Improper handwashing remains a persistent problem and one of the biggest sources of contamination risk for any food processing business. In theory, the problem is easy to solve, as correct handwashing is a pretty simple process to perform. But despite all the training, reminders and monitoring methods, it remains an issue.

1. Sheer numbers

Handwashing is a hygiene process that is performed far more frequently than any other process. A CIP tank clean, equipment washdown or other cleaning process may be performed multiple times every day, but handwashing is performed multiple times every day by every employee. As such, there are perhaps 100 times as many handwashing events per year as there are instances of any other cleaning process. This means that even very low non-compliance rates add up to high risks. Consider this: a factory with 100 workers will have close to 200,000 handwashing operations performed each year. That means that even a 99% compliance rate would mean 2,000 improper hand washes per year.

2. Everyone needs to comply

Most hygiene processes will be performed by a team of people who are trained; it will be their job to do this. To complete a washdown process properly, we just need the team doing it to comply with the process. As it is their job to do this, they generally will. In contrast, handwashing needs to be performed by every employee every time. For the most part, they are not hygiene specialists and, whilst it may be written into their job description, handwashing is not what they are actually tasked with doing; it’s not part of their day job.

3. Less obvious when it’s not done properly

Improper washdowns and other hygiene processes can normally be spotted. For starters, there are normally multiple eyes on these processes and secondly, the process itself is quite big and obvious. In contrast, handwashing is a private affair and it’s very hard to tell if it’s been done correctly and every part of the hand has been washed properly.

4. Less consequential when not done properly

The individual risk posed by a failed handwashing process is vastly lower than the risk posed by a failed CIP tank cleaning or conveyor washdown. This might seem like a good thing, but it can also create a lax attitude towards the process. The human brain is not very good at processing very low-risk events and generally registers them subconsciously as having zero chance of occurring. Our brains register them as not mattering that much. Left unchecked, this can be devastating because, as noted in point 1, the sheer number of handwashing events means that those very low risks actually add up to big risks over time. It only takes one improperly washed pair of hands to cause a contamination event.

So, what can be done?

With traditional, manually performed handwashing, there are three broad strategies that can be deployed. We look at each one below and rate them for how easy they are to implement. Our assessment takes into account the cost and effort involved as well as the overall effectiveness of each.

1. Behavioural measures

• Defined wash technique and duration, with training and periodic recertification
• Trigger points internalised (entry, post-break, post-toilet, post-glove change, post-raw handling)
• Visible signage and reminders at wash stations
• Supervisor spot-checks and hygiene audits, with positive reinforcement

In principle, these are all relatively simple to implement and not particularly expensive, but improper handwashing remains a stubborn issue to solve. The measures above are often not very effective because handwashing is a mundane, everyday process which is prone to human error and variation. As such, we are trying to work against basic human psychology and so behavioural measures to mitigate this risk require constant vigilance. Despite being quite difficult to implement successfully, these behavioural measures remain the focus of many companies.

• Initial cost – low
• Maintenance – medium (constant vigilance is required)
• Effectiveness – average

2. Better equipment

• Hands-free (foot/elbow/sensor-operated) sinks
• Automatic soap and sanitiser dispensers
• Single-use paper towels or air dryers (no cloth)
• Entry turnstiles/interlocked doors requiring a detected wash
• Badge/RFID-linked hygiene stations that log compliance

All the measures above are relatively straightforward and are only of moderate cost. They certainly play their part but require that the equipment is used properly and, as noted above, behavioural compliance is a big problem. All the equipment listed still requires a human operator to use skill and judgement in performing a mundane, repetitive task. Good equipment can improve the uniformity of the process but only to a point.

• Initial cost – average
• Maintenance – low
• Effectiveness – average

3. Better process design

• Wash stations at every point of use, not just facility entrances
• Separate handwashing sinks from food-prep/equipment-cleaning sinks
• Build wash time into the time/line schedule
• Glove policy tied to the same trigger points (wash, then glove, rather than gloving instead of washing)

These measures can be costly to implement, as they may require significant layout changes. Essentially, these process measures are all designed to make the process as simple, easy and quick to perform as possible. If the process is designed well, with properly positioned and easily accessible equipment, the “burden” of handwashing can be reduced, which will help with behavioural compliance.

• Initial cost – medium to high (depending on factory layout and the need for more wash stations)
• Maintenance cost – low
• Effectiveness – medium

Which method is best?

All three broad categories have their drawbacks and none are universally effective. As such, to approach anywhere near 100% compliance, any food factory will need to deploy methods from all three in a combination of good behaviour management, good equipment and good process design. If we focus on one area, it may mean we don’t need to deploy quite such drastic measures in others. So, for example, with excellent process design and easy-to-access handwashing stations in the correct places, we make compliance much easier for workers and so we can perhaps lessen the need for strict behavioural enforcement.

Meritech – a new way to wash hands

The picture completely changes when we consider the new breed of automated hand-cleaning systems. Automated hand-cleaning systems dramatically reduce the need for behavioural change/enforcement. They do this by removing almost all effort and human judgement from the handwashing process. Instead of each worker having to follow the steps of a proper hand-cleaning process, all they need to do is put their hands in the machine and wait. The required behaviour, therefore, becomes vastly easier and requires no thought at all. It is also significantly faster than a 20–30-second manual hand wash and so again makes compliance easier for time-pressured workers.

Automated hand washers eliminate most of the need for behavioural compliance measures by making the process so easy that it’s actually more effort not to comply than to comply. People will actually have to try harder to be non-compliant than to comply. Most non-compliance is not wilful; it occurs because people are tired or distracted and so are not concentrating on perfectly executing the handwashing technique. With an automated machine, it does not matter if the person using it is at the end of a double shift, having been up the previous night due to a screaming toddler. The hand wash will be executed just as perfectly as when a new recruit has just had their initial training and their supervisor is standing over them checking their handwashing technique.

• Initial cost – medium
• Maintenance – low
• Effectiveness – very high

Automated handwashing offers perhaps the most effective method of increasing handwashing compliance. It does this by working with natural human behaviour rather than trying to modify it. With automated handwashing, it actually takes more effort and time for someone not to comply than to comply. And that fact alone ensures almost 100% compliance.

Find out more about Meritech hand wash stations here.