Exhaust System Guide for the Food Processing Industry

The food processing industry is divided into the consumption, catering, & supply of food products. Energy efficiency, hygiene, & reduction of waste are crucial benchmark criterium to be met.

The three primary industry sectors are

Agriculture – Raising livestock & crops.

Manufacturing – Commodities supporting production.

Food processing -Preparation & manufacture of commodities for the market.

Food processing has significant exhaust needs, including cooling & heating to maintain ambient temperatures for both workers & products, proper ventilation of produce to reduce premature ageing, freezer recirculation air, odour control, caustic gas expulsion, or air turnover throughout wash-down cycles.

Ventilation of Food Processing Factory

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In food processing companies, enough ventilation should be supplied to deal with steam, odours & harmful vapours. A safe & comfortable working environment should be coupled with care not to contaminate food, packaging materials, or food-contact surfaces. Indeed, bad heating, ventilation & air conditioning (HVAC) construction, unfiltered air, & installation practices & negative pressure in food-manufacturing processes are primary sources of disease-causing contamination.

HVAC duct systems that are hard to clean have been found to shelter Listeria & other pathogens. The appropriate placement of exhaust, air-blowing equipment, & intake vents & ducting might help reduce these risks.

An ideal exhaust system for food processing equipment will

• Maintain appropriate temperature & humidity;
• Purify air by filtering;
• Pressurize the contingent space;
• Keep ducting attainable, but on the side-lines of processing operations;
• Supply ample volumes of air where required;
• Prevent contamination & be easy to clean.

Humidity & Temperature

Cooling & humidification are two crucial elements of the exhaust system. Too much relative humidity might cause condensation & unpleasant working conditions & lead to the growth of mold & bacterial, which tend to cause bad quality products, production losses, & increased appliance maintenance costs.

Food manufacturing operations such as cooking, washing, & cleaning often use a great deal of water that will enhance the humidity level. In chilled rooms, fog often builds during cleaning due to the use of hot water. However, this might present a threat to the cleaning staff & leads to heavy condensation on surfaces.

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The HVAC system might use up to 35-percent of the power in many operations, & dehumidification may take up nearly half of this energy. If a refrigerating system is used, appropriate handling of the condensate is required to prevent the growth of bacteria & fungus. Air reheating might be necessary as well.

Desiccant wheel arrangements are another substitute. An appropriate HVAC system provided with heating equipment or desiccant dryers might prevent condensation & minimize cleaning times.

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Establishing Suitable Pressure

Generally, positive air pressure zones need to be maintained, with the utmost positive air pressure in the region where the product will be exposed to open-air for the last time (packaging). Usually, this happens where packaging & sealing happens & immediately after the kill step. For lack of a kill step, this region will involve everything from washing & trimming up to packaging.

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Progressively low pressures will be maintained in ensuing & previous steps of processing & handling. However, this system keeps up a pecking order of contamination risk, with the zones in which the product’s properties are concluded having the lowest danger.

While this system is appropriately designed in food processing plants, the individuals entering the building will apparently feel the airstream. The air will travel from high pressure to low-pressure zones at nearly 100 m/min. However, airflow from polluted to clean areas will be improbable. It is especially crucial for RTE (Ready to Eat) or near-RTE products. Moreover, dust collection systems also avail from developing positive pressure regions.

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Too much exhaust fan capacity & use can develop negative pressure in food manufacturing plants, which leads to pollutants entering the space when there is an opening such as a window, open door, or even a gap. Without control over the inflow of airborne microorganisms, vapors, & dust, hygiene & equipment maintenance becomes extremely difficult & the quality of the final product might suffer as a result.

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Makeup air extracted from outside can be utilized to build positive pressure. However, it is advisable that the air drawn in must exceed the exhausted air by 10-percent to attain this. Makeup air & recirculated & purified air from within the facility can be mixed.

System Design

Duct design is a crucial element of the HVAC (heating, ventilation & air conditioning) system. Preferably, it should be installed outside manufacturing areas & be easy to access for cleaning & maintenance, for instance, on a walk-on ceiling. However, ducting suspended over manufacturing areas is also likely. In that case, round ductwork (that will pile up less dust on top) or GI ducts closely installed to the ceiling must be installed. Access doors are required to allow proper clean-up of the inside.

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Exhaust stacks must be higher than inlets & leeward where possible. In any case, the exhaust that reaches intake ducts must be minimized, & intake vents should be placed away from likely sources of contamination. While this might seem obvious, it is often ignored in renovating a building, resulting in considerable costs.

Ventilation stacks also require hoods to keep rain & other precipitation out & avail unwanted draughts, & insect screens & a self-closing damper for when it’s not operating.

Insulated pp FRP duct must have closed-cell insulation closed in a double wall. Prevent open insulation as it traps contaminants & condensation, &, being impossible to clear, will spread it thru the building. Routine testing must be done on the ducts & filtration system to assure cleanliness.

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The amount of filtration needed depends on the products manufactured. Generally, recirculated air is mixed with make-up air inside the HVAC (heating, ventilation & air conditioning) unit, then filtered, conditioned & filtered again. The final filtering should be very effective for sensitive RTE (ready-to-eat) products, with the ability to get rid of 99-percent of particles of 1 micron or even smaller. Intakes along with the HVAC unit are usually located on the roof & must also be filtered properly.

Air Exchange

Air changes must be high enough to get rid of odors, unwanted steam, & other contaminants by filtering with keeping up the appropriate temperature & humidity conditions. The standards for ready-to-eat (RTE) product manufacturing plants have grown steadily, & today they might maintain more than 25 air changes per hour, where 20 is usual.

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The precise number relies on the manufacturing operations that are occurring & should be customized for the factory & process by an experienced exhaust engineer. Sluggish areas might collect dust, fumes, & contaminants, so the duct system must be built to prevent them. Where construction work is carried out on an existing plant, this is particularly crucial, as fumes & oil might affect workers, materials, & products.

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Usual Challenges

In food manufacturing companies, the methods are classified by non-traditional, usually custom-made cooking appliances, for both their capacity & power requirements. They are often built on a unique kind of cooking, frying, or steam-based, for instance. The method generates a lot of heat, mixed with large amounts of steam, smoke, & grease.

Because of the cooking equipment’s physical size, particularly their height, & the use of conveyors or lifting mechanisms, the exhaust systems are many times installed higher. However, the relationship of the size & location of the exhaust system makes it more challenging to effectively remove the contaminants while also needing to modify the shape & dimension of the system.

At last, hygiene is a crucial factor in emissions when the food processing industry is operating near household neighborhoods.

Conclusion: Food processing works are as unique as the food they manufacture & require calculation processes that are not just gathering standard commercial kitchens ventilation airflow rates. Therefore, a keen insight into how the air behaves & how the thermal plumages expand from the appliance is needed to provide the appropriate recommendations on the airflows.