UNIT-1
BASIC DESIGN
CONSIDERATIONS AND
MATERIALS OF CONSTRUCTION
INTRODUCTION :
◦ Food process equipment design involves the engineering and optimization of
machinery used in food production to ensure safety, efficiency, and quality.
THE BASIC CONSIDERATIONS IN PROCESS EQUIPMENT DESIGN:
◦ The design of food process equipment requires careful consideration of multiple
factors to ensure efficiency, safety, and product quality.
Hygienic & Sanitary Design:
Requirements:
• Smooth, non-toxic, corrosion-resistant surfaces (e.g., stainless steel 316L)
• minimal crevices (to prevent bacterial accumulation)
• Easy to clean
Standards:
• EHEDG (European Hygienic Engineering & Design Group) and FDA
• 3-A Sanitary Standards (for dairy & meat processing)
Material Selection:
• Stainless steel (most common, resists corrosion)
• Food-grade plastics (for lightweight applications)
• Avoid toxic materials (e.g., lead, cadmium)
◦ Another key consideration is the nature of the food product being processed,
including its physical and chemical properties such as viscosity, acidity, and
sensitivity to heat.
◦ The equipment must handle the product gently, when necessary, especially for
delicate items like fruits or dairy products, while being Robust(durable and strong)
enough for tougher materials like grains or meats.
• Liquids vs. solids (e.g., pumps for liquids, conveyors for solids)
• Sensitivity to heat/shear (e.g., gentle handling for yogurt vs. high-shear mixing
for sauces)
◦ Energy efficiency plays a significant role in design, as food processing often involves
substantial energy consumption for heating, cooling, and mechanical operations.
Challenges: Food processing consumes ~30% of global industrial energy.
Solutions:
• Heat recovery systems (e.g., regenerative heat exchangers).
• Optimized insulation (reduces thermal losses).
◦ Alongside this, water usage and waste management need attention to ensure
sustainable operations.
Operational & Maintenance Factors:
• Capacity & Scalability: Must match production volume (small batch vs.
continuous flow).
• Flexibility: Adjustable for handling different products (e.g., multi-use tanks).
• Ease of Maintenance:
• Quick-access components while serviced.
• Modular design for easy part replacement.
Worker Safety:
• Emergency stop buttons.
• Ventilation for heat/steam.
Economic & Regulatory Compliance:
• Cost-Benefit Analysis:
• High initial cost vs. long-term savings (energy, maintenance, durability).
• Regulatory Standards:
• Local (FDA, EU regulations) + International (ISO 22000, HACCP).
• Documentation for audits (material certifications, design validations).
◦ The design must justify its cost through improved productivity, reduced waste, and
extended equipment lifespan.
Materials of construction-mechanical properties and materials:
◦ The selection of materials for food process equipment is critical to ensure hygiene,
durability, and compliance with food safety regulations. The materials must
withstand mechanical stresses, resist corrosion, and prevent contamination while
maintaining efficiency in processing operations.
Key Mechanical Properties for Food Equipment Materials:
A. Strength & Hardness:
• Tensile Strength: Resistance to breaking under tension (e.g., conveyor belts,
mixer shafts).
• Hardness: Resistance to abrasion (e.g., cutting blades, grinding surfaces).
• Measured via Rockwell or Brinell tests.
• Example: Stainless steel (high hardness) vs. plastics (lower hardness).
B. Corrosion Resistance
• Pitting & Crevice Corrosion: Common in acidic/salty foods (e.g., tomato sauce,
seafood).
• Galvanic Corrosion: Occurs when dissimilar metals interact (e.g., aluminum +
stainless steel).
• Prevention: Use inert materials (stainless steel 316, plastics) or protective coatings.
C. Thermal Conductivity
• Important for heating/cooling applications (pasteurizers, heat exchangers).
• High Conductivity: Metals (copper, aluminum, stainless steel).
• Low Conductivity: Plastics (require modifications for heat transfer).
E. Hygienic Design Compatibility:
◦ Surfaces must be smooth, non-porous, and easy to clean to meet sanitary
standards (e.g., FDA, EHEDG(European Hygienic Engineering & Design Group), 3-A
Sanitary standards USA. Avoid materials that harbor bacteria or react with cleaning
agents.
F. Fatigue Resistance:
• Equipment undergoes cyclic stress (e.g., pumps, mixers, conveyors).
• Fatigue Failure: Cracks develop over time due to repeated loading.
• Solution: Use ductile materials (stainless steel, reinforced polymers).
G. Fabrication & Weldability:
◦ Materials should be easy to machine, weld, and form into complex shapes without
losing structural integrity.
Common Materials Used in Food Process Equipment:
A. Metals:
1. Stainless Steel (Grades 304 & 316)
- Most widely used due to excellent corrosion resistance, strength, and cleanability.
- Grade 304: General-purpose (tanks, pipes, mixers).
- Grade 316: Higher corrosion resistance (salt, acidic foods, marine environments).
2. Aluminum & Aluminum Alloys
- Lightweight, good thermal conductivity (used in heat exchangers, baking trays).
3. Carbon Steel (with Coatings)
◦ - Used in non-contact parts (structural supports, frames).
B. Plastics & Polymers:
1. Polypropylene (PP) & Polyethylene (PE)
- Chemically inert, lightweight, and cost-effective for tanks, hoppers, and cutting
boards.
- Limited to low-temperature applications (melts at high heat).
2. Polytetrafluoroethylene (PTFE – Teflon®)
- Non-stick, chemically resistant (used in gaskets, seals, conveyor belts).
- Poor mechanical strength; often used as a lining.
3. Polyvinyl Chloride (PVC) & Acrylics
- Used for transparent piping, inspection windows.
◦ - Must be food-grade and free from plasticizers.
4. PEEK (Polyether ether ketone)
• Properties: High temp resistance (260°C)
• Applications: Sterilizable components
5. PVDF (Polyvinylidene fluoride)
• Properties: Excellent chemical resistance
• Applications: Piping for aggressive chemicals
C. Elastomers & Rubbers:
1. Silicone Rubber
- Heat-resistant, flexible (used in seals, gaskets, tubing).
◦ - FDA-approved grades available.
2. Fluoroelastomers (FKM/Viton)
• Chemical and heat resistant
• Applications: Aggressive chemical environments
3. EPDM (Ethylene Propylene Diene Monomer)
◦ - Resistant to steam and cleaning chemicals (used in seals).
D. Composites & Ceramics:
1. Fiberglass-Reinforced Plastics (FRP)
- Lightweight, corrosion-resistant (used in ducting, tanks).
- Not suitable for high mechanical stress applications.
2. Ceramics (Alumina, Zirconia)
- Extremely hard, wear-resistant (used in cutting blades, valves).
◦ - Brittle and expensive; limited to specialized applications.
Recommended
Equipment Type Critical Properties
Materials
Corrosion resistance,
Mixing Tanks 316L SS, PP-lined steel
cleanability
304 SS, UHMWPE(Ultra-
High Molecular Weight Wear resistance, easy
Conveyor Systems
Polyethylene) cleaning
, FDA-approved belts
316 SS, titanium, Thermal conductivity,
Heat Exchangers
aluminum corrosion resist
440C SS, ceramic Hardness, wear
Cutting Equipment
composites resistance
316L SS, PVDF, PTFE- Chemical resistance,
Piping Systems
lined smooth bore
Anodized aluminum,
Packaging Machines Lightweight, cleanability
food-grade plastics
Emerging Materials and Trends in Food
Processing Equipment Design:
1. Antimicrobial Surfaces for Food Equipment
◦ Prevent bacterial growth (e.g., Listeria, E. coli,
Salmonella) on food contact surfaces.
Types of Antimicrobial Technologies:
A. Copper and Copper Alloys (Cupronickel, Brass)
• Mechanism: Releases copper ions that disrupt
microbial cell membranes (contact killing).
• Applications:
• Door handles, cutting boards, conveyor belts
• Limitations:
• not suitable for acidic foods (may leach ions)
• Higher cost than stainless steel
B. Silver-Ion Coatings (Nano-silver)
• Mechanism: Silver ions penetrate bacteria, damaging DNA/proteins.
• Applications:
• Coatings on stainless steel (e.g., conveyor belts, mixer blades)
• Regulations:
• FDA-approved for indirect food contact
• EU restricts nanoparticle migration (<0.01 mg/kg food)
C. Organic Antimicrobial Additives
• Triclosan (phasing out due to toxicity concerns)
• Chitosan (natural biopolymer from shellfish)
• Used in biodegradable films and coatings
• Nisin (bacteriocin) for dairy equipment
2. Self-Cleaning Surfaces (Photocatalytic Coatings)
How They Work:
• Use light-activated catalysts (usually TiO₂ or ZnO) to break down organic
contaminants.
• UV or visible light triggers decomposing microbes and food residues.
Challenges:
• Requires consistent light exposure (not for enclosed equipment)
Coating Type Activation Method Applications
Conveyor belts, food
TiO₂ (Titanium Dioxide) UV Light
prep tables
Packaging films, storage
ZnO (Zinc Oxide) Visible Light
bins
SiO₂-TiO₂ Hybrids LED Light Refrigerator interiors
Future Trends:
• Photocatalytic + Silver Hybrids (e.g., TiO₂ + Ag coatings)
• Enzyme-based antimicrobials (lysozyme coatings-antimicrobial enzyme )
◦ AI-Integrated Materials: Sensors embedded in equipment surfaces to monitor
microbial loads.
Challenges & Failures in Material Selection:
- Galvanic Corrosion: Occurs when dissimilar metals interact (e.g., aluminum with
stainless steel).
- Stress Cracking: Plastics may degrade with repeated exposure to cleaning chemicals.
