Kempston Controls explores the importance of hygienic design and how the smallest design decisions can make all the difference when it comes to preventing process failure and downtime in harsh environments.
Hygiene is vital
From conveyors to control panels, every surface in a food plant is subjected to aggressive cleaning regimes and this can take its toll on components. Smaller ones like push buttons and emergency stops can face some of the harshest conditions. Exposure to high-pressure water, chemicals, steam, and temperature swings can quickly degrade components.
Hygienic design beyond the obvious
Equipment like conveyors and vessels are often designed with hygiene in mind. Electrical components, however, can be an afterthought, despite being the most touched and exposed items on the line. When these fail, it’s not just an inconvenience. A stuck E-Stop, or corroded button can halt production, trigger safety concerns, adding cost and eating into uptime.
Studies show that unplanned downtime in food manufacturing can cost thousands of pounds per hour, with 30% of failures linked to control switches, sensors and push buttons. In high-care environments, 40% of E-Stop failures are caused by moisture ingress or corrosion, adding cost, risk and complexity to pressured operations. Today, food manufacturers want components designed for hygienic environments that are sealed, smooth, easy to clean and are IP69K rated.
Function meets form in harsh environments
Components used in food and beverage applications need to resist high pressure hot water, fats, cleaning agents, acids and thermal shock. Equally, they must be intuitive for operators wearing gloves and rugged enough to ensure a long service life. Tactile reliability is important too, a push button should feel the same today as it did a year ago. Engineers know that preventing downtime involves removing failure points. In high-care areas this means choosing components that don’t just survive but thrive in these locations.
Resistance is in their DNA
Schmersal has developed a wide range of operator control devices designed precisely for these conditions. With stainless steel options, hygienic design and industry leading protection ratings, these components are helping manufacturers meet both compliance and uptime goals
Good hygiene starts with a good design, right down to the smallest components. By thinking carefully about material choices, ingress protection and ergonomics, engineers can avoid common failures and reduce reactive maintenance. It’s a simple shift, but one that supports the bigger picture of safe, efficient and uninterrupted food production. Because when everything works, down to the push of a button, the rest falls into place.
Find the Schmersal product you need here
Kempston Controls is committed to finding you the ideal solution for your application. Call us today on +44 (0) 1933 411 411, email us at sales@kempstoncontrols.co.uk, or alternatively contact us here, we will be happy to help.
