Ensuring the seamless delivery of commercial sterile products to consumers, sourced from over 220 lines spanning across 30 nations, may not appear as complex as rocket science. With a well-established recipe and advancements in aseptic technologies over the past two decades, aseptic production has evolved into a standardised practice. Yet, the ongoing commitment of food producers like Nestle towards maintaining food safety and quality at a competitive cost persists. This challenge transcends mere adherence to aseptic principles and technological designs. Operational reliability is indispensable beyond the initial line commissioning, beyond routine day shifts, and even when operations deviate from the planned sequence.  

In this presentation, Xavier shares Nestle’s comprehensive approach to anticipating and preventing any lapses in sterility. Firstly, cultivating enduring partnerships with suppliers to shape user-centric designs. Secondly, assuming technical leadership during the commissioning and qualification of new lines. Thirdly, mastering operational fundamentals with precision. Lastly, but indispensably, cultivating competencies and fostering the right mindset across all operational facets. Through this multi-faceted strategy, Nestle endeavors to fortify its commitment to delivering food safety and quality to consumers worldwide. 

Achieving Hygienic excellence by design - A Habasit case

At the EHEDG World congress 2024 Enrico and Wesley will highlight the critical role of hygienic design to achieve the hygienic excellence.

Hygienic excellence within the food processing industry refers to the highest standard of cleanliness and sanitation, which is essential for maintaining the consumers health and preventing disease.

This concept is not only about being free of dirt and bacteria but, also includes the design of facilities, equipment, and components to ensure they can be easily, efficiently, and effectively cleaned.

Hygienic excellence is a comprehensive approach that combines proper design, maintenance, and cleaning protocols to achieve an environment that supports health and cleanliness at the highest level.

By means of a case study, the Habasit team will provide insights into various aspects of a successful, hygienic design driven, new product development of a critical industrial component.

The exercise will highlight how the hygienic design can contribute to increase food safety and sanitation protocols’ efficiency, by reducing resource utilization such as labor, water, detergents, and water sewage treatments.

The presentation will also show the validation methodologies that Habasit, in collaboration with Fraunhofer IVV put in place to measure the achieved hygienic performance.

Turkiye joined EHEDG in 2012. Commencing in mid-2014, Hygienic Design Training and face-to-face hygienic design introduction visits began at the company level by Onur Devres. In 2015, the first three members joined EHEDG from Turkiye.

As stated under GFSI 2020 JI and JII topics, food processing facilities' construction and food processing equipment should be designed and engineered according to hygienic design principles. However, explaining all this to companies and ensuring they understand, accept, and internalize it (and become members and pay the EHEDG membership fees) takes time. Primarily since 2016, visits and briefings have been conducted every year for current, global, and potential members. Consequently, the number of members increased, and existing members continued to stay within EHEDG.

At the end of 2021, Sadef decided to establish a freeze-dryer facility in Aydin. For the design of the facility, Onur Devres and Ugur Uzuner, who had previously received hygienic design training from him, started discussions with architects, constructors, installation engineers, building element manufacturers, refrigeration companies, fruit processing machinery manufacturers, and freeze dryer equipment manufacturers. Positive discrimination was particularly applied to EHEDG members in the selection of subcontractor companies. After creating the preliminary construction project, work began on the placement of devices, installations, and drainage. To eliminate the problems encountered during this period and to ensure better project realization, non-member subcontractor companies were encouraged to join EHEDG and the architects, engineers, and designers from Sadef and subcontractor companies involved in the project attended the EHEDG Advanced Course on Hygienic Engineering and Design.

As of 2024, the construction of the 23,000 m² Sadef company facility has been completed; the number of members has approached 40; and nearly 40 global member companies have participated in EHEDG activities in Turkiye.

The Sadef project has actually been an example of constantly addressing the importance of hygienic design and engineering in a country and observing its development over time on a unique company basis. We believe that this will set a new state in benchmarking for other companies.

3-A SSI has a long and respected history of developing criteria for the design of equipment and systems used to produce, process and package milk and dairy products, other foods, and beverages. This presentation will explore the role of 3-A SSI today as a valued and trusted partner in helping to assure food safety through hygienic design. Specifically, this will describe the content and use of 3-A Sanitary Standards and 3-A Accepted Practices, the voluntary 3-A Symbol authorization and other certificate programs, 3-A SSI Knowledge Resources and the benefits of ongoing collaboration with EHEDG.

The presentation will explore current strategies for reducing the environmental impact of mandatory cleaning and disinfection operations in the food industry, which currently involve high consumption of drinking water, chemicals, and energy. Fouling of food processing surfaces and the necessary cleaning operations remain significant industrial challenges. These challenges typically result in economic penalties due to the fouling of heated surfaces and the substantial effort and cost required to ensure food quality and hygiene standards. 

However, with dwindling water resources, increasing costs of water treatment and chemical disposal, and new regulations mandating reduced environmental impact, it is imperative to find sustainable solutions. The presentation will highlight research findings on the advantages of hygienic design, innovative cleaning systems such as foam cleaning, and the use of new bio-based chemicals. These elements will be discussed in the context of Life Cycle Assessment (LCA) analyses to demonstrate their effectiveness in mitigating environmental impacts. 

Turkiye joined EHEDG in 2012. Commencing in mid-2014, Hygienic Design Training and face-to-face hygienic design introduction visits began at the company level by Onur Devres. In 2015, the first three members joined EHEDG from Turkiye.

As stated under GFSI 2020 JI and JII topics, food processing facilities' construction and food processing equipment should be designed and engineered according to hygienic design principles. However, explaining all this to companies and ensuring they understand, accept, and internalize it (and become members and pay the EHEDG membership fees) takes time. Primarily since 2016, visits and briefings have been conducted every year for current, global, and potential members. Consequently, the number of members increased, and existing members continued to stay within EHEDG.

At the end of 2021, Sadef decided to establish a freeze-dryer facility in Aydin. For the design of the facility, Onur Devres and Ugur Uzuner, who had previously received hygienic design training from him, started discussions with architects, constructors, installation engineers, building element manufacturers, refrigeration companies, fruit processing machinery manufacturers, and freeze dryer equipment manufacturers. Positive discrimination was particularly applied to EHEDG members in the selection of subcontractor companies. After creating the preliminary construction project, work began on the placement of devices, installations, and drainage. To eliminate the problems encountered during this period and to ensure better project realization, non-member subcontractor companies were encouraged to join EHEDG and the architects, engineers, and designers from Sadef and subcontractor companies involved in the project attended the EHEDG Advanced Course on Hygienic Engineering and Design.

As of 2024, the construction of the 23,000 m² Sadef company facility has been completed; the number of members has approached 40; and nearly 40 global member companies have participated in EHEDG activities in Turkiye.

The Sadef project has actually been an example of constantly addressing the importance of hygienic design and engineering in a country and observing its development over time on a unique company basis. We believe that this will set a new state in benchmarking for other companies.

Compressed Air in a food factory is often considered as a part of utilities and its importance in food production is often overlooked. Electricity, steam, and water often attract all the attention and investment and the compressed air system is often neglected. Compressed air generated at the compressor house is often presumed to be clean and filtered to the required ISO level ready for use in the factory.    

But what happens when that “clean filtered” compressed air leaves the compressor room to perform its job of work in the factory? What legacy debris, rust, oil, water vapour, particulates, bacteria are hiding in your compressed air network ready to be blown directly on to your food products, associated food contact surfaces and packaging? The risk of microbiological, physical, or chemical contamination is high.   

Current guidance from the likes of BRCGS, IFS, FSSC 22000 and SQF is vague and with the release from the GFSI of Scopes J1 and J2 there is an increased focus on hygienic design and food safety.Now is the time to reassess your compressed air at point of use filtration in light of your HACCP and prerequisite requirements. 

Based on our proven Drum Motor, which has been in use for years in thousands of food applications around the world, the SHC is the new solution for packed food applications. Engineered under European Hygienic Engineering and Design Group (EHEDG) guidelines, these conveyors ensure compliance with hygiene standards and withstand dedicated cleaning procedures. The innovation lies in the drive and control units, incorporating proven technology from Interroll’s leading position in the material-handling industry.  

Waterproof rollers, as well as proven solutions such as the RollerDrive, MultiControl and Power Supply enable advanced 24/48V technology and facilitated automation in packed food applications. Energy-efficient stainless steel roller conveyors, driven by the 50-watt RollerDrive and zone-specific control units, offer over 50 percent energy savings compared to conventional systems. Additionally, the zero pressure accumulation reduces wear and tear on modular belts, eliminating the need for frequent belt changes and reducing microplastic generation. With waterproof rollers, the risk of cross-contamination due to leakages is mitigated. Encapsulation prevents the accumulation of water, dirt, and cleaning agents inside rollers, addressing customer concerns about product contamination. Experience the future of sustainable and efficient box transportation with Interroll's innovative solutions; let’s work together to develop a business case for your business. 

At the EHEDG World Congress 2024 Sam will highlight the critical role of crack detection inspections within the food industry's preventative maintenance programmes. Drawing from his experience in the food processing industry, he will provide insights into various aspects of crack detection – from types and root causes, to specific equipment involved (such as spray dryer systems, tanks and silos) and associated food safety risks.  
Emphasising the importance of preventative maintenance, Sam will delve into the frequency of inspections necessary to mitigate risks effectively, exploring different methods and strategies.  

Having spent almost 30 years working in and assessing food manufacturing sites across the globe, Russell has seen some of the best and the worst that is out there. In this interview style session, Russell will be sharing his real life experiences of how equipment design, factory layout and poor practices lead to food safety challenges.

In this presentation, Robert will bridge best practices and global trends in the professional cleaning and hygiene industry with food safety and hygienic design. He will provide valuable insights into the critical areas of training and education, emphasising their role in fostering behavioural change and promoting sustainability. Robert will also offer a brief introduction to the professional cleaning and hygiene sector, highlighting its significance in maintaining high standards of cleanliness and safety. Attendees will gain a comprehensive understanding of how industry-leading practices can be applied to enhance food safety and hygienic design, driving improvements in both areas. This session is essential for professionals seeking to stay informed about the latest developments and innovations in cleaning and hygiene, and their impact on food safety. 

Hygienic design can be a lever for innovation and a business opportunity by meeting the current and future expectations of food processors, especially in certain markets such as the United States, and in sectors like meat and dairy. In response to these food safety-related challenges, new regulations and standards are emerging.  

In preparation for these changes, Liftvrac’s R&D department has implemented a comprehensive routine that spans from monitoring to collaborative construction, encompassing training and methodology for all staff members engaged in hygienic design. In his presentation, Quentin will share a case study with major advancements in hygienic design pertaining to Liftvrac’s conveyor systems and their strategies for penetrating new, increasingly demanding markets. The company is committed to collaborating with all stakeholders involved in hygienic design to effectively address these challenges. 

Peter's presentation, aims to provide an overview of the latest initiatives undertaken by the EHEDG Working Group ‘Welding’. The presentation will highlight the recent revision of EHEDG Guideline 35, detailing its main changes, and will discuss the upcoming revision of EHEDG Guideline 9, focusing on the incorporation of additional welding technologies used in hygienic applications. Attendees will gain valuable insights into the evolving standards and practices in hygienic welding, emphasising the group's commitment to advancing welding technologies to meet stringent hygiene requirements. This session is essential for professionals seeking to stay abreast of the latest developments and innovations in the field of hygienic welding. 

Join me at the upcoming EHEDG World Congress during my break-out session on the way to advance food safety and quality through Hygienic Design Risk Management (HDRM). During this session I will present a comprehensive new EHEDG guideline on assessing and managing hygiene risks in the design and operation of food-related buildings and equipment. Aimed at both suppliers and users within the food supply chain, the HDRM framework integrates hygiene risk assessment with risk reduction strategies, covering design, construction, integration, and operational procedures. Aligned with industry standards like EN1672-2 and ISO 14159, this new EHEDG guideline 58 offers a step-by-step approach supported by practical checklists and examples. Attendees will gain valuable insights into establishing hygiene risk criteria, identifying and analysing risks, and implementing effective control measures. My session offers strong insights for professionals dedicated to enhancing food safety, sustainability, and productivity in food manufacturing.

Turkiye joined EHEDG in 2012. Commencing in mid-2014, Hygienic Design Training and face-to-face hygienic design introduction visits began at the company level by Onur Devres. In 2015, the first three members joined EHEDG from Turkiye.

As stated under GFSI 2020 JI and JII topics, food processing facilities' construction and food processing equipment should be designed and engineered according to hygienic design principles. However, explaining all this to companies and ensuring they understand, accept, and internalize it (and become members and pay the EHEDG membership fees) takes time. Primarily since 2016, visits and briefings have been conducted every year for current, global, and potential members. Consequently, the number of members increased, and existing members continued to stay within EHEDG.

At the end of 2021, Sadef decided to establish a freeze-dryer facility in Aydin. For the design of the facility, Onur Devres and Ugur Uzuner, who had previously received hygienic design training from him, started discussions with architects, constructors, installation engineers, building element manufacturers, refrigeration companies, fruit processing machinery manufacturers, and freeze dryer equipment manufacturers. Positive discrimination was particularly applied to EHEDG members in the selection of subcontractor companies. After creating the preliminary construction project, work began on the placement of devices, installations, and drainage. To eliminate the problems encountered during this period and to ensure better project realization, non-member subcontractor companies were encouraged to join EHEDG and the architects, engineers, and designers from Sadef and subcontractor companies involved in the project attended the EHEDG Advanced Course on Hygienic Engineering and Design.

As of 2024, the construction of the 23,000 m² Sadef company facility has been completed; the number of members has approached 40; and nearly 40 global member companies have participated in EHEDG activities in Turkiye.

The Sadef project has actually been an example of constantly addressing the importance of hygienic design and engineering in a country and observing its development over time on a unique company basis. We believe that this will set a new state in benchmarking for other companies.

Soil adhesion to food processing environment surfaces, including floors, is unwanted as it may result in increased cleaning costs and act as a reservoir for undesirable pathogenic microorganisms. In France, a list of agreed floors for use in food production facilities is edited based on their slipperiness and their cleanability. This parameter is currently assessed by microscopic observation and enumeration of the surface imperfections (holes, cracks and aggregates)(Carpentier, B. 2011). This method is highly dependent on the evaluator experience and lacks of reproducibility. Therefore, a new standard method would be appreciated. The protocol described in the recently published EHEDG Doc.57 for the assessment of open process equipment cleanability was then tested and optimized for use on floors. This approach was also compared to a more conventional microbiological method. All three tested protocols allowed to differentiate floors samples as a function of their cleanability but results were inconsistent for a majority of samples as a function of the implemented test. This highlights the need for further research on floors hygiene in order to develop a new reliable standard method to assess the cleanability assessment test dedicated to floors.  

Sustainability has become a focal point within the food industry, with the dairy sector experiencing increasing pressure to reduce its environmental impact and adopt more sustainable practices. This imperative is compounded by the need to maintain product quality, to meet consumer demands and adhere to regulatory standards. A pivotal aspect in this journey is the optimisation of cleaning-in-place (CIP) cycles, which requires constant monitoring and involvement by all supply chain stakeholders.  

At the EHEDG World Congress 2024 Niamh will be presenting on the Effects of Process and Environmental Influences on Product and Process Optimisation, with a strong focus on cleaning-in-place (CIP) programmes for the dairy sector. Join me as we explore the challenges and opportunities in navigating the dynamic landscape of sustainable dairy operations.  

Incorporating hygienic design principles in a production facility reduces cleaning times and operational costs. This approach involves optimizing cleaning time through lean concepts and hygienic component design, minimizing cleaning frequency by optimizing product planning, and streamlining the overall cleaning process. While some design decisions may require a higher initial investment, they enhance cleaning efficiency over time. Utilizing materials that resist buildup and are easy to clean reduces maintenance time and resources. Additionally, analyzing changeover times during the design phase impacts operational expenses. Improved cleaning efficiency increases production cycles, thereby boosting productivity and profitability. Shorter cleaning times also reduce labor costs and water and energy consumption, contributing to sustainability and cost savings. Prioritizing cleaning efficiency ensures sustained high production performance. 

Without validated cleanability, you will never be able to sterilise a plant or reliably place your products on the market. A whole plant is more than the sum of its single parts. Even if you use certified components for construction a lot of hygienic critical effects are likely to occur. Hygienic testing of plants is mandatory before use and – much more critical – after years of production. During operation biofilm colonies were unintentionally promoted which resist the established cleaning and sterilisation procedures. Every food plant has got its own bacteriological biosphere. Therefore, adapted methods for cleaning/sterilisation validation need to be installed. 

Finding microbiologic problems is possible with a manageable amount of technical and organisational efforts. These methods are in use for the validation of aseptic filling machines. For other sections of a plant these methods need to be modified. The results are clear and reliable for detecting recontaminations down to 10-9 cfu/ml. For the location of problems plants need to be checked in separate sections. It makes sense to validate non-aseptic plants to qualify improvements or changes in construction. The detection of non-bacteriological soil is difficult and not reliable because it is unlikely to flush out CIP-unremovable soil. Accessibility is seldom given for direct surface testing methods (EPS-coloration). Therefore, tailored differential methods should be used to choose the one which leads to the most striking results. In several bachelor professional studies, the effectivity of some testing methods where quantified on pilot plants. You need to determine the best option for your plant through trial and error. 

To date, food plants have been designed primarily for food safety, with hygiene zones to control microbial hazards and segregation to separate allergens.  Following the 9/11 terrorist incident, there has also been a US led requirement to design food plants to resist bioterrorism.  The need for this design approach to control known and perceived hazards was further enforced with the publication of the GFSI 2020 benchmark scopes, JI and JII. 

As a key driver for future plant design, food safety has been joined by customer choice, climate change, power demand and, following the COVID-19 pandemic, food operative respiratory protection. Customer choice will favour vegan, vegetarian and religious based foods, which will lead to an exploration of the concept of ‘what is free-from’ in terms of the segregation of specific ingredients e.g., meat or a particular meat species. Climate change will require protection from weather events e.g., flooding, high winds, high snowfall, drought, but also a proliferation in pest and pathogen varieties and numbers.  Big data, AI, automation, electric vehicles etc. will all lead to enhanced power demands and may require on-site solar panelling or wind farms.  With pandemics estimated to be now every 4 years, together with the need to keep food factories in production, factory design will need to focus on operative separation, directional air flows and humidity/temperature control. 

The decontamination of surfaces using UV-based methods is an important and widespread option, particularly in the food industry. Microbiological validation with suitable test microorganisms are required to quantify the disinfection efficiency of such methods. The widely used mould strains Aspergillus brasiliensis and Aspergillus niger were classified as “S2” germs in Germany some time ago. As a result, these strains may only be used in authorised laboratories and are not allowed to be used at the site of machine manufacturers or in food facilities. It is to be expected that they may also be categorised “S2” in other countries. Furthermore, the recommendations of the VDMA (Machinery and Equipment Manufacturers Association) regarding the validation of UV-based sterilisation processes are used throughout Europe. The Aspergillus strains were also named as test germs in these recommendations.  

The identification of suitable surrogates for Aspergillus species was the aim of a research project at the Fraunhofer Institute IVV (Freising, Germany). Two suitable replacement strains for efficacy tests of xenon flash light and UV medium and low pressure lamps were tested in extensive studies and recommended for practical use. These strains have now also been included in the VDMA recommendations and replace Aspergillus niger resp. Aspergillus brasiliensis. 

Ensuring hygienic design in food and beverage plants is of prime importance for both product safety and regulatory compliance. However, the industry often zooms in on isolated details of equipment, overlooking key elements of conceptual process design, project preparation, commissioning and validation. At the EHEDG World Congress 2024 Jeroen would like to offer a holistic perspective on hygienic plant design, showcasing a typical engineering project as an illustrative example, with a focus on technical engineering solutions aligned with hygiene standards. Navigating through each phase and level of detail (LOD), he will highlight challenges, tools and the crucial relationship with commissioning and validation, unveiling success factors for scale-ups, greenfield and brownfield projects. Recognising the consequences of inadequate project preparation, this presentation will emphasise how a coordinated engineering approach is a fundamental investment to mitigate project risks, ensure quality and fulfill production requirements. 

Food industry has been significantly advancing the last decades in terms of monitoring and surveillance as well food safety standards and regulations. Food security, reduction of waste and carbon food print has been significantly targeted as areas that need improvement. This puts a lot of pressure to business owners ensuring that investment perform to their financial expectations while at the same time they remain compliant to their applied regulations. To this we already know that even a perfect food safety plan and Environmental Monitoring programs although they may ensure consumer safety they pose a significant operation cost due to poor Hygienic Engineering Design standards.

A key success factor to mitigate this is by streamlining the communication and delivery of knowledge and information needed between business owners in the supply chain of infrastructure and asset development lifecycle., is key to ensure equipment and facility development are build fit for purpose. 

Is this presentation we will be able to have a short look into the actual figures and practical quantifiable examples of how engineering specifications affect performance of operations.

The optimal selection of equipment needs to balance many factors, such as quality, performance, safety, cleanability, cost and sustainability. 

In this presentation, Jim and Dimitri will share approaches taken by one of the largest food manufacturing companies in the world.  This will cover topics such as processes, technical requirements, competencies and capabilities of those involved, as well as some of the challenges of managing this in a global manufacturing company. It will also cover how EHEDG guidelines are applied and the importance of collaboration between Original Equipment Manufacturers and end users in understanding and implementing user requirements. 

EHEDG has developed and published a new test method for assessing the cleanability of food processing equipment intended to be used in open processing and wet spray cleaned without dismantling. This test will now reinforce the Certification Scheme and provide a practical approach for certifying equipment used in open processing applications. The test follows the basic principles of EHEDG Guideline 2 method and consists of  soiling the piece of equipment to be tested, followed by a mild cleaning procedure and a final assessment. A reference piece is used to monitor correct implementation of the cleaning procedure to differentiate between good and poor design features.  

The reproducibility and repeatability of the test is achieved using an industrial robot to conduct the cleaning procedure in a controlled way using sophisticated 2D mapping software. The degree of cleanliness is based on the removal of a soil containing a UV tracer and is assessed by evaluating the residual soil using a UV light. The test is intended as a basic screening test for identifying areas of poor hygienic design in equipment used in open processes and is not indicative of performance in industrial cleaning situations. You can download (or purchase) EHEDG Guideline 57, ‘A Method for the Assessment of Open Process Equipment Cleanability’ here.  

This presentation draws from the extensive expertise of Subramani Asaithambi, Lactalis India Quality Director and a respected member of EHEDG. It explores the critical hazards associated with the heat treatment stage in food processing, particularly focusing on the potential survival of virulent pathogens originating from raw materials. While heat treatment is essential for ensuring food safety, many real-life quality and safety incidents stem not from the process itself but from inadequately designed or improperly operated heat treatment equipment. 

At Lactalis, emphasis is placed on seven key hygienic design principles to mitigate these risks:  

1. No mixing of untreated product with heat-treated 

2. Safe separation of product from CIP 

3. Cleanability 

4. Holding section design 

5. Self draining 

6. Compatibility of materials 

7. Smooth surfaces and accessibility 

In particular, cleanability is a critical factor in ensuring food safety. Key principles include: 

1. 7T + 4S principles 

2. No dead ends 

3. Hygienic dampeners 

4. Vortex breakers 

5. No shadow areas 

6. Correct agitator design 

As the industry continues to innovate, the focus on hygienic food production is expected to remain a top priority for stakeholders across the food supply chain, especially in food processing facilities that handle products such as ready-to-eat meals, fresh produce, seafood, dairy products and baked goods. These items are susceptible to contamination and require extra precautions to maintain their safety and quality. 

High care rooms, also known as high-risk or high-care areas, are specialised environments within food production facilities dedicated to handling and processing these sensitive or high-risk food products. These areas are designed to minimise the risk of contamination and ensure the safety and quality of the finished food product. They are comparable in many ways to cleanrooms, as known from the pharmaceutical and electronic industries. With a long history of cleanroom standards and guidelines, there is much we can learn from these industries related to the design, construction and start-up of these controlled environments. 

The recent ISO 14644-4:2022 document, ‘Cleanrooms and Associated Controlled Environments Part 4: Design, Construction, and Start-Up’, is an internationally recognised standard that provides guidelines and requirements for the design, construction and start-up of cleanrooms and associated controlled environments. This presentation will explain the systematic approach to creating an environment that suits the needs of the product. 

Ensuring food safety and meeting microbial specifications are critical goals in dairy production. At FrieslandCampina, we focus on designing production processes that bridge the gap between raw milk and the final product. This involves not only achieving microbial safety but also maintaining essential product attributes such as taste, structure, and nutrient integrity.

Traditional heating technologies, such as pasteurization and UHT, are widely used in the dairy industry to ensure microbial safety and extend shelf life. These methods rely on established standards for hygienic design and operation, ensuring effective microbial inactivation without recontamination.

 However, emerging preservation technologies offer new opportunities for microbial reduction in liquid streams. These technologies, which include high-pressure processing (HPP), pulsed electric fields (PEF), ceramic micro filtration (CMF), and UV-C treatment, operate on different inactivation principles compared to heat. As a result, they present unique challenges and opportunities for hygienic design.

 This presentation will explore the hygienic design principles that have been successfully applied to pasteurization and UHT processes and extend these principles to emerging technologies. We will discuss how to adapt hygienic design strategies to ensure sufficient microbial reduction while maintaining product quality in these new preservation methods. This includes considerations for equipment design, operational parameters, and validation procedures to prevent recontamination and ensure consistent product safety.

 Join us to gain insights into the future of dairy preservation and how innovative technologies can be integrated into your processes while maintaining the highest standards of food safety and quality.

Open equipment is widely used in the food industry and is involved in the manufacture of various types of products, including perishable food products with significant risks of microbiological contamination. Fresh cut, ready meals and other ready-to-eat refrigerated products, which are gaining more and more in popularity among consumers, are, for example, mostly manufactured in open production lines.

The new EHEDG Doc.13 focuses on design criteria for equipment used in wet-cleaned, open food-processing areas and details and illustrates how the hygienic design criteria presented in EHEDG Document 8 can be applied to open equipment.

The processing environment monitoring aims to ensure food handlers operate in a hygienic and safe environment, focusing on zoning, training, cleaning efficacy and eliminating harborages. Sampling plans should balance routine and investigative samples, identifying ‘gatekeeper’ points to prevent contamination and ‘investigation’ points to locate potential harborages. Corrective actions, including thorough cleaning and root cause analysis, follow positive results. Vector samples aid in identifying contamination sources, while strain typing helps determine necessary corrective actions.  

The dairy sector emphasises monitoring to evaluate zoning, hygiene practices and sanitation efficacy, crucial for preventing recontamination events. Following a publication on processing environment monitoring, under the umbrella of ILSI Europe with ICMSF Members, François is working together with the International Dairy Federation (IDF) on developing similar guidelines for the dairy industry.  

In November 2023, Young EFFoST (European Federation of Food Science and Technology) in cooperation with EHEDG kick-started the EYE Mentorship Programme during the EFFoST Conference in Valencia. This programme pairs young professionals with experts from the fields of food science and technology. In the programme, mentees and mentors meet regularly and work together on several topics according to their needs and preferences. In this, the focus lies on personal development as well as professional growth. Intertwined with the 1:1 meetings, on-site events are taking place to enhance networking and to provide hands-on workshops for all participants. In this talk, Felix Schottroff and Adwy van den Berg will present the highlights of the first round of the EYE Mentorship Programme and will announce the start of the 2^nd round of the programme.

The topic Ester is excited to share revolves around the everyday cleaning routines in food manufacturing, especially in Processed Food sites where Open Plant Cleaning (OPC) takes the spotlight. Traditionally, this process has required significant manual labor. However, Diversey has been developing new tools to address the daily challenges faced by the industry, including time constraints, productivity concerns and the imperative for sustainability. 

At the EHEDG World Congress 2024, Ester will introduce a fresh survey for OPC, along with an innovative product that opens the doors to optimised pre-rinses, and a tool that provides continuous data control throughout the whole open plant cleaning process. 

Achieving Hygienic excellence by design - A Habasit case

At the EHEDG World congress 2024 Enrico and Wesley will highlight the critical role of hygienic design to achieve the hygienic excellence.

Hygienic excellence within the food processing industry refers to the highest standard of cleanliness and sanitation, which is essential for maintaining the consumers health and preventing disease.

This concept is not only about being free of dirt and bacteria but, also includes the design of facilities, equipment, and components to ensure they can be easily, efficiently, and effectively cleaned.

Hygienic excellence is a comprehensive approach that combines proper design, maintenance, and cleaning protocols to achieve an environment that supports health and cleanliness at the highest level.

By means of a case study, the Habasit team will provide insights into various aspects of a successful, hygienic design driven, new product development of a critical industrial component.

The exercise will highlight how the hygienic design can contribute to increase food safety and sanitation protocols’ efficiency, by reducing resource utilization such as labor, water, detergents, and water sewage treatments.

The presentation will also show the validation methodologies that Habasit, in collaboration with Fraunhofer IVV put in place to measure the achieved hygienic performance.

This presentation aims to give participants a comprehensive understanding of how hygienic design affects the entire organisation and demonstrate how involving all departments can reduce overall project costs. Participants will learn about the importance of involving all subject matter experts (SMEs) in the hygienic design process from inception to start-up. These SMEs include quality, food safety, sanitation, operations, regulatory compliance, human safety, and engineering. 

Key points to cover: 

1. Holistic Impact of Hygienic Design: 

• Understanding how hygienic design influences every aspect of the organization. 

• Recognizing the potential cost savings achieved through effective design and departmental collaboration.

2. SMEs in Hygienic Design: 

The critical role of SMEs from various departments: 

• Quality: Ensuring the design meets quality standards. 

• Food Safety: Identifying and mitigating contamination risks. 

• Sanitation: Designing for ease of cleaning and maintenance.

• Operations: Creating efficient and practical processes. 

• Regulatory Compliance: Meeting legal and industry standards. 

• Human Safety: Ensuring a safe working environment. 

• Engineering: Integrating technical and functional requirements. 

3. Comprehensive Risk Assessment: 

• The importance of conducting a thorough Quality and Food Safety Risk Assessment. 

• Applying risk assessment insights before submitting the Capital Investment Request (CIR). 

4. Collaboration Across Departments: 

• Involving food safety, quality, engineering, operations, human safety, and sanitation leadership throughout the design and start-up phases. 

• Ensuring continuous collaboration to address potential issues proactively. 

By the end of the presentation, participants will understand the critical importance of SME involvement in hygienic design and be equipped with practical knowledge on how to apply these principles to achieve a successful, cost-effective, and compliant food manufacturing environment. 

Food industry has been significantly advancing the last decades in terms of monitoring and surveillance as well food safety standards and regulations. Food security, reduction of waste and carbon food print has been significantly targeted as areas that need improvement. This puts a lot of pressure to business owners ensuring that investment perform to their financial expectations while at the same time they remain compliant to their applied regulations. To this we already know that even a perfect food safety plan and Environmental Monitoring programs although they may ensure consumer safety they pose a significant operation cost due to poor Hygienic Engineering Design standards.

A key success factor to mitigate this is by streamlining the communication and delivery of knowledge and information needed between business owners in the supply chain of infrastructure and asset development lifecycle., is key to ensure equipment and facility development are build fit for purpose. 

Is this presentation we will be able to have a short look into the actual figures and practical quantifiable examples of how engineering specifications affect performance of operations.

The optimal selection of equipment needs to balance many factors, such as quality, performance, safety, cleanability, cost and sustainability. 

In this presentation, Jim and Dimitri will share approaches taken by one of the largest food manufacturing companies in the world.  This will cover topics such as processes, technical requirements, competencies and capabilities of those involved, as well as some of the challenges of managing this in a global manufacturing company. It will also cover how EHEDG guidelines are applied and the importance of collaboration between Original Equipment Manufacturers and end users in understanding and implementing user requirements. 

Deb thinks Hygienic Design should be considered as an essential pre-requisite for all equipment and facilities used in connection with food handling; it also extends to the safety of the materials used in contact with the food. It's surprising that many manufacturers, purchasers, and users of food industry equipment are unaware or overlook its importance. EHEDG and 3-A SSI have a long history in the promotion of hygienic design through the provision of training, guidance, certification, and expert advice. In the past, attention has primarily been directed towards the hygienic design of food processing equipment. However, there is now a growing recognition that ensuring food safety and quality also hinges on the hygienic design of the buildings where food processing occurs, the facilities supporting those structures, and the additional equipment utilised within the factory environment. As a consequence, EHEDG now publishes guidance on ‘Hygienic Design Principles for Food Factories’ (Guideline 44), and on ‘Air Quality Control for Building Ventilation’ (Guideline 47).  Additionally, food industry cleaning tools and utensils have long been identified as a major source and vector of contamination 1,2,3, and the importance of their hygienic design is reflected in GFSI food safety standard requirements. This presentation will summarise existing and developing EHEDG guidance, and GFSI food safety standard requirements related to these supplementary sources of contamination within food production areas, and will investigate the future of hygienic design as a holistic concept within food production facilities. 

As of December 2023, global discussions on the regulation of poly- and perfluorinated alkylated substances (PFAS) have gained prominence, with a particular focus on their impact on sealing technology in the food and beverage industry. The presentation will shed light on the current status of regulatory considerations, specifically those planned for implementation in the European Union. The proposed regulations encompass various polymeric materials, including PTFE, FKM, FFKM, and FEP, all integral to sealing technology. Despite the existence of secure manufacturing processes and proper waste treatment methods, there is a looming possibility of these materials being banned. Notably, these materials comply with food and pharmaceutical regulations globally, demonstrating their safety through positive lists and extraction tests during application. While some regions, such as the United States and the United Kingdom, have excluded polymers from similar regulations based on the OECD definition, the European Union is currently engaged in ongoing discussions among stakeholders. The presentation will delve into the challenges associated with these discussions and highlight the desirability of aligning with the OECD definition to mitigate potential bans. It will also present fluorine-free replacements and examine restrictions and consequences that may arise in the event of a complete ban, as proposed. 

Turkiye joined EHEDG in 2012. Commencing in mid-2014, Hygienic Design Training and face-to-face hygienic design introduction visits began at the company level by Onur Devres. In 2015, the first three members joined EHEDG from Turkiye.

As stated under GFSI 2020 JI and JII topics, food processing facilities' construction and food processing equipment should be designed and engineered according to hygienic design principles. However, explaining all this to companies and ensuring they understand, accept, and internalize it (and become members and pay the EHEDG membership fees) takes time. Primarily since 2016, visits and briefings have been conducted every year for current, global, and potential members. Consequently, the number of members increased, and existing members continued to stay within EHEDG.

At the end of 2021, Sadef decided to establish a freeze-dryer facility in Aydin. For the design of the facility, Onur Devres and Ugur Uzuner, who had previously received hygienic design training from him, started discussions with architects, constructors, installation engineers, building element manufacturers, refrigeration companies, fruit processing machinery manufacturers, and freeze dryer equipment manufacturers. Positive discrimination was particularly applied to EHEDG members in the selection of subcontractor companies. After creating the preliminary construction project, work began on the placement of devices, installations, and drainage. To eliminate the problems encountered during this period and to ensure better project realization, non-member subcontractor companies were encouraged to join EHEDG and the architects, engineers, and designers from Sadef and subcontractor companies involved in the project attended the EHEDG Advanced Course on Hygienic Engineering and Design.

As of 2024, the construction of the 23,000 m² Sadef company facility has been completed; the number of members has approached 40; and nearly 40 global member companies have participated in EHEDG activities in Turkiye.

The Sadef project has actually been an example of constantly addressing the importance of hygienic design and engineering in a country and observing its development over time on a unique company basis. We believe that this will set a new state in benchmarking for other companies.

Soil adhesion to food processing environment surfaces, including floors, is unwanted as it may result in increased cleaning costs and act as a reservoir for undesirable pathogenic microorganisms. In France, a list of agreed floors for use in food production facilities is edited based on their slipperiness and their cleanability. This parameter is currently assessed by microscopic observation and enumeration of the surface imperfections (holes, cracks and aggregates)(Carpentier, B. 2011). This method is highly dependent on the evaluator experience and lacks of reproducibility. Therefore, a new standard method would be appreciated. The protocol described in the recently published EHEDG Doc.57 for the assessment of open process equipment cleanability was then tested and optimized for use on floors. This approach was also compared to a more conventional microbiological method. All three tested protocols allowed to differentiate floors samples as a function of their cleanability but results were inconsistent for a majority of samples as a function of the implemented test. This highlights the need for further research on floors hygiene in order to develop a new reliable standard method to assess the cleanability assessment test dedicated to floors.  

The presentation explores the potential of AI-driven chatbots, like OpenAI’s ChatGPT, to enhance food safety in resource-limited settings, particularly in second and third-world countries where expert knowledge and training are scarce. It highlights how these AI tools can assist less experienced food safety professionals in small to medium food production factories by simplifying complex guidelines into more understandable formats, making critical safety information accessible in multiple languages, and providing immediate translations. This capability is especially beneficial in factories with diverse linguistic and cultural backgrounds, ensuring clearer comprehension and implementation of safety protocols. 

Furthermore, the presentation demonstrates how chatbots can generate code that integrates with presentation software, aiding the creation of customized training manuals. The future potential of OpenAI’s tools, including text-to-video and text-to-voice technologies, is discussed as a way to revolutionize training processes, transforming intricate standards into user-friendly training videos and voiceovers. This innovation could educate even illiterate maintenance staff effectively. 

EHEDG has developed and published a new test method for assessing the cleanability of food processing equipment intended to be used in open processing and wet spray cleaned without dismantling. This test will now reinforce the Certification Scheme and provide a practical approach for certifying equipment used in open processing applications. The test follows the basic principles of EHEDG Guideline 2 method and consists of  soiling the piece of equipment to be tested, followed by a mild cleaning procedure and a final assessment. A reference piece is used to monitor correct implementation of the cleaning procedure to differentiate between good and poor design features.  

The reproducibility and repeatability of the test is achieved using an industrial robot to conduct the cleaning procedure in a controlled way using sophisticated 2D mapping software. The degree of cleanliness is based on the removal of a soil containing a UV tracer and is assessed by evaluating the residual soil using a UV light. The test is intended as a basic screening test for identifying areas of poor hygienic design in equipment used in open processes and is not indicative of performance in industrial cleaning situations. You can download (or purchase) EHEDG Guideline 57, ‘A Method for the Assessment of Open Process Equipment Cleanability’ here.  

In the food and beverage manufacturing industry, water serves various purposes, impacting product safety, production reliability and workplace safety. With water scarcity on the rise, there's a growing emphasis on water reuse, posing new challenges to ensure reused water meets quality standards. Water treatment is essential to elevate reused water quality, a common practice in most food factories. Challenges also arise in storing and distributing water, necessitating controlled processes to maintain quality. Occupational health risks, particularly from Legionella spp. proliferation, are critical considerations. Legionella can lead to severe diseases like Legionellosis or Legionnaires’ disease. The upcoming presentation will cover these aspects, offering guidance on hygienic water management practices, including sourcing, storage, and distribution. It will also highlight different water categories used in the food industry and provide insights into controlling Legionella in water systems. 

JDE Peet’s has been expanding through the acquisition of various coffee and tea companies, which introduces unique challenges and risks that must be effectively managed. In her talk, Ana will discuss the strategies employed by JDE Peet’s to integrate an acquired factory into JDE Peet’s quality and food safety standards.

Ana’s presentation will cover:

• The methods used to identify and assess hygienic design risks, along with a review of risk mitigation practices.
• The prioritization of investments to address higher or more difficult-to-mitigate risks.
• The integration of HACCP (Hazard Analysis Critical Control Point) equipment risk management.

This approach highlights a business opportunity for managing food safety risks through a risk-based approach to equipment renewal.  

As of December 2023, global discussions on the regulation of poly- and perfluorinated alkylated substances (PFAS) have gained prominence, with a particular focus on their impact on sealing technology in the food and beverage industry. The presentation will shed light on the current status of regulatory considerations, specifically those planned for implementation in the European Union. The proposed regulations encompass various polymeric materials, including PTFE, FKM, FFKM, and FEP, all integral to sealing technology. Despite the existence of secure manufacturing processes and proper waste treatment methods, there is a looming possibility of these materials being banned. Notably, these materials comply with food and pharmaceutical regulations globally, demonstrating their safety through positive lists and extraction tests during application. While some regions, such as the United States and the United Kingdom, have excluded polymers from similar regulations based on the OECD definition, the European Union is currently engaged in ongoing discussions among stakeholders. The presentation will delve into the challenges associated with these discussions and highlight the desirability of aligning with the OECD definition to mitigate potential bans. It will also present fluorine-free replacements and examine restrictions and consequences that may arise in the event of a complete ban, as proposed. 

In November 2023, Young EFFoST (European Federation of Food Science and Technology) in cooperation with EHEDG kick-started the EYE Mentorship Programme during the EFFoST Conference in Valencia. This programme pairs young professionals with experts from the fields of food science and technology. In the programme, mentees and mentors meet regularly and work together on several topics according to their needs and preferences. In this, the focus lies on personal development as well as professional growth. Intertwined with the 1:1 meetings, on-site events are taking place to enhance networking and to provide hands-on workshops for all participants. In this talk, Felix Schottroff and Adwy van den Berg will present the highlights of the first round of the EYE Mentorship Programme and will announce the start of the 2^nd round of the programme.

Effective cleaning and disinfection linked with hygienic design in food factories are pivotal for enhancing productivity, sustainability, and food safety. With focus on hygienic design, factories can deliver many improvements by reducing water usage, conserving chemicals, improving utility consumption, and preventing microbiological contamination. These practices offer significant savings and operational efficiencies. You might ask yourself how is this possible? 

Adam will talk about how a strong focus on hygienic design in OPC (Open Plant Cleaning) and in CIP (Cleaning in Place) applications can have a positive impact on costs, but also on employee satisfaction, all while driving environmental sustainability.