Gelenk-Manipulator mit spezieller Saugvorrichtung für das Umsetzen von Käse
Gelenk-Manipulator mit spezieller Saugvorrichtung für das Umsetzen von Käse
Guide · Food Industry · Certification
Hygienic Design in Handling Technology: Standards and Requirements for the Food Industry
Pneumatic, electric or individual, objectively compared: The ZH lifting and rotating device brings components into any ergonomic working position at the touch of a button, including component adapter and optionally with insertion and layout via manipulator, ZH90 lifting axis or ZH lifting lift.
CHAPTER 1
Introduction
Hygienic design is not a marketing claim, but an engineering discipline. The European Hygienic Engineering & Design Group (EHEDG) has defined design principles that serve as an international standard for machinery and components in food, beverage, and pharmaceutical production. Crucially, it is not just the material stainless steel that matters, but the entire design: dead-space-free geometries, defined slopes, gap-free connections, and surfaces that can be cleaned without leaving any residue.
For handling technology, this means specifically: Every point where product residues, moisture, or cleaning agents can accumulate is a potential contamination risk. A manipulator or lifting axis in food-grade quality must avoid these risk points through its design, not just by looking like stainless steel.
CHAPTER 2
Regulatory framework: Which standards apply?
Several sets of regulations overlap for handling technology in the food industry:
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EHEDG guidelines: technical design principles for hygienic design, including documents 8, 13 and 35.
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HACCP: the hazard analysis in the workplace, in which the handling technology used is also assessed as a potential source of contamination.
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IFS Food and BRC: Certification standards whose audits include checks of cleaning validation and material documentation of the plant technology.
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EU Regulation 1935/2004: Requirements for materials and articles that come into contact with food, relevant for grippers and devices that handle product contact.
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LFGB: national supplement to the European food contact material regulation.
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DGUV Regulation 54: annual safety inspection for lifting aids, regardless of hygiene status. More information can be found in the guide "Safety Inspection for Lifting Aids" .
CHAPTER 3
Hygienic Design vs. Cleanroom: What is the difference?
The two terms are often used interchangeably, but they follow different sets of rules. Hygienic design primarily concerns direct product contact and the cleanability of surfaces, relevant for food and beverage companies. Cleanroom suitability concerns the absence of particles and germs in the surrounding air according to cleanroom classes as defined in ISO 14644, relevant for pharmaceutical and semiconductor manufacturing.
In practice, these two requirements often overlap, for example in the filling of sterile food products. For cleanroom applications without specific food hygiene requirements, see our article Lifting aids for cleanrooms and pharmaceuticals .
CHAPTER 4
Design principles according to EHEDG
Materials
Stainless steel 1.4301 (V2A) for most applications, 1.4404 (V4A) for aggressive cleaning agents, acids or chloride-containing environments such as brines.
welds
Completely sanded and smoothed, with no pores or breaks where residues can accumulate.
Surface roughness
Product-contact and cleaning-relevant surfaces with Ra below 0.8 µm, smoothly ground and polished to prevent adhesion of microorganisms.
Protection class
Drives and controls in wet areas in stainless steel design with IP69K protection class for high-pressure and steam jet cleaning.
Dead space freedom
No open profiles, no dirt edges, defined slopes on horizontal surfaces so that cleaning fluid drains away completely.
Drive technology
Fully electric drives without compressed air, where particle-free operation is required, as compressed air can introduce oil mist and exhaust air.
CHAPTER 5
What this means for Zeilhofer lifting aids
Zeilhofer HHT designs manipulators, lifting axes and lever lifts in stainless steel with hygienic design, individually tailored to the process and cleaning requirements of the respective food processing plant.
Load capacity up to 100 kg
Mobile, battery-powered, without compressed air.
Load capacity up to 800 kg
Stainless steel version, pneumatic or fully electric.
Load capacity up to 1,200 kg
Fully electric for sensitive areas.
Grippers and devices are manufactured as custom-designed, food-grade products. Zeilhofer Handling Technology from Holzkirchen is certified according to ISO 9001 and TISAX Level 2 with prototype protection and plans every lifting aid from process analysis through design and manufacturing to commissioning – all from a single source.
CHAPTER 6
Is the extra effort worthwhile?
Hygienic stainless steel versions typically cost 15 to 30 percent more than standard versions. This is offset by lower cleaning costs, shorter downtimes during audits, and a significantly reduced risk of product recalls. In regularly audited facilities, the additional investment usually pays for itself within a few years through savings in cleaning time and lost downtime. A detailed pricing structure for manipulators is shown in the article "What does an industrial manipulator cost ?"
CHAPTER 7
This is how a hygienic design project works.
Analysis: Hygiene class, cleaning concept and load requirements, on site or via video call.
Concept: Individual design including material selection, installation plan and binding price indication.
Design and manufacturing: in Holzkirchen, Germany, according to ISO 9001, with documented materials.
Commissioning and service: On-site assembly and training, worldwide, optionally with a maintenance contract.
CHAPTER 8
Checklist for your tender
You should be able to answer these questions before purchasing a lifting aid for the food industry:
✓ Which hygiene class or cleanroom class is required for the place of use?
✓ Which cleaning method is used: dry cleaning, wet cleaning, high-pressure cleaning or CIP cleaning?
✓ What cleaning agents and chemicals are used, such as acids, alkalis or chloride?
✓ Does the device have direct product contact and therefore fall under EU 1935/2004?
✓ What load capacity and working area are required for the process?
✓ Is compressed air permitted in the area or excluded for hygiene reasons?
✓ Which certification does your customer or auditor require, for example IFS Food or BRC?
✓ What documentation is required for material traceability?
CHAPTER 9
Technical data
Our industry examples demonstrate how these principles are implemented in specific food processing companies: An overview of applications in the dairy, meat processing, bakery, and beverage industries can be found in the article "Lifting Aids for the Food Industry ." A real-world project showcases the articulated arm manipulator for... Dairy farms .
FAQ / Q&A
Frequently Asked Questions about Hygienic Design
01 What does hygienic design mean in handling technology?
Hygienic design refers to the structural design of machines and components according to the guidelines of the European Hygienic Engineering & Design Group (EHEDG). The aim is to minimize contamination risks through smooth, dead-space-free, and easily cleanable surfaces.
02 What standards and regulations apply to handling technology in the food industry?
Relevant regulations include the EHEDG guidelines for design, the HACCP principles for hazard analysis, certification standards such as IFS Food or BRC for audits, EU Regulation 1935/2004 for food contact materials, and the national German Food and Feed Code (LFGB). For occupational safety, DGUV Regulation 54 also applies.
03 Which stainless steel is used for hygienic lifting aids?
For most applications, stainless steel 1.4301 (V2A) is sufficient. For aggressive cleaning agents, acids, or chloride-containing environments, 1.4404 (V4A) is used.
04 What does the Ra value mean in hygienic design?
The Ra value describes surface roughness. The EHEDG requires an Ra value of less than 0.8 µm for product-contacting or cleaning-relevant surfaces. Smooth surfaces prevent microorganisms from mechanically adhering to them.
05 Why are electric drives without compressed air used in hygienic design?
Compressed air can introduce oil mist and exhaust air into sensitive areas. All-electric drives avoid this risk and are therefore particularly suitable for areas with high hygiene requirements.
06 How much additional cost is incurred for hygienic design solutions?
Hygienic stainless steel versions typically cost 15 to 30 percent more than standard versions. This is offset by lower cleaning costs, shorter downtimes during audits, and a reduced risk of product recalls.
07 What is the difference between hygienic design and cleanroom suitability?
Hygienic design concerns direct product contact and the cleanability of surfaces, relevant for food and beverage companies. Cleanroom suitability concerns the absence of particles and germs in the ambient air according to cleanroom classes as defined in ISO 14644, relevant for pharmaceutical and semiconductor manufacturing. These two requirements can overlap, but they follow different sets of regulations.
08 Does every lifting aid in the food industry need IFS Food certification?
No, the lifting aid itself is not IFS Food certified; the certificate applies to the food business. However, the lifting aid must be designed in such a way that it does not compromise the audit requirements regarding cleanability and material documentation.
09 Do grippers and devices also need to be hygienically designed?
Yes, especially in cases of direct product contact. EU Regulation 1935/2004 for food contact materials also applies here. Zeilhofer manufactures grippers and devices using food-grade materials.
10. How long does it take to implement a hygienic design lifting aid?
Depending on complexity and special design, typically 20 to 25 weeks from order confirmation to commissioning. Custom equipment may extend the lead time.
11. Does Hygienic Design also apply to mobile lifting aids such as the ZH lifting lift?
Yes. Mobile systems such as the ZH lifting platform are also available in stainless steel with smooth, easy-to-clean surfaces and are suitable for use in food processing plants up to 100 kg.
12. Who do I contact for a hygienic design assessment?
Speak directly with the engineers at Zeilhofer Handling Technology. We analyze your hygiene class, your cleaning concept, and your certification requirements, and develop a suitable, documented solution.