Food & Beverage

Hygiene in Food Production: A Legal Requirement and the Foundation of Brand Trust

In food production, hygiene is not merely a quality factor; it is a legal requirement and the foundation of brand trust. Every stage a product passes through—from production to reaching the end consumer—must be designed and controlled in compliance with hygiene standards. One of the most critical stages in this process is filling and packaging lines.

A poorly designed filling line or one where hygiene criteria are neglected can jeopardize product safety, cause production downtime, and lead to serious reputational damage for the business.

Why Is Hygienic Filling So Important?

Food products are highly sensitive to bacterial growth, cross-contamination, and external factors. Even the smallest hygiene issue during filling and packaging can:

• Shorten the shelf life of products

• Increase the risk of product recalls

• Lead to legal sanctions and a decline in brand value

For this reason, hygiene must be sustainable not only during operation but also during cleaning, maintenance, and downtime of the filling line.

Essential Design Criteria for Hygienic Filling Lines

Food-Grade Material Selection

• All surfaces in contact with the product should be made of stainless steel (AISI 304 / 316)

• Smooth and non-porous surfaces minimize bacterial adhesion

• Seals and gaskets must be made of materials suitable for food contact

Easy-to-Clean and Open Design

A hygienic filling line must allow fast and effective cleaning:

• Product paths without dead spots

• Components that can be disassembled without tools or with minimal equipment

• A machine frame design that facilitates cleaning

This reduces cleaning time, minimizes production losses, and ensures sustainable hygiene standards.

The Importance of Diverter Valves in Terms of Hygiene

One of the components that is often overlooked in food filling lines, yet critically important for hygiene, is diverter valves. Since these valves are in direct contact with the product and control product flow, they represent one of the most sensitive points in the hygiene chain.

Standard 3-way valves operate by opening and closing the product path using an internal ball. However, over time, the following issues may arise:

• Product leakage into the area where the ball rotates when flow is stopped

• Residual product in this area causing odor over time

• Increased bacterial growth and hygiene risks

• Malfunctioning of the valve and flow problems

Especially in products such as dairy, honey, sauces, and similar foods, these issues directly threaten production safety.

For this reason, the food industry recommends the use of:

• Hygienically designed diverter valves

• Internal structures without dead zones

• CIP-compatible or easily dismountable valve systems

Removability of Product Paths and Operator Cleaning

Hygiene cannot be achieved solely through the correct valve or material selection. All surfaces through which the product flows must be easily removable and cleanable by the operator.

In a well-designed hygienic filling line:

• Product contact surfaces should be easily accessible to the operator

• No dead spots should remain during cleaning

• Visual inspection should be possible

Otherwise, cleaning processes remain superficial, the machine cannot be fully cleaned, and hygiene risks persist.

A properly designed filling line must address not only production but also cleaning and maintenance processes as key engineering considerations.

CIP (Clean-In-Place) Compatible Systems

For dairy products, beverages, sauces, and other liquid foods, CIP systems provide significant advantages:

• Cleaning is performed without dismantling the line

• Human intervention is minimized

• Cleaning time and water consumption are reduced

CIP-compatible systems ensure that hygiene is standardized and repeatable.

Conclusion: Hygiene Starts with Engineering

In the food industry, hygienic filling and packaging solutions are essential not only for regulatory compliance but also for sustainable and safe production. Incorrect valve selection, non-removable product paths, or non-hygienic design can put even the highest-quality products at risk.

TÜRESAN provides turnkey hygienic filling and packaging lines for the food industry with an engineering-driven approach that includes product analysis, correct material selection, hygienic valve systems, and operator-friendly design.

Proper hygiene is only possible with proper engineering.