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Hygiene maps and critical point analysis

The hygiene maps and critical point analysis (HACCP) service offered by INFINITIA Industrial Consulting is a key tool for detecting critical microbiological accumulations and proposing effective improvements in industrial processes where hygiene is a determining factor.

This service, which is based on the collection and microbiological analysis of samples from surfaces, environments, or products, allows risk areas to be visualized using “traffic light” representations and corrective strategies to be established.

In our specialized industrial laboratory, hygiene maps are developed by expert technicians in microbiology and forensic engineering, applying reference methodologies and up-to-date technologies to guarantee reliable data and effective decisions.

What is a hygiene map?

A hygiene map is an analytical representation of the microbiological load present in different areas of a facility, equipment, or product. To do this, exhaustive sampling is carried out by swabbing surfaces or air, followed by microbiological culture in the laboratory and subsequent counting of colony-forming units (CFU).

These figures are translated into color codes: green areas indicate a low presence of microorganisms, orange areas reflect a moderate load, and red areas warn of a high risk.

At INFINITIA, this process includes not only the identification and quantification of aerobes, total coliforms, E. coli, or other relevant pathogens, but also the analysis of biological hazards in accordance with the HACCP system. This allows critical control points (CCPs) to be identified with a preventive approach, supported by technical criteria, industrial experience, and empirical evidence. This service can also be combined with the validation of antimicrobial treatments (such as UV light or special coatings) to assess their actual effectiveness.

Hygiene maps and critical point analysis

Benefits of hygiene maps and HACCP analysis

One of the key benefits of the service is the reduction of microbiological risks through the proactive detection of contamination sources. For example, certain companies have managed to improve their safety, reduce the number of incidents and rejections, and improve the productivity of their factories thanks to the data provided by INFINITIA.

In other cases, such as in the manufacture of industrial components, unexpected microbial accumulations have been identified that affected product performance under real conditions of use.

In addition, this analysis serves to validate the effectiveness of cleaning or disinfection processes already in place, as well as to compare different materials or surface finishes. By identifying critical areas, it is possible to apply targeted solutions, reduce operating costs, and strengthen hygiene protocols in a specific and evidence-based manner.

Critical point analysis at INFINITIA

At INFINITIA Industrial Consulting, we approach this service from a comprehensive and interdisciplinary perspective, combining expertise in microbiology, surface engineering, hygienic design, and HACCP regulations. Our team conducts the study directly on site or on the product, designing sampling protocols tailored to each client’s context.

We have laboratory equipment for culturing, identifying, and counting microorganisms, as well as visualization and analysis tools that allow us to present results in a clear and actionable way.

Furthermore, at INFINITIA, we don’t just detect the problem: we also propose hygienic solutions and test their effectiveness, generating technical evidence to facilitate decision-making.

Hygiene maps and critical point analysis

Types of Hygiene Maps and Critical Point Analysis

At INFINITIA, we develop different types of hygiene maps and critical point analyses to identify areas with high microbiological risk in industrial environments. This information allows us to make informed decisions on the validation of cleaning processes, the implementation of hygiene solutions, or the development of preventive control systems.

Our studies combine the systematic collection of microbiological samples with hazard analysis based on HACCP criteria, adapting to the needs of each sector.

Microbiological load maps on surfaces

These maps provide a visual representation of the quantity of microorganisms present in different work areas, machinery, or finished products. They are obtained by sampling using swabs, culture, and colony-forming unit (CFU) counts, including aerobic bacteria, coliforms, E. coli, molds, and yeasts.

At INFINITIA, we use this approach to generate “traffic light maps” that indicate green (clean) areas, orange (medium risk) areas, and red (high microbiological load) areas. This type of map is used by an industrial manufacturer to identify fungal accumulations in rubber seals.

Hazard analysis and critical control points (HACCP)

HACCP analysis is a systematic tool for identifying biological hazards and defining critical control points in a facility or process. At INFINITIA, we integrate this approach with the results of microbiological maps to generate corrective or preventive proposals.

This type of study is particularly useful in industry, where we have helped clients redesign workstations after detecting contamination during manufacturing.

These studies allow us to evaluate the real effectiveness of the cleaning and disinfection protocols applied in the plant. An initial sampling is carried out before cleaning, followed by another sampling, with statistical analysis of the results.

At INFINITIA, we apply this methodology to validate the incorporation of technologies such as UV light or antimicrobial surfaces. In a recent case, we compared two cleaning systems, and the maps showed a substantial improvement in the reduction of microbial load.

Microbiological accumulation maps on products

When the analysis focuses on the final product or its components (e.g., taps, filters, removable parts), the objective is to identify areas of bacterial accumulation that could compromise safety or performance in use.

In a project to validate new materials, we mapped bacterial contamination on plastic components and detected that certain geometries promoted biofilm growth.

Applications of Hygiene Maps and Critical Point Analysis

Hygiene maps and critical point analysis have strategic applications in multiple industrial sectors. At INFINITIA, we adapt each project to regulatory requirements, perform accelerated testing tailored to our clients’ needs, helping them control risks, improve processes, and validate effective hygiene solutions.

Food Industry

In food environments, the detection of critical contamination points is vital to ensure product safety and comply with HACCP regulations. Maps allow areas where cleaning protocols are not effective to be identified, as well as new equipment or materials in contact with food to be validated.

  • Creation of hygiene maps.
  • Validation of cleaning through different protocols.
  • Support in redefining HACCP plans in industries.

Appliance Industry

Although not a food industry, appliances (especially those related to water or humidity) can develop sources of internal contamination.

At INFINITIA, we create microbiological load maps on functional parts, seals, gaskets, or internal areas.

  • Detection of microorganism accumulations in rubber and polymers.
  • Comparative evaluation of plastic materials with antimicrobial coatings.
  • Redesign of components to minimize stagnation zones and biofilm.

Industrial Hygiene

In sectors with controlled environments (pharmaceutical, cosmetic, laboratories), it is essential to ensure that hygienic conditions are maintained within established parameters. Hygiene maps allow compliance to be justified, equipment to be audited, and protocols to be improved.

  • Assessment and support of rooms with critical contamination points.
  • Evaluation of the impact of renovations and production changes on hygiene.
  • Design of periodic microbiological sampling plans as preventive failure analysis on batches of raw materials and finished products.

Automotive Sector

In components exposed to humidity, temperature, and organic matter (cabin filters, interior areas of the vehicle, removable elements), the microbiological load can influence comfort, durability, or user perception.

  • Analysis of critical points in air conditioning circuits after accelerated use testing.
  • Comparison of different plastic formulations in areas of frequent human contact.
  • Support in the development of functional surfaces with antibacterial effect.

Hygienic optimization and microbiological control with the technical support of INFINITIA

Hygiene maps and critical point analysis (HACCP) are essential tools for guaranteeing microbiological safety and optimizing industrial processes in environments where cleanliness and biological control are critical. At INFINITIA, we develop this service with a rigorous technical approach, integrating knowledge of applied microbiology, surface engineering, health and hygiene regulations, and cleaning process validation.

Thanks to the application of systematic sampling techniques, microbiological culture, and analytical representation, we are able to identify areas with high accumulation of microorganisms, characterize the actual bacterial load, and establish improvement proposals based on the type of risk. This service not only allows you to comply with regulatory requirements, but also opens the door to innovation strategies in hygienic design, implementation of antimicrobial materials, and evaluation of new technologies such as UV light disinfection.

In a context where traceability and safety in the industrial environment are increasingly valued, counting on INFINITIA to carry out this type of study is a competitive advantage. Our team combines experience, advanced technical equipment, and a results-oriented approach. Furthermore, we don’t just detect problems: we propose solutions and validate them with data.

The trend in the coming years points to greater integration of predictive tools, continuous monitoring, and preventive protocols against cross-contamination and biofilms. At INFINITIA, we are prepared to accompany industrial companies in this evolution, developing tailor-made projects, adjusted to each need, with a practical, scientific, and applied vision.

Hygiene maps and critical point analysis

If your organization is looking to improve its hygiene standards, comply with HACCP regulations, or innovate in microbiological control, having INFINITIA as your technology partner can make all the difference.

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