Hygienic design is often seen through the lens of compliance, but its role extends far beyond passing an audit. For manufacturers in the food, beverage and pharmaceutical sectors, it supports daily operational performance, cost control and sustainability goals. Equipment designed with hygiene in mind is not just about protecting public health; it is essential for efficiency and long-term resilience.
With production costs rising and environmental expectations becoming more stringent, businesses are focusing on reducing waste, energy use and downtime. Hygienic design plays a key role in achieving these objectives by making cleaning processes faster, more predictable and less resource-intensive.
The real cost of poor design
The biggest impact of poor equipment design is felt in ongoing inefficiencies rather than rare incidents. Extended cleaning cycles consume water, energy and chemicals, driving up operating costs and adding to environmental impact. Every additional minute spent on cleaning is time not spent producing, which lowers throughput and affects delivery schedules.
Equipment that requires complex dismantling or features inaccessible surfaces adds unnecessary labour and increases the risk of human error during sanitation. These factors combine to create recurring costs that affect profitability and sustainability over time.
Why hygienic design matters
Hygienic design focuses on making cleaning faster, easier and more reliable by eliminating features that trap residue or complicate sanitation. The objective is simple: equipment should be cleaned thoroughly, repeatedly and in less time, without introducing new risks.
This starts with structural design. Surfaces should be smooth and rounded to prevent product build-up, while open frames and sloped profiles allow water to drain freely. Fully welded or sealed joints remove gaps where bacteria could accumulate, reducing the likelihood of contamination.
Corrosion-resistant components for high-pressure cleaning
Material choice is equally important. Components must comply with legal food-contact standards and resist corrosion under high-pressure cleaning conditions. Electrical enclosures should be sealed and positioned above splash zones, and cabling routed to avoid areas that are difficult to reach. These details not only protect sensitive components but also simplify maintenance and reduce downtime.
Hygienic design: Shorter cleaning cycles and reduced resource consumption
These features deliver measurable benefits: shorter cleaning cycles, reduced water and chemical consumption and lower labour costs. For facilities managing multiple SKUs, quicker changeovers increase flexibility without adding extra production lines. At the same time, resource savings support sustainability initiatives, helping businesses reduce environmental impact and meet regulatory and corporate targets.
The same principles apply to inspection systems such as checkweighers, metal detectors and x-ray machines. Positioned near unpackaged goods or between hygiene zones, these systems must be designed for thorough, efficient cleaning. If they cannot be sanitised effectively, they increase the risk of contamination across the production line.
Compliance through hygienic design: The starting point, not the goal
Regulations provide essential guidance but meeting them does not automatically create efficient operations. Bodies such as the United States Food and Drug Administration (FDA), the European Hygienic Engineering and Design Group (EHEDG) and the Global Food Safety Initiative (GFSI) set requirements for cleanability, ingress protection and material compatibility. These frameworks help reduce risk, but the greatest value comes when design goes beyond compliance to enable faster, more consistent cleaning and improved operational performance.
Investment that delivers long-term value
Hygienic design is sometimes perceived as an added cost, but its return on investment is significant. Reduced downtime, fewer maintenance issues and lower cleaning resource requirements quickly offset any initial outlay. Over time, these savings become substantial.
Systems that incorporate hygienic design principles help manufacturers reduce risk and improve resilience. They make it easier to maintain product integrity, meet regulatory expectations and deliver consistent results. This creates confidence for both the business and its customers.
Choosing equipment with hygiene in mind
Not all equipment marketed as washdown-ready offers true hygienic performance. Ingress Protection ratings confirm resistance to water and dust but do not guarantee cleanability. When selecting inspection systems, manufacturers should ask practical questions. Can the system be cleaned thoroughly and quickly? Are all parts accessible without specialist tools? Does the design actively support sanitation protocols rather than simply withstand them?
When equipment is designed for hygiene from the outset, the benefits extend far beyond compliance. Manufacturers gain the ability to produce more efficiently, meet safety expectations and reduce operational costs in a competitive, margin-sensitive market.
Author
Holger Schmidt
Global Industry Manager Food & Beverage, Mettler-Toledo Product Inspection
