Know: Equipment Commissioning

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Equipment Commissioning in Food Manufacturing

Definition

Equipment commissioning refers to the process of validating and verifying that newly acquired or modified equipment operates as intended within the production environment. This process ensures compliance with food safety standards, operational efficiency, and alignment with regulatory and site-specific requirements. Commissioning involves activities such as installation, hygiene clearance, performance verification, and risk mitigation to ensure equipment is fit for purpose and ready for production use.

Sequential Overview

Effective commissioning relies on a systematic approach that begins with equipment sourcing and approval, progresses through compliance with design and construction standards, and culminates in a structured commissioning process. This ensures that the equipment meets all legal, safety, and operational requirements at every stage.

Stage 1: Equipment Sourcing and Approval

The success of commissioning is rooted in robust procurement practices:

1. Documented Purchase Specifications
   A clear, detailed specification document is needed when sourcing equipment. This should include:
• Confirmation of relevant legislation compliance, such as food contact material standards.
• Requirements for food contact surfaces to meet legal and safety obligations.
• The intended use of the equipment and details about the materials it will handle.
2. Supplier Evidence of Compliance
   Before delivery, suppliers must provide proof that the equipment meets site-specific requirements. Documentation might include certificates of conformity, technical drawings, or material compliance records.
3. Multi-Disciplinary Approval
   Equipment approval should involve input from engineering, technical, production, and quality assurance teams. This ensures that the equipment meets legal, safety, and operational needs before procurement is finalised.
4. Suitability for Food Contact and Contamination Risk Management
   Equipment must be designed to minimise contamination risks. Considerations include:
• The use of smooth, impervious surfaces in areas contacting food.
• Avoiding joints, welds, or gaps where residues could accumulate.
• Ensuring compatibility with cleaning chemicals.

By addressing these factors during procurement, organisations can reduce the risk of delays or non-conformances during commissioning.

Stage 2: Equipment Design and Construction

After sourcing, a review of the design and construction ensures that equipment is suitable for its intended use and mitigates contamination risks.

1. Risk-Based Design
   Equipment design must prioritise hygiene and minimise risks of contamination, including:
• Using food-safe materials and construction techniques.
• Avoiding sharp edges, rough surfaces, or difficult-to-clean areas.
• Implementing correct seals and welds to prevent the accumulation of foreign bodies, microorganisms, or allergens.
2. Suitability for Food Contact
   Equipment in direct contact with food must comply with relevant legal standards, ensuring it is safe for its intended application. For example, surfaces that contact raw meat must be corrosion-resistant, non-toxic, and easily cleanable.

These design considerations must be verified during commissioning to confirm that the equipment meets food safety and operational requirements.

Stage 3: Equipment Commissioning

Once equipment has been sourced and installed, a structured commissioning process ensures it is ready for use in production.

1. Documented, Risk-Based Commissioning Procedure
   The commissioning process must include clear steps to validate that the equipment operates safely and effectively within the production environment. This should include:
• Inspection and testing to ensure compliance with purchase specifications.
• Functional tests to confirm the equipment meets performance and safety expectations.
2. Hygiene Clearance and Inspection
   Before the equipment is used in production, a hygiene clearance procedure must be completed. This ensures the equipment has been thoroughly cleaned, sanitised, and validated for food safety.
3. Stakeholder Involvement
   Authorised personnel from multi-disciplinary teams (e.g., engineering, QA, and production) should inspect and approve the equipment before commissioning is finalised.
4. Updating Site Procedures
   The commissioning process must also involve updates to related operational systems, including:
• Cleaning and maintenance schedules.
• Operating procedures and staff training.
• Environmental monitoring and audit schedules.
5. Validation of Risk Management
   Equipment commissioning provides the final opportunity to validate that contamination risks have been addressed. For example, during commissioning of a conveyor system, ensure that all surfaces are food-safe, welds are smooth, and the system can be easily dismantled for cleaning.

Practical Application

To integrate these principles into your food manufacturing environment:

1. Early Planning and Cross-Functional Collaboration
• Engage engineering, technical, and QA teams early in the procurement process to define specifications and commissioning requirements.
2. Supplier Engagement
• Work closely with suppliers to ensure equipment is designed and manufactured according to agreed specifications. Request documentation such as compliance certificates or calibration reports to confirm suitability before delivery.
3. Sequential Validation
• Validate compliance at every stage, from sourcing to design, installation, and commissioning. For example, when commissioning a mixer, ensure the material construction aligns with purchase specifications, validate performance during operational tests, and confirm hygiene clearance before use.
4. Post-Commissioning Monitoring
• Monitor newly commissioned equipment closely during initial operations. Conduct periodic reviews to ensure equipment performance aligns with expectations and operational risks remain managed.

Expert Insights

1. Risk-Based Approach
   A thorough risk assessment must be conducted before commissioning begins, identifying potential hazards associated with equipment installation and use. For example, a poorly designed seal on a mixing vessel could harbour pathogens if not addressed during commissioning.
2. Documentation
• Clear and comprehensive documentation of the commissioning process, including hygiene clearance, training records, and inspection checklists, is essential for audit readiness and regulatory compliance.
3. Hygiene By Design
• Equipment commissioning is most effective when paired with the ‘hygiene by design’ principle, which ensures that equipment is inherently easy to clean and maintain. For instance, a filler machine designed with sloped surfaces prevents liquid accumulation, reducing cleaning time and risk of contamination.
4. Collaborative Approach
• Successful commissioning requires collaboration among multidisciplinary teams, including engineering, quality, and operations personnel. This ensures that all functional and safety aspects are addressed comprehensively.
5. Common Challenges
• One of the most common challenges during commissioning is unforeseen downtime caused by misaligned expectations between the equipment supplier and the site. Clear communication of site-specific requirements can mitigate such issues.
• Another challenge is maintaining food safety during installation, particularly in live production environments. Careful planning and effective segregation can minimise risks.

Conclusion

Equipment commissioning is a critical step in integrating new or modified equipment into food manufacturing operations. By following a risk-based, documented procedure, manufacturers can ensure that equipment meets all food safety and operational requirements. Proper commissioning not only minimises risks of contamination and operational inefficiencies but also supports compliance with stringent standards like the BRCGS Food Safety Standard. Emphasising hygiene, training, and procedural integration during commissioning sets the foundation for consistent, safe, and high-quality production.

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