from being introduced in the first place. Components that rely on loose fasteners or small detachable parts can present a risk if elements become dislodged. As a result, many hygienic designs now favour one-piece constructions or captive components, reducing the likelihood of foreign object contamination while also simplifying cleaning procedures.
Low-friction plastic spiral belts, such as the Rexnord KleanTop 6400 Series, can operate without the lubrication required by traditional metal systems
leaning interrupts throughput, requires labour – in environments with high moisture or grease, it can consume an
eight-hour shift – and introduces variability into tightly controlled processes. For manufacturers needing to increase output while maintaining quality, this creates a difficult balance. There is therefore a need to reduce the burden
that cleaning places on production in the first place and, increasingly, this comes down to the way that equipment is designed.
Every cleaning cycle represents planned downtime. Even when efficiently managed, these interruptions reduce overall equipment effectiveness and limit throughput. In high- volume operations, the cumulative impact can be substantial.
At the same time, inadequate or inefficient
cleaning carries its own impact on productivity. Residues can accumulate on belts, chains and supporting structures, leading to increased friction, uneven movement, and accelerated wear. Over time, this can reduce efficiency and drive up the likelihood of unexpected failures. More critically, poor hygiene means bacteria
can easily develop in hard-to-reach areas or within poorly designed components. The consequences – product recalls, reputational damage, and regulatory scrutiny – can be severe. According to a report from the Grocery
Manufacturers Association, the estimated cost of food recall is $30 million. Ultimately, cleaning is a key factor in reliability,
cost, and risk management. Often, the root cause of cleaning challenges lies in the equipment itself.
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Systems that require lubrication, contain enclosed or inaccessible spaces, or rely on complex assemblies, can all increase the time and effort required to clean effectively. In these cases, operators are left managing the consequences of design decisions that did not prioritise hygiene from the outset. Equipment must therefore be designed with
cleanability as a core principle, which means considering not only how components perform during operation, but also how they behave during cleaning and maintenance. Design principles supporting this include:
• Fast, easy access Systems that can be opened quickly, without specialised tools, allow operators to carry out cleaning and maintenance far more efficiently. Modular conveyor belt designs, for example, support this approach by enabling rapid opening and reassembly. This can reduce cleaning times and help ensure that hygiene procedures are carried out consistently.
• Open, hygienic geometry Open designs, with fewer enclosed spaces or tight crevices, allow cleaning agents and washdown systems to reach all surfaces more easily. This is especially valuable in demanding applications such as meat and poultry processing, where grease and debris can accumulate within the belts or chains.
• Minimal contamination risks Cleanability is not only about removing contaminants, it is also about preventing them
• Materials tailored to washdown environments Components must be able to withstand frequent exposure to water, cleaning chemicals, and temperature variation without degrading or requiring additional maintenance. For example, corrosion-resistant bearings designed for washdown environments can operate reliably under high-pressure, high-temperature cleaning regimes. IP69K-rated units, such as Sealmaster washdown bearings, are fully sealed against water and contaminants, allowing them to withstand intensive washdowns without the need for frequent re-lubrication. The same principles apply across the wider drivetrain. Hygienically designed geared motors, such as Bauer HiflexDrive solutions, are engineered for use in demanding food processing environments. These have smooth, easy-clean surfaces, and stainless steel and advanced polymer components with excellent resistance to cleaning agents across a wide pH range, ensuring durability and consistent performance.
• Cleaning-free designs In some cases, the most effective approach is to reduce the need for cleaning altogether. Designs that minimise friction can eliminate the need for lubrication, removing a common source of contamination and reducing the frequency of cleaning cycles. Low-friction plastic spiral belts, such as the Rexnord KleanTop 6400 Series, can operate without the lubrication required by traditional metal systems, helping to reduce residue build-up while also simplifying maintenance. This kind of design thinking shifts the focus from managing hygiene challenges to avoiding them altogether.
As food manufacturers continue to try and balance the demands of safety, efficiency, and cost, cleanability is becoming a central consideration in equipment design. The most effective systems are those that recognise cleaning not as a disruption, but as an integral part of ensuring reliable performance. By designing equipment that is easier to
clean, quicker to maintain, and less prone to contamination, manufacturers can reduce downtime, improve reliability, and protect product quality.
Hygiene should not be all about meeting
standards or doing just enough to meet requirements. Instead, it becomes a means of improving how the entire production line operates. For those willing to rethink how their systems are designed, it offers a clear path to more efficient, resilient, and competitive food processing.
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