Hygienic Packaging Machinery 101: What Does Washdown Really Mean?

In the food packaging industry, the terms "hygienic," "sanitary," and "washdown" are often used interchangeably when describing equipment. However, these distinctions carry significant implications for food safety, operational efficiency, and long-term cost of ownership. Understanding these differences is crucial for making informed decisions about hygienic packaging machinery selection and facility design. 

Defining the Terms: Hygienic Packaging Machinery and Beyond 

When discussing or selecting the hygienic packaging machinery that’s right for your application, knowing the difference between wipedown and washdown is essential. Within the category of washdown packaging machines, JLS uses a framework of construction levels to describe how far a machine’s design goes — these are JLS design levels, not universal industry certification levels, and the right level depends on your application. In every case, use the cleaning procedures specified for the equipment and the application. 

Wipedown

If a machine is described as wipedown, it means it has easy-to-clean stainless components and can be wiped down for cleaning. However, it cannot be hosed down without jeopardizing the integrity of the machine. This is for several reasons, including ingress concerns and insufficient durability.  

For instance, these machines contain electric components such as motors, sensors, and wiring that can be damaged by water exposure. Since extra care is not taken to prevent water ingress, things like short circuits, corrosion, and equipment failure are possible. 

Unlike washdown-rated equipment, which we’ll talk about more in a little bit, wipedown machines aren't built with the proper IP (Ingress Protection) ratings needed to withstand water spray or immersion. Seals, gaskets, and enclosures may not be waterproof, and as a result, the risk of bacterial harborage increases in hidden spaces, crevices, or internal components. 

Additionally, the materials used (electronics housings, bearings, etc.) may not be designed to resist moisture and cleaning chemicals used in washdown procedures. Water pressure from washdown procedures can force moisture into bearings, drive components, and other mechanical parts not designed for wet environments, leading to premature wear and failure. 

Washdown

The term “washdown” is used to refer to an environmental condition where a piece of equipment, like a packaging machine, will be in operation. Washdown usually implies the need for hygienic design. However, that is not automatically, or expressively the case. Washdown simply means that the equipment will be wet during operation or cleaning. The degree of harshness for washdown conditions will vary significantly depending on the application or machine use case. A machine suitable for washdown alone simply means the equipment’s components are rated (IP65-IP69K) by design to be suitable for withstanding certain washdown procedures. Again, washdown procedures will vary depending on application — cleaning methods, chemicals, pressure and temperature must match the specified equipment and its cleaning instructions. 

Within the category of washdown, JLS describes four levels of construction: 

Level 1: Non-Sanitary These machines are not specifically designed to eliminate harborage areas and can use a low-pressure hose for washdown without chemicals. They can have a combination of stainless steel and non-stainless-steel components, such as anodized aluminum or painted carbon steel. These machines would be ideal for items that don’t require adhering to strict requirements, such as packaged foods like pasta or candy where the machine handles the package, rather than touching the food item. 

Level 2: Sanitary The term “sanitary” refers to conditions that are clean and free from dirt, bacteria, germs, and so on that can pose a risk to health. The degree of effectiveness and ease of effort to sanitize something (or make sanitary, like a packaging machine) is dependent on the process used for sanitation and the design of the equipment to be sanitized, or, to make the equipment hygienic. Sanitary design is not really a thing. To be hygienically designed is to be suitable for becoming sanitary with proper cleaning and sanitation procedures. 

Machines with this designation are designed for some, but not all, harborage areas to be eliminated. They are constructed with stainless steel and can use a low-pressure hose, but without chemicals, just water. Sanitary washdown machines are ideal for a wide variety of food items such as snacks, wrapped bakery items, candy, pet food, and more that do not come in direct contact with the machine.  

Level 3: Cleanable Construction Level 3 machines feature what JLS calls cleanable construction: stainless steel throughout, round-tube frames that shed water, smooth welds, sloped surfaces and accessible cable management. They can undergo washdown with the use of chemicals, with procedures matched to the equipment’s component ratings. This level covers a wide range of food packaging applications where the machine handles primary packages. 

For a washdown protocol to work as intended, the equipment up and downstream should also meet the same specifications [such as Ingress Protection (IP) ratings]. This is because if an IP65-rated component is mounted next to IP69K-rated equipment, the lower-rated component becomes vulnerable during high-pressure, high-temperature washdown procedures. Repeated exposure to IP69K washdown conditions may cause water ingress over time, leading to premature failure of the IP65 component. 

Level 4: Hygienic Design The strictest designation in the JLS framework — and the one that applies to the applicable TALON^® configuration — is hygienic design. These machines can undergo high-pressure washdown with chemicals, and extra effort is made to eliminate harborage areas (special finishes, ground welds, standoffs, sloped surfaces, etc.), with an open-channel frame or solid barstock construction made from bent solid stainless-steel sheets or plates, further eliminating harborage points compared to hollow-body alternatives. 

One important element of hygienic design is the ability to inspect all surfaces of a piece of equipment. Both visual inspection and physical inspection, as well as the ability to touch all surfaces with a swab to test for bacteria, are critically important. For this reason, at this level, closed tubular sections that cannot be inspected internally are avoided or fully sealed: rotating tubes, like a hollow film roller, should be fully sealed by welding and then filled with several ounces of blue food coloring to expose any cracks that develop over time. Small harborage cavities like the hex slot in a socket head cap screw are also avoided in favor of standard head fasteners. These machines can be designed to support 3-A sanitary standards where the application requires, and are ideal for industries such as dairy, meat, seafood and produce with fresh, IQF and ready-to-eat (RTE) foods. 

Understanding these distinctions ensures that your packaging machinery investment supports both food safety objectives and operational efficiency while minimizing long-term maintenance costs and compliance risks. 

Need a washdown packaging machine and not sure where to start? We’ve seen it all and are ready to help. 

Sources 

International Electrotechnical Commission (IEC). "Ingress Protection (IP) ratings." https://www.iec.ch/ip-ratings 

Clarion UK. "IP Ratings Explained | Ingress Protection Rating | IP Codes." October 4, 2022. https://clarionuk.com/resources/ip-ratings/ 

Things Embedded USA. "Importance of High Ingress Protection: IP65, IP66, IP67, IP68, IP69K." September 4, 2023. https://things-embedded.com/us/white-paper/importance-of-high-ingress-protection-ip65-ip66-ip67-ip68-ip69k/