Test & measurement
no unnecessary seams, screws or inaccessible parts. And it calls for corrosion-resistant materials that will not break down under pressure - literally. Because in many facilities, equipment must withstand high- pressure, high-temperature cleaning with aggressive detergents multiple times per shift. Surfaces should also be large and wide to allow for effective self-draining, preventing the build-up of moisture that could harbour contaminants. Further, wherever components join, they must either be welded or sealed with a gasket to accommodate temperature variations and maintain a reliable hygienic seal over time.
Systems like checkweighers, metal detection systems and x-ray inspection machines may not process food or pharmaceuticals directly, but they sit at key points in the production flow, usually very close to the packaging machines and, therefore, share the same hygienic environment. If those systems harbour bacterial contamination or are too complex to sanitise properly between product runs, the risks ripple outward, such as by these systems’ own contaminants making their way into the final product.
WHERE INSPECTION EQUIPMENT COMES UNDER PRESSURE
Product inspection systems often operate at Critical Control Points (CCPs) - handling raw materials and unpackaged goods, transitioning between hygiene zones or sitting directly in the product path. These locations are some of the most vulnerable within a manufacturing environment, yet inspection equipment is sometimes an afterthought in hygienic design planning.
Dr Jürgen Hofmann, a leading expert in hygienic engineering, notes that design flaws are frequently missed until cleaning starts. “Sometimes it’s just enough to watch someone clean a system to see where the weak points are. Cavities, dead spaces and seams all add to cleaning time and increase risk. On top of that, the natural tendency for cleaning personnel - who are often not the same team that operates the machine - is to look for shortcuts when the effort required is too high. The greater the effort needed for cleaning, the more likely it is that quality will suffer,” he says. In high-moisture, high-protein, or high-sugar environments - or any combination of these - bacteria find the perfect conditions to thrive. They favour areas where water can pool, where organic material can accumulate, and where
surfaces are rough, cracked or inaccessible. If left unchecked, these environments allow microbes to colonise and spread, making contamination not just possible but likely.
To combat this, equipment must do more than resist corrosion and dust or water ingress - it must actively repel contaminants through smart, hygienic design. Rounded frames eliminate pooling. Welded seams prevent bacterial harbourage. Fully enclosed tubing stops unseen moisture seepage. Thoughtful placement of components is equally vital: electrical boxes should be sealed and elevated; sensors kept out of the product contact zone; and cables routed for easy cleaning and inspection. Every design detail must work to reduce cleaning effort and minimise potential failure points.
Crucially, hygiene under pressure demands more than mechanical durability. It demands design that works with cleaning teams - not against them - by making surfaces accessible and cleaning straightforward. Material selection plays a key role here: materials must withstand both production and repeated high-intensity cleaning without becoming hard, brittle or compromised over time. Only by aligning material choice, construction and cleanability can facilities maintain true hygienic design standards.
FROM COST CENTRE TO EFFICIENCY DRIVER
Too often, hygienic design is seen as an up-front cost rather than a long-term investment. But every extra minute spent cleaning, every damaged belt, every unplanned repair adds up. Multiply those over weeks, months, years - and the total cost of ownership tells a very different story. Well-designed systems reduce chemical and water usage. They cut back on wear and tear. They improve changeover times and reduce
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the risk of cross-contamination between SKUs. And they help teams get more done with fewer slowdowns and less rework.
For instance, checkweighers with open- frame stainless steel construction allow for faster washdowns. X-ray inspection and metal detection systems with sloped surfaces prevent pooling. Belt systems designed for tool-free removal cut minutes from maintenance routines. Every small design choice adds up to meaningful operational gain.
BUILDING HYGIENE INTO THE BLUEPRINT In a landscape shaped by consumer and cost pressure, stricter rules and razor-thin margins, manufacturers need every advantage they can get. Hygienic design offers a way to not only protect product integrity, but to run cleaner, leaner and smarter.
But not all “washdown-ready” systems are equal. Some are designed with hygiene at the core. Others are adapted to meet the minimum standard. Many systems advertise washdown capabilities with IP65 or IP66 ratings, indicating protection against dust and high-pressure water jets. However, these ratings alone don’t guarantee hygienic design or easy cleanability. So, the next time you evaluate product inspection equipment, do not stop at the IP rating. Ask:
Can it be cleaned quickly and thoroughly? Are all parts accessible without tools?
Has it been designed to support our cleaning protocols — or just survive them?
Because when hygiene is built in - not bolted on - the benefits flow through every part of your operation.
Mettler-Toledo Product Inspection
www.mt.com/hygienicdesigneguide-pr
August 2025 Instrumentation Monthly
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