The importance of cleanliness and sanitation of air handling for food hygiene compliance

Food manufacturers, processors, and packers must comply with a variety of food safety rules and regulations. From microbiological hygiene to cross contamination and allergen control. These rules and regulations address not only the final food product itself, but also the processes and facilities that are part of the operation. Although they may seem like an obstacle at times, standards and regulations are essential to ensure that food manufacturing and production operates in a clean, safe and hygienic environment.

The entire food industry is focused on perishable products that, at some point, can be negatively affected by bacteria. In the manufacturing and processing of food products, there are many opportunities for various airborne particles to be emitted into the indoor environment through the air handling system and ductwork.

Sources of air pollution include:

• Raw Materials
• Cooking and processing of food products.
• allergens
• Dust
• packaging
• People
• Poorly designed, cleaned, or maintained air handling systems
• Machinery, computers and equipment.

Air pollution control and removal of airborne bacteria should be considered in an overall plan to improve indoor air quality. Indoor air quality in a food manufacturing or processing facility must meet certain requirements that are outlined in food hygiene audits and inspections.

Air Pollution Removal Methods

It is essential that a manufacturing facility provide adequate ventilation or control equipment to reduce odors and vapors in areas where they may contaminate the production process. This includes steam and VOCs.

It is recommended that the location of air outlets, fans and extraction units be effective for air hygiene management and the locations are determined to ensure that the possibility of airborne contamination is minimised. Care must also be taken to ensure that air moves from high to low care areas or from low to high dust loading areas.

Properly designed air handling systems control airborne particles and odors, thereby minimizing risks to products from airborne contamination from infectious pathogens. Pathogens such as Salmonella and Listeria, toxigenic pathogens such as Staphylococcus aureus and finally spoilage microorganisms such as yeasts, moulds, Pseudomonas and lactic acid bacteria.

More than just hygiene

Air handling systems not only help reduce cross-contamination caused by these airborne impurities, but are also important in ensuring efficient air filtration and distribution. Effective air filtration and distribution helps remove heat imposed by processes and people within a food factory. They also provide plenty of fresh air, keep airborne pollution out, and avoid regions of stagnant air.

Manufacturers can sometimes overlook the temperature within their production environments. Food manufacturing facilities operating in temperatures below 13°C could be harming your production. Evidence shows that it is detrimental to food safety to ensure that air distribution maintains a constant temperature above 13°C, unless there are specific requirements outlined. A clean and efficiently functioning air handling system can ensure effective air mapping and the ability to control temperatures throughout a facility.

A breeding ground for bacteria

However, no matter how well a ventilation system works, grease and other exhaust products will accumulate in the ducting and air handling units of an exhaust system. As a result, dust and bacteria will accumulate in air ducts and air handling systems. These contaminants enter the HVAC system and recirculate up to 10 times per day, on average. Over time, this recirculation causes a buildup of contaminants in the ductwork, which then becomes a breeding ground for bacteria and mold.

Dust, dirt, and grease buildup in air ducts can cause significant health and safety concerns due to potential fire hazards and poor performance.

Reduced efficiency of an extraction system can affect the life of the equipment. Plus, it has the potential for more serious problems later on.

The importance of cleanliness

The hygiene of the air system is controlled by periodic cleaning (and disinfection) to prevent the accumulation of dust, products or condensates that could be a source of microbial growth. Without regular cleaning, air will pass through the contaminated ductwork and carry bacteria to or around food processing areas. Comprehensive duct work cleaning and housekeeping surveys also highlight duct conditions and help manage needed repairs that might go unnoticed.

It’s not my job!

It is the duty of the building owner or facility manager to ensure that the ductwork and air handling systems are maintained and cleaned. They must also be able to provide adequate maintenance and sanitation records to support audit compliance.

A lot of benefits

In addition to minimizing air pollution and reducing health and safety risks, cleaning can lead to significant long-term energy savings. When an HVAC system isn’t maintained and cleaned, it has to work harder. Research shows that dirty coils and fans in commercial buildings can reduce efficiency by up to 40%. Consequently, when a system works efficiently, less energy is used and that saves you money.

With less potential for contamination, improved efficiency, and fewer health and safety risks, it’s safe to say there are a host of benefits to be had from ensuring the cleanliness of your ductwork and air handling systems.