Food manufacturing runs on tight margins, high throughput, and the constant pressure of certification audits. Engineering decisions made at the design stage determine whether your HACCP plan works, whether your allergen controls hold, and whether your CIP system actually cleans what it's supposed to. We make those decisions correctly the first time.
Food safety failures almost always have an engineering root cause. A CCP that couldn't be controlled by the equipment. An allergen that crossed a boundary the facility wasn't designed to maintain. A CIP that couldn't reach what needed cleaning. We find these problems at the drawing board — not the audit table.
HACCP plans are developed separately from the facility design, then reconciled after the fact. Critical Control Points that can't be monitored by the installed instrumentation. Preventive measures that the equipment layout makes impossible. We integrate HACCP into the design process from the first P&ID review — so the engineering and the food safety plan are telling the same story.
Pipework dead-legs that can't be reached by CIP. Surfaces that collect product residue. Horizontal ledges where condensate pools. Equipment installed in positions that make cleaning impossible without disassembly. EHEDG principles aren't applied retrospectively — they have to be built into equipment specification and plant layout from the start.
Shared pipework between allergen-containing and allergen-free products. Air handling systems that distribute dust across boundaries. Production scheduling that doesn't align with the engineering of the cleaning programme. Allergen control is an engineering problem first, and a procedure problem second. We design the engineering controls so the procedures can actually work.
CIP systems installed without flow velocity validation. Dead-legs and low-points that trap product and cleaning chemical. Spray coverage gaps in tanks. We validate CIP programmes during commissioning — not after the first NVWA inspection finds residues.
A new production line is added. A product formulation changes. A new ingredient is introduced. Each of these events should trigger a HACCP review of the engineering — and usually doesn't. We build change-managed systems so your HACCP plan evolves with your facility.
Acceptance tests that check machine function but not hygienic performance. No verification of CIP coverage on installed equipment. No allergen cleaning validation in the SAT scope. We build food-sector FAT and SAT programmes that cover the hygiene and food safety performance your certification bodies will ask about.
From concept design through to FAT/SAT and certification support — all integrated under one team that understands food safety engineering, not just general process plant.
Process design and P&IDs developed in step with HACCP. CCPs defined before equipment is specified, not after it's installed. Hazard analysis integrated into every design stage — so your HACCP plan reflects how your facility actually works.
Equipment specification, layout, and detail design to EHEDG principles. Material selection for food contact surfaces. Drainability, cleanability, and accessibility verified before anything is ordered. We work to EHEDG Guideline Doc. 35 and beyond.
CIP circuit design, flow velocity calculations, spray coverage analysis. CIP validation protocols aligned with FSSC 22000 and BRC requirements. Allergen cleaning validation as part of SAT scope. No surprises when NVWA arrives.
CAPEX project management for brownfield expansions, new line installations, and facility upgrades. Certification deadline management built into the schedule. FSSC 22000 and BRC timeline awareness throughout.
On-site EPCM management with food safety awareness. Contractor coordination, quality control, and HSE management. We manage your contracts — you keep control and visibility throughout.
Our fixed-scope entry product for food clients. We walk your facility and map your HACCP plan against the engineering. Delivered in 5 working days. Learn more →
The Netherlands is the world's second-largest agricultural exporter. Every processing facility in that chain has CAPEX needs, certification pressures, and engineering decisions that affect food safety. These are the client types we work with most.
CIP, spray dryers, filling lines, FSSC 22000 compliance
Allergen segregation, hygienic design, HACCP for slaughter and processing
Frying, blanching, CCP control, capacity expansion EPCM
CIP/SIP, filling line FAT/SAT, line extension EPCM, BRC compliance
New UHT line installed in an operating dairy factory. Zero unplanned production stops. FSSC 22000 passed first time. €340K under budget.
HVAC zoning redesigned across 3 production halls. BRC Grade A restored from Grade C. Allergen test positives dropped from 23/month to zero.
Physical segregation, air handling, drainage separation, and cleaning validation to add allergen-containing product lines to an existing shared filling hall.
HACCP is a food safety management system. But most of the controls it depends on are engineering controls — temperature, pressure, flow rates, physical separation, surface cleanability. If the engineering isn't right, the HACCP plan is a document that describes what should happen, not what does.
The most common HACCP findings we see in food facilities trace back to three engineering failures: a CCP that can't be adequately monitored by the installed instrumentation, a preventive measure that the physical layout makes inconsistent, or a CIP programme that doesn't reach the surfaces it's supposed to clean.
We treat HACCP as an engineering discipline, not a food safety management system that engineering has to accommodate. The difference shows up at your next audit.