Food industry

Food processing

Food processing plants such as ready meals, pastries, bakery… face numerous challenges where filtration is the key to their solution.

A good air filtration system will guarantee a quality and safe product for consumers, better conditions for facilities and workers. At Venfilter, we offer you our range of certified FOOD SECURE products suitable for food processing.

What causes poor air filtration in food processing plants?

Poor air quality management can put both consumers and plant workers at serious risk. The main problems caused by not having a good filtration system are:

• Virus transmission
• Cross-contamination
• Particulate contamination
• Microbial contamination

Contaminants present in food processing

When talking about food processing, it must be taken into account that, whether in the same plant or in separate plants, very different foods may be processed. Even so, there are some contaminants that are quite common in most plants that present a significant risk for the production of foodstuffs.

Particles 

Small particles are deposited on open foodstuffs, e.g. ready meals, pastries, etc. during production or packaging processes.

Also, fine powders of sugar, flour and other dry ingredients can present a risk to the final product.

Mould and fungi

It can occur due to inadequate hygiene processes by employees or due to the presence of moisture or heat. These bacteria are airborne and if not removed by filtration can become a major liability problem.

Food allergens

The main food allergens include cereals such as gluten, fish… If these foods are improperly mixed in any way, we can cause serious problems for the end consumer.

Viruses and bacteria

Food outbreaks start in food processing plants and are usually caused by poor air filtration. These outbreaks affect 48 million people.

With a good filtration system we will avoid common infections from processed foods such as Salmonella, Listeria, E-coli O157:H7, Clostridium Botulinum, among others.

Why is air filtration important?

Quality standards in the agri-food sector are among the most stringent because the consequences of poor air management can even be lethal for end consumers.

One of the biggest enemies of food processing plants is cross-contamination, which can be completely avoided with good air filtration.

Cross-contamination causes numerous problems such as product losses due to spoilage, production downtime, etc. These problems affect both the profitability and the performance of the plant. To eliminate cross-contamination, an optimal filtration system is necessary to achieve a totally isolated environment.

Meet processing 

In the meat and deli meat processing and treatment industry, it is very important to maintain air quality, as they are susceptible to the spread of viruses and bacteria that will damage the final product and generate production costs.

At Venfilter, we have certified and adapted FOOD SECURE filtration systems for the meat processing industry. We ensure you reduce the risk of product contamination, protect the health of the consumer and your workers, and save on production and maintenance costs.

Why is air filtration important?

Especially in the meat industry it is a challenge, as meat has to be kept refrigerated. If temperature and humidity levels are not well regulated by a filtration system according to the needs of the plant, the possibility of spreading viruses and bacteria increases exponentially.

Why is the transmission of viruses in meat processing increasing?

In meat processing, the possibility of spreading viruses, such as Salmonella, is higher in these facilities. Some of the causes are:

• Inadequate filtration: A poorly chosen filter can lead to increased levels of particulate matter, which can lead to an increase in microbes and viruses being held in the air.
• Environmental conditions: Failure to maintain good temperature and humidity levels creates the perfect habitat for bacteria and viruses.
• Poor air renewal: Meat processing creates a lot of particles in the production process. It is therefore crucial to eliminate the spread of these harmful agents.
• Working conditions: Working in spaces where there is no safety distance, nor optimal hygienic conditions, will generate viruses and bacteria directly to the meat.

Critical stages of meat processing

Each meat and other deli processing plant has its own stages, which will require very different filtration needs from pre-filtration to HEPA systems or molecular filtration. Some of these stages are:

• Admission process

  This is one of the first stages within the plant. The biggest filtration challenges in this process will be dirt and moisture.

• Processing line

  This is probably one of the most sensitive areas of the entire plant, requiring the most efficient filtration. Filtration systems have to cope with high temperatures and flow demands.

• Cutting and chopping area

  Another highly sensitive area which, in addition to facing the challenges of the previous areas, is also the most exposed to airborne biocontamination, i.e. human-generated contamination.

Dairy Processing

In dairy and milk production plants, maintaining good air quality is paramount to the final product outcome and to avoid risks that can damage the product. Throughout the entire dairy production process, there are many vulnerable processes that require filtration of the air entering the facility.

Areas within the dairy industry

• General environments

  This area comprises the spaces intended purely for distribution, it does not take into account the spaces where production takes place.

• Sensitive environments

  In this section we find areas for storage or reception of milk, processing of raw ingredients… They must be kept clean so as not to compromise the product.

• Critical areas

  In these areas, such as drying rooms, packaging for creams, yoghurt, cheeses, etc., they are highly sensitive to contaminants due to the delicate processes that are carried out. For this reason, the flow must be at high volume and pressure levels.

Common contaminants in the dairy industry

Contaminants in large quantities are introduced through the outside air and have an average size of 0.6 microns which makes them more difficult to filter.

Contaminants such as fungi or some types of yeasts, can damage the preservation process of some dairy products such as milk, yoghurt, ice cream…

Bacteria such as E.coli, volatile organic compounds, ingredients that can cause cross-contamination or microbes transported as people also jeopardise the final product and can lead to production losses.

The importance of filtration in the production of milk and other dairy products

In dairy food production, regulations are very strict in terms of safety to protect the final consumer. Therefore, filtration will play a key role during all parts of the process such as ripening, slicing, packaging….

Especially in the filling lines, the air cleanliness conditions must be optimal because the product is very delicate and can be damaged by atmospheric contamination which would lead to increased production costs due to the losses generated.

We achieve this purity thanks to our HEPA/ULPA filtration systems and our FOOD SECURE certified products that comply with the strictest conditions in the sector.

Beverage Industry

Unlike other sectors where the filtration system will depend on the material being treated, in this case whether water, soft drinks, juices, etc. are bottled, the aseptic process will be very similar and the big challenge will be the high degree of humidity.

Beverage production plants have forming, belt conveying, filling and sealing areas. All these areas must have an ISO Class 5 filtration standard.

Why is filtration important in beverage production?

Filtration in these production plants is vital to avoid any contaminants or moisture that can damage the final product.

It is important to keep in mind that products in many stages of the areas are open and highly sensitive to contamination. During the bottling process, contaminants can be introduced into the beverages, completely damaging the product and causing production losses.

Risks and contaminants in beverage production

In beverage production there are numerous contaminants that can damage the final product and cause losses to the company.

One of the biggest challenges is the humidity that generates mould and bacteria. When dealing with liquids, the risk of humidity is very high, but with a good filtration system adapted to the needs of each installation we avoid any risk.

We also find contaminants that come from the air such as dust, but products can also be contaminated due to human activity that generates biocontamination. In addition, we can find malodorous compounds such as in vinegar or other beverages.

Advantages of good filtration in beverage production

There are numerous advantages when installing a good filtration system in beverage production plants. Venfilter filtration systems are guaranteed to reduce risk, reduce costs and protect consumers, personnel and equipment.

• Reduce the risk of microbiological and biological contamination in all areas of beverage production.
• Flavour is an essential factor, and poor quality can be detrimental to taste. A good filtration system ensures consistent quality and taste in the final product.
• Reducing costs by avoiding damage to machinery and bad batches of product. Also, saving energy due to energy efficiency.
• Ensuring that the final product that reaches the consumer is of high quality.
• Ensuring the human team a space free of contaminants for their health.
• Compliance with current international regulations with our certified air filters, avoiding the closure of the production plant due to negligence.

Infant Food 

Infant foods are considered to be all foods intended to meet the special needs of infants and young children. These foods are used as a complement to their diet or to adapt to a normal diet.

Therefore, they will be the foods that will help the growth of the smallest and most vulnerable to possible contaminants. This makes filtration a key element in the production plants of these types of foods in order for children to grow up healthy.

These foods include powdered milk, vegetable purees, fruit, among others.

Venfilter offers you FOOD SECURE filtration solutions for hygienic air conditioning systems that are sensitive to microbial contamination and corrosion suitable for the EC1935/2004 food contact standard.

Contaminants in production plants

In food production processes such as milk powder, there is a risk of contamination due to Enterobacter sakazakii bacteria, as the production of milk powder requires a cooling process.