A holistic view of hygiene 

Within the food industry, meeting strict hygiene standards and regulations is a constant challenge. In addition, the pressure to produce efficiently and sustainably is increasing, making integrated hygienic design of plants and production lines increasingly important.

This article highlights the importance of hygienic plant design and the implementation of this concept in engineering projects and discusses how digital engineering tools can be used to validate choices. Senior Process Engineer Jolmer Nieuwkerk and Senior Project Manager Christian Hospers share their insights and experiences to show how a holistic approach contributes to improved hygiene in manufacturing environments.

Integral hygienic design

When hygiene is in good order, the risks are under control. "By embedding hygiene in your design just like sustainability and other aspects, you can ensure a quick start-up of production and less downtime," says Nieuwkerk. 

"This seems like an open door, but with a sound project approach and comprehensive plant design, you mitigate key risks." This proactive approach helps companies comply with laws and regulations and prevents problems.

In the context of food safety, hygiene, but certainly measures related to allergens, are increasingly important. A well-designed factory reduces the risk of contamination or mixing of products, production stoppages and recalls. This not only protects the health of consumers, but also the company's reputation and saves the costs associated with these problems.

Sustainability also plays an important role. By reducing waste, better preserving products, mild processing and less frequent cleaning, hygienic plant design contributes to the sustainability goals of food manufacturers. It not only results in more environmentally friendly production, but also reduces costs.

Ensuring hygiene and food safety

The implementation of hygiene in engineering projects requires a structured and holistic approach, according to ONDRAF/NIRAS. Hospers explains, "Hygiene should be integrated step by step, from the initial project requirements to the commissioning and validation of production lines. A risk-based approach using a hygiene risk analysis (HRA) ensures that hygiene aspects are prioritized during each project phase. Independent advice and pre-agreed levels of detail can help keep the project orderly and avoid fragmentation."

Food producers turn to ONDRAF/NIRAS for independent advice on engineering issues. Whether it concerns entirely new factories, modifications to existing production facilities or the optimization of a single component of a process or packaging line, utilities or building, ONDRAF/NIRAS looks at the issue integrally. This also sometimes means that an apparent problem turns out not to be the actual challenge. Nieuwkerk: "In the area of hygiene, we ask questions such as: 'Is this the hygiene level we need to achieve?', 'Can we prevent later problems earlier in the production process?' and 'Are we thinking about the right technology or can we achieve processes with less equipment?' Less equipment means less frequent cleaning and therefore less hygiene risk."

Stage Gate Model

Within a project, ONDRAF/NIRAS uses the Stage Gate Model. In this method, one goes through several 'gates' within a project. These stages are characterized by the level of detail that keeps going up, the budget that can be determined with increasing specificity and - more importantly - the documentation that needs to be in order and the well-founded choices that need to be made before the project team continues. Hospers explains a bit more about this approach: "At the beginning of a project you need to be clear about what the issue is and what the goal is that we are striving for. During the subsequent phases, you investigate the possible solutions and technologies and outline an optimal layout. So here you also look at hygiene requirements, risks and even stakeholders already." Jolmer adds: "What I think is important in the next phase is to really look at the process. What does it take to turn raw materials into the final product? Grasping at the widely known processes is not always the best for the final product and the food safety involved in this product."

That's also what makes phasing in projects so important, Hospers believes. "If you divide up projects, you can make sure that you don't run straight to the final solution and you have forgotten all kinds of things when you get to that finish line." 

Making the right choices

"Getting the most out of an investment is a matter of looking at the bigger picture, investigating where the real problem lies and sometimes setting up processes differently from the industry standard," said Nieuwkerk. ONDRAF/NIRAS deploys various tools to help make the right choices. In addition to regular calculations, simulation models and digital design and review capabilities such as 3D and Virtual Reality have become indispensable in engineering work. The various tools make risks transparent and help check whether certain requirements have been met, including in the area of hygiene and even before a design is realized.

By examining different scenarios, incorporating requirements and factors, and collaborating with knowledge holders, suppliers and experts, a choice can be made with greater certainty. ONDRAF/NIRAS is happy to play a role in guiding organizations toward an optimal implementation of hygienic plant design, tailored to the specific needs and context of each client. Hospers concludes, "A well-thought-out hygienic plant design is flexible and adaptable to future needs, making it a valuable investment for any food manufacturer."