A Practical Guide to Hygiene Equipment Trials and Standardisation in Food Factories

Whether you are introducing a new cleaning tool, hygiene monitoring system or colour-coding policy, a successful outcome depends on more than the equipment itself.

Effective trials help sites to evaluate performance and make informed decisions before standardising new ways of working.

If you are considering an equipment trial and want to maximise its chances of success, this article will guide you through the process.

Setting Up Your Equipment Trial

Most equipment trials begin with a specific challenge. Whether the objective is to improve cleaning validation, increase efficiency, strengthen safety controls, or reduce the risk of cross-contamination, understanding the problem you are trying to solve is an important first step.

The examples below highlight some of the common reasons sites choose to trial different types of equipment and the outcomes they are looking to achieve.

Example 1: Trialling the A3 Hygiene Monitoring System

A3 trials are often driven by a lack of confidence in a site’s cleaning validation methods. While ATP testing is widely used to verify cleanliness, it can have limitations in food manufacturing environments. This is because ATP degrades to ADP and AMP during common processes like heating, cooking, fermentation, and even cleaning.

By measuring ATP, ADP and AMP, the A3 System provides a more complete picture of surface cleanliness. Trials are typically carried out to compare A3 against existing validation methods and assess whether the additional data can improve cleaning verification, strengthen hygiene controls, and provide greater confidence in cleaning effectiveness.

Example 2: Trialling Industrial Vacuums

Industrial vacuum trials are commonly introduced to improve cleaning efficiency or address safety concerns associated with existing cleaning methods.

In some cases, teams may be spending excessive time removing dust, debris, or product residue. In others, sites handling powdered ingredients such as flour may be looking to reduce the risks associated with airborne combustible dust and improve compliance with ATEX requirements. Trials help to determine whether a vacuum system can improve cleaning performance, reduce labour requirements, and provide a safer, more controlled approach to dust management.

Example 3: Trialling Double Blade Squeegees

Double blade squeegee trials are usually focused on improving cleaning performance and reducing the time it takes to remove water and debris from production areas.

If standing water remains after cleaning or multiple passes are required to achieve the desired result, cleaning can become both time-consuming and inefficient. Trials allow teams to evaluate whether double blade designs can improve liquid removal and reduce cleaning times by removing water and debris in a single pass.

Trials also provide an opportunity to assess how easy it is to clean the new equipment. This is often a key consideration when evaluating squeegee performance. Hygienically designed double blade squeegees can help to address these concerns through smooth, moulded construction and minimal crevices.

Example 4: Trialling Colour-Coded Equipment

Colour-coded equipment trials are typically undertaken to improve segregation and strengthen controls around cross-contamination risks.

Trials are often centred around introducing a more structured colour-coding system, making it easier for teams to identify the correct equipment, follow established procedures, and maintain consistency across departments and shifts.

By evaluating the system in a controlled way, sites can assess how effectively colour coding supports operational standards before implementing it more widely.

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Running Your Equipment Trial

Once a trial has been set up, the next step is ensuring it is carried out in a way that produces clear, meaningful results. After all, a trial that is not properly managed can lead to mixed feedback, inconsistent use, and ultimately no clear conclusion.

The examples below highlight how different types of trials are typically run on site, and the factors that influence whether they deliver successful outcomes.

Example 1: Trialling the A3 Hygiene Monitoring System

A3 trials are most effective when run alongside existing validation methods rather than in isolation. This allows teams to compare results directly and understand how the system performs under real production conditions.

In practice, this often involves testing the same surfaces with both ATP and A3 swabs over a defined period. The side-by-side comparison helps to identify where results differ and assess whether ATP, ADP and AMP detection provides a more complete indication of cleanliness.

Consistency is important throughout the trial. Using the same test points, timings, and procedures helps to ensure results can be compared accurately. It is also important to establish clear benchmarks from the outset.

Example 2: Trialling Industrial Vacuums

Industrial vacuum trials are typically carried out as part of normal cleaning routines, focusing on areas where existing methods are least effective.

This may include zones where dust or debris are difficult to remove, or where traditional cleaning methods require significant time and effort. In environments handling powders, trials may also focus on ensuring dust can be removed in line with ATEX requirements.

During the trial, attention is usually placed on real-world performance. This includes assessing how quickly material can be removed, how easy the equipment is to handle, and whether the available attachments allow teams to clean hard-to-reach or high-level areas effectively.

Example 3: Trialling Double Blade Squeegees

In most cases, the double blade squeegee is compared directly against existing floor cleaning equipment, with attention focused on how effectively water and debris are removed. Particular emphasis is often placed on whether floors can be cleared in a single pass.

This can have a significant impact on cleaning efficiency, particularly in larger production areas where reducing cleaning time can help to shorten hygiene windows and improve operational efficiency.

Ease of cleaning is also an important consideration during the trial. Hygienically designed double blade squeegees with smooth surfaces and minimal crevices can be easier to clean and inspect, helping to support consistent hygiene standards.

Example 4: Trialling Colour-Coded Equipment

Colour-coded equipment trials typically involve assigning specific colours to designated areas, processes, or allergens and monitoring how consistently the system is followed over a defined period. The aim is to assess whether colour coding improves segregation, increases clarity, and reduces the risk of equipment being used incorrectly.

During the trial, teams can evaluate how intuitive the system is in practice and identify opportunities to strengthen compliance. This may include introducing colour-coded shadow boards with bespoke messaging and visual instructions.

Consistency across shifts is also an important consideration. For a colour-coding system to be effective, it must be understood and applied consistently by all teams, helping to maintain standards and reduce the risk of cross-contamination.

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Rolling Out to Standardisation

Once a trial has been completed and the results are understood, the next step is deciding how to implement the solution. Successful roll out should focus on introducing a clear approach as early as possible, as using different methods for too long can create confusion.

The examples below highlight how different types of equipment are typically rolled out following a successful trial, plus the factors that influence whether they become part of standard site practice.

Example 1: Rolling Out the A3 Hygiene Monitoring System

Following a successful A3 trial, the focus shifts to integrating the system into existing hygiene verification programmes. This typically involves reviewing Cleaning Instruction Cards (CICs), cleaning validation procedures, environmental monitoring programmes, and allergen control plans to determine where A3 testing should be incorporated.

It is also important to establish clear action limits and response procedures so the additional information provided by ATP, ADP and AMP testing can be used consistently. Teams should understand not only how to carry out testing, but also how to interpret results and respond when limits are exceeded.

Training forms an important part of the rollout process. Operators, hygiene teams, and supervisors should be confident in using the system and recording results correctly. Ongoing support from Klipspringer’s Technical Team can help sites justify benchmark levels, update documentation, and demonstrate the effectiveness of the new approach during audits.

Example 2: Rolling Out Industrial Vacuums

Once proven effective, industrial vacuums should be incorporated into routine cleaning procedures and reflected within relevant CICs.

Training should focus on safe operation and correct use. It is also important to highlight the reasons for the change, whether that’s to improve cleaning efficiency, enhance dust control, or support ATEX compliance.

Dedicated storage solutions, such as shadow boards with clear instructions, will help to ensure equipment remains accessible, organised, and is consistently returned after use.

Example 3: Rolling Out Double Blade Squeegees

Following a successful trial, double blade squeegees should be introduced into areas where they provide the greatest operational benefit.

Cleaning procedures and CICs should be updated to define where and how the equipment is used, while training should reinforce correct technique and the advantages of the double blade design over existing methods.

Dedicated shadow board storage can further support standardisation by making equipment easy to locate and return.

Example 4: Rolling Out Colour-Coded Equipment

The success of a colour-coding system depends on site-wide consistency. Following a trial, existing equipment should be reviewed and any items that do not align with the agreed structure should be removed, replaced, or reassigned.

Procedures and CICs should clearly define colour allocations for specific areas, processes, or allergen zones. Visual management tools, including colour-coded shadow boards and signage, can reinforce segregation and support correct equipment selection.

Training for both operatives and supervisors should ensure consistent application across all departments and shifts, while routine monitoring will help with maintaining standards and identifying opportunities for improvement.

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A well-structured trial ensures decisions are based on clear evidence rather than assumption, helping to deliver consistent, long-term improvements when new equipment is introduced.

If you would like to learn more about Klipspringer trials or any of the solutions mentioned in this article, contact our team on 01473 461 800 or email sales@klipspringer.com. Alternatively, complete the form below.

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