Mastering Hygiene in Food Manufacturing: The Washdown Process

Washdown is critically important in food and beverage manufacturing, though its meaning can vary depending on who you ask. While engineers might have different interpretations, their goals are the same: maintaining hygiene, ensuring food safety, and meeting regulatory standards. These environments tend to be cool and wet, which often require components made of 316L stainless steel and equipped with IP69K* ingress protection, along with specific industry ratings.

The washdown process: what it really takes

The washdown process in food and beverage manufacturing is a rigorous and essential practice, involving the following combination of elements.

• High temperatures for effective sanitization: The washdown process eliminates harmful pathogens by using water heated to at least 140°F, which breaks down organic matter and eradicates all contaminants.

• Intense pressure for thorough cleaning: High-pressure water jets, up to 1000 psi, effectively remove stubborn residues and contaminants from equipment surfaces, ensuring thorough cleaning and reducing contamination risk.

• Harsh environmental conditions: The washdown process uses caustic solutions, acid detergents, and foaming agents to remove tough grime and contaminants like fats, oils, and proteins.

• Manual labor for precision cleaning: Despite the use of advanced equipment, manual scrubbing and cleaning are essential in washdown, as they ensure thorough cleaning of hard-to-reach crevices and intricate parts that automated systems may miss.

• Frequent and consistent cleaning schedules: Equipment undergoes 15-20 hours of washdown weekly, with more time for dairy and meat processing, to prevent contamination and meet health and safety standards.

Meeting the demands of washdown

Components used in food and beverage manufacturing must meet stringent requirements to withstand the rigorous washdown process. Manufacturers typically choose these components made of 316L stainless steel for their exceptional corrosion resistance, essential for withstanding exposure to water, chemicals, and high-pressure cleaning. Polished surfaces on these components further reduce bacterial hiding spots.

Additionally, components must meet various industry-specific standards and certifications suitable for food and beverage environments. They must pass ECOLAB chemical testing to endure harsh cleaning agents, manufacturers must use FDA-approved materials to ensure safety. Equipment in U.S. food processing must comply with 3A sanitary standards, while European equipment should adhere to EHEDG standards to minimize contamination risk and facilitate easy cleaning.

Components must also have appropriate ingress protection (IP) ratings to withstand harsh washdown conditions. Manufacturers often require an IP69K to protect against high-pressure, high-temperature steam cleaning, as specified by DIN 40050 part 9.* However, while IP69K provides protection against high-pressure cleaning, it does not guarantee resistance to prolonged immersion. For environments where immersion is a concern, components should also have an IP67 to ensure they remain sealed and functional.

*IP69K is an ingress protection (IP) rating that denotes a device's resistance to dust and high-pressure water jets. The "6" indicates maximum dust protection, while "9K" signifies resistance to high-pressure water jets and steam cleaning from close distances. According to DIN 40050 part 9, a standard from the German Institute for Standardization (DIN), devices must withstand high-pressure water jets at various angles, typically at around 80°C (176°F) and 100 bar (1450 psi), to achieve this rating.