Food safety depends not only on clean equipment but also on the quality of the air and the surfaces that come into contact with products.
A poultry-processing plant in Samara needed a UVC system for its cutting and packaging areas. The goal was to treat products moving along a conveyor and reduce airborne microbial contamination inside the production rooms.
The Challenge
The plant produces semi-finished poultry products. These are handled in open production areas, where strict sanitation is essential to reduce the risks associated with bacteria, mold, and cross-contamination.
The conveyor belt was 400–500 mm wide. Its speed changed depending on the production mode: travelling one metre took between 15 and 50 seconds.
This was an important detail. The faster the belt moves, the less time the product remains inside the UVC treatment zone. The equipment therefore had to provide sufficient exposure even at the highest conveyor speed.
Another challenge was the shape of the product. Poultry pieces are not flat, so folds and irregular surfaces can create shadows. UVC only treats areas that receive direct radiation.
Conveyor Surface Treatment
A VOZUF 410 mm conveyor irradiator was selected for the production line.
The unit has an AISI 304 stainless-steel housing suitable for food-processing environments. It uses an 85 W germicidal lamp and includes an electronic ballast and lamp connector.
The main characteristics are:
length: 410 mm;
width: 120 mm;
lamp power: 85 W;
stainless-steel AISI 304 housing;
electronic ballast;
antishatter lamp protection.
The antishatter version was selected at the customer’s request. This reduces the risk of glass fragments reaching the production area if the lamp is accidentally damaged.
The irradiator was positioned above the conveyor so that UVC radiation reached the exposed upper surfaces of the products. The exact mounting height and position had to account for conveyor width, product height, and possible shadows from guides or other equipment.
Air Treatment in the Production Rooms
Conveyor treatment addressed product surfaces, but the plant also needed to reduce airborne contamination.
For this purpose, UVL-Aero 400 recirculators were selected for the cutting and packaging rooms.
Each unit processes up to 400 m³ of air per hour. Air passes through an enclosed UVC chamber and then returns to the room. Because the radiation remains inside the housing, the recirculators can be used in occupied production areas when installed and operated correctly.
The main parameters include:
airflow: up to 400 m³/h;
specified UVC dose: 385 J/m³;
UVL 19310-144 amalgam lamp;
lamp life: up to 12,500 hours;
dimensions: approximately 1200 × 400 × 160 mm.
The required number of recirculators was determined separately for each room. Engineers considered room volume, ceiling height, equipment placement, and air circulation—not only floor area.
Implementation
The project began with telephone consultations and a technical questionnaire. The customer provided information about the conveyor and the different production rooms.
The equipment was then selected in two parts:
a compact UVC irradiator for direct treatment on the conveyor;
enclosed recirculators for treating room air.
This approach addressed two different contamination routes. The conveyor unit treated accessible product surfaces, while the recirculators reduced the number of viable microorganisms circulating in the air.
Benefits for the Plant
The completed configuration provided:
UVC treatment of exposed poultry-product surfaces;
air treatment in cutting and packaging rooms;
equipment adapted to different room sizes;
stainless-steel construction suitable for food production;
antishatter lamp protection;
integration without rebuilding the conveyor;
convenient operation and maintenance.
The system can help reduce risks associated with total viable count, molds, and pathogens such as Salmonella. However, the actual microbiological result should be confirmed by sampling and testing under real production conditions.
UVC is an additional hygiene barrier. It does not replace washing, chemical sanitation, temperature control, or routine microbiological monitoring.
Conclusion
This project shows why surface and air treatment should be considered separately.
A conveyor irradiator delivers UVC directly to exposed products, while enclosed recirculators continuously treat the air inside production rooms. Together, they provide a practical solution for strengthening microbiological control at a poultry-processing facility.
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