Process Equipment Standards for Hygienic Food Plant Design

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Process Equipment Standards for Hygienic Food Plant Design

Introduction: Why Equipment Design Matters in Food Plants

Hygienic design is the foundation of food safety, operational efficiency, and regulatory compliance in food processing facilities. From minimizing contamination risk to reducing cleaning downtime, designing equipment and layouts with hygiene in mind leads to:

Safer food production
Faster cleaning and maintenance
Longer equipment life
Compliance with GFSI, FSSAI, ISO 22000, and 3-A Sanitary Standards

A seasoned food consultant ensures your plant equipment meets both productivity and sanitation benchmarks.

Key Benefits of Hygienic Equipment Design

Reduces food contamination risk
Accelerates cleaning cycles
Lowers water and chemical usage
Supports fast equipment disassembly and maintenance
Improves overall productivity

General Equipment Design Considerations

Key Design Criteria:

Criteria for Hygienic Equipment Design

GFSI (Global Food Safety Initiative) emphasizes hygienic design, especially post-2020 via GFSI JI standards. Equipment should:

Be cleanable and self-draining
Have non-porous, non-absorbent, non-toxic contact surfaces
Use corrosion-resistant materials
Avoid crevices, cracks, and sharp corners
Include enclosed threads on adjustment parts
Ensure top covers are inclined at ≥45° to avoid water/dust accumulation

A food processing consultant helps in sourcing and validating such equipment during the factory planning phase.

Basic Equipment Construction Standards

For Contact Surfaces:

Polished or lacquered internal surfaces
Free from sharp edges, welding defects, or pitting
Designed for easy cleaning and self-draining

For Non-Contact Surfaces:

Should be smooth, drainable, sealed
Prefer mild steel or painted steel for cost-efficiency
Avoid ledges where dust can collect

Pipe and Pipe Rack Standards

Piping systems used for:

Material transfer
CIP (Clean-in-Place)
Drainage

Must follow:

Self-sloping installation for complete drainage
Seamless or sanitary-welded joints
Color-coded for differentiation (product, water, waste)

Equipment Layout and Location Guidelines

Proper layout improves hygiene, safety, and maintenance access.

Consider:

Easy access for cleaning and servicing
Logical flow from raw to finished product
Avoid equipment clusters that block sanitation access
Place machinery away from walls and drains to reduce contamination risk

Consultants use 3D layout modeling to ensure ergonomic flow, regulatory spacing, and future scalability.

Hygienic Design Reference Standards

Refer to:

3-A Sanitary Standards (USA)
EHEDG (European Hygienic Engineering & Design Group)
ISO 14159 and ISO 16732-1 for risk reduction
GFSI JI and FSSC 22000 for global benchmarking

Conclusion: Hygienic Equipment Design Ensures Compliance and Cleanliness

Implementing hygienic standards in process equipment design ensures:

Enhanced product safety
Quicker changeovers and cleaning cycles
Minimal downtime and maintenance costs

A skilled food manufacturing consultant brings expertise in:

Equipment selection and layout design
Plant construction and utility planning
Regulatory compliance for local and export markets

PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Process Equipment: Basic Standard For Plant Design Build World-Class Food Factories Build World-Class Food Factories 1 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering CONTENTS 1 2 3 4 5 6 X Introduction Criteria for Hygienic Designing Basic Standards for Equipment Designing Standards for Pipe & Pipe Rack Equipment Location & safety aspect References About PMG Engineering Build World-Class Food Factories Build World-Class Food Factories 2 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1. Introduction • Hygienic design is “the designing method keeping components associated with food process machinery designed in such a way that cleaning can reduce the risk of contaminating food products with potential hazards”. • Hygienic design significantly reduces food preparation contamination risks by creating easy-to-clean, durable, and moisture-free equipment. t I s e s i r p m o c Engineering principles, Environmental considerations, Safety protocols Operational efficiency to create a functional and Sustainable production environment. Build World-Class Food Factories Build World-Class Food Factories 3 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1.1 Benefits of hygienic design • Minimize the chance of contamination and shield the products from potential hazards. • Assists in achieving compliance to food safety rules and regulations • Increase productivity by ensuring industrial facilities and equipment are constructed using sanitary design principles. • Aids in accelerating extensive cleaning procedures • Cut down on the amount of time and money companies spend on cleaning their equipment. Build World-Class Food Factories Build World-Class Food Factories 4 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1.2 General Consideration for Equipment Generally following point to be account regarding designing selecting equipment for the food factories: and • MOC: Selected according to their food; with contact metal/plastic/glass. • Indirect food additive: No or to some instant; For material such as glass/ plastic. • Internal angle: Rounded at specific angle • Manufacturing procedure: Before designing and selecting any equipment for the industry, general or specific manufacturing procedure of machinery should be known. Build World-Class Food Factories Build World-Class Food Factories 5 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 1.2 General Consideration for Equipment • Opening: Lipped, opening should be covered to prevent contaminations • Cover: Shoebox design. • Top rim: Resistant to water and dust. • Product handling capacity: Designing should be done and considering handling capacity of the products per hour basis. selection * GFSI has introduced GFSI JI, a more robust set of benchmarking requirements for hygienic design for building constructors and equipment manufacturers in 2020. Build World-Class Food Factories Build World-Class Food Factories 6 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 2. Criteria for Hygienic Designing • The criteria for selection of Hygienic equipment is based on following characteristics: Characteristics Specification Product Contact Material • Inert to product, detergents and antimicrobial chemicals (sanitizers), & Corrosion-resistant, mechanically stable, smoothly finished and easily cleaned • Make: SS (SS 304, SS 316) • Inert to detergents and antimicrobial chemicals Product Non-Contact Material (sanitizers), Corrosion-resistant, mechanically stable, smoothly finished and easily cleaned Surface roughness • Make: Mild Steel • Smooth enough to be easily cleanable • Max. roughness of Ra = 0.8 µm (Acc. to EHEDG; European Hygienic Engineering and Design Group and American 3-A Sanitary organization) 7 Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 2. Criteria for Hygienic Designing Characteristics Specification Dead areas • Difficult to clean, should be avoided Screw threads Corners Drain-ability • Should be avoided. If not, crevices created should be sealed, at min. • Sharp corners should be avoided • Designed to be self-drainable Shaft passages and seals • Double seals with microbiocidal barrier liquids Threads Internal angle of corners Build World-Class Food Factories Build World-Class Food Factories 8 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 2. Criteria for Hygienic Designing Characteristics Specification Top rim • Avoid ledges, where product can lodge • Open-top rim, rounded and sloped for draining Drain-ability • Designed to be self-drainable Top rim Build World-Class Food Factories Build World-Class Food Factories 9 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Basic Standards for Equipment (a) Contact surfaces i. Standards for surface • Type: Smooth and resistive • Make: Non-porous, non-absorbent material, Non-leaching/ non-reactive constituent, non-toxic, food to odourless • Corrosion: Less or no corrosive • Surface faults: Without single cracks (crevice) or pores on surface • Durability: Extremely high • Service requirements: Cleanable, require less or no maintenance Effect of Corrosion Build World-Class Food Factories Build World-Class Food Factories 10 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Basic Standards for Equipment (Cont.) ii. Standards for Surface Texture • Surface of equipment should have characteristics such as - Smoothness, - Crack free, - Meeting sanitary standards. To create finished internal surface, methods such as - Polishing, - Lacquering, - Texturizing etc • Done as per American 3-a Sanitary Organization. Build World-Class Food Factories Build World-Class Food Factories 11 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Basic Standards for Equipment (Cont.) iii. Standards for Machine Construction • Equipment to be Free of sharp corner, - - Cracks/ crevices - Easy assembly, & disassembly for cleaning Self-drain using draining port. - • Piping to be at proper self-slope for efficient draining Build World-Class Food Factories Build World-Class Food Factories 12 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 3. Basic Standards for Equipment (Cont.) (b) For non-contact surfaces • Most of the specification is same as for food contact surfaces such as Smoothly finished and easily cleaned, drainable and entirely sealed and not penetrable having some differences - Make: Fabricated with material having properties such as corrosive and excellent malleable, mechanically maintenance free such as, MS (Mild steel) is generally specified. less stable, and - Ledges or areas where dust can collect should be avoided. - Tops: Equipment, shields, covers, or boxes should have their tops inclined at least 45 degrees. - Threads used on leveling components should be of the enclosed type. Build World-Class Food Factories Build World-Class Food Factories 13 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 4. Standards for Pipe & Pipe Rack Pipes used for material handling, Drainage and CIP, following consideration is assumed: # Purpose Type of pipe Flow rate (m/s) Dimension (mm) Make: SS 304 (stainless steel) Joints: • For high pressure handling – seamless, • For med. pressure handling – SS for food contact pipes < 1.2 25.4, 38.1, 50.8, 63.5,or even 76.2 CIP done using same piping used for product processing > 1.5 to 2.1 25.4, 38.1, 50.8, 63.5,or even 76.2 1 2 Process flow CIP for process line Build World-Class Food Factories Build World-Class Food Factories 14 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Equipment Layout and locations 5. Equipment Location & safety aspect Equipment Location Safety aspect 1. Grouped, offsite to the plant 2. Lower elevations, Surrounded by a dike wall to maintain integrity, maintain temp. & reduces contamination risk Silos Tanks Dryers Possibly grouped with avg. dia of 1/2 between tanks, onsite- 2 m to the building wall 2.5 m away from building walls Furnaces and fired heaters 15 m away from process zone Evaporator Barometric leg type (with height at least 10 mm) • Jacketed to control temp. change. • Provision for Containment loss As can be source of contaminants. Extremely hot air or direct flame can be hazardous to personnel or even processing unit. Hazard of explosion or implosion due to extreme pressures, Burns and scorches (due to hot water and leaking steam) 15 Build World-Class Food Factories Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Equipment Layout and locations 5. Equipment Location & safety aspect Equipment Location Safety aspect Process reactors • Access area 40 m2, for each 30 cm3 reactor volume • Either side of the pipe rack, As close as possible to the heater (minimizes cost of high heating piping) Heat exchanger Horizontal: Placed on grade, Vertical: Accessible to mobile crane or monorail with hoist High risk of fire, exploding (to a hazardous material explosion) during working or maintenance. Pumps Close to suction source, axis perpendicular to other equipment Premature failure, risk of fire due to leakage or excess heat. Air compressor • At clean and dry place • Sufficiently away from the HAC of equipment Risk of contamination, release of flying particles. Packaging machine At clean & dry place with 2-2.5 m distance in between, near to ware- house room Highly risk zone, potential area of contaminations, change of leakage in-case of failure. 16 Build World-Class Food Factories Build World-Class Food Factories PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering 6. References • Equipment Layout - Thepiping.com • Plant Layout Design Rules | Piping Layout Rules (PDF) – What Is Piping • Introduction of food plant design (bbsbec.edu.in) • https://www.mpofcinci.com/blog/guide-to-sanitary-and-hygienic-design/ • https://www.food-safety.com/fsm/assets/Image/2303CoverStory2Fig1-4.jpg • https://foodsafetyworks.com/wp-content/uploads/2022/09/Equipment.jpg Build World-Class Food Factories Build World-Class Food Factories 17 PMG Engineering Private Limited The End-to-End Engineering Company in Food Industry info@pmg.engineering |www.pmg.engineering Our Clients Build World-Class Food Factories Build World-Class Food Factories # We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients We deliver End-to-End Engineering Design and Construction Management Projects in Food and Beverage Industry. Meeting Global Benchmarks In ENGINEERING DESIGN and PROJECT MANAGEMENT for FOOD and BEVERAGE Industry with SINGLE POINT ACCOUNTABILITY Process Engineering | Project Management | Mechanical | Electrical | Automation | Food Safety Key Clients

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