applied
Sciences (ZHAW) introduced a lecture on Hygienic
Design in their master study courses in 2010. Those
lectures were held by Mr. Matthias Schfer (Regional
Secretary) in Sion and Wdenswil. Nevertheless the
biggest event was the 2010 seminar on Cleaning of
process plants... at the Feldschlsschen Brewery in
Rheinfelden (Switzerland). An incredible (and unexpected)
number of 115 attendees joined this seminar. Most of the
01.04.11 08:51
 130 EHEDG Regional Sections

participants were from the Swiss food and beverage can only function and exist if enough people can be found
industry. Some attendees had even joined the seminar to contribute to the organisation of events beside their daily
from Germany and Liechtenstein. work. We thank the EHEDG Secretary for the great support
This success encouraged the RC already now to plan and all Swiss EHEDG members who have helped to make
th
another seminar for November, 24 2011. this young Regional Section a success!
Further activities will be the general assembly in May/June
2011. In the meantime the Swiss Regional Section has a
total of 40 members and is looking forward to a successful
2011. Last but not least it has to be said that such a group

EHEDG Taiwan
A new EHEDG Regional Section in the Far East

Dr. Bing-Huei Barry Yang, Phone: +886-6-3847301,

E-mail : bby@firdi.org.tw

Kick-off meeting

The EHEDG Taiwan Kick-off Meeting was held on January

5, 2011.
On the same day, the Symposium on Hygienic Engineering
and Design for Food Machinery in Taiwan was also held.
The event was organized by the Food Industry Research
and Development Institute (FIRDI).
This kick-off meeting officially started the EHEDG Taiwan
Regional Section. At the symposium, the EHEDG
President, Knuth Lorenzen, and Regional Section
Chairman, Dr. B. Barry Yang, both signed on the Regional
Section By-Laws.
At this symposium, topics concerning the legal Figure 2. Mr Lorenzen giving a presentation at the Symposium on
requirements for hygienic design, EHEDG guidelines, Hygienic Engineering and Design for Food Machinery in Taiwan
EHEDG test procedures and certification, and other matters
were discussed. These topics are targeted to increase the
attention for the subject of food safety, which can be Approximately 100 attendees from more than 35
attained by the hygienic design of processing machinery. companies, from both food processors and the machinery
manufacturing industry, participated in this symposium. In
the future, EHEDG Taiwan will schedule meetings to be
held quarterly and hopefully will gain ever more attention
from local companies to disseminate EHEDG activities.
For more information and if interested in the activities of
EHEDG Taiwan, please contact Dr. Bing-Huei Barry Yang,
Phone: +886-6-3847301, E-mail : bby@firdi.org.tw.

Figure 1. Signing the foundation of EHEDG Taiwan

EHEDG_Innenteil.indd 130 01.04.11 08:51

 EHEDG Regional Sections 131

EHEDG Thailand
Thai Regional Section

Navaphattra Nunak, Taweepol Suesut, King Mongkuts Institute of Technology Ladkrabang, Faculty of Engineering,
Department of Food Engineering, Thailand
E-mail: kbnavaph@kmitl.ac.th

EHEDG Thailand was established in 2009 officially started EHEDG Thailand Seminar 2010
on 20 April 2009. The Thai Section was initiated between
There were two seminars in 2010. The first seminar (28th to
the EHEDG centre and the Department of Food
29th January 2010) and second seminar (8th April 2010)
Engineering, King Mongkuts Institute of Technology
were held at KMITL, Bangkok.
Ladkrabang (KMITL).
The first seminar was focused on the basic knowledge of
Presently, just one institute member from KMITL is a
application of hygienic design in both wet and dry food
member of EHEDG. However, several industrial companies
processes.
are interested and attended the activities of Thai Section.
x Hygienic Design of Food Processing Equipment:
Application in Both Wet and Dry Food Process
Guideline translation (January 28th-29th 2010):
Speakers: Dr. Gerhard SCHLEINING
Guideline no. 1, 2, 3, 4, 6, 8, 11, 14, 16, 21, 27, 28, 32, 35,
Dr. Taweepol SUESUT
37 is now in the process of translating.
Guideline No. 1, 3, 6
The second one was the general hygienic engineering
Person responsible:
design in the food industry.
Asst. Prof. Dr. Pimpen Pornchaloempong, KMITL
x Hygienic Engineering Design in the Food Industry:
Guideline No. 2, 4 (April 8 2010)
Person responsible: Dr. Kankanit Kwanpruk, KMITL Speaker: Mr. Knuth LORENZEN
Guideline No. 8, 16
Person responsible: Asst. Dr. Navaphattra Nunak, KMITL There were about 20 and 60 participants who attended the
Guideline No. 11, 21 Person responsible: seminars respectively. The participants could be divided
Mr. Samak Rakmae, KMITL into 3 groups as follow.
x Government officers
Guideline No. 14
Person responsible: Assoc. Prof. Satip Rattanapaskorn, x Technology and engineering consultants
KMITL x Owner and staff from food factories

Guideline No. 27, 28

Person responsible: Asst Prof.Dr. Maradee Pongpipatpong,
KMITL
Guideline No. 32, 35
Person responsible: Dr. Kiattisak Roonprasang, KMITL
Guideline No. 37
Person responsible: Assoc. Prof. Dr. Taweepol Suesut and
Assoc. Prof. Suphan Gulphanich, KMITL

Website translation is also now in the progress. Contact

For more information and if you are interested in the
activities of EHEDG Thailand, please contact
Dr. Navaphattra Nunak (E-mail: kbnavaph@kmitl.ac.th),
Dr. Taweepol Suesut (E-mail: kstaweep@kmitl.ac.th),
Phone: +66 2 3298356-8

EHEDG_Innenteil.indd 131 01.04.11 08:51

 132 EHEDG Regional Sections

EHEDG Ukraine
Prof. Yaroslav Zasyadko*, National University of Food Technologies, Kyiv, Tel.: +38 044-287 96 40
E-mail: yaroslav@usuft.kiev.ua

During 2010, the Ukrainian Regional EHEDG Section On December 15, we held an EHEDGUkrUFoST
dedicated its efforts to the Guidelines translation and Conference in Kyiv. Professor Huub Lelieveld attended the
adaptation to the Ukrainian State Standards where Conference as an Honorable Representative of the
applicable. EHEDG Ukraine has the following Guidelines EHEDG. He made a presentation describing the EHEDG
ready for publication: activities.
Doc 1 Microbiologically safe continuous pasteurisation of
liquid food
Doc 2 A method for assessing the in-place cleanability of
food processing equipment.
Doc 4 A method for the assessment of in-line
pasteurisation of food processing equipment.
Doc 5 A method for the assessment of in-line
sterilisability of food processing equipment.
Doc 6 The microbiologically safe continuous flow thermal
sterilisation of liquid foods.
Doc 7 A method for the assessment of bacteria-tightness
of food processing equipment.
Doc 8 Hygienic equipment design criteria.

In the process of translation is:

Figure 1. Huub Lelieveld giving his presentation
Doc 3 Microbiologically safe aseptic packing of food
products.
He also signed the Protocol on the prolongation of the
Ukrainian Regional Group Activities. From the Ukrainian
The Guidelines
side the Protocol was signed by Professor S. Ivanov, newly
Doc 9 Welding stainless steel to meet hygienic elected President of the Ukrainian Regional EHEDG
requirements. Section.
Doc 10 Hygienic design of closed equipment for the
processing of liquid food.
Doc 11 Hygienic packing of food products.
Doc 12 The continuous or semi-continuous flow thermal
treatment of particulate foods.
Doc 13 Hygienic design of equipment for open
processing.
Doc 14 Hygienic design of valves for food processing.
Doc 15 A method for the assessment of in-place
cleanability of moderately sized food processing
equipment.
are currently being adapted to the Ukrainian Standards.
Since June 2010, the Ukrainian EHEDG Regional Section
has developed an active web page which has a link to the
EHEDG web page.
Currently we are in the process of translating the EHEDG
web page into Ukrainian, and so far approximately 60% of Figure 2. Huub Lelieveld and S. Ivanov signing the contract
the contents have been translated.
EHEDG Ukraine has also developed a programme of Contact:
teaching materials including presentations and EHEDG
Prof. Yaroslav Zasyadko
movies, that have been translated and adapted to the MS
National University of Food Technologies Kyiv, Ukraine
(Mechanical Engineering) curricular. This course is planned
to be taught in the next academic year.

EHEDG_Innenteil.indd 132 01.04.11 08:51


EHEDG Guidelines
Titles available and description
The Guidelines can be ordered from the Webshop by non-
members and individual members. They are free for
EHEDG Company and Institute Members while Individual
EHEDG Members receive a 50 % discount.
Doc. 1. Microbiologically safe continuous
pasteurisation of liquid foods
First Edition, November 1992 (17 pages)
There are many reasons why, in practice pasteurised
products sometimes present a microbiological health
hazard. Due to distribution in residence time, not all
products may reach the temperature required for
pasteurisation or may do so for too short a time. Further
there may be a risk of contamination with a non-
pasteurised product, or the cooling medium. This document
describes the requirements particularly for liquid foods
without particulates.
Languages available: Dutch, English, French
Doc. 2. A method for assessing the in-place
cleanability of food processing equipment
Third Edition, June 2007 (16 pages)
The method is intended as a screening test for hygienic
equipment design and is not indicative of the performance
of industrial cleaning processes (which depend on the type
of soil). See Doc 15 for a test procedure designed for
moderately-sized equipment.
Training DVD available.
Languages available: Armenian, Dutch, English,
French, German, Italian, Spanish
Doc. 3. Microbiologically safe aseptic
packing of food products
First Edition, January 1993 (15 pages)
This guideline stresses the need to identify the sources of
micro-organisms that may contaminate food in the
packaging process, and to determine which contamination
rates are acceptably low. It clarifies the difference in risk of
infection between aseptic processing and aseptic packing
and recommends that aseptic packing machines be
equipped with fillers that are easily cleanable, suitable for
decontamination and bacteria-tight. Requirements for the
machine interior include monitoring of critical
decontamination parameters. See also Doc. 21 on
challenge tests.
Languages available: Armenian, Dutch, English,
French, Ukranian
Doc. 4. A method for the assessment of
in-line pasteurisation of food processing
equipment
First Edition, February 1993 (12 pages)
Food processing equipment that cannot be or does not
need to be sterilised may need to be pasteurised to
inactivate relevant vegetative micro-organisms and fungal
spores. It is important to test the hygienic characteristics of
EHEDG_Innenteil.indd 133
European Hygienic Engineering & Design Group
such equipment to ensure that it can be pasteurised
effectively. This document describes a test procedure to
determine whether equipment can be pasteurised by
circulation with hot water.
Training DVD available.
Languages available: Armenian, Dutch, English,
French, Ukranian
Doc. 5. A method for the assessment
of in-line sterilisability of food processing
equipment
Second Edition, July 2004 (9 pages)
Food processing equipment may need to be sterilised
before use, and it is important to ensure that the
sterilisation method applied is effective. Thus, it is
necessary to determine under which conditions equipment
can be sterilised. This paper details the recommended
procedure for assessing the suitability of an item of food
processing equipment for in-line sterilisation. It is advisable
to conduct in-place cleanability trials (ref. Doc.2) prior to
this test in order to verify the hygienic design of the
equipment.
Training DVD available.
Languages available: Armenian, Dutch, English,
French, German, Ukrainian
Doc. 6. The microbiologically safe
continuous flow thermal sterilisation of liquid
foods
First Edition, April 1993 (26 pages)
Thermal sterilisation is aimed at eliminating the risk of food
poisoning and, when used in conjunction with aseptic filling,
at achieving extended product storage life under ambient
conditions. Whereas pasteurisation destroys vegetative
micro-organisms, sterilisation destroys both vegetative
micro-organisms and relevant bacterial spores. This
document presents guidelines on the microbiologically safe
continuous sterilisation of liquid products. The technique of
Ohmic heating was not considered in this paper but may be
included in an update being prepared. See Doc. 1 for
guidelines on continuous pasteurisation of liquid foods.
Training DVD available.
Languages available: Dutch, English, French,
Ukrainian
Doc. 7. A method for the assessment
of bacteria tightness of food processing
equipment
Second Edition, July 2004 (10 pages)
This document details the test procedure for assessing
whether an item of food processing equipment, intended for
aseptic operation, is impermeable to micro-organisms.
Small motile bacteria penetrate far more easily through
microscopic passages than (non-motile) moulds and
yeasts. The facultative anaerobic bacterium Serratia
marcescens (CBS 291.93) is therefore used to test
01.04.11 08:51
 134 EHEDG Guidelines
bacteria-tightness or the impermeability of equipment to
micro-organisms. The method is suitable for equipment that
is already known to be in-line steam sterilisable (see also
Doc. 5).
Training DVD available.
Languages available: Armenian, Dutch, English,
French, Spanish, Ukrainian
Doc. 8. Hygienic equipment design criteria
Second Edition, April 2004 (16 pages)
This guideline describes the criteria for the hygienic design
of equipment intended for the processing of foods. Its
fundamental objective is the prevention of the microbial
contamination of food products. It is intended to appraise
qualified engineers who design equipment for food
processing with the additional demands of hygienic
engineering in order to ensure the microbiological safety of
the end product. Upgrading an existing design to meet
hygiene requirements can be prohibitively expensive and
may be unsuccessful and so these are most effectively
incorporated into the initial design stage. The long term
benefits of doing so are not only product safety but also
increased life expectancy of equipment, reduced
maintenance and consequently lower operating costs.
This document, first published in 1993, describes in more
detail the hygienic requirements of the Machinery Directive
(98/37/EC ref.1). Parts of it have subsequently been
incorporated in the standards EN1672-2 and EN ISO
14159.
Training DVD available
Languages available: Armenian, Dutch, English,
French, German, Italian, Macecdonian, Spanish,
Ukranian
Doc. 9. Welding stainless steel to meet
hygienic requirements
First Edition, July 1993 (21 pages) update in progress
since 2010 in conjunction with Doc. 35
This document describes the techniques required to
produce hygienically acceptable welds in thin walled (< 3
mm) stainless steel applications. The main objective was to
convey the reasons and requirements for hygienic welding
and to provide information on how this may best be
achieved. This document is superseded by Doc 35,
recently published. The subgroup will continue with a
guideline on inspection of the quality of welds in food
processing machinery.
Training DVD available
Languages available: Dutch, English, French,
Spanish, Ukrainian
Doc. 10. Hygienic design of closed
equipment for the processing of liquid food
Second Edition, May 2007 (22 pages)
Using the general criteria for the hygienic design of
equipment identified in Doc 8, this paper illustrates the
application of these criteria in the construction and
fabrication of closed process equipment. Examples, with
drawings, show how to avoid crevices, shadow zones and
areas with stagnating product, and how to connect and
position equipment in a process line to ensure unhampered
draining and cleaning in-place. Attention is drawn to ways
EHEDG_Innenteil.indd 134
of preventing problems with joints, which might otherwise
cause leakage or contamination of product.
Training DVD available
Languages available: Dutch, English, French,
German, Italian, Macedonian
Doc. 11. Hygienic packing of food products
First Edition, December 1993 (15 pages)
Products with a short shelf-life, or whose shelf life is
extended by cold storage or in-pack heat treatments, do not
have to conform to such strict microbiological requirements
as aseptically packaged foods (Doc 3 discusses aseptic
packing). This paper discusses the packing of food
products that do not need aseptic packing but which
nevertheless need to be protected against unacceptable
microbial contamination. It describes guidelines for the
hygienic design of packing machines, the handling of
packing materials and the environment of the packing
machines. See also Doc. 21.
Languages available: Dutch, English, French,
Macedonian, Ukrainian
Doc. 12. The continuous or semi-continuous
flow thermal treatment of particulate foods
First Edition, March 1994 (28 pages)
Thermal sterilisation is a process aimed at eliminating the
risk of food poisoning and, when used in conjunction with
aseptic filling, it aims to extend product storage life under
ambient conditions. This is achieved by the destruction of
vegetative micro-organisms and relevant bacterial spores.
Liquid foods containing particulates are inherently more
difficult to process than homogenous liquids due to heat
transfer limitations in particulate-liquid mixtures and the
additional problems of transport and handling. This paper
presents guidelines on the design of continuous and semi-
continuous plants for the heat treatment of particulate
foods. Ohmic heating techniques are not covered. See also
Doc. 1 on continuous pasteurisation and Doc. 6 on
sterilisation of liquid products without particles.
Languages available: Dutch, English, French,
Ukrainian
Doc. 13. Hygienic design of equipment for
open processing
Second Edition, May 2004 (24 pages)
updated version 2010
It is important that the plant design takes into account
factors affecting the hygienic operation and cleanability of
the plant. The risk of contamination of food products during
open processing increases with the with the concentration
of micro-organisms in the environment and their opportunity
to grow in poorly designed equipment. This means that in
open plants, environmental conditions, in addition to
appropriate equipment design, have an important influence
on hygienic operation. The type of product and the stage of
the manufacturing process must also be taken into
consideration.
This paper deals with the principal hygienic requirements
for equipment for open processing and applies to many
different types, including machines for the preparation of
dairy products, alcoholic and non-alcoholic drinks, sweet
oils, coffee products, cereals, vegetables, fruit, bakery
01.04.11 08:51
 EHEDG Guidelines 135

products, meat and fish. It describes methods of
construction and fabrication, giving examples as to how the
principal criteria can be met. See also guidelines on
hygienic design criteria Doc 8, hygienic welding Doc 9, and
the hygienic design of equipment for closed processing Doc
10.)
Languages available: Dutch, English, French,
German, Macedonian, Ukrainian
Doc. 14. Hygienic design of valves
for food processing
Second Edition, July 2004 (17 pages)
update in progress since 2009
Valves are essential components of all food processing
plants and the quality used strongly influences the
microbiological safety of the food production process.
These valves must therefore comply with strict hygienic
requirements.
The guidelines apply to all valves used in contact with food
or food constituents that are to be processed hygienically or
aseptically. Aside from general requirements with regard to
materials, drainability, microbial impermeability and other
aspects, additional requirements for specific valve types
are also described. See also Doc. 20 on double-seat
mixproof valves.
Training DVD available.
Languages available: Dutch, English, French,
Spanish
EHEDG_176x117,5_101108.ai 1 11.11.2010 14:50:28
Doc. 15. A method for the assessment of
in-place cleanability of moderately-sized food
processing equipment
First Edition, February 1997 (12 pages)
This document describes a test procedure for assessing
the in-place cleanability of moderately sized equipment,
such as homogenisers. The degree of cleanliness is based
on the removal of a fat spread soil, and is assessed by
evaluating the amount of soil remaining after cleaning by
visual inspection and swabbing of the surface. This method
is not as sensitive as the microbiological method described
in Doc. 2.
Languages available: Armenian, Dutch, English,
German, Spanish
Doc. 16. Hygienic pipe couplings
First Edition, September 1997 (21 pages)
This paper identifies and defines critical design parameters
for welded pipe couplings: easily cleanable in-place; easily
sterilisable in place; impervious to micro-organisms, reliable
and easy to install.
Gaskets of various types were tested for reliability and
hygienic aspects using EHEDG cleanability test methods
and repeated sterilisation. The objective was to provide a
reliable dismountable joint which is bacteria-tight at the
product side under the conditions of processing, cleaning
and sanitation.
Training DVD available.
Languages available: English, French, German

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EHEDG_Innenteil.indd 135 01.04.11 08:51

 136 EHEDG Guidelines
Doc. 17. Hygienic design of pumps,
homogenisers and dampening devices
Second Edition, September 2004 (16 pages)
update in progress since 2008
This paper sets the minimum requirements for pumps,
homogenisers and dampening devices for hygienic and
aseptic applications. The scope includes all pumps
intended for use in food processing, including centrifugal,
piston, lobe rotor, diaphragm, screw and gear pumps. The
requirements also apply to valves integral to the pump
head and the complete homogeniser head. Design aspects
and the characteristics of materials, surfaces and seals are
discussed and additional requirements for aseptic
equipment are identified. This document is currently being
updated.
Training DVD available.
Languages available: English, French, German
Doc. 18. Passivation of stainless steel
First Edition, August 1998 (13 pages)
update in progress since 2009
Passivation is an important surface treatment that helps
assure the successful corrosion resistant performance of
stainless 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 and
guidelines relative to equipment passivation. The complete
passivation process is described and environmental, as
well as safety, concerns are discussed.
Training DVD available.
Languages available: English, French, German,
Macedonian
Doc. 19. A method for assessing the bacterial
impermeability of hydrophobic membrane
filters
First Edition, June 2000 (9 pages)
Research has shown that hydrophobic membrane filters,
with a pore size of 0.22m, do not retain micro-organisms
under all process conditions. Investigations were conducted
into risk assessment of sterilising hydrophobic membrane
filters, evaluating the performance of the filters under a
range of operating conditions.
To validate the bacterial retention ability of sterilising grade
hydrophobic membrane filters, a bacterial aerosol
challenge test methodology was developed.
Languages available: Dutch, English
Doc. 20. Hygienic design and safe use of
double-seat mixproof valves
First Edition, July 2000 (20 pages)
update in progress since 2009
This document describes the basic hygienic design and
safe use of single-body double-seat mixproof valves.
Today, food process plants incorporate various
multifunctional flow paths. Often one piping system is
cleaned while another still contains product. This
simultaneous cleaning can potentially result in the
EHEDG_Innenteil.indd 136
dangerous situation where product and cleaning liquid are
separated by just one single valve seat. Any cleaning liquid
that leaks across such a seat will contaminate the product.
Therefore, often two or three single seat valves in a block-
and-bleed arrangement are applied.
Training DVD available.
Languages available: Dutch, English, French
Doc. 21. Challenge tests for the evaluation of
the hygienic characteristics of packing
machines for liquid and semi-liquid products
First Edition, July 2000 (32 pages)
After documents 3 and 11, this is the third test method in
the series. It discusses how packing machines should be
designed to comply with hygiene design criteria and
thereby with the requirements specified in Annex 1 of the
Machinery Directive1. To determine whether those criteria
are met requires validation of the design and measurement
of essential parameters. Proven methods for testing the
performance of the various functions of packing machines
are described.
These methods may also be used by the manufacturer to
optimise or redesign a packing machine and by the food
processor who may want to compare different packing
machines.
Upon delivery, a packing machine needs to be checked by
a commissioning procedure to be agreed in advance
between the food processor and the supplier.
Commissioning may include physical as well as
microbiological tests. Additional tests are specified for
commissioning of machines for aseptic packing.
1 Machinery Directive 98/37/EC Annex 1, point 2.1, Agri-
foodstuffs machinery
Languages available: English, French,
German, Spanish
Doc. 22. General hygienic design criteria
for the safe processing of dry particulate
materials
First Edition, March 2001 (23 pages)
Dry food processing and handling requires equipment that
are different from those typically associated with wet and
liquid products. This is the first in a series of documents
that go beyond equipment design and covers installation
and associated practices. In the case of dry materials, other
considerations include material lump formation, creation of
dust explosion conditions, high moisture deposit, formation
in the presence of hot air, and material remaining in the
equipment after shutdown. Appropriate cleaning
procedures are described, dry cleaning being favoured to
reduce risks of contamination.
Languages available: Dutch, English, French,
German, Macedonian, Spanish
Doc. 23. Production and use of food-grade
lubricants, Part 1 and 2
Second Edition, May 2009 (Part 1: Use of H1 Registered
Lubricants 23 Pages / Part 2: Production of H1
Registered Lubricants 10 Pages)
Lubricants, grease and oil are necessary components for
the lubrication, heat transfer, power transmission and
01.04.11 08:51

corrosion protection of machinery, machine parts,
instruments and equipment. Incidental contact between
lubricants and food cannot always be fully excluded and
may result in contamination of the food product. This risk
applies to all lubricants equally. PART 1 of this guideline
covers the hazards that may occur when using food grade
lubricants and describes the actions and activities required
to eliminate them or to reduce their impact or occurrence to
an acceptable level. PART 2 of this guideline lays down the
general requirements and recommendations for the
hygienic manufacturing and supply of food-safe lubricants.
Training DVD available.
Languages available: English, French, German,
Macedonian, Spanish
Doc. 24. The prevention and control of
legionella spp (incl. legionnaires disease) in
food factories
First Edition, August 2002 (21 pages)
There are many locations in food industry sites where the
potential for the proliferation of Legionella spp in water
systems exists. These bacteria can give rise to a potentially
fatal disease in humans, which is identified as legionellosis
or legionnaires disease.
This document applies to the control of Legionella spp. in
any undertaking involving a work activity and to premises
controlled in connection with a trade, business or other
undertaking where water is used or stored and where there
is a means of transmitting water droplets which may be
inhaled, thereby causing a reasonably foreseeable risk of
exposure to Legionella spp.
The guidelines summarises the best practice for controlling
Legionella in water systems. It consists of two parts;
namely, Management Practices and Guidance on the
Control of Legionella spp. in Water Systems.
The first section describes a management programme: risk
identification and assessment; risk management (incl
personnel responsibilities); preventing or controlling risk of
exposure to the bacteria; and record keeping.
The second part provides guidance on the design and
construction of hot and cold water systems as well as the
management and monitoring of these systems. Water
treatment programmes, with attention to cleaning and
disinfection, are also discussed.
Languages available: English, German,
Macecdonian
Doc. 25. Design of mechanical seals for
hygienic and aseptic applications
First Edition, August 2002 (15 pages)
This guideline compares the design aspects of different
mechanical seals with respect to ease of cleaning,
microbial impermeability, sterilisability or pasteurisability. It
can serve as a guide for suppliers and users of this
important component. Using EHEDG definitions,
mechanical seals are classified according to use in the food
industry into three categories: Aseptic, Hygienic equipment
Class I, and Hygienic Equipment Class II. Both single and
dual mechanical seals fall under the first two categories,
which by definition, are subject to more stringent hygienic
demands. General design criteria and basic material
requirements for food applications are explained. Materials
EHEDG_Innenteil.indd 137
EHEDG Guidelines 137
covered include carbon-graphite, ceramics, elastomers and
metals. Hygienic implications of seal elements and
components are also discussed. Finally, installation
requirements are described and illustrated, taking into
account the product environment side, the flushing side and
the cartridge design.
Languages available: Armenian, English,
German
Doc. 26. Hygienic engineering of plants for
the processing of dry particulate materials
First Edition, November 2003 (30 pages)
This document describes general engineering guidelines to
be applied to ensure that buildings, individual equipment
items and accessibility of equipment when integrated within
the plant layout are designed so that aspects of the process
operation, cleaning and maintenance comply with hygienic
design standards. It details requirements related to plant
enclosure, including hygienic zoning, building structures
and elements (from floor to ceiling) as well as process line
installation. Attention is also given to air stream and water
related aspects within the plant as well as cleaning and
contamination aspects. See also Doc. 22.
Languages available: Dutch, English, French,
Spanish
Doc. 27. Safe storage and distribution of
water in food factories
First Edition, April 2004 (16 pages)
Water is a vital medium used for many different purposes in
the food industry. Systems for storing and distributing water
can involve hazards, which could cause water quality to fall
below acceptable standards. It is therefore critical to ensure
that water storage and distribution in a food manufacturing
operation takes place in a controlled, safe way. This
Guideline summarizes the best practice for three water
categories used in the food industry: product water,
domestic water and utility water. See also Doc. 24.
Languages available: English, French,
Macedonian
Doc. 28. Safe and Hygienic Water Treatment
in Food Factories
First Edition, December 2004 (21 pages)
Water is a vital medium used for many different purposes in
the food industry. Systems for storing and distributing water
can involve hazards, which could cause water quality to fall
below acceptable standards. It is therefore critical to ensure
that water storage and distribution in a food manufacturing
operation takes place in a controlled, safe way. This
Guideline summarizes the best practice for three water
categories used in the food industry: product water,
domestic water and utility water. See also Doc. 24.
Languages available: Armenian, English, French
Doc. 29. Hygienic design of packing systems
for solid foodstuffs
First Edition, December 2004 (24 pages)
This document addresses packing systems of solid food
products and supplements earlier guidelines. Solid food is
characterised as having a water activity of > 0.97, low acid,
01.04.11 08:51
 138 EHEDG Guidelines
not pasteurised or sterilised after packaging, and
distributed through the cool chain. Examples include fresh
meat and some meat products, cheeses, ready meals, cut
vegetables, etc. Hygiene requirements of the packaging
operations, machinery as well as personnel, are described
and reference is made to the American Meat Institutes
principles of sanitary design. See also Docs. 3 and 11.
Languages available: Dutch, English
Doc. 30. Guidelines on air handling in the
food industry
First Edition, March 2005 (43 pages)
The controlled properties of air, especially temperature and
humidity, may be used to prevent or reduce the growth rate
of some micro-organisms in manufacturing and storage
areas. The particle content dust and micro-organisms
can also be controlled to limit the risk of product
contamination and hence contribute to safe food
manufacture. Airborne contaminants are commonly
removed by filtration. The extent and rate of their removal
can be adjusted according to acceptable risks of product
contamination and also in response to any need for dust
control.
These guidelines are intended to assist food producers in
the design, selection, installation, and operation of air
handling systems. Information is provided on the role of air
systems in maintaining and achieving microbiological
standards in food products. The guidelines cover the choice
of systems, filtration types, system concepts, construction,
maintenance, sanitation, testing, commissioning, validation
and system monitoring. They are not intended to be a
specification for construction of any item of equipment
installed as part of an air handling system. Each installation
needs to take account of local requirements and specialist
air quality engineers should be consulted, to assist in the
design and operation of the equipment.
Languages available: Armenian, English
Doc. 31. Hygienic engineering of fluid bed
and spray dryer plants
First Edition, May 2005 (19 pages)
Because these plants handle moist products in an airborne
state, they are susceptible to hygiene risks, including a
possible transfer of allergens between products. It is
therefore critical to apply hygienic design considerations to
both the process and machinery to prevent occurrence of
such risks.
Starting from the basics with regard to design, construction
materials, layout, and zone classification of the drying
systems to meet hygienic requirements, this paper outlines
component design aspects of the processing chamber, with
particular attention to the atomization assembly and the
distribution grids for fluidization. Systems for both supply
and exhaust air should operate in a hygienic manner and
recommendations for the use and installation of various
types of filters are listed. Finally, operational aspects,
including sampling, control and general housekeeping are
briefly discussed.
Languages available: Dutch, English
EHEDG_Innenteil.indd 138
Doc. 32. Materials of construction for
equipment in contact with food
First Edition, August 2005 (48 pages)
This guideline aims to offer a practical 'handbook' for those
responsible for the specification, design and manufacture of
food processing equipment. It offers guidance on the ways
in which materials may behave such that they can be
selected and used as effectively as possible. The
properties and selection procedures with regard to metals,
elastomers and plastics are covered in detail. Potential
failure mechanisms and influenced of manufacturing
processes are also discussed. A more general overview of
composites, ceramics and glass and materials is provided.
The guideline can serve as an aide-memoir during the
design process, so that equipment manufacturers and end-
users can together ensure that all aspects of materials
behaviour are taken into account in designing safe,
hygienic, reliable and efficient equipment which can be
operated, maintained and managed economically.
Training DVD available.
Languages available: English, French, German,
Macedonian
Doc. 33. Hygienic engineering of discharging
systems for dry particulate materials
First Edition, September 2005 (16 pages)
The introduction of the product into the processing system
is a key step in maintaining the sanitation and integrity of
the entire process. Discharging systems are designed to
transfer, in this case dry solids, from one system into
another without powder spillage, contamination or
environmental pollution. Many dry systems do not have any
additional protective heating steps, as they are merely
specialty blending processes. Therefore, any contamination
that enters the system will appear in the finished product.
Guidelines for the design of bag, big bag, container and
truck discharging systems are presented. They are
intended for use by persons involved in the design, sizing,
and installation of bag, big bag and truck discharging
systems operating under hygienic conditions.
Languages available: Dutch, English
Doc. 34. Integration of hygienic and aseptic
systems
First Edition, March 2006 (45 pages)
Hygienic and/or aseptic systems comprise inter alia
individual components, machinery, measurement systems,
management systems and automation that are used to
produce for example food products, medicines, cosmetics,
home & personal products and even water products. This
horizontal guideline is about the hygienically safe
integration of hygienic (including aseptic) systems in a food
production/ processing facility.
Systems and components are frequently put together in a way
that creates new hazards, especially microbiological ones.
Deficiencies during the sequence of design, contract, design-
change, fabrication, installation and commissioning are often
the cause of these failures, even when specific design
guidelines are available and are thought to be well understood.
Errors in sequencing and content can also result in major
penalties in terms of delays and in costs of components and
construction. This document examines integration aspects that
01.04.11 08:51

can affect hygienic design, installation, operation, automation,
cleaning and maintenance and uses system flow charts and
case studies describing the integration processes and decision
steps. It does not provide detailed guidance on specific manu-
facturing processes, products, buildings or equipment.
Training DVD available.
Languages available: Armenian, English,
German, Italian, Macedonian
Doc. 35. Welding of stainless steel tubing in
the food industry
First Edition, July 2006 (29 pages) update in progress
since 2010 in conjunction with Doc. 9
Abundantly illustrated, this paper provides guidelines for
the correct execution of on-axis hygienic (sanitary) welding
between pipe segments, or between a tube and a control
component (e.g. valve, flow meter, instrument tee, etc.) It
deals with tube and pipe systems with less than 3.5 mm
wall thickness, 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 a weld destined for hygienic uses are first described,
then the possible defects which can affect the weld are
listed, and at the end the procedure for a state-of-the-art
welding execution is illustrated, including preparation of
pipe ends, final inspection and a trouble shooting guide. It
mainly refers to the part of the weld in contact with the
finished or intermediate product and the only welding
y our p roce ss
WESTINGHOUSE Feed
AXL airlock with SAL small sanitary
slide bars airlock
Dairy Rotary valves and Diverters
EHEDG Type EL Class I compliant
USDA Dairy accepted
ATEX compliant
www.dmnwestinghouse.com
EHEDG_Innenteil.indd 139
EHEDG Guidelines 139
method considered is the GTAW (Gas Tungsten Arc
Welding, commonly known as TIG) without filler material
(autogenous weld), since this technique is capable of
assuring the best performance in the execution of welds for
the fabrication of thin wall stainless steel tubing. Inspection
of welds will be covered in more detail in the next project.
Training DVD available
Languages available: English, French, German,
Macedonian
Doc. 36. Hygienic engineering of transfer
systems for dry particulate materials
First Edition, June 2007 (21 pages)
Transfer (also known as transport or conveying) of dry
particulate materials (products) between or within plant
components in a process line is well practiced in the food
industry. The transfer operation must be carried out in a
hygienic and safe manner and the physical powder
properties must not be affected during this operation. In this
document, hygienic transfer systems for transport of bulk
materials within a food processing plant are described. This
document also covers situations where transfer systems
are used as a dosing procedure.
In principle, the less the need for product transfer within a
food processing plant, the easier it is to make a factory
hygienically safe. Furthermore, with a minimum of product
transfer between equipment, there are the added ad-
vantages of a more compact plant, lower energy consump-
tion and reduced cleaning time. Less product handling
results in less adverse effects on product properties.
COMPONENTS FOR BULK SOLIDS HANDLING
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01.04.11 08:51
 140 EHEDG Guidelines
This guideline is intended for use by persons involved in
the design, technical specification, installation and use of
transfer systems for dry bulk particulate materials operating
under hygienic conditions.
Languages available: Dutch, English
Doc. 37. Hygienic design and application of
sensors
First Edition, November 2007 (35 pages)
According to their working principles, all sensors rely on an
interaction with the material to be processed. Therefore, the
use of sensors is commonly associated with hygiene risks.
In many cases, the basic measuring aspect of a sensor and
the optimum hygienic design may conflict.
This guideline is intended to advise both, sensor designers
and manufacturers as well as those in charge of production
machinery, plants and processes about the appropriate
choice of sensors and the most suitable way for application
in dry and wet processes.
Sensors are crucial in the monitoring of the critical process
steps as well as the CCPs as established by the HACCP
study of the process. Therefore validation and calibration of
sensors in time sequences are essential.
This guideline applies to all sensors coming into contact
with liquids and other products to be processed
hygienically. However, it focuses upon sensors for the most
common process parameters, particularly temperature,
pressure, conductivity, flow, level, pH value, dissolved
oxygen concentration and optical systems like turbidity or
colour measurements.
Languages available: English, German
Doc. 38. Hygienic engineering of rotary
valves in process lines for dry particulate
materials
First Edition, September 2007 (13 pages)
Rotary valve selection and operation has a considerable
influence on the hygiene standard of a process line and
thus, the end-product quality of the dry material handled.
Incorrect selection of valve type and size must be regarded
as a serious hygienic risk in the food industry. Hence, only
valves strictly conforming to hygienic design standards and
suited for hygienic operations must be used.
This guideline applies to rotary valves that are in contact
with dry particulate food and/or food related materials being
processed hygienically in designated dry particulate
material processing areas. The objective of this guideline is
to provide guidance on the essential requirements for
hygienic rotary valve design and operation. The guideline is
intended for persons involved in the design, selection,
sizing, installation and maintenance of rotary valves
required to operate under hygienic conditions.
Languages available: English
Doc. 39. Design Principles for Equipment and
Process Areas for Aseptic Food
Manufacturing
First Edition, June 2009 (14 pages)
In many areas there is an increasing demand for self stable
products. However, microbial product contamination limits
the shelf life of sensitive products which are not protected
EHEDG_Innenteil.indd 140
by any preservatives or stabilised by their formulation.
Products which fail this inherent protection have to be
sterilised and in consequence, the equipment must be
cleanable and sterilisable. Micro-organisms which are
protected by product residues or biofilms are very difficult
or impossible to inactivate and the same applies to process
areas if resulting in a recontamination risk. This guideline is
intended to describe the basic demands for equipment and
process areas for aseptic food manufacturing.
Languages available: English
Doc. 40. Hygienic Engineering of Valves in
Process Lines for Dry Particulate Materials
First Edition, October 2010 (26 pages)
Every process plant is equipped with valves. In dry
particulate materials processing, valves fulfil numerous
functions: shut-off and opening of flow lines, direction and
flow control, protection against excessive or insufficient
pressure and against intermixing of incompatible media at
intersection points in the process. The quality of the valve
has a considerable influence on the quality of the
production process and hence, the product itself. Hygienic
deficiencies resulting from poor valve design must be
regarded as a production risk in the food industry which
must ensure that only valves strictly conforming to hygienic
requirements are used. This Guideline describes in detail
the hygienic requirements of butterfly valves, slide gate
valves and ball segment valves. It also briefly mentions
pinch-off valves, ball and plug valves as well as cone
valves. The hygienic design requirements of rotary and
diverter valves are subject of separate EHEDG Documents
(Doc. 38 and 41).
Languages available: English
Doc. 41. Hygienic Engineering of Diverter
Valves in Process Lines for Dry Particulate
Materials
First Edition, February 2011 (23 pages)
Every process plant is equipped with valves, which fulfil
numerous functions. These include line shut-off, opening,
change-over and control of product flow, while also giving
protection against both excessive or insufficient pressure
and intermixing of incompatible media at intersection points
in the process line.
When dry particulate material (product) flow has to be
diverted into several directions during processing or
product coming from different lines converges into one line,
diverter valves are applied. In the area of dry product
handling, these valves need a dedicated design.
This Guideline deals with the hygienic aspects of diverter
valve design.
Valve construction, however, has a considerable influence
on the quality of the production process and hence, the
product itself. Hygienic deficiencies resulting from poor
valve design must be regarded as a production risk in the
food industry which must ensure that only valves strictly
conforming to hygienic requirements are used.
Languages available: English
01.04.11 08:51

EHEDG Subgroup work
Within EHEDG a number of international experts gathered in Subgroups are responsible for the
development of Guidelines. Each Subgroup is responsible for an area of expertise, and within
each area certain specific scopes are defined.
The EHEDG Subgroup specialists meet regularly to update
existing and draw up new Guidelines. They originate from
many different countries ensuring the international validity
of the work. Participants with the relevant expertise are
always welcome to join these Subgroups and share in the
work and contribute their expertise and point of view.
New guidelines still in the process of being
drawn up are
- Seals
- Hygienic design requirements for the processing of
fresh fish
- Test methods
- Separators: disc stack centrifuges
design and cleanability
- Essential hygienic design requirements for equipment
used for open processes
- Meat processing
- Conveyor systems
Training A prerequisite in hygienic food processing to
enjoy safe food each and every day and everywhere
Knuth Lorenzen, Chairman of EHEDG Sub group Training & Education and President of EHEDG
E-mail: knuth.lorenzen@ewetel.net
In the year 2000, EHEDG started its activities to establish
training courses to provide education in hygienic design.
Between 2000 and 2004, Training Material and the
Trainers Toolbox, comprising 20 DVDs of audiovisual
materials including the Training Facilitator, was developed.
Since then we have been offering EHEDG Advanced
Courses on Hygienic Engineering and Design every year,
presented by hygiene experts with teaching skills to
educate effectively. Authorised trainers are listed on the
EHEDG/Training & Education web page.
To measure the effectiveness of our EHEDG Advanced
Course on Hygienic Engineering and Design we have
integrated a written exam as an opportunity for all
participants. Attendees passing this exam can be shown on
the EHEDG/Training & Education web page.
EHEDG_Innenteil.indd 141
European Hygienic Engineering & Design Group
Currently under revision:
- Hygienic design of pumps, homogenisers and
dampening devices (Doc. 17)
- Hygienic design of equipment for open processing
(Doc. 13)
- Hygienic design of valves for food processing (Doc. 14)
- Design of mechanical seals for hygienic and aseptic
applications mechanical seals (Doc 25)
- Chemical treatment of stainless steel
(to substitute Doc 18: Passivation of stainless steel)
- Materials of construction for equipment in contact with
food (Doc 32)
- Welding stainless steel to meet hygienic requirements
(Doc 9)
- Hygienic welding of stainless steel tubing in the food
processing industry (Doc 35)
The following Guidelines are currently being
planned:
- Cooling / Freezing equipment
- Bakery equipment
- Building design
- Cleaning validation
Still, by this action we have been able to reach only a
number of interested parties who are able to understand
and speak English. Our goal, however, is to reach
interested parties globally.
For this reason we have started in 2010 to up-date the
training material in accordance with an up-dated Training
Facilitator and all Guidelines to achieve identical material in
all languages on request.
As the basic language of all our documents is English, it is
up to our EHEDG Regions to translate the content into local
languages to carry out EHEDG Advanced Courses on
Hygienic Engineering and Design in their countries.
So far we have developed 15 Training Modules based on
the latest EHEDG Guidelines which will be translated for
the use of currently 18 countries.
01.04.11 08:52
 142 EHEDG Subgroups

With our group of EHEDG Authorised Trainers we offer a

wealth of knowledge which has been collated and created
by experts from the global hygiene network to bring our
future hygiene experts in our EHEDG regions up to speed
to execute EHEDG Advanced Courses on Hygienic
Engineering and Design in their local language.

We believe this is the way to guarantee that over the

course of time we shall be able to broaden and spread
knowledge about food hygiene and hygienic design
worldwide so that we can enjoy safe food each and every
day and everywhere.

Chairman:
Knuth Lorenzen
Flurstrae 37
21445 Wulfsen
Phone +49 4173 83 64
Fax +49 69 66 03 22 17
E-mail knuth.lorenzen@ewetel.net

EHEDG_Innenteil.indd 142 01.04.11 08:52


New EHEDG Subgroup on Conveyor Systems
kick-started 27th of January 2011
A new guideline on the hygienic design of conveyor systems, will be based on solid European
hygienic conveyor design experience, will be available to be used in the food industry
By Jon J. Kold, regional chairman EHEDG Denmark and chairman of the EHEDG Subgroup Conveyor Systems
E-mail: jon.kold@staalcentrum.dk
In January 2011 the newest EHEDG Subgroup Conveyor
Systems became active at a large kick-off seminar, which
took place on January 27, at Billund Airport Meeting Centre
in Denmark.
The purpose of the Subgroup is to prepare a new EHEDG
Guideline on hygienic design of conveyor systems to be
used in food manufacturing or processing. The subgroup
consists of some 20 professionals from companies and
institutions. This underlines the industrys broad interest in
the subject.
Conveyor systems are widely used in food manufacturing
for moving raw materials, processed food and packaged
products. The upcoming guideline is primarily aimed at
conveyors used in high risk areas, i.e. the processing of
non-packaged foods in direct contact with the conveyor or
transported in open boxes.
There are several reasons to reduce the hygiene risk by
applying hygienic design to conveyor systems.
Firstly, a good hygienic design reduces cleaning time and
cleaning costs. Therefore, the upcoming guideline will be
relevant in all production environments that require minimal
cleaning time. Special care has to be taken if food is
transported in a humid environment, which is particularly
conducive to the spread of bacteria and thus to the
transference of pathogenic or food spoilage bacteria to
products.
Secondly, the guideline may be used by construction
engineers in connection with the conveyor design. It may
also be used by purchasing officers when deciding on the
specification of parts for conveyor systems.
The guideline may also be used as a communication tool
between purchasing companies and suppliers making sure
that new conveyors comply with hygienic requirements
specification.
Danish initiative
EHEDG Subgroup Conveyor Systems is chaired by Jon
Kold, head of EHEDG Regional _Section Denmark which
has previously elaborated a guideline for the hygienic
design of conveyers for the food industry.
EHEDG Denmark is a relatively new EHEDG Regional
Section. It was formed in 2008 to strengthen the
cooperation between Danish equipment manufacturers, the
EHEDG_Innenteil.indd 143
EHEDG Subgroups 143
Danish food industry and EHEDG. A major goal for EHEDG
Denmark is to establish a broader knowledge of EHEDH
and the EHEDG guidelines in Danish companies. All
though the guidelines are well known to some companies,
there is a large potential for other companies to benefit
from them.
EHEDG Denmark closely collaborates with the industrial
network Stlcentrum, which was established in 2003 and
now has more than 80 company members representing
several industry segments. Being the most important
company network in the field of hygienic equipment design
in Denmark, Stlcentrum is in a good position to facilitate
and support the future development of EHEDG Denmark.
As a matter of fact the inspiration for the upcoming
guideline is a Danish guideline (Guideline 3: Conveyors
with focus on hygiene). This guideline was prepared by
Stlcentrums conveyor working group and published in
2007. It offers general advice with regard to the hygienic
design of conveyors for the food industry.
Hygienic design of conveyor systems
Hygienic design of conveyor system is complex and
demanding. Many solutions with regard to function, design,
cleanability and service of the equipment should be
considered thoroughly.
This article describes a few of the important considerations
the designer should have in mind when designing conveyor
systems. The upcoming EHEDG guideline will describe
these and many other areas of consideration in far greater
detail.
General design
First of all the construction engineer must ensure that the
delivered equipment meets the requirements and quality
demands that is consistent with the intended use. Reliability
and general function is of course just as important in
hygienically designed conveyor systems as in all other
equipment.
Next, the conveyor must be designed to allow for easy
cleaning. The equipment must be designed without sharp
corners and edges, and the design must be free of cracks,
ends, holes, unevenness, rough surfaces etc. in areas
where cleaning is difficult or impossible. Such areas may
harbour bacteria which can continuously contaminate the
product. Ideally, surfaces should reduce the development
of bacterial films on the machines.
01.04.11 08:52
 144 EHEDG Subgroups
All horizontal surfaces should be reduced to an absolute
minimum and designed with a 5 inclination to allow water
to run off. Constructions/brackets should also be inclined to
allow water to run off, which will facilitate drying of the room
after cleaning.
Finally the equipment should be as open as possible. The
number of guards should be minimised to what is
necessary for reasons of safety and should not prevent
efficient cleaning. Guards should be removable during
cleaning/disinfection, either through opening or by
unhinging.
Further topics to be elaborated during the working period of
the Subgroup:
- Different types of belts
- Lateral guides for belts
- Lateral guides for product
- Drive stations
- Drum motors
- Gear motors
- CIP cleaning systems
Details for this work will be communicated later.
EHEDG Subgroup Design Principles
Chairman: Dr. Gerhard Hauser
E-mail: gerhardwrhauser@yahoo.de
The Subgroup Design Principles has different working
groups dealing with specific topics. The group started with
the publication of the three fundamental guidelines on
hygienic design. The essential requirements are published
in Guideline no. 8 which is also the basis for EHEDG
equipment certification. More details about design
requirements can be found in Guidelines no. 10 and 13
about equipment used in closed and open production
processes respectively.
Aseptic food manufacturing has additional needs with
respect to equipment design and the process area. All this
is explained and summarised in Guideline no. 39.
Published Guidelines
Doc. 8 Hygienic equipment design criteria
Doc. 10 Hygienic design of closed equipment for the
processing of liquid food
Doc. 13 Hygienic design of equipment for open
processing
Doc. 18 Passivation of stainless steel
Doc. 39 Design Principles for Equipment and Process
Areas for Aseptic Food Manufacturing
EHEDG Subgroup Chemical Treatment of
Stainless Steel Surfaces
This Subgroup is currently working on a new edition of the
EHEDG Guideline
EHEDG_Innenteil.indd 144
Time schedule
The new guideline is intended to be finalised within the next
2430 months. It is planned to have 3 meetings per year to
evaluate progress.
New participants welcome
If you are an expert in this field and wish to contribute to the
good work, EHEDG Denmark would highly appreciate your
initiative in participating yourself or nominating an expert
of your company.
If you are interested in joining this Subgroup please contact
the chairman, Mr. Jon J. Kold, jon.kold@staalcentrum.dk,
or the EHEDG Secretariat juliane.honisch@ehedg.org.
Chairman:
Jon Kold
Fredensvang 38
7600 STRUER
DENMARK
Phone (+45 40) 57 13 46
E-mail jon.kold@staalcentrum.dk
Doc. 18 Passivation of Stainless Steel
which is undergoing an extensive amendment by including
further information on passivation, pickling and electro
polishing. In addition, chromium oxide and chemical
processes will be addressed in more detail. The guideline
title will be changed to Chemical Treatment of Stainless
Steel Surfaces".
Subgroup Equipment in Open Food
Production
To complement the existing EHEDG Guideline
Doc. 13 Hygienic Design of Open Equipment for
Processing of Food,
this subgroup is currently developing a new document on
Hygienic design requirements for equipment used in the
splash area or near open food production.
The amended document will deal with all kinds of
equipment installed between the ceiling, floor and walls
i.e. equipment that, followed by a risk assessment, is
determined to have a potential adverse influence on the
product safety when integrated into open equipment,
machinery or open processes.
01.04.11 08:52
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EHEDG_Innenteil.indd 145 01.04.11 08:52
 146 EHEDG Subgroups

For example, sensors used in open processes are often Chairman:

mounted in a way that makes them difficult to be cleaned. Dr. Gerhard Hauser
Cable connections, drives and displays often result in a lot Goethestr. 43
of crevices or are even uncleanable. The working group 85386 Eching
identifies such gaps in hygienic design and describes the Germany
requirements for this kind of equipment. Phone +49 89 3 19 12 67
E-mail gerhardwrhauser@yahoo.de

EHEDG Subgroup Dry Materials Handling

Chairman: Mr. Karel Mager
E-mail: karel.mager@givaudan.com

When the EHEDG started in 1989 most of the knowledge Doc. 38 Hygienic engineering of rotary valves in process
available was about liquid handling and liquid processing lines for dry particulate materials (2008)
equipment. In the following years a couple of documents Doc. 40 Hygienic engineering of valves in process lines
about test methods and design principles concerning this for dry particulate materials (2010)
topic were published.
The new EHEDG Doc. 40 Hygienic Engineering of Valves
In the area of dry particulate materials (powders) there was in the Dry Materials Handling Area" has been finalised and
a need for similar documents: design principles and published in October 2010.
guidance for hygienic engineering for the safe processing
of dry particulate materials. The draft document on Hygienic Engineering of Diverter
Valves in the Dry Materials Handling Area" is under final
The subgroup started in 1998 and has published several revision.
documents since then.
Future Subgroup topics may include dust handling
Published guidelines equipment and powder pack-off systems.
Doc. 22 General hygienic design criteria for the safe
processing of dry particulate materials (2001) Chairman:
Doc. 26 Hygienic engineering of plants for the processing Mr. Karel Mager
of dry particulate materials (2003) Givaudan Nederland B.V.
Doc. 31 Hygienic engineering of fluid bed and spray dryer Huizerstraatweg 28
plants (2005) 1411 GP Naarden
Doc. 33 Hygienic engineering of discharging systems for Netherlands
dry particulate materials (2005) Phone +31 35 6 99 21 86
Doc. 36 Hygienic engineering of transfer systems for dry Fax +31 35 6 94 37 19
particulate materials (2007) E-mail karel.mager@givaudan.com

EHEDG Subgroup Fish Processing

Chairman: Dr. Sanja Vidacek
E-mail: svidacek@pbf.hr

The future EHEDG document Hygienic Design Fish processing includes many different types of open
Requirements for the Processing of Fresh Fish will equipment.
describe and illustrate how the design principles of the
EHEDG Guidelines This document will cover the processing of fresh fish from
grading, gutting, de-heading, deboning, pin-boning,
Doc. 8 Hygienic Equipment Design Criteria trimming, filleting, skinning and portioning (including its ice
and producing system) until packaging. Its scope will not,
Doc. 13 Hygienic Design of Equipment for Open however, further fish processing including the smoking,
Processing cooking, frying, marinating etc. or the manual processing of
fish.
can be applied to the mechanised and/or automated
processing of fish.

EHEDG_Innenteil.indd 146 01.04.11 08:52


Specific hygienic risks related to fish properties and
processing conditions will be defined. The document will
describe the specific hygienic requirements of the fish
processing lines and their cleaning practices as well as
environmental issues associated with fish processing.
EHEDG Subgroup Mechanical Seals
Chairman: Mr. Goran Anderberg
E-mail: goran.anderberg@huhnseal.se
The Subgroup Mechanical Seals is currently editing and
revising the Guideline
Doc 25 Design of Mechanical Seals for hygienic and
aseptic applications (Description, Design and
Layout)
to bring it up to date. The last issue dates back to 2002 and
is in need of revision. This guideline compares the design
aspects of different mechanical seals with respect to ease
of cleaning, microbial impermeability, sterilisability and
pasteurisability. As such, the document can serve as a
guide for suppliers and users of this component.
Using EHEDG definitions, mechanical seals are classified
into three categories, according to use in the food industry:
Aseptic, Hygienic equipment Class I, and Hygienic
equipment Class II. The guideline covers both single and
dual mechanical seals under the first two categories, which
by definition, are subject to more stringent hygienic
demands.
EHEDG Subgroup
Pumps, Homogenisers and Dampening Devices
Chairman: Mr. Ralf Stahlkopf
E-mail: ralf.stahlkopf@geagroup.com
The Subgroup is currently working on the 3rd revised
edition of EHEDG Guideline
Doc. 17 Hygienic Design of Pumps, Homogenisers and
Damping Devices.
The revised edition is scheduled to be published in 2011.
EHEDG_Innenteil.indd 147
EHEDG Subgroups 147
Chairman:
Dr. Sanja Vidacek
Laboratory for Meat&Fish Technology
University of Zagreb
Faculty of Food Technology&Biotechnology
Department of FoodProcessing/Engineering
Phone (+385 1) 4 60 51 26
Fax (+385 1) 4 60 50 72
E-mail svidacek@pbf.hr
General design criteria are described, as well as the basic
requirements for materials used for components in
mechanical seals for food contact applications. Materials
covered include carbon-graphite, ceramics, elastomers and
metals. The hygienic implications of seal parts and
components are also discussed. Finally, installation
requirements are described and illustrated, taking into
account the product environment side, the flushing side and
the cartridge design.
A first draft has been completed in 2010 and is currently
being verified. A final version has still to be agreed on.
Chairman:
Goran Anderberg
Huhnseal AB
Box 288
26123 Landskrona
Sweden
Phone +46 41 8 44 99 42
Fax +46 41 8 44 99 69
E-mail goran.anderberg@huhnseal.de
The objective of this guideline is to provide a set of
minimum requirements for pumps, homogenisers and
dampening devices for hygienic and aseptic applications, to
ensure that food products are processed hygienically and
safely.
These requirements will apply to all pumps intended for use
in food processing, including centrifugal pumps, piston
pumps, lobe rotor pumps, peristaltic pumps, diaphragm
pumps, water ring pumps, progressive cavity pumps, screw
pumps, and gear pumps and also to homogenisers and
dampening devices. It will include any valves integral with
the pump head and the complete homogeniser head.
01.04.11 08:52
 148 EHEDG Subgroups

A classification of the pumps discussed will be provided Chairman:

together with illustrations and pictures to explain graphically Mr. Ralf Stahlkopf
the issues, problems (such as gabs and dead-ends) and GEA Tuchenhagen GmbH
their solutions. Am Industriepark 2-10
21514 Bchen
Germany
Phone +49 4155 49 25 78
Fax +49 4155 48 27 76
E-mail ralf.stahlkopf@geagroup.com

EHEDG Subgroup Seals

Chairman: Dr. Till Riehm
E-mail: till.riehm@freudenberg-ds.com

This new EHEDG document is meant for the application of The Subgroup would benefit from a few more specialists
seals within machinery, plants and components used in the from the food producing industry. Please contact the
processing of food, pharmaceutical products and personal Chairman or the Secretariat if you would like to participate.
products. Currently the document is still without a final title.
It not only deals with the materials to be used but also with Chairman:
their construction and fitting, the operating conditions and Dr. Till Riehm
the environment in which seals are to be used. Pipes and Freudenberg Process Seals GmbH & Co. KG
pipe coulings will also be dealt with. Lorscher Str. 13
69469 Weinheim
The document will discuss the adequate use and properties Germany
of elastomers while plastics and metal seals are not Phone +49 6201 80 89 19 00
included in the scope. Further, the processing of drinking Fax +49 6201 88 89 19 69
water will be explicitly included in the Guideline. E-mail till.riehm@freudenberg-ds.com

The Subgroup work was started under Christine Riebesell

who is currently taking a break from chairmanship. She was
succeeded by Dr. Till Riehm.

EHEDG Subgroup Separators

Chairman: Reinhard Moss
E-mail: reinhard.moss@geagroup.com

The Subgroup Separators is working on a new EHEDG Doc. 32 Materials of construction for equipment in contact
document dealing with the hygienic aspects of disc stack with food
centrifuges, used to separate fractions of liquid food Doc. 35 Welding of stainless steel tubing in the food
products or to remove dense solid matter from products. industry

Work on the final draft is in progress and the document is The Subgroup has defined specific rules applicable to the
under final revision . CIP-cleaning capability of separators which are not yet
covered by existing EHEDG documents.
Many of the design principles applicable to such kind of
equipment are already shown in the EHEDG Guidelines Chairman:
Reinhard Moss
Doc. 8 Hygienic equipment design criteria GEA Westfalia Separator GmbH
Doc. 9 Welding stainless steel to meet hygienic Technisches Produktmanagement
requirements Werner-Habig-Str. 1
Doc. 10 Hygienic design of closed equipment for the 59302 Oelde
processing of liquid food Germany
Doc. 16 Hygienic pipe couplings Phone +49 2522 77 25 71
Doc. 17 Hygienic design of pumps, homogenizers and Fax +49 2522 77 22 96
dampening devices E-mail reinhard.moss@geagroup.com

EHEDG_Innenteil.indd 148 01.04.11 08:52


EHEDG Subgroup Test Methods
The EHEDG Test Methods Subgroup was one of the first Subgroups established by EHEDG
and is responsible for publishing test methods, defining validation criteria and providing
assessments of equipment according to the hygienic design criteria of EHEDG in conjunction
with the EHEDG Certification Scheme.
Andrew Timperley, Chairman, Timperley Consulting, U.K., E-mail: andy.timperley@tesco.net
Following the launch of the new EHEDG website in 2009,
the Test Methods Subgroup concentrated its activities on
the implementation of an extended Certification Scheme to
include new categories of equipment. In connection with
this new Scheme a flow chart and matrix was produced to
define the assessment criteria and Certification Classes
applicable to these additional categories of equipment. The
structure of this new scheme can be viewed on the EHEDG
website and manufacturers are encouraged to liaise with
their local Test Institutes in order to co-ordinate certification
activities.
In 2010 the Group authorised a new Test Institute based at
Ainia, Centro Tecnolgico in Spain and received
applications from ADRIA Normandie in France and
Universit degli Studi di Parma in Italy to join the Group.
These new Institutes will add more accessibility to
manufacturers for testing and certification of equipment in
their regions and the Group will work with these new
Institutes to satisfy the criteria for authorisation.
Additionally, in 2010, all the Test Institutes completed a
reproducibility trial for the assessment of in-place
cleanability testing. The results were independently
reviewed to ensure that all Institutes are continuing to
achieve comparable results and providing consistent report
formats.
EHEDG Subgroup Valves
Chairman: Mr. Ulf Thieen, E-mail: ulf.thiessen@geagroup.com
The EHEDG Subgroup Valves is currently working on
extending the scope of the existing Guidelines
Doc. 14 Hygienic design of valves for food processing
(2nd edition, 2004)
Doc. 20 Hygienic design and safe use of double-seat
mixproof valves (1st edition 2000)
The new version will include additional topics such as
- the use of different valve types and their special
features in the food processing and pharmaceutical
industry,
- the static and dynamic closing behaviour of different
valve types
- cleaning and environmental aspects.
The guideline will apply to all valves to be used in contact
with fluid food or food constituents to be processed
EHEDG_Innenteil.indd 149
EHEDG Subgroups 149
This reproducibility exercise is conducted every three years
and the next trial will commence in the second quarter of
2011. The Group is responsible for updating and publishing
revisions to existing test methods and are currently
reviewing all the test method documents for re-printing in
2011. The Group has recognised the need for the
development of new test methods, specifically for the
assessment of open equipment cleanability, and will
continue to work on this topic during 2011.
As a result of the day to day testing activities of the
Institutes, information is collected to provide equipment
manufacturers with guidance on the selection of suitable
pipe couplings and process connections for hygienic
integration of equipment into processing systems. This list
is available to download from the free documents section of
the Guidelines area on the website and will be updated on
a regular basis as new information becomes available.
Chairman:
Andy Timperley
Timperley Consulting
GREAT BRITAIN
Phone +44 1789 49 00 81
Fax +44 1789 49 00 81
E-mail andy.timperley@tesco.net
hygienically or aseptically like butterfly valves, single-seat
valves, mixproof valves, process valves, etc.
International experts mainly from the user industries,
(pharmaceutical) engineers and validation consultants are
still welcome to join the group. All EHEDG members and
other experts interested in valves are invited to contribute
by their know-how.
Chairman:
Mr. Ulf Thieen
GEA Tuchenhagen GmbH
Am Industriepark 210
21514 Bchen
Germany
Phone +49 4155 49 27 09
Fax +49 4155 49 24 23
E-mail ulf.thiessen@geagroup.com
01.04.11 08:52
 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 Group

Company Membership Application

A company membership is open to companies, institutes and organisations. The annual contribution is based on the companys
turnover in food related business as outlined in the following table. Companies and institutes avail of at least one free individual
membership as well as of the whole series of EHEDG guidelines.

Company Turnover EHEDG contribution Free staff Training Toolbox

member type in EUR p. a. in EUR p. a. members (Prices in EUR)
1 over 500 millions 10,000 4 complimentary
2 50 to 500 millions 5,000 2 complimentary
3 10 to 50 millions 2,500 1 3,000
4 1 to 10 millions 1,000 1 3,000
5 less 1 million 500 1 3,000

Institutes / Universities / Schools / EHEDG contribution Free staff Training Toolbox

Research Centres / Governmental in EUR p. a. members (Prices in EUR)
Authorities 500 up to 4 1,000

My company / institution expresses commitment to become a company member of the EHEDG for the
contribution of: EUR p.a. Our annual company turnover is: EUR p.a.
(Please attach a company letter stating anual turnover p. a.)

All corporate and personal data will be treated confidentially. Fields marked by * to be filled in mandatory.

Company / Institution*

Address*

VAT number if within EC*

Invoice address (if different from above)

Name and position of company representative* (Please also attach business card)

e-Mail*

Phone*

Fax

Other free staff members (full names, only for company member types 1 and 2): (Please also attach business cards)
1. 3.

2. 4.

We understand that our membership becomes effective upon receipt of our application by the EHEDG Secretariat who will then
issue a membership invoice for the current year. To renew membership, subsequent invoices will be issued each during the first
quarter of the following year, unless a written request for cancellation is sent to the Secretariat by the end of December of the
current year.

Date / Signature

Please return to:

EHEDG Secretariat Phone +49 69 66 03 12 17
Lyoner Strae 18 Fax +49 69 66 03 22 17
60528 Frankfurt am Main E-Mail secretariat@ehedg.org
Germany Web www.ehedg.org

EHEDG_Innenteil.indd 150 01.04.11 08:52

 European Hygienic Engineering & Design Group

Individual Membership Application

I would like to become an individual member of EHEDG at an annual membership fee of EUR 100 (excl. VAT).

Working party Corresponding

Topics of interest:

All corporate and personal data will be treated confidentially. Fields marked by * to be filled in mandatory.

Name / First Name*

Company / Institution*

Address*

e-Mail*

Phone*

Fax

VAT number if within EC*

Invoice address (if different from above)

I understand that my membership becomes effective upon receipt of my application by the EHEDG Secretariat who will then
issue a membership invoice for the current year. To renew membership, subsequent invoices will be issued each during the first
quarter of the following year, unless a written request for cancellation is sent to the Secretariat by the end of December of the
current year.

Date / Signature

Please return to:

EHEDG Secretariat Phone +49 69 66 03 12 17
Lyoner Strae 18 Fax +49 69 66 03 22 17
60528 Frankfurt am Main E-Mail secretariat@ehedg.org
Germany Web www.ehedg.org

EHEDG_Innenteil.indd 151 01.04.11 08:52

 European Hygienic Engineering & Design Group

Published by
EHEDG Secretariat
European Hygienic Engineering
and Design Group
Lyoner Str. 18
60528 Frankfurt
Phone (+49 69) 66 03-22 17 / - 2430
Fax (+49 69) 66 03-22 17 / - 2430

Publishing House:
VDMA Verlag GmbH
Lyoner Str. 18
60528 Frankfurt
GERMANY

Technical Production
LEiTHNER GmbH & Co. KG
Bahnhofstr. 8
97500 Ebelsbach
GERMANY

Printing:
Sellier Druck GmbH, Freising

Executive Editor
Julie Bricher
Quiddity Communications
677 SW Tanglewood Circle
McMinnville 97128
UNITED STATES OF AMERICA

Editorial Board
Dr. John Holah, Campden BRI, GREAT BRITAIN
Juliane Honisch, EHEDG Secretariat, Frankfurt, GERMANY
Knuth Lorenzen, Wulfsen, GERMANY
Huub Lelieveld, Bilthoven, NETHERLANDS
Dirk Nikoleiski, Kraft Foods R&D Inc. Munich, GERMANY
Eric Partington, Nickel Institute, Cirencester,
GREAT BRITAIN

Copyright
Copyright rests with EHEDG. All rights reserved.

The copyright of the pictures and illustrations within the

articles belongs to the authors, respectively the companies
or institutes they represent unless otherwise stated.

Illustrations:
Cover:
1. GEA Tuchenhagen GmbH, Bchen, GERMANY
2. Interroll (Schweiz) AG, Sant' Antonino,
SWITZERLAND
3. KHS GmbH, Dortmund, GERMANY
4. Wire Belt Co Ltd, Sittingbourne, Kent,
GREAT BRITAIN
5. GEA Tuchenhagen GmbH, Bchen, GERMANY
6. Technische Universitt Dresden Fakultt
Maschinenwesen Dresden, GERMANY
7. Serac, La Ferte-Bernard Cedex, FRANCE
8. Wire Belt Co Ltd, GB-Sittingbourne, Kent,
GREAT BRITAIN

EHEDG_Innenteil.indd 152 01.04.11 08:52

 EHEDG
Yearbook 2011/2012

European Hygienic
Engineering & Design Group
EHEDG Yearbook 2011/2012

EHEDG Secretariat Phone +49 69 6603-1217 and -1430

Lyoner Strasse 18 Fax +49 69 6603-2217 and -2430
60528 Frankfurt am Main E-mail secretariat@ehedg.org
Germany Web www.ehedg.org

EHEDG Umschlag.indd 2 01.04.11 08:40