What is really needed to ensure food safety in production

On paper, a plastic component may seem perfectly suited for the food industry. The material is certified, meets the appropriate standards, and is widely used. Yet in practice, situations regularly arise in which components wear out more quickly, are difficult to clean, or even pose a risk to the production process.

That’s because food safety isn’t determined by the material alone. It’s about the big picture, where material selection, design, processing, and application all come together. As soon as one of those factors is off, it can have direct consequences for quality, cleanability, and reliability.

Especially in environments where processes run continuously and hygiene is paramount, it is essential to look beyond the term “food grade.” In this blog, we’ll delve deeper into what is actually required to use plastic components safely and reliably within the food industry.

What does food-safe plastic mean in practice?

The term “food-grade” is often used as a starting point when selecting materials. Essentially, this means that a plastic is suitable for contact with food and complies with regulations such as EC 1935/2004.

However, this classification primarily says something about the base material and much less about how that material behaves in an operational system.

In practice, food safety revolves around a material’s ability to retain its properties under the conditions in which it is used. This means that a plastic must not only be safe under normal use but also when exposed to temperature, stress, and cleaning.

A component that functions well initially may, over time, deform, wear out, or become more difficult to clean. This often happens gradually and is not always immediately visible. It is precisely this that leads to situations where components still function but no longer meet food safety requirements.

Material properties that determine food safety

When selecting a plastic for food applications, it is important to consider properties that affect long-term performance.

The most important factors are:

• Migration behavior and chemical stability: A material must not leach substances into the product, even when exposed to cleaning agents or temperature fluctuations. Chemical stability plays a key role here, especially during intensive cleaning processes.
• Abrasion resistance and surface behavior: Components that are in constant motion or under load must be resistant to wear. If material particles are released, this can affect product quality and process reliability.
• Moisture absorption and dimensional stability: Some plastics absorb moisture, which can lead to dimensional changes. In applications where tolerances are critical, this can affect a component’s performance.
• Temperature resistance: Plastics react differently to temperature. Not only is the maximum temperature relevant, but especially whether the material retains its properties during prolonged exposure.
• Cleanability and surface texture: A smooth surface is essential to prevent contamination and ensure effective cleaning. Rougher surfaces increase the likelihood of product residues and microorganisms adhering to the surface.

Together, these properties determine whether a material is not only theoretically suitable but also continues to function reliably in practice.

Common plastics and their behavior in food applications

Various engineering plastics are used in the food industry, each with its own properties and areas of application.

HMPE is widely used in applications where low friction and wear resistance are important, such as guides and conveyor components. The material does not absorb moisture and performs well in dynamic applications. At the same time, it is more susceptible to scratches, which can affect the surface’s hygienic properties.

POM is known for its high dimensional stability and mechanical strength. This makes it suitable for precision parts such as bearings and components that require a precise fit. In food applications, it is often produced in a blue color to facilitate detection.

PA6 offers a combination of strength and wear resistance, but absorbs a relatively high amount of moisture. It performs excellently in dry environments, but in humid applications this can lead to dimensional changes and deviations.

PETP is used when dimensional stability and low moisture absorption are essential. The material is suitable for parts with tight tolerances but is less resistant to prolonged exposure to hot water.

For more demanding conditions, such as high temperatures or aggressive cleaning, PEEK is often chosen. This material retains its properties under extreme conditions, but is primarily used when performance outweighs cost.

The importance of hygienic design

In addition to material selection, the design of a component plays a major role in food safety. Even a well-chosen plastic can still cause problems if the component is not designed with cleaning and use in mind.

Hygienic design focuses on preventing areas where dirt can accumulate and on improving a component’s cleanability. This requires attention to shape, finish, and detailing.

In practice, this means that components are designed to be easy to clean and do not contain spaces where product residues can remain. Small details, such as rounded edges, transitions, and surface texture, make a big difference here.

Components that are not designed with this in mind can lead to the accumulation of dirt over time. This not only affects hygiene but also the performance and lifespan of the component itself.

The impact of processing and manufacturing

One aspect that is often less visible but certainly has an impact is the way in which a plastic part is manufactured.

Plastic usually starts as a semi-finished product, such as a sheet or rod, which is then cut to size and further processed.  During these processes, differences in surface structure, tolerances, and finish arise. This directly affects how a part functions and how easily it can be cleaned.

In addition, hygiene during the production process plays a crucial role. When parts are processed under uncontrolled conditions, contamination can occur that is difficult to detect later.

That is why the food industry often operates in accordance with GMP guidelines. This approach focuses on controlling the production process, preventing cross-contamination, and ensuring traceability. At Lakwijk, we comply with these guidelines.

Traceability is essential in this regard. It must always be clear which material was used, where it came from, and how the component was produced. This is important not only for internal control but also for audits and certifications.

Conclusion

Food-safe plastic is not a one-size-fits-all solution that works for every application. It is the result of a combination of choices that bring together material, design, and production.

By looking beyond basic classifications and focusing on properties such as wear resistance, dimensional stability, and cleanability, we can create a solution that not only complies with regulations but also continues to function reliably in practice.

Especially in an environment where continuity and hygiene are paramount, that extra level of detail makes the difference between a component that simply works and one that contributes to a stable and safe production process over the long term.

Want to learn more about food-safe plastics? Then contact our specialists - we’d be happy to help you further!