In an interactive session available to watch on-demand here, Food Manufacture was joined by Dave Heathcote (DH) industrial vacuum specialist from Nilfisk; Adrian Watts (AW) hygiene improvement manager for Weetabix; and Duncan Reed (DR) partner at Birketts who threw the spotlight onto hidden hazards facing food and drink producers.
Whilst the experts fielded as many questions as they could on the day, there were others they didn’t get a chance to address. Here, the trio come back together again with their responses.
Q. Do you believe we’ll see more factories use third party contractors (e.g. hygiene specialists) and how do you know who to trust?
AW: I’m sure many are looking into dedicated hygiene specialists already as there is the potential for a faster and more effective clean with a well-trained team.
Look for a company that has low staff turnover and a training programme that aligns with a recognised standard similar to the BICSc apprenticeship.
DH: I echo what Adrian says, and we do find our customers may use either in-house or externally appointed cleaning/hygiene teams depending on their own internal set up and preferences.
In terms of who to choose, references can be a helpful tool from a trusted source as well references directly from the third parties end-customer. Segment specific case studies and testimonials can also be helpful tools.
DR: If third party contractors are used then it will be important to have appropriate contractual arrangements in place with relevant KPIs and reporting obligations to ensure the overall risk is managed as far as possible.
Q: What would you say is the biggest hidden hazard F&B need to be aware of?
AW: With the advent of AI and production lines being fully automated, there is a danger that the hygienic design process is not being considered from a human perspective. Although a machine can operate without much human intervention the nature of hygiene tasks means the need for human intervention is needed and access for hygiene tasks is critical (and often not on the minds of engineers and manufacturing teams).
DH: From my perspective, ‘dust’ is the biggest hazard in F&B due to the potential danger involved, it would absolutely be combustible dust settling and not being properly cleaned from high and hard to reach areas, hence the focus from Nilfisk during our section of the Webinar.
It can be a relatively easily remedied hazard/issue when the correct equipment and operator training is provided. Always check that your cleaning equipment is third-party certified.
DR: It will be a hazard that is present but has yet to be identified by the operator, which is why it’s always useful to have an extra pair of eyes or consult with industry experts to ensure you aren’t missing anything.
The legal test is doing what is ‘reasonably practicable’ to ensure safety, so risk awareness is the starting point to be able to consider what appropriate protective actions to take.
Q. The new system you introduced meant more tools into the factory – what space, flow or storage considerations did you need to factor into your set up?
AW: We replaced the brushes with squeegees so no increase there. The extra vacuums and tools were only needed in areas not covered currently and will eventually be replaced as we roll out a central vacuum system upgrade.
Effective use of tool boards helped and not limited your opportunities for development by only having shadow boards allows easy expansion.
We also worked closely with a tool manufacturer to develop a tool board where the shadows are magnetic and can be upgraded as required rather than replacing whole boards which is proving very cost effective.
Q. Regulation is moving quickly, what upcoming legal developments or enforcement trends should hygiene and health and safety managers be preparing for now?
DR: Operational safety remains a key risk area for many producers and technological developments which may allow closer monitoring are continuing to advance. It’s worth keeping up to date on any credible solutions which could assist to minimise risk.
Q. Where do you see the biggest gaps between what manufacturers think is compliant versus what auditors and regulators actually expect to see on site?
DR: Regular independent audits and reviews will help to support manufacturers here and engaging with the industry around ‘what compliance looks like’ is always recommended. Currently the HSE are focusing on work-related ill health including hazardous dusts which is a key risk area.
Q. Why do new regulations come into place sometimes removing the old ones as well?
DR: Broadly, the regulatory framework around food safety and worker safety will remain pretty static over time – for example the Health and Safety at Work Act is over 50 years old and still considered fit for purpose. New risks can arise which are covered under existing regulations or sometimes entirely new regulations are introduced to deal with them.
Q. How can food manufacturers better identify and mitigate hidden hazards before they lead to incidents, particularly in high-pressure production environments - and how important is hands-on, real-world training in preparing operators for those situations?
DR: Training and engaging with operators is going to be key to reducing the overall risk of hazard management in this context.
Evidencing this is also important when you are looking to manage the potential legal risks arising. It’s important to have something that is appropriate for each production setting and working environment to make this work for producers.
Q. For those just starting out or scaling and worried about hazards and risks – where can they go to ensure they remain compliant and safe?
AW: Get friendly with the experts. I have lots of contacts in the hygiene tool and process industries who I can phone up for advice. Go to trade shows and look out for innovation and ask for demonstrations on your site. Bring hygiene companies into your business to consult on issues and speak to several companies to see what the common themes are. Finally, ask your own operators and cleaning staff what their ideal solution would be and get them involved with visits from OEM’s.
DH: I personally find trade shows to be really helpful as you have so much industry knowledge all in one place at one time that you can tap into. Most companies do truly want to help.
Secondly, from our position as an equipment supplier, I always find the best customer site visits I take part in are those where there are individuals from various internal departments all present to give their own point of view and feedback – this tends to end in a very rounded solution when it comes to equipment.
DH: Join relevant safety groups and look out for training and events which might be low or no cost. Speak to intermediaries such as banks, insurers or brokers as they may also have relevant resources or events. If an incident does occur it’s also important to get early legal advice.
