Hygienic design improves process technology

IN BEVERAGE and liquids food production, the microbiological and hygienic demands are very high. There are clear requirements for the implementation of hygienic design. These include an engineering design that is as simple as possible, access to all surfaces, no unnecessary surfaces, no hidden ‘dead’ spaces or roughness, and all liquids should be able to run off freely. Of continued importance is the use of materials that have outstanding process and cleaning characteristics with regard to surface structure and temperature and chemicals resistance –from the smallest seal through to the largest tank.

“Designing and building machinery and plant in line with the requirements of hygienic design is an absolute must in our sector,” says Richard Clemens, managing director of the Food and Packaging Machinery Manufacturers Association (Fachverband Nahrungsmittelmaschinen und Verpackungsmaschinen), affiliated in the VDMA (Germany’s engineering federation) and conceptual sponsor of drinktec*.

Hygienically designed technology optimised for production processes offers more than just microbiological safety. Whilst product safety is the main focus, the hygienic design of process, filling and packaging systems also offers benefits in terms of efficiency such as easy-to-clean surfaces and components will save on water, cleaning agents and energy. “The total time spent on cleaning is shorter,” Mr Clemens says, “and that means longer production times and increased efficiency of the systems technology.”

The importance of on-going hygiene monitoring

Standards will slip if on-going cleaning in beverage and food production is underestimated. Targeted hygiene monitoring helps maintain the microbiological status. In product analysis, swabs and samples are taken and cultivated on selective micro culture media. The current status of production is thereby made transparent. If the monitoring takes place on a defined schedule as regards sample time and place, then the hygiene status of production can be effectively controlled through preventive cleaning and disinfecting processes.

Broadly when it comes to cleaning, organic dirt is removed by alkaline and mineral-acid cleaning agents. Specific cleaning qualities can be achieved with the use of further additives. For the disinfection of surfaces and media, the beverage and food industry can also call on tried-and-trusted products that are based on chlorine, ozone, UV light, aldehydes, peracids, haloacetic acids, alcohol and ammonium compounds.

ECA disinfection gives rise to new applications

Electrochemically activated (ECA) water, also known as hypochlorous acid, is applied in the food and beverage industry as a disinfectant. The use of ECA water in disinfection has become a popular topic amongst manufacturers. In this process, membrane-cell electrolysis is used to produce a disinfecting chlorine compound from a watery salt solution. The use of ECA water has been investigated thoroughly, and interesting new fields of application can be found for processes in beverage and food production.

Robert Günther, branch manager Food & Beverage/Drinking Water from ProMaqua, says the company’s electrolysis process means that ECA water can be produced effectively on site. “In practice the minimal chloride concentration of our ECA water means a minimisation of the corrosion risk. Pipes, machine and system components are not attacked. With CIP applications, this also reduces the time input and energy consumption. When filling microbiologically sensitive beverages such as apple spritzer, and cKD VIII N7 Glowing