The hygiene challenges faced in the food processing sector extends beyond readily visible surfaces to microscopic contaminants that can accumulate in closed loop systems, heat exchangers, valves and other difficult to access areas. These can lead to quality concerns and potential damage to brand reputation. Rajiv Mitra, a seasoned leader in the Indian dairy and agri-food sector, addresses these concerns and emphasizes that a proactive and comprehensive approach is the only way of tackling them
Invisible residues in hard-to-reach areas pose serious hygiene risks. A system-wide, automated cleaning approach is now essential.”
— Rajiv Mitra
Everyone is veering towards automation to find solutions to counter the persistent hygiene issues. Automated Clean in Place (CIP) systems, equipped with conductivity sensors, flow validation and temperature monitoring, are becoming standard practice.
These systems reduce the need for human intervention, lowering the chances of contamination and bacterial load. Additionally, the use of optical and ATP-based verification tools provides scientific validation of hygiene post cleaning.
Automation Way Ahead
The addition of programmable logic controllers with sanitation routines helps track compliance and reduces the possibility of human error. This automation ultimately results in a superior finished product strengthening consumer trust.
Sustainability is now a central tenet of modern business operations, combining profitability with a responsibility for the future. Within the food processing industry, this focus shapes the transformation of manufacturing processes rather than altering the food products themselves.
For example, in cheese production, the goal is to make the manufacturing process more environment friendly and sustainable, which in turn reduces the carbon footprint, enhances efficiency and boosts productivity. This includes improving productivity per litre of milk, per hour of human effort, and per rupee of consumer spend.
Increasing Yield
A key element in enhancing sustainability is the improvement of productivity across the entire value chain. Consider the example of a dairy cow: If a cow yields 10 litres of milk and emits a set amount of methane, it is effectively divided by the 10 litres produced.
By implementing improvements in feed quality, animal management, general health, wellbeing, and veterinary services, the milk yield can increase to 20 litres. This increase in productivity directly leads to a reduction in methane emissions per litre of milk produced. Therefore, enhancing productivity becomes a powerful solution for achieving greater sustainability throughout the entire business process — from animal welfare to human effort, making all products more sustainable.
Modern companies are moving beyond conventional hygiene practices towards a more encompassing approach to cleaning and sanitation. Sustainability in cleaning is no longer an optional extra; it is fundamental to operational excellence and brand responsibility. This involves optimising cleaning-in-place cycles through segmented cleaning routines and recovery loops, which significantly reduces water and chemical usage.
Cleaning Solutions
There is also a shift away from traditional caustic-based cleaners towards enzyme based and biodegradable solutions, which are both effective and environmentally compliant. In terms of waste management, organisations are actively exploring zero liquid discharge frameworks and on-site effluent treatment plants with chemical oxygen demand reduction systems. These measures not only contribute to meeting environmental, social and governance (ESG) goals but also lead to considerable cost savings over time.
Balancing strict regulatory compliance with practical operational needs in cleaning protocols is achieved by adding hygiene into the design and daily rhythm of operations. This involves prioritizing hygienic design principles from the initial planning stage, ensuring equipment has sloped surfaces, is crevice free and features sanitary welds.
Operationally, a risk-based approach is adopted, aligning with HACCP and FSSC 22000 standards. Digital standard operating procedures and audit ready traceability logs are embedded into plant operations. Continuous training for teams focuses on understanding the underlying reasons behind protocols, fostering a mindset where compliance becomes an organic part of daily work rather than a forced imposition.
New Methods
The adoption of cleaning equipment on shop floors is undergoing a clear transformation. Steam-based sanitation, ozone fogging, ultraviolet surface disinfection, and robotic floor scrubbers are becoming more common, particularly in high throughput facilities.
Internet of Things enabled CIP systems, which provide real-time feedback and optimize downtime, are also gaining traction. However, a significant gap remains in integrating data from these diverse devices into unified hygiene dashboards, as most tools currently operate in isolation.
There is a considerable opportunity for technology providers to develop interoperable platforms that integrate cleaning data with quality, energy and maintenance systems.
Another area needing support is providing training for Tier 2 and Tier 3 operators to help them maximize the return on investment from advanced equipment.
Seeking Solutions
Looking ahead, future ready food processing units will be defined by three key pillars: Predictive hygiene, circular resource use and strong regulatory trust building.
Cleaning will evolve from being reactive to predictive, driven by sensor data, microbial load mapping and even artificial intelligence-based residue detection. To meet growth and sustainability goals, food processing companies seek support from solution providers for integrated cleaning intelligence platforms, modular systems adaptable to different scales and product types, green certified cleaning solutions tailored for various soil types and energy efficient cleaning equipment that aligns with carbon reduction targets.
Partnerships that extend beyond just selling a product, providing ongoing analytics, training and innovation, will be instrumental in shaping the hygiene ecosystems of tomorrow.