Guideline no.

Conveyors
– with focus on hygiene

Authors:
Jensen, Erik-Ole; Arla Foods amba
Øgaard, Erik; Arla Foods amba
Brygmann, Lars; Danish Crown AmbA
Pedersen, Steen; Gram Equipment A/S
Hansen, Anders Staf; Interroll A/S
Lassen, Anders; Jens S. Transmissioner A/S
Melbye, Hans-Henrik; Jorgensen Engineering A/S
Krüger, Peter; KJ Industries A/S
Winther, Klaus Kjærgaard; KJ Industries A/S
Cortzen Jan; Niels Burcharth A/S
Broe, Peter; uni-chains A/S
Boye-Møller, Anne R.; Danish Technological Institute

Prepared by the conveyor task group under the auspices of the competence centre of
the Danish stainless steel industry.

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Den Rustfri Stålindustris Kompetencecenter

c/o Teknologisk Institut
Holbergsvej 10
DK-6000 Kolding

Tel.: +45 72 20 19 00
Fax: +45 72 20 19 19

info@staalcentrum.dk
www.staalcentrum.dk

This guideline is developed with the support of the Danish Ministry of Science,
Technology and Innovation.

Published for the Centre by:

Holbergsvej 10
DK-6000 Kolding

www.teknologisk.dk

© Danish Technological Institute

ISBN: 87-7756-752-8

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Summary
This guideline offers general advice with regard to the hygienic design of conveyors for
the food industry.

Special attention points will be illustrated by drawings/photographs.

The guideline will be divided into parts as illustrated in the photograph below.

Lateral Belt Drive stations

Idler end guide for
product

Belt support
Conveyor frame Sub-frame

Fastening Nozzle beam

Figure 1. Overview of conveyor parts.

Key words
Conveyor belt, hygienic design, construction, foods, cleaning, nozzles, material, motor,
guard, food approved, service, joints.

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Definition and use of guidelines

A good hygienic design reduces cleaning time. Therefore, this guideline will be relevant
in all production environments that require minimal cleaning time.

High hygiene requirements lead to high cleaning requirements, which makes the design
even more crucial.

The guideline can be used by construction engineers in connection with the design of
conveyors.

It can also be used by purchasing officers when deciding on the specification of parts for
a conveyor.

Finally, the guideline can be used as a communication tool between conveyor

purchasing officers and suppliers.

It is not the purpose of the guideline to recommend certain types of solutions or

suppliers.

This guideline is prepared by a task group under the competence centre of the Danish
stainless steel industry and is one in a collection of guidelines. The others are:

Guideline no. 1: Cabling and electrical cabinets – with focus on hygiene

Guideline no. 2: Check list for the purchase/sale of production equipment – with focus
on hygiene
Guideline no. 3: Conveyors – with focus on hygiene
Guideline no. 4: Stainless steel in the food industry – an introduction
Guideline no. 5: Design of piping systems for the food processing industry – with focus
on hygiene
Guideline no. 6: Installation of components in closed processing plants for the food
processing industry – with focus on hygiene

Enjoy!

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Contents
1. Domain ........................................................................................................................ 6
2. Limitations .................................................................................................................. 6
3. Important design rules for the construction engineer ............................................ 6
3.1. General design .................................................................................................................... 6
3.2. Particularly hygienic design .............................................................................................. 7
4. Belt types .................................................................................................................. 11
4.1. Modular belts..................................................................................................................... 11
4.2. Synthetic belts (PVC, PU, PE, silicone, rubber) ............................................................. 15
4.3. Toothed synthetic belt (thermoplastic polyurethane, TPU) .......................................... 18
4.4. Apron belt (= apron chain) ............................................................................................... 19
4.5. Roller conveyor................................................................................................................. 21
4.6. Wire belts........................................................................................................................... 24
5. Lateral guides for belts ............................................................................................ 27
6. Nozzle beams............................................................................................................ 30
7. Lateral guides for product ....................................................................................... 31
8. Support of belts ........................................................................................................ 35
8.1. Slide guides....................................................................................................................... 35
8.2. Half-moons ........................................................................................................................ 36
8.3. Support rollers and return rollers ................................................................................... 37
8.4. Plates as support .............................................................................................................. 38
9. Drive stations............................................................................................................ 40
9.1. Drum motor for synthetic belt ......................................................................................... 40
9.2. Drum motor for modular belt and toothed synthetic belt ............................................. 42
9.3. Gear motor for synthetic and modular belts .................................................................. 44
10. Idler end................................................................................................................... 46
11. Conveyor frame ...................................................................................................... 48
12. Sub-frame................................................................................................................ 51
13. Fastening................................................................................................................. 54
13.1. Fastened .......................................................................................................................... 54
13.2. Mobile............................................................................................................................... 56
14. Applied methods .................................................................................................... 57
15. Safety and environmental precautions................................................................. 57
16. Further information ................................................................................................ 57
16.1. Related guidelines .......................................................................................................... 57
16.2. Links................................................................................................................................. 58
17. Literature ................................................................................................................. 59
18. Concepts/terminology............................................................................................ 59
19. Appendices ............................................................................................................. 59
19.1. Protection grades – IP nomenclature (according to IEC 529/DIN 40 050) ................. 59
20. Change protocol ..................................................................................................... 60

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1. Domain

This guideline offers general advice with regard to the hygienic design of conveyors for
the food industry.
The guideline offers comments on various types of solutions with regard to function,
design, cleanability and service.

2. Limitations

The guideline is limited to conveyors used in high risk areas, i.e. the
manufacture/processing of non-packaged foods in a humid environment. The same
guidelines for the equipment apply to direct food contact and transport of the product in
open boxes alike. A humid environment is particularly conducive to the spread of
bacteria and thus to the transference of disease-producing bacteria to the foods.

3. Important design rules for the construction engineer

The construction engineer must ensure that the delivered equipment meets the
requirements and is of a quality that is consistent with the intended use.

3.1. General design

• The equipment must be designed to allow easy cleaning. If dismounting/opening

of doors etc. is required, the design should be such as to facilitate this, and in no
way should doors obstruct cleaning. The design must be free of cracks, ends,
holes, unevennesses, rough surfaces etc. in areas where cleaning is difficult or
impossible. Such areas may harbour bacteria which can continuously contaminate
the production. Surfaces must be such as to prevent the development of
zoogloeal film on the machines.
• The equipment must be designed without sharp corners and edges.
• The design of the equipment should be such as not to hold back product particles.
• All horizontal surfaces should be reduced to an absolute minimum.
• All horizontal surfaces should be designed with a 5° inclination to allow water to
run off. Constructions/brackets should also be inclined to allow water to run off,
which will facilitate drying of the room after cleaning.
• The equipment should be designed to prevent the collection and accumulation of
water and detergents. The construction should be designed without hidden areas
or positions where water, detergents or dirt may accumulate.
• The design should enable the setting of the equipment to several washing
positions to allow proper cleaning of all parts.
• The equipment should be as open as possible. The number of guards should be
minimised to what is necessary for reasons of safety and should not prevent
efficient cleaning. Guards should be removable during cleaning/disinfection, either
through opening or by unhinging.

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• Should it be necessary to disassemble machinery, this should be described in
detail in the cleaning manual. The design should include a system for the
storage/placement of loose parts.
• The equipment must comply with the guidelines of the Machine Directive.
• Prior to commissioning of new equipment, or after repair, the equipment must be
thoroughly cleaned as any dust will cause abrasion and reduce the lifetime of the
equipment.

3.2. Particularly hygienic design

• All tops of boxes, cabinets and control panels etc. should have an inclination of 5
to 30° to allow water to run off. (The box may be inclined)
• All electric cable supports should be designed to prevent the accumulation of
product particles and parts between the cables.
• The quick setting to cleaning position of any equipment that is cleaned during
production should be facilitated.
• All materials and media (seals, oil...) with direct product contact or risk of product
contact must be food approved for the market in question (documentation
required). Use the links at the end of this guideline or learn more in EHEDG
guideline no. 23: ”Safe production and use of food-grade lubricants”
(www.ehedg.org).

For further reference, see the European Hygienic Engineering & Design Group
(EHEDG) guideline no. 8 on Hygienic equipment design criteria (see
www.ehedg.org). This document includes a number of general directions for the
design and manufacture of equipment to ensure microbial safety and product quality.
They deal with, among other things, cleaning, validation of hygienic quality, surfaces,
geometry, design and materials.

Machines and conveyors

• For cleaning reasons, it is recommended to use batch start-stop of machinery or
belts. This will reduce the energy consumption/wear and the noise in the room
during cleaning.
• For components and electrical boxes mounted directly on the equipment, there
should be a minimum distance of 25 mm between the backside of the component
and the surface/component on which it is fixed. The top of the box should have an
inclination of 5 to 30°.
• All legs should be adjustable by +/- 75 mm to allow for uneven floors.
• It would be an advantage if the conveyor belt can be loosened without any
significant use of tools.

Fastening to floor or ceiling

• Equipment that is fastened to the floor should be sealed to keep the floor
completely tight and prevent the accumulation of dirt.
• Equipment that is fastened to supporting ceiling structures should be lead through
a false ceiling. The lead-throughs should be as few as possible.

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Placement and mounting of components

• For wall-mounted components and electrical boxes there should be a minimum
distance of 50 mm between the backside of the component and the surface on
which it is mounted.
• The distance from fixtures and fittings to wall and between machines/equipment:
60 cm is recommended, a minimum of 30 cm is required. However, it should be
possible to open doors up to 90°.
• A minimum clearance from the floor to machinery of 30 cm is recommended.

Cabling
• Main supply lines for electricity, water and air in the ceiling should be led down
through vertical piping.
• Vertical piping should be included in the offer.
• Horizontal cable routing where cables lie openly should be designed with stainless
steel wire mesh cable trays that are covered with stainless steel plates. See how
in the example below.
• The cross section of the cable tray should be adapted to the number of cables.

Openly placed cables

Figure 2. Cables are mounted openly in wire mesh trays covered with drainable stainless steel plates.
Figure 1 on the left shows a cross section of a horizontal cable routing, whereas figure 2 to the right shows
a cable tray from the side. Cables to photo sensors, motors etc. can be routed openly over distances of
less than 500 mm as shown in the bottom figure.

• Cables to photo sensors, motors etc. can be routed openly over distances of less
than 500 mm as shown in the bottom figure.
• The cable inlet on equipment in production rooms should be placed at the bottom
of cabinets and boxes.
• For further reference, see Guideline no. 1 in this series: Cabling and electrical
cabinets – with focus on hygiene.
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Pneumatic components
• Pneumatic valve blocks should be assembled in, as a minimum, AISI 304
stainless steel boxes. The top of the box should have an inclination of 5 to 30° to
allow water to run off.
• The hose inlet should be placed at the bottom.
• The ventilation air of the box should be connected to the central ventilation
system.
• Additional ventilation air from pneumatic components should be connected to the
central ventilation system.

Materials
• All materials used must be approved for use in the food industry.
• Be aware that steel and plastic have different coefficients of expansion when
heated. Therefore, joints of plastic and steel should only be tightened/fastened in
one place. The coefficient of expansion for most plastic materials is approx. 10
times that of steel (plastic expands by approx. 1.8 mm per 10°C temperature
range, whereas steel expands by approx. 0.2 mm per 10°C temperature range).

Metal constructions: For further reference, see Guideline no. 4 in this series: Stainless
steel in the food industry – an introduction. Ground and glass-blown
surfaces should not be used in places with direct food contact. All all-
welds should be smooth.
Plastic: Plastic material should have a high maintenance and hygiene standard.
The plastic materials should be resistant to products and detergents.
Belt: Belt types should be approved for the food industry. Synthetic conveyor
belts should have sealed edges to prevent damage to the edges and
subsequent disintegration.
Aluminium: Should generally not be used. Aluminium cannot withstand the
detergents used in the food industry and will corrode.
Brass: Should generally not be used. Brass will corrode (becomes green from
verdigris).

Design
• The supplier should make sure that the design of the equipment is according to
the set design requirements and that approved materials are used.
• It is the supplier's responsibility that all work is carried out by skilled personnel that
are specially trained to do the job.
• On request, the supplier should be able to produce evidence that each employee
is skilled for the job.

Welding of stainless steel

• The welded seams on machines, pipes and equipment should be all-welded,
pickled, cleaned and ground. Point welding should be avoided.
• As a minimum, all welds should comply with quality level B according to DS/EN
26817.

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• Welding of stainless steel should be carried out by welders at a level
corresponding to DS/EN 287-1.
• All welds should undergo a complete visual inspection according to DS/EN 970.

Joints
• Use a minimum of joints and move them as far away from the production side as
possible.
• Use welds instead of bolt joints wherever possible.
• The thread should point away from the production side.
• Inner hexagon bolts (and similar) should be avoided.

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4. Belt types

The following sections describe six different types of belts. Modular belts, synthetic belts
and synthetic toothed belts are all recommended when direct food contact is involved.
Apron belts should not be used for direct food contact. Roller conveyors and wire belts
can be used for direct food contact.

4.1. Modular belts

Modular belts consist of modules that are assembled by means of cross pins. The
modular belt is driven by a chain sprocket or a toothed, vulcanized rubber coating. The
modules can be assembled into different lengths and widths.

Figure 3 and figure 4. Examples of modular belts.

Function Modular belts can run in straight lines or in curves. By using curve running belts, it
is possible to combine straight and curved sections in one belt and thus reduce the
number of drive stations, which is an advantage in terms of hygiene. There should
be as few joints/modules across the belt as possible. Antimicrobial substances may
be cast into the material, but please note that these must be food approved for
product contact.

Construction Modular belts are based on a traditional load-carrying structure that is adapted to
design requirements for the modular belt. The modular belt consists of plastic
modules that can be put together using different types of joints, designed for
specific purposes. The choice should depend on the task, products and
environment (chemistry, temperature, pH, time, concentration of detergents). Belt
lift can be used if the construction cannot be made sufficiently open.

The modular belt will have a droop immediately after the drive sprockets (the same
applies to apron belt conveyors). This is to ensure that the chain/belt is drawn tight
towards the sprocket. At the same time, the droop will compensate for varying
chain or belt length as a result of the load, temperature, wear, etc.

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Cleanability The belt may prove difficult to clean. Cleaning can be carried out manually or
automatically through CIP (Cleaning In Place), i.e. nozzle cleaning with screening
of the area to prevent the spread of dirt. Make sure that the proper types of nozzles
are used.

The nozzles can be mounted both outside and in between the chains dependent
on belt type. Make sure to select the proper nozzles, correct pressure, number and
location of nozzles. A nozzle beam must be placed so that impurities are washed
out of the belt when it opens on the return roller. Also make sure that product
residue is washed off the inside, underside and screens so that any product
residue is removed after cleaning.

If rotating brushes are used for cleaning, they should be in a colour different from
both the product and the belt. The brushes must be cleaned and heat-treated, or
placed in a vat with a suitable disinfectant, after use.

Service/maintenance Be aware of wear and damage and increased belt width (adjustments are
particularly important early in the belt lifetime and on temperature changes).
Nozzles must be dismounted and cleaned regularly. The washwater particle filter
must be cleaned regularly.

The following pages show examples of modular belts and attention points in terms of
hygiene.

Figure 2. Example of a modular belt with a drum motor drive with

sprockets. This is a excellent solution as long as the belt can be lifted
for cleaning.

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Figure 3. Underside of a modular belt (on the return side) with product
residue before cleaning. The belt can be difficult to clean.

Figure 7 and figure 8. Modular belts where the individual joints are shorter than the belt width. The belt is
more difficult to clean than belts where the width of the joints is identical to the belt width. The small picture
shows how dirt settles between the short joints.

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Figure 4. Modular belt where the length of the modules is Plastic module in
identical to the belt width. This is an advantage in terms of full width
hygiene as the number of joints is reduced.

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4.2. Synthetic belts (PVC, PU, PE, silicone, rubber)

Synthetic belts are designed as endless belts. Carriers, guide profiles, wavy edges and
trimmings can all be welded onto the belt. Synthetic belts are driven by a friction
roller/drum motor which is often higher in the middle (camber/crowning).

Figure 5. Example of synthetic belt.

Function Synthetic belts mostly run straight, down or up. Must be food approved. Synthetic
belts have a homogenous surface, which is easy to clean. Damaged belts lead to
poor hygiene.

Construction The belt needs guidance to stay in place (see chapter 5, Lateral guides for belts).
The belts are made from synthetic material and are often reinforced with textile
fibres encapsulated in the belts. It is important that the encapsulated textiles are
kept dry as they may otherwise be conducive to the spread of bacteria. Damaged
belts lead to poor hygiene (frayed edges). To avoid frayed edges, trimmings can be
welded onto the belt. Carriers can be extruded from pure synthetic material or
textile reinforced. The latter should always be provided with trimmings.

Cut textile reinforced belts should always be sealed.

In connection with curve conveyors, special attention must be paid to the machine
design. An extruded, purely synthetic guide profile can be welded to the backside
of the belt for guidance.

Cleanability The belts are easy to clean as long as they are not damaged. Cleaning can be
carried out manually or automatically through CIP (Cleaning In Place). The design
must allow the release of the initial tension so that the belt can be removed or lifted
and cleaned on the underside.

It must be possible to dismount the belt for cleaning, when it is supported by a

plate. It cannot be cleaned from below and from both sides unless it is dismounted.

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Service/maintenance Check the construction for impurities to avoid restricted guidance of the belt. Make
sure that the initial tension of the belt is correct to avoid drive drum slippage.
Ensure that the tensioning during operation is correct, that the tensioning sections
are intact and fully functional, and that all rotating components (drive drum, tail and
return roller) are clean and functional. Check the belts for damage.

The following pages show examples of synthetic belts and attention points in terms of
hygiene.

Figure 11 and figure 12. Good edge seals.

Figure 13 and figure 14. Extruded synthetic carriers are an advantage in terms of hygiene. They have no
crevices/pockets where impurities may settle, and they are easy to clean.

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Figure 15. Cut textile reinforced carrier. The seal Figure 16. The edge sealing has been removed, and
is broken and represents a hygiene risk. Should the belt is fraying, which represents a hygiene risk.
be resealed. Should be resealed.

Figure 6. Damaged belt due to wear. The

coating is worn off and there is direct contact
with the textile reinforcement, which is a
hygiene risk. The belt must be replaced to
ensure a sealed/uniform surface that will not be
conducive to bacterial growth, and which can
be easily cleaned.

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4.3. Toothed synthetic belt (thermoplastic polyurethane, TPU)

Extruded thermoplastic polyurethane with toothing on the backside. Driven by chain

sprocket or drum motor with toothed vulcanized rubber coating.

Figure 7. Example of toothed synthetic belt.

Function Uniform extruded polyurethane without textile reinforcement or joints, which is a

hygiene advantage. The belt runs straight, up or down. The belt is cut and wear
resistant, and anti-microbial substances can be cast into the material. The belt
must be food approved.

Construction The belt is designed to run on the same constructions as jointed modular belts. The
belt requires no initial tension or tensioning.

Cleanability The belt is very easy to clean. Cleaning can be carried out manually or
automatically through CIP (Cleaning In Place), i.e. nozzle cleaning with screening
of the area to prevent the spread of dirt. Make sure that the proper types of nozzles
are used.

Belt lift can be used if the construction is not sufficiently open.

Service/maintenance The belt must engage correctly with the drive drum to avoid slippage.

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4.4. Apron belt (= apron chain)

Apron belts consist of apron plates that are hinged to the underside with a single or
double hinge. Apron belts are driven by a chain sprocket. Belt width and apron plate
width are identical. Note: Apron belts are not recommended for direct food contact.

Figure 8. Example of apron belt.

Function Apron belts can run in straight lines or in curves. Apron belts cannot be
recommended for direct food contact as the fastening of the steel pin makes
cleaning around the hinge difficult (see figure 21).

The apron belt will have a droop immediately after the drive sprockets (the same
applies to modular belt conveyors). This is to ensure that the chain/belt is drawn
tight towards the sprocket. At the same time, the droop will compensate for varying
chain or belt length as a result of the load, temperature, wear, etc.

Construction Apron belts are constructed from plastic parts that are joined in endless lines by
means of pins. The pins are normally produced in stainless steel. The stainless
steel pin is fastened with a press fit or riveting.

Using apron belt for curves will lead to relatively large openings which may
constitute a safety risk for personnel or cause products to get stuck/damaged.
Safety belts with overlapping joints will reduce the above-mentioned hazard (see
figure 20).

The support below the “wings” is necessary.

Cleanability When choosing detergents, it should be taken into account that apron belts are
normally made of POM (polyoxymethylene = acetal plastic) which has limited
resistance to chlorine-containing detergents.

The fastening of the steel pin makes it difficult to clean around and inside the
hinge.

Service/maintenance Generally, apron belts are characterised by requiring little continuous maintenance.
The mentioned droop eliminates the need for regular tensioning. In the case of
substantial wear, the droop can be reduced by removing one or more joints.

Belts are usually replaced due to wear. In this connection, the bendings on the
underside can be used to indicate the extent of the wear. Alternatively, reduced
engagement with the drive sprocket may indicate wear and subsequent increased

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chain pitch.

Support below the Safety apron belt with

”wings” is overlapping joints
necessary. reducing the risk to
personnel and of
products getting
stuck/damaged.

Figure 20. Normal apron belt (left) and safety apron belt (right).

Figure 21. Apron belts cannot be recommended for direct food contact as the fixation of the steel pin
makes cleaning around the hinge difficult.

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4.5. Roller conveyor

A roller conveyor consists of several rollers.

Figure 9. Example of a roller conveyor.

Function Conveying large, solid objects. Often used as transition between lines and in
connection with directional changes.

Construction The rollers themselves must be of one material, e.g. full turned plastic roller or all-
welded stainless steel roller. If both plastic and steel are used in the roller, the
materials will expand differently. This could lead to cracks which may be a breeding
ground for bacteria.

Roller bearings in rollers should be avoided. If roller bearings are necessary, they
should be IP66 sealed.

Cleanability In so far as possible, the construction should be open/removable and thus easy to
clean. Rollers should be removable. Plastic rollers disintegrate over time due to
detergents.

Rollers should be cleaned thoroughly before start-up as dust will cause abrasion.

Service/maintenance

The following pages show examples of roller conveyors and attention points in terms of hygiene.

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Figure 23. Unhygienic construction. Plenty of dirt can accumulate between the synthetic roller and the
metal pin.

Figure 10. The rollers themselves must be of one material, e.g. full turned plastic roller or all-welded
stainless steel roller (as shown to the left and right). Roller bearings in rollers (as shown in the middle)
should be avoided, if possible. If roller bearings are necessary, they should be IP66 sealed.

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Figure 25. The width of a roller should not be increased by placing more rollers beside each other, as it
would be impossible to remove dirt. Must be solid-cast in the full width.

Figure 26. Pop-riveted roller produced in two different materials – is unhygienic. Dirt will accumulate inside
the roller and in the rivet. The distance between the roller and the frame is too small for cleaning to be
sufficient. Alternatively, the roller must be dismounted for cleaning.

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4.6. Wire belts

Wire belts consist of metal wires that have been woven into different designs. Driven by
either chain sprockets or friction rollers.

Figure 11. Example of wire belt.

Function Wire belts can run in straight lines or in curves. Wire belts can be woven in different
types of material and weave patterns dependent on the task. The belts are well-
suited for extreme temperatures between -200°C and +1,200°C. Wire belts are cut
and wear resistant and are used for conveying solid objects. Suitable for draining
(wet or dry) of products or for fast heat release from products.

Construction Normal support construction adapted to the requirements of the task at hand.
Large fluctuations of temperature do not significantly affect the belt.

Cleanability The small surface and the open construction are an advantage. The metal will
retain the heat during cleaning, which is an advantage over plastics. Wire belts are
generally easy to clean. It is recommended to “braid” the belts together to endless
lines to avoid joints/bushings (see figure 30).

Service/maintenance Dependent on the construction, the belts may be difficult to guide. If the belt is not
running straight there is a risk that wires burst or catch the construction.

The following pages show examples of wire belt conveyors and attention points in terms
of hygiene.

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Figure 28. Wire belts are suitable for the draining of wet products (e.g. chocolate).

Figure 29. Likewise, wire belts are suitable for draining of dry products (e.g. spices). An open belt with a
small surface is an advantage in terms of hygiene. Fastening of the roller with split pin is, however, not
ideal.

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Figure 12. Unsuitable joining (bushing) of two wires in the wire belt – constitutes a hygiene risk.

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5. Lateral guides for belts

Lateral guides can be used for toothed synthetic belts and modular belts to ensure
straight running. Lateral guides should not be used for smooth synthetic belts as they will
wear the belt. Instead, the belt is guided by means of camber/crowning on the drum
motor/drive motor where it may be combined with a guide profile on the belt.

Function Lateral guides are used to keep the belt in place so as to ensure straight running.

Construction The lateral guide can be designed as part of the support. The material should be
more resistant to wear and/or of a harder quality than the belt itself. Boltings of
plastics and steel should be avoided as the materials have different expansion
properties.

Cleanability If the construction does not allow belt lift, the belts must be running during cleaning,
and inspection/checks must be carried out subsequently.

Service/maintenance Be aware of wear an and possible material expansion.

The following pages show examples of lateral guides for belts and attention points in
terms of hygiene.

Figure 31 and figure 32. Examples of hygienic L-shaped lateral guides for modular belt (right) and toothed
synthetic belt (left). Functions as support (slide guide) and lateral guide. Manufactured in one piece, which
means that the number of joints is reduced and cleaning is improved. It should be possible to lift the belt
during cleaning. Fastening of the synthetic guide (right) should be designed to allow removal of the guide
during cleaning.

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Figure 33. Unsuitable lateral guide for the belt. The belt has cut into the green block and
is damaged at the edges. (Likewise, the block is damaged and an area that is difficult to
clean and thus will serve as breeding ground for bacteria, has been formed). Lateral
guides should not be used for smooth synthetic belts as they will wear the belts. Instead
the belt should be guided by a camber/crowning on the drum or drive motor, possibly in
combination with a guide profile on the belt.

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Figure 34. Unsuitable lateral guide for the belt. It is not possible to remove of dirt from under the metal
brackets (which have even been fastened with Allen screws that are known to cause the accumulation of
dirt). Lateral guides should not be used for smooth synthetic belts as they will wear the belt. Instead, the
belt should be guided by means of a camber/crowning on the drum motor/drive motor where it may be
combined with a guide profile on the belt.

Figure 35 and figure 36. Unsuitable lateral guide for the belt (green edge). For belt guides, bolt joints of
both steel and plastic should be avoided as the materials expand differently. Alternatively, plastic items
should only be used in one place.

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6. Nozzle beams

Nozzle beams are used for automatic CIP cleaning of belts.

Function CIP cleaning of belts.

Construction The nozzle beam must open at one end to allow the removal of accumulated dirt.

Cleanability The nozzles can be mounted both outside and between the belts dependent on
belt type. Make sure to select the proper nozzles, correct pressure, number and
location of nozzles. An inner nozzle beam must be placed so that impurities are
washed out of the belt when it opens on the return roller. Also make sure that
product residue is washed off the inside, underside and screens so that any
product residue is removed after cleaning.

To prevent the spread of dirt, ensure sufficient screening of the area where the
stationary nozzle cleaning is carried out.

Service/maintenance Nozzles must be dismounted and cleaned regularly. For the recirculation of
washwater, a particle filter must be mounted. The washwater particle filter must be
cleaned regularly.

The following pages show examples of nozzle beams and attention points in terms of
hygiene.

Nozzles

Figure 37. The nozzles can be mounted both outside and in between the chains dependent on belt type.
Make sure to select the proper nozzles, correct pressure, number and location of nozzles. To prevent the
spread of dirt, ensure sufficient screening of the area where the stationary nozzle cleaning is carried out.
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7. Lateral guides for product

Lateral guides are mounted on the conveyor to keep the product or box in place on the
belt.

Function Keeps the product on the belt.

Construction Lateral guides are mostly mounted on the frame, alternatively on the belt. Boltings
of plastics and steel should be avoided as the materials have different expansion
properties.

For loose products, the belt can be shaped to a u or v-shape profile where products
are collected in the middle (see figures 44 and 45). The supporting rollers must
have hygienic construction, cf. chapter 8.

Cleanability In so far as possible, the construction should be open/removable and thus easy to
clean.

Service/maintenance Any lateral guide makes cleaning more difficult. The choice of lateral guide must be
adjusted to the construction and the product type.

The following pages show examples of lateral guides for belts and attention points in
terms of hygiene.

Figure 38. Easy-to-clean, self-draining lateral Figure 39. The same lateral guide as in figure
guide. 38, but set to cleaning position.

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Figure 40. Example of lateral guide for product that is incorporated in the belt.

Figure 41. Example of wavy edge belt for conveying small loose products.

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Figure 42 and figure 43. Lateral guides in a fine open, easy-to-clean design.

Figure 44 and figure 45. The belt is shaped as a through (U-shape) by means of the support rollers. The
belt is shown from below (left) and from above (right). The support rollers must be cleanable, cf. chapter 8.

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C-profile

Figure 46. Very unhygienic lateral guide. It is shaped in a C-profile which is impossible to clean and
therefore should not be used.

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8. Support of belts

Support of belts is performed by the use of rollers, slide guides or plates. The support
carries both belt and product.

Return runs of belts are necessary for relatively long belts to prevent sagging and to
ensure a proper wrap angle on the drive end.

8.1. Slide guides

Function Can be used for return run and support of belts.

Construction Offers partial or full support of belt. Must be in another material/of another
hardness than the belt itself.

Cleanability Must allow dismounting. As open a design as possible. Some dust will settle due to
friction between the belt and slide guides. Therefore, it will be necessary to wash
even belts used for e.g. suspended conveying of trays, at least once a week.

Service/maintenance Slide guides and transitions between these must be checked for damage and wear.

The following pages show examples of slide guides for belts and attention points in terms
of hygiene.

Figure 47. Slide guide which offers good support with a small contact surface, which is an advantage in
terms of hygiene. The synthetic guide can move lengthwise and has a small contact surface, which is a
hygiene advantage.

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8.2. Half-moons

Function Can be used for return runs, tensioning and change of direction. Large radius.

Construction Fixed unit – friction with belt. Simple solution. The material should be more
resistant to wear and/or of a harder quality than the belt itself.

Cleanability Open and cleaning-friendly design.

Service/maintenance Must be checked for wear.

The following pages show examples half-moons for belts and attention points in terms of
hygiene.

Support/slide guide for forward run of

the belt.

Half-moon for return run of the belt.

Figure 48. Half-moon used for both return run and lateral guidance.

Figure 49. Half-moon in solid plastic.

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8.3. Support rollers and return rollers

Function Improved support for and reduced friction with the belt.

Construction Available in many forms but should, however, been designed in one material.

Cleanability Should be easy to dismount/disassemble for cleaning.

Service/maintenance Rollers, bearings and pin must be checked regularly for damage, which may occur
due to wear, load and chemical reactions.

The following pages show examples of support and return rollers and attention points in
terms of hygiene.

Figure 50. The belt is supported by rollers.

Different materials have been used for the rollers
which is unsuitable as they are not impermeable.
Dirt may accumulate inside the rollers.

Figure 51. Example of rollers used for return run of belt.

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8.4. Plates as support

Function Used for support of synthetic belts conveying of relatively heavy products.

Construction The construction must be left very open when the support plates are removed to
allow cleaning. Be aware of the guidance of the belt during operation and cleaning.

Cleanability Plates are removed for cleaning. Rack for cleaning/storage of the plate is
necessary.

Service/maintenance -

The following pages show examples of support plates and attention points in terms of
hygiene.

Figure 52. When using plates for support, there is a risk that the belt sticks to the plate during operation in
a wet environment. The example shown is hygienic.

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Figure 53. Belts that are supported by a plate. A ”lift” has been mounted to prevent the belt from sticking
to the plate. It must be possible to dismount the belt as well as the “lift” for thorough cleaning.

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9. Drive stations

The belt is moved by drive stations/motors. The choice of motor depends on the belt
type, load and external requirements such as cleaning.

9.1. Drum motor for synthetic belt

Function Used to move all types of synthetic belts.

Construction Make sure that the drum engine is constructed exclusively in stainless steel. Also
check the cable inlet. Make sure there are no crevices and cracks in the cable inlet
for the motor, just as covers and seals in and around the drum motor must be
intact. Defects may cause oil to leak from the drum motor or water to leak into the
motor.

Terminal boxes for the motor must be mounted so as to comply with the hygiene
design requirements. They must not cause product residue to accumulate and
should preferably be in stainless steel although chemical resistant plastic can be
used.

The bottom edge of the belt should always be lower than the top of the roller.
Guidance of the belt can be ensured by choosing a roller or drum motor with a
camber or crowning.

Cleanability When using drum motors, be aware of the motor’s protection grade (IPxx) in
connection with cleaning. This grade is crucial to the degree of cleaning the motor
can withstand. Make sure that the motor has a minimum protection grade of IP66
(see appendix 19.1).

Service/maintenance Any noise from the drum motor during operation may indicate that it requires
service to avoid unintended stoppage. When replenishing grease through
lubricating nipples, use forced lubrication until grease exits.

The following pages show examples of drum motors for synthetic belts and attention
points in terms of hygiene.

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Inner hexagon
bolt is an
uhygienic type of
fastening.

Figure 54. Drum motor for synthetic belt. Generally, this is a good solution as it is a sealed (contained)
cleaning-friendly unit.

Stainles piping
for cables – very
hygienic.

Terminal box for the collection of cables.

Figure 55. Terminal box mounted on the outside of the drum motor. Cable routing in stainless pipes, which
is good.

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9.2. Drum motor for modular belt and toothed synthetic belt

Function Used to move all types of synthetic modular belts within all fields of application in
the food industry.

Construction The drum motor is mounted either with sprockets used for the individual belt type
or equipped with a profiled rubber coating. The rubber coating must be food
approved and designed with a stainless steel casing, as corrosion beneath the
coating can be conducive to the spread of bacteria, etc.

Furthermore, all matters relating to section 9.1 must be observed.

Cleanability When using drum motors, be aware of the motor’s protection grade (IPxx) in
connection with cleaning. This grade is crucial to the degree of cleaning the motor
can withstand. Make sure that the motor has a minimum protection grade of IP66
(see appendix 19.1).

Service/maintenance Any noise from the drum motor during operation may indicate that it requires
service to avoid unintended stoppage. When replenishing grease through
lubricating nipples, use forced lubrication until grease exits.

The following pages show examples of drum motors for modular and toothed synthetic
belts and attention points in terms of hygiene.

Figure 56. Drum motor with profiled

vulcanized rubber coating for modular
belts and toothed synthetic belts.

Good solution that ensures support in the

entire width and is cleaning-friendly as
there are no “hidden” places as is often
the case with sprockets.

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Figure 57. Drum motor with sprocket for

modular belt and toothed synthetic belt.
Also an excellent solution provided the
belt can be lifted for cleaning.

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9.3. Gear motor for synthetic and modular belts

Function Used for all types of conveying.

Construction The gear motor is a closed unit with seal rings keeping oil or grease inside the
gear. The motor is also closed and available in different protection grades (IPxx)
dependent on the environment, see appendix 19.1.

The gear motor surface is normally in aluminium or cast iron. The surface should
have a finish that is resistant to a number of aggressive detergents.

Furthermore, the motor should be guarded or moved away to avoid direct food
contact. Be aware of the heat released from the motor. The guard should be such
that it can be cleaned on the inside as well.

Shafts or hollow shafts in the gear can be made of stainless material. Gears and
motors may also be available in a completely stainless design.

Standard oils and greases for the gear are normally not food approved, but such
lubricants are available and can be supplied on request.

The drive drum construction is according to the description in chapter 10, Idler end.

Cleanability The gear motor is normally mounted on the side of the conveyor, directly on a
prolonged axle stub on the drive drum or above or below the conveyor with a belt
or chain drive connection to the drive drum.

The gear motor will normally not come into direct contact with the material
conveyed, and the gear motor (+ belt or chain drive) is guarded dependent on
location and risk contact with product or personnel. The guard must be designed to
enable necessary cleaning.

Service/maintenance Gear motors must be checked. The frequency of the checks depends on the
operating conditions. Seals must be checked for wear and leaks. Oil change
intervals must be observed. Any noise from the gear motor bearing may indicate
the need for service.

The following pages show examples of gear motors for synthetic and modular and belts
and attention points in terms of hygiene.

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Figure 58. Partially guarded motor that

is difficult to clean.

Figure 59. Guarded gear motor. The guard must be designed so that it can be tipped up and cleaned
manually on the inside. It should not be possible to dismount the guard as it may be damaged during
cleaning.

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10. Idler end

The idler end is the end opposite to the drive station. The idler end can rotate with the
belt or be a knife edge.

Function Rollers are only used for synthetic belts to tension the belt in the end opposite to
the drive station, and for adjustment purposes.

For modular belts and toothed synthetic belts, rollers are used for adjustment/free
running.

Construction The idler end generally consists of a roller with diameter more or less equal to that
of the drive station.

The requirements for the construction are the same as for drum motors. See
section 8.1. Sealed bearings should be used at the ends of the idler roller, and it
should have a protection grade of no less than IP66.

For modular belts, shafts with a square cross-section that fit the modular belt
sprocket are normally used.

Cleanability When using drum motors, be aware of the motor’s protection grade (IPxx) in
connection with cleaning. This grade determines the degree of cleaning the motor
can withstand. Make sure that the motor has a minimum protection grade of IP66
(see appendix 19.1).

Service/maintenance Any noise from the drum motor during operation may indicate that it requires
service to avoid unintended stoppage. When replenishing grease through
lubricating nipples, use forced lubrication until grease exits.

The following pages show examples of idler ends and attention points in terms of
hygiene.

Figure 60. For modular belts, shafts with a square cross-section that fit the modular belt sprocket are
normally used.

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Figure 61. Idler end in a half-moon shape.

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11. Conveyor frame

Function Supporting and, if necessary, guiding the conveyor belt so that the belt can carry
the required load. Drive station, tail, and support rollers etc. are mounted on the
frame.

Construction The conveyor frame should be an open construction. However, there should be no
crushing hazard in connection with the drive station and tail/support rollers, etc. It
may be necessary to mount guards in these areas.

It should be easy to dismount any guards to allow complete cleaning.

Dependent on the belt type and the load, the construction should be made as a
central pipe or profile with welded-on cross members or as a frame construction
with square pipes mounted on the edge.

Cleanability To ensure optimum cleaning, the construction should be all-welded with inclined
surfaces and a minimum of hidden areas/surfaces. Bolted joints without distance
washers should not be used.

Service/maintenance Check for wear.

The following pages show examples of conveyor frames and attention points in terms of
hygiene.

Bearer

Figure 62. The picture shows how the frame design at the same time serves as guard where the belt runs
onto the drive roller sprocket. Notice the few support rails and the open construction which constitute a
hygiene advantage. When the belt is heavily loaded, the supports must be adjusted to the load.

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Figure 63 and figure 64. Show an all-welded frame design where cross members/belt supports are parts
of the design. Notice the open design with inclined surfaces, open profile and distance washer, all of which
make it cleaning-friendly. No bolt holes or nuts were used for fastening the support rails. Here there are
three belt supports in synthetic material.

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Figure 65. Conveyor with central pipe without side member. Do not drill holes in the
central pipe.

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12. Sub-frame

Function To support or carry the actual conveyor belt construction.

Construction Legs and supports should be designed with open profiles where the folding is
turned outward for easy cleaning, or alternatively as completely closed pipes.
Generally with adjustable feet. For adjustable feet with thread, it is required that the
thread is hidden in closed profiles/pipes or enclosed so as not to cause the
accumulation of impurities around the thread. See figure 66.

All horizontal profiles should be designed with round pipes, pipes mounted on the
edge or open, inclined profiles.

All mounting brackets for legs/supports should be mounted with distance washers
or all-welded on the actual frame structure.

Suspension straps should be designed with bars or alternatively completely sealed

pipes. They should be height adjustable.

Cleanability To ensure optimal cleanability, it is crucial that surfaces are inclined, that any
bolted joints include distance washers, and that there is only a minimum of hidden
areas/surfaces.

Service/maintenance Generally, the sub-frame requires no maintenance procedure. It is, however,

important that defects are repaired to avoid risks to personnel or hygiene. Never
drill or cut sealed pipes and profiles.

The following pages show examples of sub-frames/suspensions and attention points in

terms of hygiene.

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Figure 66. Completely open construction without horizontal surfaces in the actual construction. Thereby,
hollows and dirt traps are avoided to the benefit of hygiene. Feet are adjustable, which is necessary to
allow for even/or inclining floors. The adjustable feet offer no possibilities of fastening to floor.

Figure 67. Sealed design in sub-frame. The sealed profiles allow easy cleaning from all sides. But if a weld is
leaky or holes have been drilled in the profiles, liquid may leak into the profiles and cause bacterial growth,
which is as hygiene risk.

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Figure 68. Suspended conveyor.

The suspension is height-adjustable.

Figure 69. Height-adjustable suspended conveyor.

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13. Fastening

The fastening must be such that the conveyor is properly secured.

Supports are important obstacles for cleaning and service personnel. The number of
supports should be minimised so that they are all collected in the main frames on which
the conveyors are fastened.

When the conveyor is fastened to the floor, the type of floor should be taken into
consideration. There may be heating and other installations immediately below the
surface.

When anchor bolts have been drilled into the floor, the holes must be sealed with epoxy
or similar materials, dependent on the floor, so that water and dirt are not allowed to leak
into the hole.

13.1. Fastened

Function The fastening must be such that the conveyor is properly secured.

Construction The conveyor feet must be adjustable by min. +/- 75 mm. The contact face of the
foot must be sufficient to absorb the pressure. The contact face should be even so
as to ensure complete contact with the floor. The contact face should allow the
fastening to be fixed, preferably without the use of extra brackets.

Support legs with skidproof feet can be used where bolting of the foot plate to the
floor is not allowed.

Threads must be enclosed, e.g. in a sealed pipe or similar, as dirt would otherwise
settle in the thread, which is unacceptable and constitutes a hygiene risk. See
figure 70 for an illustrative example.

Acid-resistant AISI 316 steel should be used as material.

Cleanability Practically, all dirt accumulates at floor level, so particular attention should be paid
to the cleaning of joints and brackets.

Service/maintenance If the legs are secured to the support with Allen screws, be aware that long-term
load may cause the conveyor to sink into the support.

The following pages show examples of fixed fastenings and attention points in terms of
hygiene.

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Figure 70. Adjustable USDA-approved threaded spindle designed to be placed on a skidproof, rubber-
coated stainless steel foot. At the top, the thread is hidden by a sealed stainless steel pipe all-welded on a
normal stainless nut – a hygienic solution. At the bottom, the thread is covered by a cap nut which also
acts as a check nut in connection with height adjustment. Height adjustment is easy and precise. The
support leg is a standard item that is available in many variations. The adjustable foot shown in the picture
is USDA-approved.

Figure 71 and figure 72. Examples of fixed fastenings. The threads must be enclosed, e.g. in a sealed
pipe or similar (as shown in the picture to the right), as dirt would otherwise settle in the thread, which is
unacceptable and constitutes a hygiene risk (as shown in the picture to the left).

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Figure 73. Example of chemical anchor. When anchor bolts have been drilled into the floor, the holes must
be sealed with epoxy or similar materials, dependent on the floor, so that water and dirt are not allowed to
leak into the hole.

13.2. Mobile

Function In places where cleaning requires that the conveyor be moved, it should be
equipped with wheels. These should be lockable.

The conveyor feet must be adjustable by min. +/- 75 mm. The support must be
Construction more rigid than normally due to mobility. When choosing wheels and material, be
aware of special circumstances related to chemical issues, etc.

Cleanability Practically, all dirt accumulates at floor level, so particular attention should be paid
to the cleaning of joints and brackets.

Service/maintenance Bearings in wheels must be lubricated and checked. Wheel surfaces must be
checked for chemical damage, etc.

The following pages show examples of mobile fastenings and attention points in terms of
hygiene.

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14. Applied methods

Knowledge is acquired from June 2004 to September 2005 through visits to companies
and group meetings held at the companies of the authors.

15. Safety and environmental precautions

In connection with hygienic design, it is often necessary to make a balanced choice

between open constructions and personnel safety.

16. Further information

16.1. Related guidelines

EHEDG Doc. 13, 1996: Hygienic design of equipment for open processing
The guideline describes hygienic design and construction of equipment used in open
processes for the production of foods. Among other things, it includes a description of
materials, joints, placement and construction of movable parts, and hygienic design of
the immediate surroundings. The guideline includes several examples and illustrations.
The guideline can be bought at EHEDG: http://www.ehedg.org.

Campden and Chorleywoods Technical manual no. 7, 1983: Hygienic Design of Food
Processing Equipment
Contains a series of illustrations with hygiene advice for, in particular, conveyor belts, lift
conveyors, inspection belts and chutes. With focus on good transitions from one machine
to another. The guideline can be bought from CCFRA (Campden & Chorleywood Food
Research Association), http://www.ccfra.com

EHEDG Doc. 8, 2004: Hygienic equipment design criteria

This document describes design criteria that must be met before equipment used for the
production of food is regarded hygienic and sterile. A number of general directions for the
design and manufacture of equipment have been issued to ensure microbial safety and
product quality. They deal with, among other things, cleaning, validation of hygienic
quality, surfaces, geometry, design and materials. The guideline can be bought at
EHEDG: http://www.ehedg.org.

EHEDG Doc. 9, 1993: Welding stainless steel to meet hygienic requirements

The guideline describes techniques to ensure hygienic welds. The descriptions are for
stainless steel thinner than 3 mm. The guideline mentions both manual and automatic
welding techniques. Furthermore, it describes typical errors and methods for quality
control. The guideline can be bought at EHEDG: http://www.ehedg.org.

EHEDG Doc. 22, 2001: Hygienic design criteria for the safe processing of dry particulate
materials
The guideline describes criteria for hygienic design of processing equipment for the
manufacture of dry matter. The guideline includes cleaning requirements dependent on
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product and production type and cleaning method. It furthermore includes descriptions of
dry and wet cleaning. The guideline also includes mentioning of suitable design materials
and more general design criteria for e.g. welds, seals, joints and insulation. The guideline
can be bought at EHEDG: http://www.ehedg.org.

16.2. Links

EUR-Lex offers free and direct access to EU legislation. Go to www.europa.EU.int/eur-

lex (choose language code; DA for Danish, EN for English). The system also makes it
possible to consult the Official Journal of the European Communities, which includes
treaties, legislation, case-law and draft proposals. The system offers comprehensive
searching facilities. Any questions in relation to the status of legislation can be directed at
tel. 00 800 6789 10 11. The number is toll-free.

The EU has furthermore collected all legal aspects concerning materials relating to
materials with food contact. Go to
http://europa.eu.int/comm/food/food/chemicalsafety/foodcontact/eu_nat_laws_en.pdf.

In the US, NSF (National Sanitation Foundation) has taken over the registration of
lubricants, disinfectants, etc. from the USDA (United States Department of Agriculture).
See the NSF White Book Listing of Non-food Compounds at
http://www.nsf.org/business/nonfood_compounds/index.asp?program=NonFoodComReg
.

Furthermore, the www.staalcentrum.dk knowledge portal contains a wide range of

relevant links to authorities and organisations, etc. The portal also provides a clear
picture of the guidelines, standards, legislation etc. available for specific fields/types of
equipment and locations. It is easy to search the material and read a short description of
the actual contents. The relevant links makes it possible to order material from the
source.

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17. Literature

The photographs were taken at Danish food manufacturers and suppliers of

equipment/plants. We have sought to anonymise the photographs by leaving out many
pictures containing products.

18. Concepts/terminology

EHEDG European Hygienic Engineering & Design Group

DS/EN Danish Standard/European Norm
AISI American Iron and Steel Institute
CIP Cleaning In Place
TPU Thermoplastic polyurethane
IP Ingress Protection. IP codes are used to indicate the enclosure grade of the
material
USDA United States Department of Agriculture
NSF National Sanitation Foundation

For further information, please see the EHEDG Glossary (http://www.ehedg.org). Go to

Guidelines > Library > Glossary.

19. Appendices

19.1. Protection grades – IP nomenclature (according to IEC 529/DIN 40 050)

IP codes are used to indicated the enclosure grade of the material, i.e. the degree of
protection offered by the enclosure – e.g. IP66.
The first digit always indicate the degree of protection against the ingress of foreign
matter into the material, but at the same time it indicates a certain minimum degree of
protection of people from contact with dangerous parts
The second figure indicates the degree of protection against the ingress of water in the
material.
Any letter in the third position, indicates the degree of protection of people from contact
with dangerous parts, but it is only used in the following two cases: – If the degree of
contact prevention is higher than indicated by the first digit.

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20. Change protocol

This is the first edition. Future changes will be listed here.

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