In hygienic production, an interesting race exists between the food and pharmaceutical industries. While pharma often prides itself on stringent cleanliness standards, the food sector has quietly been innovating in ways that could revolutionize hygienic design across both fields.
But what is driving the innovation in hygienic technologies in food production?
Economics, plain and simple. But don't be fooled – the implications are far-reaching and potentially game-changing for pharma operations worldwide.
Let's explore how tight margins in food production have pushed for clever solutions, and why pharma executives should be taking notes.
Economic Pressures Driving Innovation
In the pharmaceutical world, blockbuster drugs can yield sky-high profits, at least until patents expire. This financial cushion has, paradoxically, led to a certain complacency in equipment design. Why reinvent the wheel when earnings are soaring?
The food industry, however, tells a different story. Razor-thin margins from day one have necessitated a relentless focus on efficiency. Every drop of product, every second of production time, counts. This pressure cooker environment has created a business environment of innovation, particularly in hygienic design.
"In the pharma industry, first of all […] every day, every hour, you don't make [the drug], you've lost the chance of making a very large amount of money. Whereas in the food... the margins are very tight from the outset. So I believe that's naturally led to a different pattern of attitude to equipment design,” explains Dr. Roland Cocker, a seasoned expert in the field, in an interview with BLÜCHER (See full interview below).
Organizations like the European Hygienic Engineering and Design Group (EHEDG) have been at the forefront, constantly refining and improving equipment designs, and the result are clear: Machinery that’s both cleaner and more efficient, elegant, and cost-effective. Pharma, take note.
EHEDG Certification: A Benchmark for Excellence
Imagine having a standardized "seal of approval" for hygienic components. That's precisely what EHEDG offers with its certification process. For hygienic design and manufacturing, it's a game-changer.
Here's how it works: valves, pumps, and other critical components undergo rigorous challenge tests. Pass, and you've got a baseline assurance of cleanability. It's not a guarantee for every possible scenario, but it's a solid starting point.
For pharma execs, this could be a goldmine. Picture streamlining your procurement process, starting with a pre-vetted list of components. You'd still need to conduct your risk assessments and final validations, of course. But wouldn't it be nice to begin with equipment that's already proven its hygienic capability?
"EHEDG offers certification of components […] according to a standard challenge test. So it's a reference test for its hygienic performance, its cleanability. Now, it doesn't guarantee that it would be cleanable in every process and for every product […] but it tells you at least a baseline. It's a kind of pre-validation,” Cocker explains.
Innovations in Action: The Double Seat Mix Proof Valve
Let's talk specifics. The double seat mix proof valve is a prime example of food industry ingenuity that pharma could – and should – embrace.
This clever piece of engineering allows two product streams to cross paths without a hint of contamination. Imagine running cleaning solutions through one line while your valuable product flows through another. No mixing, no contamination.
The effects for pharma are enormous. Cross-contamination risks would drop. Changeover times between batches would shrink. It's the kind of innovation that could transform production schedules and boost bottom lines.
Lean Manufacturing and Sustainability
The food industry's focus on hygienic design isn't just about cleanliness – it's about overall efficiency. And according to Cocker, that's a lesson pharma needs to learn.
"A lot of the benefits of hygienic design are […] lean manufacturing. So that simplicity in equipment, cheaper production, more elegance, fewer product losses and so on. So, there's a lot of pressure now on sustainability, even for blockbuster drugs. [Hygienic design] will help a lot with that too."
Think about it. Simpler, more elegant equipment designs lead to fewer product losses. They're easier to clean, reducing downtime. They often require less energy to operate. All of this adds up to a leaner, more sustainable manufacturing process.
Conclusion
The pharmaceutical industry has long been a beacon of innovation in many areas. But when it comes to hygienic design, it's time to acknowledge that food manufacturers might just have the upper hand.
As Dr. Cocker succinctly puts it: "I think the pharmaceutical industry should beat a path to the door of EHEDG."
From economic pressures spurring creative solutions to standardized certifications and clever component designs, the food industry has developed a toolkit that pharma would be foolish to ignore.
So, to our fellow pharma executives: Let’s combine the knowledge from both industries and make both food and pharma safer, more productive, and more profitable.
