Syllabus

Introduction to the importance of hygienic design, its historical evolution, and the microbiological risks associated with food processing, including contamination sources, biofilms, and pathogen control. The economic impact of poor hygienic design on productivity, recalls, and foodborne illness outbreaks is also discussed. Key international standards and regulations, such as EHEDG Guidelines , 3-A Sanitary Standards, ISO 14159, Codex Alimentarius, FDA’s Good Manufacturing Practices (GMPs), and EU Regulations.

Materials of construction, FDA (21 CFR 177) and EU Framework Regulation (EC) Corrosion resistance, material compatibility (e.g., stainless steel, polymers, composites), cleanability, surface properties, and migration concerns (e.g., bisphenol A in polymers). Hygienic coatings, non-stick surfaces, self-polishing materials, and material selection criteria based on processing conditions (e.g., high-temperature, acidic, or high-fat foods).
The hygienic design principles. Cleanability, sanitization, and the avoidance of microbial harborage points. Eliminating dead spaces, cracks, and crevices, ensuring appropriate surface finish requirements, and designing hygienic welds, seals, and gaskets to prevent leakage and contamination. Structural design features such as self-draining systems, sloped surfaces, and open-frame construction.

The hygienic design principles for specific equipment, including tanks and vessels (interior finishes, access points), pumps and valves (aseptic connections, dead-leg prevention), heat exchangers (plate vs. tubular designs, fouling control), conveyors and belts (materials, modular belt hygiene, ease of disassembly), and filling and packaging machines (aseptic filling, sealing mechanisms, automated cleaning).

CIP (Clean-in-Place) and COP (Clean-out-of-Place), the selection and application of sanitizing agents, hygienic drain design, and self-draining equipment to minimize microbial growth. Validation methods like ATP bioluminescence testing and microbial swabbing, as well as biofilm formation, detection, and control strategies.

Regulations and standards, including EHEDG Guidelines, 3-A Sanitary Standards (applications in dairy, beverage, and pharmaceutical industries), ISO 14159, and the FDA Food Safety Modernization Act (FSMA). Case studies of compliance and non-compliance with hygienic design standards.

Design and assessment, introducing risk assessment methodologies (e.g., HACCP-based assessments, FMEA), simulation and modeling tools.

To explain the fundamental principles of hygienic design and their role in ensuring food safety and regulatory compliance, with a focus on EU and international export requirements.

To analyze material selection, equipment design, and sanitation requirements to minimize microbial risks and enhance cleanability in food processing equipment.

To interpret and apply key international standards and guidelines (EHEDG, 3-A, ISO 14159) in the evaluation and design of hygienic food processing systems.

To develop practical skills in hygienic equipment design and assessment, enabling students to contribute to the global competitiveness of Indian food equipment manufacturers.

1. Describe and apply hygienic design principles to prevent food contamination and ensure compliance with international food safety standards.
2. Select and justify appropriate materials and design food processing equipment for easy cleaning, sanitization, and maintenance.
3. Interpret and implement relevant international standards and regulations (EHEDG, 3-A) for designing and evaluating hygienic food processing equipment.
4. Design and assess hygienic food processing equipment for specific applications, demonstrating an understanding of engineering principles and regulatory requirements for global market access.

J. Holah and H.L.M. Lelieveld, Hygienic Design of Food Factories, Woodhead Publishing

John A. Troller, Sanitation in Food Processing, Academic Press

EHEDG, EHEDG Guideline Documents, EHEDG

3-A Sanitary Standards, 3-A Sanitary Standards, Inc, 3-A Sanitary Standards

Food Control, Elsevier

Journal of Food Protection, Elsevier