As outlined in our previous article on how to simplify colour-coding policy, segregation is a vital tool to eliminate any possibility of cross-contamination, a common non-conformance.

Segregation, however, is not limited to colour-coding.

Physical segregation is also a crucial consideration for food manufacturers, not just for health and safety reasons, but also for production efficiency. Machinery downtime is lost time – and money.

In an exclusive interview, Alex Carlyon – a Klipspringer Director with over eighteen years of experience in the food safety industry – explained the importance of segregating production lines responsible for allergenic products.

Typical factories have anywhere between two and five production lines under one roof. If an allergenic product is being manufactured on one line, the traditional approach to washdowns is to leave the production line between the allergen product and the other products empty, creating a barrier of space.

An example of a physical barrier at a Bakkavor factory.

Instead, assembling a physical barrier during washdowns prevents any cross-contamination between these allergenic and non-allergenic production lines – without forcing one of these lines into idleness.

In Alex’s words, “If the two production lines are segregated effectively, a factory can be running a product on Line A while their hygiene team are cleaning down Line B”.

Efficiency is boosted, non-conformances are avoided, and there is a third benefit – staff safety.

Much emphasis is placed on the compliant production of allergenic food from a customer-facing point of view, sometimes at the cost of employee health during washdowns.

When hygiene teams are cleaning a production line with jet-foaming chemicals, physical segregation barriers eliminate any possibility of a worker crossing segregated lines and receiving a face full of chemicals. Assembling a simple screen can significantly lower the probability of such an accident occurring.

At Klipspringer, we have collaborated with food manufacturers and suppliers for several decades to help teams continue production during washdowns.

With regard to segregation, we provide several innovative solutions – the most popular being our SegriScreen.

Depicted above, the SegriScreen forms a continuous, connected barrier to clearly isolate a production line or piece of machinery during washdowns.

Most importantly, the SegriScreen enhances food safety and reduces downtime. Its hygienically designed, robust material also improves sustainability – eliminating flimsy single-use plastic.

When asked about the SegriScreen, a Site Hygiene Manager at Bakkavor said that:

“Features such as the ability to move as one continuous barrier, the flexibility around production lines and the ease of connecting were all really important to us. The visual impact of the SegriScreens also made it clear to all employees that this is a no entry area. There isn’t anything I’ve come across which does as comprehensive job or ticks as many boxes as SegriScreen does!”

Also used and praised by manufacturers including Kerry, Two Sisters and Cranswick, the SegriScreen is an innovative, long-term solution to the problem of washdown downtime.

Click here for more information, or browse the SegriScreen’s features below.

The SegriScreen