While the Canadian Food & Beverage industry prioritizes things such as the quality of raw ingredients, air quality is often overlooked. However, it’s a vital part of the mix that affects product safety, shelf life, taste, and brand integrity. Air quality must be examined throughout the supply chain, from production to packaging. In this article, we will talk about the importance of air quality in food and beverage production and how you can improve it.
The Threat Contaminants Pose to Food and Beverage Production
Conditions like intense Canadian wildfires and high heat and humidity in warming Canadian climates present growing air quality challenges, necessitating proactive and well-thought-out air filtration measures within the F&B sector. Biological contaminants, particulates, volatile organic compounds (VOCS), odours, smoke and combustion particles, allergens, and compressed air contamination are a constant threat to F&B operations.
Types of contaminants most concerning for the food and beverage industry:
Biological Contaminants:
- Sources: Damp areas, moisture and condensation in ducts, and poorly maintained HVAC systems can spread bacteria, mould spores, and viruses. Contaminants can become airborne and infiltrate food products and surfaces.
- Impacts: Food spoilage, food-borne illnesses, product recalls, litigation.
- Examples: Listeria, Salmonella, E. coli.
Particulate Matter (PM):
- Sources: Cooking processes, raw materials dust, and contaminated outdoor air infiltration. PM can range in size, with PM2.5 and PM1 being particularly concerning because they can get deep into the respiratory system of facility staff.
- Impacts: Cardiovascular problems for facility staff, pollution and odours emitted in the community, potential contamination of food products.
Volatile Organic Compounds (VOCs):
- Sources: Cleaning agents and sanitizers, cooking-related degreasers, fumes, and building materials.
- Impacts: Eye, nose, and throat irritation, headaches, negative health effects for staff and the public, unpleasant odours that can affect customer experience.
Smoke and Combustion Particles:
- Sources: Produced during cooking with solid fuels.
- Impacts: Respiratory issues for production staff. Fire hazards.
Odours:
- Sources: Grease and oil, food waste, mould, bacterial growth.
- Impacts: Negative experiences for customers, building occupants, people in the vicinity of F & B facilities. Harsh working conditions.
Allergens:
- Sources: Allergens can be released into the air during the production and processing of food. Cross-contamination can occur.
- Impacts: Health risk to consumers with allergies.
Typical Air Quality Challenges in Canada’s Food and Beverage Industries
Wildfire smoke contains harmful gases and fine particulate matter, and it is becoming a bigger concern for Canadian F&B facilities. Contaminates often cover a wide area over North America and air quality can be impacted far from the source and can get into facilities impacting indoor air quality, necessitating more complex air filtration systems to protect products and employee health. Indoor contaminants can be generated in the production and packaging stages, through the use of cleaning agents, and by means of staff activities.
Mould spores
While some mould spores can be harmless, others, like black mould, can have severe consequences. Therefore, it’s essential to address indoor air quality comprehensively, targeting both harmful and less harmful agents because discerning one from the other in the air is nearly impossible.
Addressing High Humidity Challenges
Industries like meat and seafood processing in some Canadian regions often have to deal with high-humidity environments. For this challenge, the choice of air filters becomes even more critical. To deal with moisture-resistant options, Canadian Air Filter Expert Berni Baier acknowledges that humidity poses significant challenges, especially during cleaning processes. Filters like the 30/30 or 30/30 Dual 9 are noted for their durability under such conditions. Baier suggests utilizing wet-laid glass media instead of high loft glass, which can absorb moisture and lead to filter sagging. In cases of persistent moisture issues, Baier recommends implementing a three-stage filtration system, as it might be necessary to manage humidity adequately.
Corrosion Resistance in Canadian Coastal Regions
For facilities located in coastal areas such as British Columbia and the Atlantic provinces, exposure to salt air necessitates the use of corrosion-resistant filters. Baier details several options, including stainless steel filters designed to withstand harsh environmental conditions.
The Critical Role of Air Filtration in Food Safety and Quality Assurance
High-quality air filtration systems prevent airborne particulate matter, microorganisms, and other contaminants from directly contacting food and beverage products, reducing the number of quality issues and the chances of food or beverage spoilage. High-efficiency air filtration, particularly properly designed and tested MERV 14-A filters and HEPA filters for highly sensitive areas, maintains purity standards required in aseptic processing and packaging environments. Positive pressure zones, achieved through high-efficiency filtered air, in critical processing areas, prevent the entry of unfiltered, potentially contaminated air.
Effective air filtration plays a major role in extending product quality and shelf life, inhibiting fat oxidation, and reducing food waste. Removing airbourne contaminants like fine particulate matter and allergens reduces occupational respiratory conditions by reducing the amount going into the surrounding community. It improves employee wellbeing and productivity inside a facility. Removing contaminants through proper air filtration can result in reduced cleaning and maintenance requirements, extended equipment lifespan, and lowered energy consumption when desired.
Better filtration systems help prevent external contaminants from entering processing areas and mitigate the risk of cross-contamination during food handling. During processing, if F & B processing machinery comes into contact with contaminated products, there’s a significant risk that subsequent products handled with the same equipment will also be contaminated.
The Canadian Food Inspection Agency (CFIA) mandates that food processing occur in sanitary environments and adheres to strict cleaning protocols. While cleaning at night, when, for example, production does not take place, can ensure machinery is sanitized, issues can arise during peak production hours. It is, therefore, vital to take proactive measures to maintain air quality.
The Importance of High-Quality Filtration
Baier emphasizes the necessity of high-efficiency particulate air (HEPA) filters in enclosed units used for filling processes that are not pasteurized. He recommends a minimum filtration standard of HEPA 99.97 to ensure airborne contaminants are effectively captured. The responsibility for choosing appropriate filters ultimately lies with the manufacturers, who must assess their specific environments and needs.
Effective Air Filtration Technologies and Solutions for F&B:
| Air Filtration Technology | Efficiency (Typical) | Key Applications in F&B | Key Considerations |
| HEPA Filters | ≥ 99.97% @ 0.3 microns | Cleanrooms, aseptic processing, sensitive areas | Higher cost, higher pressure drop, lower airflow |
| ULPA Filters | ≥ 99.999% @ 0.12 microns | Ultra-clean environments, highly sensitive areas | Highest cost, significant pressure drop, less airflow |
| MERV Ratings (1-16) | Varies by rating | General air filtration, prefilters, bioaerosol capture | Efficiency varies; use an appropriate MERV rating |
| Molecular Filters, Such As Activated Carbon Filters | Adsorption of gases/VOCs | Odour control, removal of specific gases | Limited particulate removal requires more frequent replacement |
| Specialized Filters | Specifically tailored to needs | High-humidity areas, antimicrobial needs | Higher maintenance costs can vary |
| Portable Air Cleaners | Up to HEPA level | Localized filtration, added filtration | Limited area coverage, effectiveness depends on CADR |
| Moisture/Corrosion-Resistant Filters | Varies by design | High-humidity regions | Prevents degradation of HVAC systems |
Maintaining adequate ventilation rates and proper airflow are essential complements to proper air filtration.
Understanding Canadian Air Quality Standards for Food Processing
Gaps in Air Quality Standards
Despite the CFIA’s protocols regarding equipment cleaning and sterilization, its standards for air quality are not as stringent as those in other countries. They simply state that food processing facilities must use suitable air filters, leaving too much ambiguity. As a result, facilities may choose inappropriate filters or filters that perform poorly and do not adequately deal with airbourne contaminants, posing potential problems in product safety.
Several key points are important to consider when looking at F&B regulations and compliance that relate to filtration systems:
While the Canadian Food Inspection Agency (CFIA)‘s Safe Food for Canadians Regulations (SFCR) mandate sanitary conditions and preventive controls against contamination, it does not specify air filter types.
Health Canada provides guidance on food safety and the health impacts of air quality, but does not directly regulate air filtration in food and beverage processing facilities.
The Canadian Environmental Protection Act, 1999 (CEPA 1999) and the collaborative Air Quality Management System (AQMS) with its Canadian Ambient Air Quality Standards (CAAQS) establish a framework for air quality that indirectly affects the F&B sector. Provincial air quality regulations vary (e.g., Ontario Regulation 419/05: Air Pollution – Local Air Quality, Quebec Clean Air Regulation, British Columbia’s municipal air quality permits, Alberta’s air quality management, and similar legislation in the Maritime provinces). Voluntary industry standards like SQF and ISO 8573 for compressed air provide additional guidelines and best practices.
Navigating the F&B Regulatory Landscape
The Safe Food for Canadians Act and the Canadian Food Inspection Agency (CFIA) are key in setting the standards for food and beverage safety. However, while the CFIA oversees many regulations, its requirements are not always as stringent as those found in other countries like England. For example, the BFI-British Food Inspection is often cited as a benchmark that offers guidelines for managing airbourne contaminants and ensuring high air quality in food processing facilities.
Investing in Total Cost of Ownership: Choosing Energy-Efficient and Cost-Effective Air Filtration
When choosing the best air filtration solution, F&B businesses can prioritize energy efficiency alongside particle capture efficiency. Conducting a Total Cost of Ownership (TCO) analysis, which considers factors like filter lifespan, replacement frequency, labour costs, and the energy consumption impact of filter pressure drop, can identify significant long-term savings. Investing in higher-quality filters with extended lifespans and lower average pressure drops often proves more cost-effective than cheaper alternatives. And the savings can amount to as much as tens of thousands of dollars.
Real-World Impact: Case Studies of Successful Air Filtration in Food and Beverage Facilities
CASE STUDY #1:
Company Profile: Fry processing and frozen food production plant air filters
“30/30 prefilter and Hi-Flo ES filter combination reduce annual filtration expense by more than 50%.“
COMPANY PROFILE
One of North America’s largest food companies and specialty potato providers to restaurants and other food service establishments.
THE SITUATION
The sweet potato fry production generated high contaminant levels over the batter and fry lines. Filters in three large air handling units (AHUs)required frequent change-outs with another six AHUs serviced less often. Despite vastly different contaminant scenarios due to the production process, the current filters selected for all AHUs were exactly the same.
Each AHU was configured for two stages of prefilters. The filters in both stages were 2″ MERV 8 pleats from company X. The third and final stages had company X’s Rigid-Air MERV 13 box-style filters. In the high-contaminant plant areas, the first two stages of pleated prefilters lasted less than a month. The contaminant bypass in the units caused premature failure of the second stage and final filters due to a lack of surface area to handle the dirt load and maintain the required airflow.
The two stages of prefilters in the AHU’s over less challenging plant areas were lasting no more than three months despite lower dirt loads. The units‘ final filters were changed every six months by an outside contractor regardless of the condition.
THE ACTION
Camfil representatives categorized the AHUs by the production process contaminant level. In the high contaminant area, the pleated prefilters in stage one were replaced with Camfil‘s 22″ deep Hi-Flo® MERV 9 bags, and Camfil 30/30® 2″ deep MERV 8 pleated filters were installed in stage two. The Hi-Flo filters provided the required strength in stage one, allowing the 30/30 panel filters to handle stage two. In the medium load process, Camfil 30/30 2″ deep MERV 8 prefilters were installed in the return air and make-up air stage, and Hi-Flo ES 22″ bag filters were selected for the final stage. In the low load process, 30/30 2″ deep MERV 8 prefilters were installed in the first stage return air, and MERV 13 Hi-Flo ES bags were used as the final filter, eliminating one filter stage.
THE RESULT
After Camfil’s filter selections had been in use for nine months, samples from each area were removed and tested on-site using Camfil’s mobile testing unit. Results from all three contamination areas showed positive results with a calculated annual savings of $56,571.
CASE STUDY #2:
Company Profile: One of North America’s largest beef processing plants
THE SITUATION
The facility had five large air handling units (AHUs) with three-stage filtration, which caused high energy costs and frequent filter change-outs due to rapid pressure increases and structural weaknesses in the filters.
THE ACTION
Camfil performed a Life Cycle Cost (LCC) analysis and recommended replacing the first two stages with a single-stage Hi-Flo ES MERV 11 bag filter, and using Durafil ES MERV 14 filters in the final stage.
THE RESULT
The new filters reduced energy costs by 63%, labour costs by 74%, and disposal costs by 86%, with an annual cost savings potential of $14,622 per AHU.
THE DATA
The LCC analysis showed significant improvements in pressure drop and filter life, leading to substantial savings in energy, product, and labour costs.
For details on these case studies or for other information, contact Camfil.ca.
Conclusion – Breathing Easier: Ensuring a Safe and High-Quality Future for Canadian Food and Beverage through Effective Air Filtration
Improving air quality involves identifying and mitigating the invisible threats posed by airborne contaminants in the food and beverage industries.
By proactively investing in proper air filtration, Canadian food and beverage businesses can realize significant benefits. At Camfil, we believe that it’s best to shift away from simply meeting basic F&B regulations to fostering a culture of safety and quality in food processing, ensuring that all aspects of production, from the raw ingredients and production to the kitchen table, prioritize the well-being of Canadians.
Where can I buy Camfil air filters in Canada?
Camfil air filters are available directly or through authorized distributors across Canada.
Contact Camfil Canada for more information or to get expert advice on choosing the right air filtration system for your needs. Start by asking for a complimentary site survey for your commercial building, public building,or other facility. Use this contact form.
About Camfil Canada Clean Air Solutions
For more than 60 years, Camfil has been helping people breathe cleaner air. As a leading manufacturer of premium clean air solutions, we provide commercial and industrial systems for air filtration and air pollution control that improve worker and equipment productivity, minimize energy use, and benefit human health and the environment. Read more about Camfil Canada.
Sources:
inspection.canada.ca/en/preventive-controls/regulatory-requirements
inspection.canada.ca/en/food-safety-industry
canada.ca/en/health-canada.html
canada.ca/en/health-canada/services/air-quality/indoor-air-contaminants.html,
laws-lois.justice.gc.ca/eng/acts/C-15.31/
ccme.ca/en/air-quality-report
Media Contact:
Phillip Ilijevski
Camfil Canada Inc.
T: 437-929-1161