Dividing a production environment into hygiene zones ensures:

1. Risk management
   Identifying risk areas and keeping them physically separated reduces the risk of cross-contamination.
    
2. More efficient processes
   Each area has its specific cleaning and disinfection protocols, ensuring targeted and efficient hygiene practices.
    
3. Compliance with regulations
   Many food safety standards (such as HACCP, BRC and IFS) require clear zone separation of areas to ensure food safety.
    
4. Traceability
   In case of a possible contamination, the source can be traced faster when the zones are well defined.

The different hygiene zones

In the food industry, three main types of hygiene zones are generally distinguished. However, this may vary depending on specific needs within the production process.

How to create a zone layout?

Setting up an effective zone division requires a systematic approach. Here are the key steps:

1. Conduct risk analysis:

• Identify which processes and areas pose a high risk of contamination.
• Use an HACCP analysis to identify critical points.

2. Define zones:

• Classify the production environment according to risk level (high risk, medium risk, low risk).
• Take into account the flow of raw materials, products and personnel.

3. Establish protocols:

• Establish specific hygiene requirements for each zone. Consider dress code, cleaning frequency and disinfection procedures.

4. Adapt infrastructure:

• Provide physical separations, such as walls, airlocks, or changing rooms to prevent contamination.
• Install hygiene stations or hygiene locks at strategic locations.
• Provide separate access points for employees, raw materials and finished products.

5. Train staff:

• Provide training so that operators understand the different areas and adhere to the rules.

6. Regular inspections and optimisation:

• Conduct periodic inspections and audits to check that the zones are used    and maintained correctly
• Adjust the plan if processes or production lines change.