Hygienic Design Guidelines 2002

HYGIENIC DESIGN GUIDELINES
First Edition
Chilled Food Association
First Edition
2002
2002
Published by the Chilled Food Association Ltd, P O Box 6434, Kettering NN15 5XT, UK
© 2002 Chilled Food Association Ltd
Typeset in Lucida Sans Unicode 10
Printed in Great Britain by the Chilled Food Association Ltd
ISBN 1 901798 07 0
This publication may not be reproduced, stored, or transmitted in any form or by any means, without
the prior permission in writing of the publishers. Enquiries concerning reproduction should be sent to
the Chilled Food Association Ltd at P O Box 6434, Kettering NN15 5XT or to cfa@chilledfood.org
FOREWORD
This guidance identifies criteria for design, construction and installation detail conducive to
hygienic operation in food processing factories. It sets out design practices that avoid hygienic
problems in service, and provides a reference against which the food manufacturer may evaluate
equipment and specify requirements in future proposals.
1.0 SCOPE
The document is intended for use by food manufacturers and food equipment
manufacturers as a guide to good hygienic design practice for equipment used in the
production of chilled prepared food. It highlights poor design and aims to promote an
awareness of good design practices that will reduce hygiene problems inherent in
equipment. The guidance serves as a means of evaluating 'food quality' equipment and its
suitability for use in high risk areas. General hygienic design requirements for food products
equipment are given in EN 1672-2.
This guidance is intended to assist equipment manufacturers in:
(a) Identifying the level of hygienic design appropriate for the product as defined by a
HACCP study
(b) Designing a safe system for manufacturing and packing the product
(c) Determining appropriate contact materials
(d) Drafting appropriate cleaning and disinfecting procedures for the instructions for use
Equipment manufacturers shall ensure that all equipment is assessed against these
requirements by competent persons.
Any limitations of use for specific equipment items shall be clearly stated in the instructions
for their use. For example, “This machine has been designed to pack pre-packed low-risk
foodstuffs”.
The features described in these guidelines have been found by experience to be beneficial
to product hygiene in guarding against contamination by:
• Bacteriological build-up
• Infestation of insects and pests
• Foreign bodies from the environment of the equipment
• Ingredients and raw materials
The principles are designated as a minimum acceptable standard and not intended to direct
or restrict the main design purpose of equipment, but rather to ensure that the main
purpose is carried out with full consideration for hygienic operation. Hence, the principles
concern all aspects of equipment as built, covering incidental design, construction and
installation, but excluding mandatory regulations and legislative issues including health and
safety requirements as covered by UK and International law, which are taken as read (see
section 3).
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© Chilled Food Association 2002 Hygienic Design Guidelines
2.0 DEFINITIONS
Adverse influence
An effect which gives a significant reduction of the fitness for consumption of a food, A food
can be adversely influenced by microbial pathogens or other unwanted microorganisms,
toxins, vermin, domestic animals and other contaminants.
Areas of equipment:
• Food area
Area composed of surfaces in contact with food; the food area also includes the surfaces
with which the product may come into contact under intended conditions of use, after
which it returns to the product.
• Splash area
Area composed of surfaces on which part of the food may splash or flow along under
intended conditions of use and does not return to the product.
• Non food area
Any area other than those specified above.
Cleaning in Place (CIP)
Removal of physical matter without the need to dismantle the machine.
Cleaning
Removal of physical matter from surfaces by physical and/or chemical means.
Cleanable
Designed and constructed so that physical matter is removed by recommended cleaning

methods.
Contamination
The introduction or occurrence of a contaminant in a food product, ingredient or

environment.
Contaminant
Physical matter, microorganisms, toxins or chemicals that may compromise food safety.
2
Corrosion resistant material
Material resistant to normally occurring action of chemical or electrochemical nature. It

includes food processing, cleaning and disinfection according to the instructions for use.
Crevice
A surface defect e.g. crack, fissure, which adversely affects cleanability.
Dead Space
Space wherein a product, ingredient, cleaning or disinfecting agents or soils may be

trapped, retained or not completely removed during operation of cleaning.
Decontamination
Removal or reduction of contaminant(s) to an acceptable level for safety or quality.
Depositor
A machine dispensing a predetermined quantity of a product by volume and/or weight.
Disinfection
Microbiological decontamination.
Design Principles
A set of rules and concepts directed at equipment construction and installation associated
with conveyors and general mechanical handling equipment found within high risk and low
risk areas. End of line packaging equipment may, by its very nature, not be subject to this
specification.
Prior to the design and construction of any equipment, a full HACCP evaluation should be
undertaken for all equipment.
Durable
Ability of a surface to withstand the intended conditions of use, for example: to resist
damage caused by the action of the process, contact with the food being processed, thermal
actions, handling and contact with any cleaning or disinfecting agents specified.
Food
Any product, ingredient or material intended to be orally consumed.
3
Food Hygiene
Taking all of the measures during the preparation and processing of food to ensure that it is
fit for human consumption.
Food Processing Equipment
All plant and machinery that comes into direct contact with food products or ingredients
used by the processor in the treatment or handling of food.
Hazard Analysis Critical Control Point (HACCP)
A system that identifies specific hazard(s) and preventative measures for their control (see
Appendix B of CFA’s Guidelines for Good Hygienic Practice in the Manufacture of Chilled
Foods).
Joint
Junction of two or more pieces of material.
Non-absorbent material
Material which, under intended conditions of use, does not retain substances with which it
comes into contact so that it has no adverse influence on food.
Non-toxic material
Material that does not produce or release substances injurious to health under intended
conditions of use.
Product Contact Surfaces
All surfaces that ingredients may touch, condense onto, splash against and flow back from,
including utensils.
Product Processing Areas
That space within food processing equipment which food products or ingredients have
direct contact with during processing.
Seal
The closing of an aperture so as to effectively prevent the unwanted entry or passage of any
matter.
4
Self-draining
Design and construction of the shape and surface finish so as to prevent liquid from being
retained.
Smooth
Condition of a surface that satisfies operational and hygienic requirements.
Soil
Any unwanted matter, including product residues, micro-organisms, residual detergent or

disinfecting agents.
Vermin
Animals (including mammals, birds, reptiles and insects) that may adversely influence the
food.
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3.0 ESSENTIAL SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE FOR CERTAIN
CATEGORIES OF MACHINERY
3.1. Agri-
Agri-foodstuffs Machinery
Where machinery is intended to prepare and process foodstuffs (e.g. cooking, refrigeration,
thawing, washing, handling, packaging, storage, transport or distribution), it must be so
designed and constructed as to avoid any risk of infection, or contagion and the following
hygiene rules must be observed:
a) Materials in contact, or intended to come into contact, with the foodstuffs must
satisfy the conditions set down in the relevant Directives. The machinery must be so
designed and constructed that these materials can be cleaned before each use;
b) All surfaces including their joinings must be smooth, and must have neither ridges
nor crevices which could harbour organic materials;
c) Assemblies must be designed in such a way as to reduce projections, edges and

recesses to a minimum. They should preferably be made by welding or continuous
bonding. Screws, screwheads and rivets may not be used except where technically
unavoidable;
d) All surfaces in contact with the foodstuffs must be easily cleaned and disinfected,
where possible after removing easily dismantled parts. The inside surfaces must
have curves of a radius sufficient to allow thorough cleaning;
e) Liquid deriving from foodstuffs as well as cleaning, disinfecting and rinsing fluids
should be able to be discharged from the machine without impediment (possible in a
'clean` position);
f) Machinery must be designed and constructed as to prevent any liquids, organic

matter or living creature (including insects), entering or accumulating in areas that
cannot be cleaned (e.g. for machinery not mounted on feet or casters, by placing a
seal between the machinery and its base, by the use of sealed units, etc.);
g) Machinery must be so designed and constructed that no ancillary substances (e.g.

lubricants, etc.) can come into contact with foodstuffs. Where necessary, machinery
must be designed and constructed so that continuing compliance with this
requirement can be checked.
3.2 Instructions
In addition to the information required in section 1, the instructions must indicate

recommended products and methods for cleaning, disinfecting and rinsing (not only for
easily accessible areas but also where areas to which access is impossible or unadvisable,
such as piping, have to be cleaned in situ).
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4.0 GENERAL HYGIENIC DESIGN PRINCIPLES
Good hygienic design practices indicate the approach to be taken to reduce risks of product
contamination arising from equipment operation. They seek to inhibit the opportunity for
microbial build-up and prevent the introduction of non-ingredients material. This is
achieved by promoting design features which:-
a) Minimise the possibility of product stagnation in the product area and reduce the
possibility of spillage and soiling outside the equipment,
b) Allow and assist thorough cleaning and disinfecting of product contact surfaces
and all external parts of the equipment.
c) Prevent material or parts from the equipment entering or affecting the product.
d) Prevent external foreign matter entering the product areas.
Good hygienic design should take into account HACCP and full process considerations in
order to ensure that potential hazards are identified and design measures put in place to
ensure the suitability of equipment for the particular purpose to which it is to be put,
minimising potential negative impact on the final product.
The general principles apply to overall systems as well as to independent items of

equipment. In subsequent sections of the guidelines, the principles are extended in the
detailed application to various classifications, e.g. framework, welding etc. Most mechanical
handling equipment has design elements referred to in the guidelines.
• Equipment materials in contact with the product must be Food and Drug
Administration (FDA) approved and conform with The Materials and Articles in
Contact with Food Regulations 1987, as amended.
• All contact surfaces must be inert to food products
• All surfaces must be safely accessible for cleaning and for visual examination as
manual cleaning is carried out.
• Product contact surfaces must be smooth, seamless and scratch free.
• Products must move through the processing areas completely and with no temporary
retention. The design should be for streamlined flow over product contact surfaces.
This is particularly applicable to conveyors within cooling baths and Sous Vide
systems.
• Spillage of food materials is not acceptable. The system design must minimise all
possibility of spillage and provide hygienic methods of coping with instances where
spilling, splashing, blowing or other leakage may occur.
• The design should be as simple as possible. This may be achieved by using fewer
parts but of heavier design.
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• The design must be kept as open as possible, avoiding corners that are difficult to
reach.
• There should be no seams, gaps, crevices or any inaccessible recesses that are
difficult to clean even on exterior non-contact surfaces. Ledges or horizontal
surfaces must be avoided, particularly where difficult to clean. Contour such surfaces
to ensure drainage.
• The hose-down procedure should anticipate any heavy run-off so as not to pass over
cleaner parts. Ensure that run-off from external surfaces never flows across product
contact surfaces.
• The system design must allow good housekeeping practices.
• Where appropriate, the system should demarcate boundaries, e.g. between high and
low risk areas.
• Small detachable parts of machines should be properly secured. The use of Nyloc
nuts or Aero self-locking nuts is recommended.
• Parts of the equipment where product is open to the atmosphere should be covered
to prevent foreign matter falling into the product area.
• Equipment should be free-draining inside and out to the atmosphere, and should
have no stagnant regions.
• All equipment must be designed to withstand alkaline washing solutions and hosing
where HACCP demands.
• As much fabrication as practicable should be carried out off-site under clean

workshop conditions.
4.1 References and Further Reading
EN 292-1: 1991 Safety of machinery - Basic concepts, general principles for design.
Part 1: Basic terminology, methodology
EN 292-2: 1991 Safety of machinery - Basic concepts, general principles for design.
Part 2: Technical principles and specifications
EN 1672-2: 1997 Food processing machinery - Basic concepts. Part 2: Hygiene

requirements. 1997. CEN publication.
EN 60529: 1991 Specification for degrees of protection provided by enclosures (IP code)
'Hygienic Design: International Issues', J Holah. Dairy Food Env Sanit, 1998, 18 (4), 212-220.
8
'Hygienic Design Handbook', Second edition, May 1996, APV, UK
'Hygienic Design of Food Plant: A Guide to Good Hygienic Practice with Particular Reference
to the Design of Tanks, Pumps and Pipework', Food Manufacturers Federation, 1966
'A Practical Guide to the Disinfection of Food Processing Factories and Equipment Using
Fogging', Silsoe Research Institute, 1998
‘Buying new machinery’, INDG270, HSE Books, 1998, ISBN 0 7176 1559 6
‘Effective purchasing procedures for equipment in the food and drink industries’, INDG323,
HSE Books, 2000.
‘The Supply of Machinery (Safety) Regulations’. SI No. 3073, as amended. The Stationery
Office, UK. 1992
EC Directives on food contact materials: implemented in the UK by The Materials and

Articles in Contact with Food Regulations 1987 (SI 1523), as amended.
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5.0 VERIFICATION OF HYGI
HYGIENIC
ENIC REQUIREMENTS AND/OR
AND/OR MEASURES
Information taken from Table 1 EN 1672-2:
Table 1
Requirement Verification
Verification
Durable Material specification (food, process and cleaning
specification, etc.) and/or practical functional test.
Cleanable and/or capable of Visual inspection (drawing(s); on machinery) and/or
being disinfected practical test, microbiological test or functional
test.
Corrosion resistant Material specification (food, process and cleaning
specification, etc.) and/or practical functional test.
Non toxic Material specification or practical test for materials
and articles intended to come into contact with
food.
Non absorbent Material specification or practical test for materials
and articles intended to come into contact with
food.
Not transfer undesirable odours, Material specification or practical test for materials
colours or taint to the food and articles intended to come into contact with
food.
Not contribute either to the Material specification or practical test for materials
contamination of food or have and articles intended to come into contact with
any adverse influence on the food.
food.
Surface design Visual inspection (Drawing(s) on machinery)
Surface finish Measuring according to ISO468
Permanent joints Visual inspection
Dismountable joints Visual inspection
Fasteners Visual inspection
Drainage Visual inspection (Drawing(s) on machinery) and
practical tests
Internal angles and corners Measurements
Dead spaces Visual inspection
Bearings and shaft entry points Visual inspection
Panels, covers, doors Visual inspection
Control devices Visual inspection
Splash area
Non food area
Services
Note 1. Closed food processing machinery is considered to be cleanable if this can be
checked by means of a practical test of the entire plant or its individual components
Note 2. Open food processing machinery is considered to be cleanable if it complies
with the requirements of this table and of specific standards.
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6.0 INSTRUCTIONS FOR USE
Equipment suppliers/manufacturers must provide clear, detailed instructions regarding

disassembly (where necessary) and effective cleaning methods. The instructions should also
specify the preferred cleaning media and where appropriate, a list of chemicals that should
be avoided.
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7.0 EQUIPMENT GUIDELINES
7.1 CONVEYORS, ELEVATORS AND HANDLING
7.1.1 Belt Conveyors
7.1.1.1 Hazards
• Difficult to clean and dry under belt

• Contamination can build up between side guides and the belt
• Edges of belt material can shred and contaminate the product
• Contamination can build up on the underside of belt conveyors, especially
solid belt conveyors and on conveyor beds
• Belts made from non-food quality plastics can contaminate the product
• The securing edges of rubber flaps can fill with debris and are hard to
clean
7.1.1.2 Design Considerations
• The full width of both sides of the conveyor belt should be accessible for
cleaning.
• If side guides are fitted over the belt they should be designed so they can
be easily removed for cleaning
• Raised edged belts are preferable to flat belts with side guides
• The belt tensioning mechanism should be designed so that there are no
ledges or areas that cannot be accessed for cleaning and inspection
• Dead plates, transfer plates and ploughs should be designed so that they
can be easily removed for cleaning.
• Belts should be easy to slacken so they can be raised clear of the bed for
cleaning of the bed and the reverse side of the belt
• Drives should not be mounted over the belt. If it is unavoidable, the drive
should be mounted on a drip tray with drainpipe and there should be
sufficient clearance between the mounting frame and the conveyor for
cleaning
• At places vulnerable to debris build up, such as at conveyor discharge,
removable catch bins or trays should be used, which prevent lost product
re-entering the flow of good product
• Belt scrapers, reflection plates and guide rails should be designed so that
they are easily removable for cleaning
• Rubber flaps to direct the flow of product should not be used
• In situations where contamination can fall into the product from above
e.g. if steps or walkways pass over the conveyor, overhead covers should
be provided, that can be easily removed for cleaning
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7.1.1.3 Methods of Construction
• Belt conveyor edges should be hygienically sealed to prevent shredding

• Covering panels or guards should be constructed without ledges on the
inside. They should be easily accessible for cleaning.
• Avoid structural member and other surfaces over the conveyor where
debris or soil could fall onto/into the product.
• Idle rollers which contact the belt surface, for example under the belt
return should be easily removable for cleaning
• Conveyor rollers should be flat ended and the bearings sealed
7.1.1.4 Materials of Construction
• All contact parts should be made from food quality materials (e.g. plastics
and articles in contact with food, 90/128/EEC and modifications) that are
suitable for cleaning with alkali solutions
• All structures mounted above the conveyor or that come into direct
contact with the product should be made from food quality materials and
be suitable for cleaning with alkali solutions
• Splash area: See 5.2.2 in EN 1672-2:1997
• Non-food area: See 5.2.3 in EN 1672-2:1997
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7.1.1.5 Surface Finish
• Belt material must be completely impermeable and non-porous to

facilitate cleaning
7.1.1.6 References and Further Reading
prEN619 Continuous handling equipment and systems. Safety

requirements for mechanical handling of unit loads. (Draft at
time of publication of this guide) CEN.
7.1.2 Bucket Conveyors
7.1.2.1 Hazards
• Bucket elevators are very difficult to clean and are not recommended for
use in high- risk products
• Difficult to clean buckets
• Large sprockets difficult to clean, especially if design of chain guards
does not allow access
• Motor drive units are often not cleanable in place
• Materials of construction e.g. chains, bearings may not be compatible
with alkali cleaning solutions
clean
• The design should prevent retention of the product

• The design should allow all parts of the bucket conveyor to be cleaned
and inspected for cleanliness without the need for dismantling
• The chain tensioning mechanism should be designed so that there are no
areas that cannot be accessed for cleaning and inspection.
• Drives should be designed so that they can be cleaned without the need
for dismantling
• Drives should not be mounted over the path of the buckets. If it is
unavoidable, the drive shall be mounted on a drip tray with drainpipe and
there should be sufficient clearance between the mounting frame and the
conveyor for cleaning
• At places vulnerable to debris build up, such as at the discharge,
14
7.1.2.3 Method of Construction

inside. They should be easily removable for cleaning.
• Avoid structural member and other surfaces over the conveyor where
debris or soil could fall onto or into the product
• Chains and sprockets should be made from materials which are
compatible with alkali cleaning solutions
• All structures mounted above the path of the buckets or that come into
direct contact with the product should be made from food quality
materials and be suitable for cleaning with alkali solutions
• Bucket material must be completely impermeable and non-porous to

facilitate cleaning

7.1.3 Vacuum Conveyors
7.1.3.1 Hazards
• Air supply may introduce contamination

• Lubricating oil can contaminate the product
• Dust contamination at tipping points
• Retention of product leading to build up of contamination
15
• Air filters should be provided to ensure that airborne contaminants do not

combine with the product
• Vacuum pumps and other items of equipment should be selected that
minimise the risk of lubricant oils contaminating the product
• At places vulnerable to debris build up, such as at the conveyor
discharge, removable catch bins or trays should be provided, which
prevent lost product re-entering the flow of good product.
• Dust collection equipment should be provided at tipping points to prevent
the risk of dust contamination
• Smooth surfaces without ledges particularly around gaskets should be
used to prevent the retention and hold-up of product and to facilitate
cleaning

• Where lubricants are used these should be food quality
• Food contact area material must be completely impermeable and non-

porous to facilitate cleaning

requirements for mechanical handling of unit loads. (Draft)
CEN.
16
7.1.4 Screw Conveyors
7.1.4.1 Hazards
• Gaps in welding of screws provide sites for contamination

• Product can get forced into beams
• Horizontal and inclined screws will retain liquids if suitably positioned
drain holes are not provided
• If drives are mounted over the product, there is a risk of cross
contamination from gearbox oil
• Lubricants can pass through shaft seals into the product
• Difficult to inspect for cleanliness
• Damage to product
• Drives should not be mounted over the conveyor

• At places vulnerable to debris build up, such as at conveyor discharge,
re-entering the flow of good product.
• The link between the drive motor and the screw shaft should be designed
so that it can be easily cleaned
• Horizontal and inclined conveyors should be fitted with drain valves at the
lowest point in the trough so that cleaning fluids and other liquids can be
completely removed
• All welds should be continuous

• Structural member and other surfaces over the conveyor where debris can
accumulate and then fall back into the product should be avoided
17
• Food quality lubricants should be used in all situations where there is a
potential for lubricants to come into contact with the product. Oil levels
and oil seals in all such situations should be inspected regularly

• Welds should be ground smooth

requirements for mechanical handling of unit loads.
(Draft at time of publication of this guide) CEN.
7.1.5 Chain Conveyors
7.1.5.1 Hazards
• Chain links provide many sites for contamination

• Bolts and rivets provide sites for contamination and are generally
unsuitable for use in contact with product
• Chain can wear and contaminate the product with metal particles
clean

ledges, or areas that cannot be accessed for cleaning and inspection
can be removed for cleaning.
• Drives should not be mounted over the conveyor. If it is unavoidable, the
drive should be mounted on a drip tray with drainpipe and there should
be sufficient clearance between the mounting frame and the conveyor for
cleaning.
• Lubrication systems should not be fitted
• The use of loose links is preferred to facilitate cleaning
• Nuts and bolts should not be used to join chain links together
18
• All contact parts should be made from food quality materials (e.g. plastic
materials and articles in contact with food, 90/128/EEC and
modifications) that are suitable for cleaning with alkali solutions


7.1.6 Slat Band/Wire Mesh Conveyors
7.1.6.1 Hazards
• Difficult to clean under slats

• Contamination can build up in the slat to slat joint
clean
• Water and soap lubricants can contaminate the product
• The conveyor should be designed so that both sides of the slat band can
be cleaned
• CIP systems should be fitted under the slat bands where restricted access
makes other methods of cleaning impracticable.
• If side guides are fitted over the slat band they should be designed so
they can be easily removed for cleaning
19
ledges, or areas that cannot be accessed for cleaning and inspection
can be easily removed for cleaning
• Drives should not be mounted over the slat band. If it is unavoidable, the
drive should be mounted on a drip tray with drainpipe and there should
be sufficient clearance between the mounting frame and the conveyor for
cleaning.
• At places vulnerable to debris build up, such as at the discharge, use,
removable catch bins or trays should be fitted, which prevent lost product
from re-entering the flow of good product
• Water and soap lubrication systems should not be fitted
• All product contact parts should be food quality


• The surface finish required will be determined primarily by the function of
the conveyor
20

7.1.7 Vibratory Conveyors
7.1.7.1 Hazards
• Materials of construction may not be compatible with alkali cleaning

solutions
• Gating mechanism at the end of the conveyor e.g. to hopper input, may
build up contamination
• Gating mechanisms should be easy to clean and easily removable

• If side guides are fitted over the conveyor they should be designed so
re-entering the flow of good product.
accumulate and then fall into the product should be avoided
21

• The surface finish required will be determined primarily by the function of
the conveyor, but to promote product flow and avoid product retention
and facilitating easy cleaning

7.1.8 Spiral Conveyors
7.1.8.1 Hazards
• Damage to product
• Particles of product can get trapped in the joints of the belt
• Contamination may not be seen if it is not possible to inspect the whole
of the conveyor while cleaning
• Poor ease of cleaning
• The full width of both sides of the conveyor should be accessible for
cleaning and inspection
• If side guides are fitted over the conveyor they should be designed so
22

accumulate and then fall into the product should be avoided
• Splash area: See 5.2.2 in EN 1672-2:1997.
• Non-food area: See 5.2.3 in EN 1672-2:1997.
• Suitable for CIP and minimise product residue left on the belt

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7.2 MULTIHEAD WEIGHERS
7.2.1 Description of Equipment and Definition
Figure 1: Multihead Weigher Schematic
8 2/3
6
9
Typical multihead
weigher
Table 2: Description of Figure 1
Item Description Area type

1 Inlet chute Chute used to guide food onto the weigher Food area
2 Centre Cone Central feeder used to spread food evenly on to a Food area
number of radial feeders
3 Radial feeder Feeder used to deliver food to an individual Food area
weigh-head
4 Pre-Feed hopper Hopper used to pool food fed from a radial feeder Food area
and deliver it to the weigh hopper on demand
5 Weigh hopper Hopper used to weigh food Food area
6 Discharge chute Chute used to guide the discharged food into the Inside: Food area
packaging equipment Outside: Splash area
7 Timing hopper Hopper used to catch discharged food and release Food area
it into the packaging equipment.
8 Central Cage Central support for the hoppers, housing Food area
electronics and hopper drives
9 Main Frame The base usually housing electrical power circuits. Splash area
- Monitor Control unit for programming and operating the Non-food area
equipment (not shown here)
24
7.2.2 Hazards
• Contamination of product from foreign bodies entering the process

• Stagnation of product during the weighing process
• Contamination of product from residual cleaning materials
• Infestation or putrefaction in areas concealed from cleaning
Poor design or inappropriate installation of the multihead may result in exposure to

any or all of these hazards.
7.2.3 Design Considerations
• Due to the open nature of this equipment, overhead equipment should be sited
carefully to minimise the risk of foreign bodies falling onto/into the product.
• The system design should incorporate metal detection equipment, appropriately

positioned to check the product after the last point of potential contamination,
e.g. in the forming tube of a bagmaker or further downstream to check the
closed package. Wherever it is sited there should be a rejection device, which
shall separate contaminated product from production and not allow re-
contamination.
• The method of mounting the equipment should be carefully considered such that
it does not impede the ability to clean the surrounding floor area, while at the
same time allowing ease of access to remote contact parts for non-CIP cleaning.
• Generally, multihead weighers' applications do not tend to be suited to CIP

methods due to the risk of damaging the under-mounted packaging equipment.
Hoppers are to be removed for cleaning and facilities must be provided for the
easy transport, handling and disassembly of the weighhead. However, where a
CIP regime is required, the design of the multihead should be such that:-
a) Product can be drained away easily prior to cleaning and

b) The hoppers can be held open to allow throughput of cleaning agent without
dead spots
c) All contact parts should be easily removed/replaced and, where possible,
similar parts should be interchangeable to simplify cleaning procedures.
d) Contact parts should be designed with simple operation and large radiuses to
ensure efficient cleaning methods.
• Multiheads select the best combination of hoppers to discharge. It is therefore

possible that product remains in one location much longer than desired. To
avoid the risk of deterioration, there should be a facility to either
a) Force inclusion of this product within a set time (depending on product) or

b) Reject unused product within a set period of time
25
• The use of fasteners should be avoided. Where they are found to be necessary
they shall be made captive to reduce the risk of falling into product.
• The multihead installation may include a device for feeding product in; it may
also include a device for distributing the weighed product to the associated
packaging equipment. This shall be manufactured using suitable materials to a
design that can be either cleaned in place or removed/dismantled to enable
effective cleaning.
• The position and mounting of associated equipment shall not impede the
cleaning of, or disassembly for cleaning of the multihead components.
7.2.4 Method of Construction
• Where irregular surfaces are joined, e.g. the welding brackets to embossed
stainless steel, the edges should be sealed to prevent ingress of food or other
contaminant into the joint and to facilitate effective cleaning.
7.2.4.1 Inlet Chute
• The inlet chute should be crevice free and should be designed to allow
free movement of food without dead spots. The support bracket should
not include dead spots where food can become trapped and then be
allowed to re-enter production.
7.2.4.2 Centre Cone
• The centre cone should be crevice free and be designed to allow free
movement of food without dead spots.
7.2.4.3 Radial Feeders
• Radial feeders should be crevice free and should be designed to allow free
movement of food without dead spots where food can become trapped
and then be allowed to re-enter production.
• Free movement of food without dead spots will also promote the
avoidance of over or underweight packs.
7.3.4.4 Hoppers
• Hoppers should be crevice free and be designed to allow free movement

of food without dead spots. The opening mechanics should be designed
to be simple for ease and effectiveness of cleaning.
• Where springs are used there should be a method of holding the spring
open while cleaning to ensure all soil is removed.
26
7.2.4.5 Discharge Chute
• The discharge chute (or combination of chutes) should be crevice free and
should be designed to allow free movement of food without dead spots.
7.2.5 Materials of Construction
• Materials shall be suitable for use in contact with food and able to resist chemical
attack from production or alkali cleaning media
• Where possible, all food areas shall be made from Stainless Steel (SUS 304/316
or equivalent).
• For multiheads in high risk production areas the recommendation for stainless
steel is extended beyond contact parts.
• Plastics and other non-stainless materials used for contact surfaces shall be
approved to meet the appropriate European, FDA or USDA requirements.
• Plastic and other non-metallic materials should be coloured blue and to increase
the likelihood of detection by visual methods should they find their way into the
product. They should also be of food-grade materials.
7.2.6 Surface Finish
• Where the use of a liner to improve product flow is necessary, this should only be
used as a last resort because it will introduce a crevice in which product can
become trapped. Where it is unavoidable, the design of the fastening should be
such that it is outside of the normal flow of product and that it facilitates easy
removal for thorough cleaning.
• Bonded coating is preferred to loose inserts provided that it is fully bonded

leaving no crevices at exposed edges. The coating or insert shall be of a suitable
grade of material as described in section 7.2.5.
7.2.7 References and Further Reading
EN 292-1: 1991 Safety of machinery - Basic concepts, general principles for

design. Part 1: Basic terminology, methodology
EN 292-2: 1991 Safety of machinery - Basic concepts, general principles for

design. Part 2: Technical principles and specifications
EN 1672-2: 1997 Food processing machinery - Basic concepts -

Part 2: Hygiene requirements. 1997. CEN publication.
EN 60529: 1991 Specification for degrees of protection provided by enclosures

(IP code)
27
7.3 DEPOSITORS
7.3.1 Description of Equipment
Depositors can be mechanically, pneumatically or servo driven or by a combination

of two or more of these methods.
A depositor normally comprises a reservoir for product, a measuring or metering

head, a method of delivery from the reservoir to the head and all necessary pipework
and controls associated with these items.
The head can be fixed over or adjacent to the side of a track or belt, along which the
target or targets will travel or over a fixed point at which an operator will present
individual targets as required. Heads are usually mounted within a suitably designed
and manufactured framework.
7.3.2 Hazards
• Splashing/overspill may be caused by the outlet of the depositor head being

positioned too far from the target or being supplied at too great a pressure,
through the wrong sized outlet nozzle.
• Dripping may be caused by the liquid still being allowed to escape from the head
after delivery has stopped or where the head has an area in the outlet where
product can dwell after delivery has stopped and run down under the action of
gravity.
• Temperature may be critical for some products. Changes in temperature may

result in the liquid changing viscosity with possible significant effects on
performance.
• Product damage.
• Pneumatically driven: Air exhaust is a potential contamination source.
• Mechanically driven: Potential contamination from drive system and connections

to drive mechanism.
• Temperature critical: Connections to heating/cooling jackets.
• Particulate Depositors: Need to keep particulates in suspension
• Construction shall eliminate all ledges, sharp inaccessible corners and dead areas
within the product flow route.
28
• All food areas must be easily cleanable.
• Product flow adjustment should be within easy reach of the operator, i.e. without
necessitating leaning across open food products
• Design to avoid places vulnerable to product build up, but where this is not
possible, design to be easily accessible for cleaning
• Any lost product must be prevented from entering the product flow
• Drive units shall be mounted to avoid leakage/lubrication contaminating open

food products.
• Avoid mounting drives over product
• Depositors shall be mobile to enable removal from the line
• Minimise the number of structural members and/or other surfaces where debris
or soil could fall onto/into food product flow.
• Design to minimise the need for disassembly and reassembly.
• Any items requiring regular disassembly assembly shall be designed in such a

way as to limit the potential for incorrect assembly and use.
• Discharge valves shall be designed to enable safe cleaning, i.e. while

disconnected from the energy source.
• All critical operating or safety parts shall be designed so that they can only be
fitted correctly or that the system will only operate when they are fitted correctly.
7.3.4 Methods of Construction
• Framework shall be fully welded. Continuous welding is the most cost effective
hygienic method of jointing metal components currently available.
• Hollow sections should only be sealed by welding. Plastic end caps etc. are not
acceptable as they do not seal against high pressure washing normally used
within this industry thus allowing ingress of foreign matter, water etc. inside
frame with consequent hygiene problems.
• Where units are fixed to a frame then studs welded to frame or pads with
suitable tapped holes should be used a fixing points The frame, if hollow, must
never be drilled and tapped as this provides ingress routes for microorganisms
and food material.
29
• All pistons and piston cylinders should be fully demountable to ensure that no
area is in contact with food that is concealed from cleaning.
• A minimum practical number of parts should be used.
• All food contact material should be either 316 or other food grade stainless steel,
all other materials to be suitable food grade materials.
• All food contact material should be resistant to cleaning agents and elevated
temperatures normally associated with cleaning cycles.
• Galvanised, coated or painted surfaces are not acceptable.
• Non-coated surfaces should be used to prevent to flaking into the food flow after
prolonged use or damage.
• All welds to be ground smooth to prevent food build up in the food area.
• Food contact surfaces should be polished.
• External surfaces should be polished, descaled and pickled or bead blasted.
EN 292-1: 1991 Safety of Machinery - Basic concepts, general principles for

design. Part 1: Basic terminology, methodology
EN 292-2: 1991 Safety of Machinery - Basic concepts, general principles for

design. Part 2: technical principles and specifications
EN 1672-2: 1997 Food Processing Machinery - Basic concepts. Part 2: Hygiene

Requirements. 1997. CEN publication.
EN 60529: 1991 Specification for Degrees of protection provided by enclosures

(IP Code)
ISBN 011 866 335 5 Manual Handling Regulations HSE 1992
ISBN 0 7176 0411 X Manual Handling Regulations HSE 1998
30
8.0 COMPONENT GUIDELINES
8.1 FRAMEWORKS
8.1.1 Hazards
• Ledges, hollows and crevices trapping debris

• Poor access to areas beneath equipment, hindering cleaning
8.1.2 Design Cons

Considerations
iderations
• Framework construction should be as simple as possible with the minimum

number of cross members and floor mountings. Strengthening gussets are
preferable rather than cross braces. Tubular braces are preferred to angle or
rectangular hollow section.
• Hollow section structural members are preferred over angle or channel to

minimise ledges and crevices.
• Stiffeners must not form ledges that trap debris. Use hollow section or angle
welded all around and capped off both ends.
• Hollow section used as cross bracers should be fitted in a diamond configuration

to prevent unnecessary flat surfaces.
• Hollow framework members may be used to accommodate services but entry and
exit points must be fully sealed.
• Good access for personnel must be provided for cleaning and maintenance.
Reference should be made to BS473-3, BS 470, BS4211 and confined space
legislation. Note these standards are being withdrawn in favour of equivalent BS
EN standards.
• Fully adjustable feet should be used and the use of fixed feet and shims should
be avoided.
• Legs must be kept to a minimum.
• A minimum gap of 200mm should be maintained under all equipment and must
be fully and safely accessible for cleaning and inspection. When this gap rule
cannot be applied machines can have integral permanent plinths or skirt which
must be effectively sealed to the floor to prevent ingress of materials and wash
water under the equipment. Note: Sealing with a silicon surface seal is not
sufficient as it is easily washed away.
31
8.1.3 Method of Construction
• The framework should be fully welded. Continuous welding is the most hygienic
method of joining metal components, and so welding should be used wherever
possible.
• Hollow sections must be totally sealed, by welding. Plastic end caps are
unacceptable. As these do not seal against high pressure washing and allow
cleaning fluids to fill the capped sections.
• Hollow sections must not be penetrated by drilled or tapped holes. Weld blind
tapped pads or lugs for attachment. All pads must be fully welded to parent
metal this includes all nameplates and other attachments.
• The number of fixings requiring floor slab penetration must be minimised.
• Any floor fixings should be stainless steel and the use of chemical anchors is
recommended. All floor fixings should have dome nuts fitted.
• Frameworks in contact with the product shall be fabricated from T316 stainless
steel.
32
• Structural members and guards should be made from T304 stainless steel.
• Galvanised or painted finishes shall not be used in/near food contact areas or
where the cleaning regime will damage the finish.
• Food contact surfaces should be polished welds ground flush and polished
• External surfaces should be polished, de-scaled and pickled, or bead blasted.
BS EN 1672 Food processing machinery - Basic concepts. Part 2: Hygiene

33
8.2 HOPPERS AND CHUTES
8.2.1 Hazards
• Entrapment of contents and cleaning solution
• Hopper sides should be vertical or as steep as possible to minimise product

lodging.
• All corners to have internal radii of at least 10mm.
• Hoppers that are intended to be CIP cleaned must be designed for CIP, ensuring
that the correct type of spray device is selected and all surfaces thoroughly
wetted avoiding shadow areas. Correct CIP velocities must be achieved to give
adequate cleaning. Provision must be made to enable surface swab samples to
be taken.
• Avoid using stiffeners. If stiffeners are required then external bracing is

preferred and vertical stiffeners are preferred to horizontal bracing.
• Ensure the rims of panels do not form ledges. Suitably sized drain holes must be
added to unavoidable rims on access panels.
34
8.2.3 Construction Method
• Avoid lapped joints as they trap debris and are impractical to clean and disinfect.
• All internal seams shall be fully welded.
• All butt-welds shall be fully penetrating.
• All welds shall be continuous. Track or stitch welds are not acceptable.
• Hoppers shall be fabricated from 316 or other food grade stainless steel.
• Where possible spun panels should be used, as these give a good radius to
corners.
• All internal weld surfaces shall be spatter and crevice free.
• Food contact surfaces should be polished welds, ground flush and polished.
35
• External surfaces should be polished, de-scaled and pickled, or bead blasted.
Hygienic Design of Food Processing Equipment, Technical Manual No. 7 (1983

reprinted 1992), Campden & Chorleywood Food Research Association.
Hygienic Design Handbook, Second edition, May 1996, APV, UK
BS EN 1672 Food processing machinery - Basic concepts. Part 2: Hygiene

36
8.3 WALKWAYS, HANDRAILS, STEPS AND STAIRS OVER CONVEYORS
8.3.1 Hazards
• Poor resistance to loads and wear

• Materials of construction not capable of withstanding cleaning regimes
• Absence of free draining
• Material dropping onto conveyors/product below
• Avoid crevices, ledges and pockets that could harbour food residue.
• Hollow sections shall be sealed and have no penetrations.
• Careful consideration should be given to the design and use of vertical ladders,
which should be built to BS5395.
• Avoid the use of ship type ladders and stairs installed at a rake of 50° through to
65°.
• When designing cross-overs on conveyor systems use solid plate decking and
steps to prevent contaminants from falling through. Careful consideration
should be given to the fixing of deck plates to structural members to avoid
crevices.
• Encase treads of steps and stairs to prevent dirt transferring to the product
whenever over or near to product areas. This can be achieved by adding a
stainless steel back plate behind stair stringers.
37
• Decking should have a kick-plate to prevent contaminants from falling over the
edge and to keep footwear within the decking. It is preferable to manufacture
decking and kick-plate as a one rolled construction. In wet areas effective
drainage of solid deck plates must be provided, draining away from product
areas.
• Handrails should be continuous, fully welded and circular in sections.
• Stair treads should be adequately spaced from stringers.
• The surface type chosen should balance non-slip and cleanability requirements.
• Open decking must be avoided.
• The surface finish should prevent slips and facilitate cleaning
Hygienic Design Handbook Second edition, May 1996, APV, UK
BS EN ISO 14122-1: 2001 Safety of machinery – Permanent means of access for

machinery – choice of a fixed means of access between
two levels
machinery – working platforms and walkways
machinery – stairways, stepladders and guard-rails
38
8.4 GUARDS, COVERS, PANELS AND CLADDING
Guarding is required primarily for health and safety reasons, but may not be designed with
accessibility for cleaning purposes in mind.
8.4.1 Hazards
• Corrosion contaminants
• Crevices and sealant resulting in material entrapment
• Difficulty in inspecting for cleanliness
• Restricted access for cleaning
• Guards, lids, covers and other panels whose removal is necessary for thorough
cleaning, should be robust and easy to undo. They should be of manageable
sizes and completely detachable. Avoid the use of piano hinges, as they are
difficult to clean. Guards must be fully interlocked and integrated into the
conveyor safety circuit.
• Components shall be durable and resistant to corrosion, e.g. by alkali cleaning

materials
• All removable panels should be designed for easy removal/replacement, be easy

to clean, without ledges, crevices and sharp corners. Contour to avoid horizontal
surfaces. If sheet edges are folded they must be sealed all around.
• All surfaces must drain away from food areas.
• The strategic use of open mesh windows can assist hosing down.
• The fixing and removal of guards should reflect the frequency of necessary
removal, e.g. for cleaning:-
o High frequency tasks, e.g. a shift a day – use interlocked guards

o Low frequency tasks, e.g. monthly – use fixed guards
• All guarding must comply with current health and safety legislation and be
regularly inspected by a competent person.
• All burrs and sharp edges must be removed in areas accessible to operators.
• Sheet metal panel edges should be finished in one of the following methods:
39
COMMON STRUCTURE FOOD QUALITY
Unacceptable ledges where Note folded rim is welded
debris can lodge and be and 'capped'. Weld must
difficult to clean be ground and polished
• Materials for splash area: See 5.2.2 in EN 1672-2:1997

• Non food area: See 5.2.3 in EN 1672-2:1997
• Guard design: See BS EN 953: 1988
• Food contact area material must be completely impermeable, non-porous and

resistant to corrosive and abrasive cleaning agents
• Guards in the splash area need to be of the same quality as food area guards
• Guards shall be open, laser cut stainless steel to facilitate cleaning and resist
cleaning agents
BS EN 953:1998 Safety of machinery. Guards. General requirements for the

design and construction of fixed and movable guards
BS EN 1672 Food processing machinery - Basic concepts. Part 2: Hygiene requirements.

1997, CEN publication.
40
9.0 HYGIENIC DESIGN WORKING GROUP
Mr G Barnes Geest plc

Mr D Brealey Northern Foods plc
Mr M Keay Processing & Packaging Machinery Association
Mr G Whyles S&W Process Engineering Ltd
Miss K Goodburn Chilled Food Association Ltd

P O Box 6434
Kettering
NN15 5XT
www.chilledfood.org
cfa@chilledfood.org
With input from:-
Apple Engineering Ltd Ishida Europe

Unit 23 11 Kettles Wood Drive
Gothenburg Way Woodgate Business Park
Sutton Fields Industrial Estate Birmingham
Hull B32 2DB
HU7 0YG
Comments received from:-
Loma Systems Ltd Multipond

Summit Avenue 20 St Johns Road
Southwood Tylers Green
Farnborough Penn
GU14 0NY HP10 8HW
Turbo Systems Wire Belt Co Ltd

1 Gillett Street Castle Road
Hull Eurolink Industrial Centre
HU3 4JA Sittingbourne
ME10 3RF
© Chilled Food Association 2002 Hygienic Design Guidelines 41

ISBN 1 901798 00 7 0
Hygienic Design Guidelines
Published by
Chilled Food Association Ltd
P O Box 14811
London NW10 9ZR, UK
cfa@chilledfood.org
www.chilledfood.org
 2002 Chilled Food Association Ltd

Hygienic Design Guidelines 2002

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HYGIENIC DESIGN GUIDELINES

HYGIENIC DESIGN GUIDELINES

© 2002 Chilled Food Association Ltd

Typeset in Lucida Sans Unicode 10

Printed in Great Britain by the Chilled Food Association Ltd

This guidance is intended to assist equipment manufacturers in:

• Non food area

Any area other than those specified above.

Cleaning in Place (CIP)

Removal of physical matter without the need to dismantle the machine.

Removal of physical matter from surfaces by physical and/or chemical means.

Designed and constructed so that physical matter is removed by recommended cleaning

The introduction or occurrence of a contaminant in a food product, ingredient or

Material resistant to normally occurring action of chemical or electrochemical nature. It

A surface defect e.g. crack, fissure, which adversely affects cleanability.

Space wherein a product, ingredient, cleaning or disinfecting agents or soils may be

Removal or reduction of contaminant(s) to an acceptable level for safety or quality.

A machine dispensing a predetermined quantity of a product by volume and/or weight.

Any product, ingredient or material intended to be orally consumed.

Food Processing Equipment

Hazard Analysis Critical Control Point (HACCP)

Junction of two or more pieces of material.

Product Contact Surfaces

Product Processing Areas

Condition of a surface that satisfies operational and hygienic requirements.

Any unwanted matter, including product residues, micro-organisms, residual detergent or

c) Assemblies must be designed in such a way as to reduce projections, edges and

f) Machinery must be designed and constructed as to prevent any liquids, organic

g) Machinery must be so designed and constructed that no ancillary substances (e.g.

In addition to the information required in section 1, the instructions must indicate

The general principles apply to overall systems as well as to independent items of

• All contact surfaces must be inert to food products

• Product contact surfaces must be smooth, seamless and scratch free.

• The system design must allow good housekeeping practices.

• As much fabrication as practicable should be carried out off-site under clean

4.1 References and Further Reading

EN 1672-2: 1997 Food processing machinery - Basic concepts. Part 2: Hygiene

EC Directives on food contact materials: implemented in the UK by The Materials and

Information taken from Table 1 EN 1672-2:

Equipment suppliers/manufacturers must provide clear, detailed instructions regarding

7.1 CONVEYORS, ELEVATORS AND HANDLING

7.1.1 Belt Conveyors

• Difficult to clean and dry under belt

7.1.1.2 Design Considerations

• Belt conveyor edges should be hygienically sealed to prevent shredding

7.1.1.4 Materials of Construction

• Belt material must be completely impermeable and non-porous to

7.1.1.6 References and Further Reading

prEN619 Continuous handling equipment and systems. Safety

7.1.2 Bucket Conveyors

7.1.2.2 Design Considerations

• The design should prevent retention of the product

7.1.2.3 Method of Construction

• Covering panels or guards should be constructed without ledges on the

7.1.2.4 Materials of Construction

7.1.2.5 Surface Finish

• Bucket material must be completely impermeable and non-porous to

7.1.2.6 References and Further Reading

prEN619 Continuous handling equipment and systems. Safety

7.1.3 Vacuum Conveyors

• Air supply may introduce contamination

• Air filters should be provided to ensure that airborne contaminants do not