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Retaining employees, reducing downtime with hygienic design

Retaining employees, reducing downtime with hygienic design. BakingTECH 2025 recording of Case for Safety.
PHOTO COURTESY OF AVANT FOOD MEDIA
BY: Lily Cota

Lily Cota

ORLANDO, FL — The American Society of Baking (ASB)’s annual event, BakingTECH, is in full swing in Orlando, FL.

During a live recording of The Case for Safety podcast, sponsored by Corbion, industry engineers explained how hygienically designed equipment enhances safety, reduces downtime and drives operational efficiencies.

Using the ANSI/ASB Z50.1 and Z50.2 Standards for equipment design and sanitation as a foundation, Scott McCally, president of Auto-Bake Serpentine, a Middleby brand, and Jon Anderson, managing consultant for Bakery Equipment Assessment Group, discussed how implementing hygienic design can benefit a company on multiple fronts, including workforce.

“Hygienic design is absolutely fundamental to food safety,” Anderson said. “Without efficiently designed equipment, your sanitation efforts increase significantly because there’s longer downtime, less time for production and more work involved in disassembling, reassembling and cleaning.”

McCally shared that the mindset of integration helps to improve operational excellence, but it also goes further to minimize downtime in every corner of a bakery environment.

“One of our customers’ core values is to produce safe food,” McCally said. “Along with that, their number one threat or concern, in many cases, is employee retention. Their top priorities are keeping their equipment clean and their employees safe, but one of the roles that employees don’t like doing very much is the sanitation process.”

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“If you keep bacteria and viruses away, then you don't have to clean as often, which then allows you to extend your operating periods between sanitation downtime, increasing operational efficiency without adding cost.” — Scott McCally | president | Auto-Bake Serpentine

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Equipment designers are the key to addressing this issue while keeping operational efficiency top of mind.

“We always talk about clean-in-place (CIP) or clean-out-of-place (COP) types of equipment, but what we’re thinking about now moving forward is clean-in-operation (CIO).” McCally said. “CIO addresses the question: How do we extend time between sanitation cycles?”

The time between cleaning equipment ranges. Many companies disassemble their equipment and clean it daily, while others may do it weekly or bi-weekly. Some may even wait a full month before cleaning their equipment.

While it may sound unhygienic to consumers, companies can utilize the right methods and technology to not only ensure a clean environment but also satisfied employees.

“We have a significant investment in a company called Vyv, and they have a germicidal LED light that continuously cleans areas in and around the equipment,” McCally said. “If you keep bacteria and viruses away, then you don’t have to clean as often. That allows you to extend your operating periods between sanitation downtime, increasing operational efficiency without adding cost. It makes our employees happier because they’re not having to stop every single day to tear the equipment apart to clean it.”

By implementing efficiency into all aspects of operational design, equipment can work for employees — as opposed to the other way around — which leads to higher rates of retention and satisfaction among workers.

“If you can achieve that goal of efficient design, you can reduce the amount of training and education with employees, which makes life even easier for everyone,” Anderson said.

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