The importance of hygienic design in dairy processing equipment

The dairy industry faces a challenge with milk, a highly perishable product. Milk given to its low-shelf life is freely open to adulteration and growth of microbials. The products processed from raw milk like market milk, cheese, butter, and yogurt, are highly perishable and susceptible to contamination. 

The importance of hygienic design in dairy equipment becomes essential as it ensures that the processing equipment adheres to stringent hygienic standards. As it directly impacts product quality, shelf life, and consumer safety. It is necessary for dairy processors to maintain high-level hygienic condition. Let’s understand how do dairy equipment manufacturers like Neologic Engineers ensure their designs meet with all the food safety standards. 

Fundamentals of Hygienic Design

Hygienic design refers to the engineering and construction principles applied to food processing equipment. To process dairy products, the below given factors need to be considered:

1. Equipment must be constructed from materials that are non-toxic, corrosion-resistant, and non-absorbent. Stainless steel of 304 and 316 grade, is the material of choice due to its durability and resistance to microbial growth.

2. Welded surfaces should be smooth and continuous i.e. free from cracks, crevices, and sharp corners. As polished and seamless finishes reduce the likelihood of microbial buildup and prevent from bacteria to harbor.

3. Seals and gaskets must be food-grade and resistant to degradation.

4. Equipment must be designed for effective cleaning, i.e., through Clean-in-Place (CIP) systems.

5. Proper drainage design ensures that cleaning solutions and residues are completely removed.

Hygienic design in dairy processing equipment is a paramount to achieving these standards.

Importance of Maintaining Hygienic Design in Dairy Processing Equipment 

Milk’s natural vulnerability to microbial growth and adulteration demands stringent hygienic practices. Maintaining good hygiene becomes crucial for the dairy industry. Well-maintained equipment prevents contamination caused due to unhygienic equipment, milk contact surfaces, handlers, storage, or packaging conditions. 

The risks arising from equipment contamination can lead to severe consequences, especially for immuno-compromised individuals. 

Key Considerations for Hygienic Equipment Design 

As effective cleaning and sanitization are the key aspects of maintaining hygiene in milk processing plants. Dairy processing involves multiple stages, such as pasteurization, homogenization, fermentation, and packaging, each of which requires specialized equipment.

Here are some key considerations for a hygienic dairy equipment design:

• Training and Monitoring: Operators must understand equipment handling to prevent bacterial contamination and ensure routine performance checks. 

• Cleaning Protocols: Regular cleaning with industry-approved detergents and sterilization are essential to prevent residue buildup and microbial contamination. 

• Material Standards: Equipment surfaces must be non-corrosive and comply with hygiene norms to withstand rigorous cleaning. 

• Facility Design: Proper drainage systems, non-porous flooring, and hygienic workwear contribute to maintaining a sanitized production environment. 

Hygienic Design Analysis

Dairy equipment manufacturers like Neologic Engineers conduct a comprehensive Hygienic Design Analysis of processing systems and lines. This analysis evaluates every aspect of the equipment, from material selection and surface finishes to cleaning protocols. This confirms that the designs meet global hygienic manufacturing standards.

Regulatory Frameworks Supporting Hygienic Design  

To mitigate the risks related to unsafe dairy items, dairy processing facilities adopt equipment that adheres to the global food safety guidelines. Global standards such as those from FSSAI, EHEDG, FDA, and 3-A SSI emphasize the need for equipment that supports hygienic operations. These standards are best-known international experts in the area of good design practices for sanitary equipment applications.

• The European Hygienic Engineering & Design Group (EHEDG) offers guidelines to ensure food safety through hygienic machinery and facility design. EHEDG is focused on promoting safe food by improving hygienic engineering and design in all aspects of food manufacturing.

•  3-A Sanitary Standards SSI establishes sanitary standards for equipment design, facilitating safe and contamination-free food production. It aims on developing, maintaining and publishing uniform standards and practices for a sanitary design, fabrication, installation, and operation of the equipment.

• Good Manufacturing Practices (GMP) provide a framework for manufacturers to ensure product quality, safety, and regulatory compliance. This guideline helps dairy manufacturers enhance product safety by ensuring that the milk products are free from contaminants, impurities, or harmful substances.

• The Food Safety and Standards Authority of India (FSSAI) defines how the milk processing equipment should be subjected to routine microbial monitoring. It suggests a separate section for cleaning and storing mobile equipment on utensils to avoid mix up or cross contamination.

Benefits of Maintaining Hygienic Conditions in Dairy Processing

Ensures Food Safety

Contaminated dairy products can lead to foodborne illnesses, causing harm to consumers and damaging a company’s reputation. Hygienic design reduces the risk of contamination from pathogens like Listeria, Salmonella, etc.

Maintains Product Quality

Hygienic equipment minimizes the risk of spoilage, ensuring that the final product meets sensory and nutritional standards. This is especially important for products like yogurt and cheese, where microbial interactions are integral to the production process.

Regulatory Compliance

Governments and international bodies have stringent regulations for dairy processing. Compliance with standards such as those set by the FDA, EHEDG (European Hygienic Engineering and Design Group), and 3-A Sanitary Standards is facilitated by hygienic design.

Operational Efficiency

Equipment designed with hygiene in mind is easier to clean and maintain, reducing downtime and associated costs. Moreover, effective cleaning prevents cross-contamination, enabling quicker transitions between different product batches.

CIP System (Cleaning in Place) for Maintaining Hygiene in Dairy Equipment

The CIP (Cleaning in Place) system plays a pivotal role in ensuring dairy equipment remains free from contaminants. The dairy industry continues to evolve, with innovations in hygienic design enhancing safety and efficiency. CIP can be performed without requiring disassembly, which results in reduced downtime, and ensures compliance with stringent food safety regulations.

CIP System for dairy process equipment and lines by Neologic Engineers is one such innovation. CIP module ensures proper cleaning of fouling of the product contact surfaces. It effectively cleans, sanitizes, and sterilizes the interior surfaces of vessels, equipment, filters, pipes, and fittings. Maintaining hygiene is a critical aspect of dairy processing, where cleanliness directly impacts product quality, safety, and shelf life.

Conclusion

Hygiene is one of the key parameters ensuring quality and credibility of any dairy farm or production facility. It is essential to maintain hygienic conditions to ensure highest levels of food safety to end consumers. An equipment designed keeping in mind all the hygiene requirements produce products that are safe, of high-quality, and compliant with regulations. By investing in robust, hygienically designed equipment like Neologic Engineers’ CIP systems, dairy processors can ensure product safety, consumer trust, and operational efficiency.