Apply EHEDG hygienic design principles to assess equipment, piping and facility cleanability.
Engineering & Maintenance
Hygienic Design and Maintenance Practices for Food and Beverage Plants
Applies EHEDG hygienic design principles and CIP/SIP maintenance practice to help engineers control contamination, allergen carryover and foreign material risk.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
A weld with a hidden crevice, a dead leg in a sanitary line, or a maintenance tool left inside a hopper can undo months of clean audit results in a single contamination event, and the fix is rarely a cleaning problem so much as a design and maintenance discipline problem. This course applies EHEDG hygienic design principles to equipment, piping and facility layout, covering crevice-free welds, self-draining surfaces, sanitary tri-clamp and orbital-welded connections, and the valve types that keep process lines free of stagnant zones. Participants learn to design and maintain CIP and SIP systems, validate cleaning effectiveness with ATP swabbing and microbial sampling, and manage allergen changeover and cross-contamination risk during maintenance interventions. Sessions cover pest-proofing, foreign material control and food-grade lubricant selection, alongside the scheduling discipline needed to fit maintenance into production and sanitation windows without breaching hygienic integrity. The course closes with programme-level tracking and audit preparation, leaving participants able to run engineering and maintenance functions that support, rather than threaten, food safety performance.
Expected Learning Outcomes
Specify sanitary piping connections and dead-leg-free layouts for hygienic process systems.
Design and maintain CIP and SIP systems that achieve consistent cleaning and sterility outcomes.
Validate cleaning effectiveness using ATP swabbing, microbial sampling and verification protocols.
Control allergen carryover and cross-contamination risk during equipment changeover and maintenance.
Implement pest-proofing and foreign material controls during maintenance activities.
Schedule maintenance around production and sanitation windows while preserving hygienic integrity.
Who Should Attend
Engineering and maintenance managers in food and beverage manufacturing plants.
Food safety and quality assurance professionals overseeing hygienic design compliance.
Process engineers specifying new equipment and sanitary piping systems.
Maintenance technicians working within production and sanitation-controlled environments.
Hygiene and sanitation managers coordinating CIP and cleaning validation programmes.
Plant managers preparing for Global Food Safety Initiative audits and customer inspections.
Course Modules
Select any module to see its sessions and points.
01Hygienic Design Principles
2 sessions · 8 points
Session 1Equipment and Facility Hygienic Design Standards
- Apply EHEDG guidelines to assess equipment design for crevice-free welds, self-draining surfaces and accessible cleaning points.
- Evaluate material selection including stainless steel grades and food-grade elastomers for hygienic compatibility.
- Assess facility layout features such as sloped floors, hygienic wall junctions and zoning that support cleanability.
- Identify design features that prevent product and water pooling in equipment frames and support structures.
Session 2Sanitary Piping and Process Connections
- Specify tri-clamp, orbital-welded and other sanitary piping connections for hygienic process lines.
- Design dead-leg-free piping layouts that avoid stagnant zones prone to microbial growth.
- Assess valve types such as diaphragm and mixproof valves for hygienic process separation requirements.
- Verify orbital weld quality and surface finish against hygienic piping acceptance criteria.
02Cleaning Systems and Validation
2 sessions · 8 points
Session 1CIP and SIP System Design and Maintenance
- Design clean-in-place circuits including supply, return, spray ball coverage and chemical dosing systems.
- Maintain steam-in-place systems ensuring temperature and time parameters achieve required sterility assurance.
- Diagnose CIP performance issues such as inadequate flow velocity or spray ball blockage affecting cleaning efficacy.
- Plan preventive maintenance for CIP pumps, valves and heat exchangers to sustain cleaning consistency.
Session 2Cleaning Validation and Verification
- Validate cleaning procedures using ATP swabbing, microbial sampling and visual inspection methods.
- Interpret cleaning verification data to identify equipment areas requiring design or procedure changes.
- Coordinate cleaning validation protocols with allergen changeover and product changeover requirements.
- Document cleaning validation records to support food safety audits and customer inspections.
03Contamination Prevention and Foreign Material Control
2 sessions · 8 points
Session 1Allergen and Cross-Contamination Control
- Design equipment changeover procedures that prevent allergen carryover between production runs.
- Assess shared equipment and utensil risks and implement colour-coding or dedicated equipment strategies.
- Evaluate maintenance activity risks such as lubricant contact or metal shavings entering product zones.
- Coordinate maintenance scheduling with allergen and product changeover plans to reduce contamination windows.
Session 2Pest Proofing and Foreign Material Prevention
- Inspect building envelope, door seals and drainage for pest entry points during facility maintenance rounds.
- Specify food-grade lubricants and maintenance materials approved for use in production zones.
- Implement tool control and glass and hard plastic policies to prevent foreign material contamination.
- Investigate foreign material complaints to trace contamination back to specific equipment or maintenance activities.
04Maintenance Planning in a Hygienic Environment
2 sessions · 8 points
Session 1Maintenance Scheduling Around Production and Sanitation
- Plan maintenance activities around production schedules, sanitation windows and changeover downtime.
- Coordinate maintenance work permits with food safety and quality teams before entering production zones.
- Sequence equipment disassembly and reassembly to maintain hygienic integrity after maintenance interventions.
- Verify post-maintenance sanitation and inspection before returning equipment to production.
Session 2Continuous Improvement and Compliance Reporting
- Build a hygienic maintenance programme integrating design review, cleaning validation and pest control audits.
- Track key performance indicators such as micro-swab pass rates and foreign material complaint trends.
- Prepare documentation supporting Global Food Safety Initiative audits and customer hygiene inspections.
- Present hygienic design and maintenance improvement recommendations to plant and quality management.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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