Drainage | The Hidden Risk in Food Production Facilities

Proper drainage is a critical, yet often overlooked, aspect of maintaining operational efficiency, food safety, and environmental sustainability in the food industry.

While much attention is given to processing standards, and hygiene protocols, the management of water, waste, and runoff is equally important for ensuring smooth and safe operations. 

Poor drainage systems not only increase the risk of contamination but can also disrupt productivity, create safety hazards, and lead to environmental damage.

Total Construction has worked closely with the food and beverage industry for decades, and during this time the company has built up expertise on how to best address drainage requirements in production facilities. 

“It’s up there as one of the biggest issues you find in primary industry,” said Rob Blythman, group general manager, Food & Beverage Division, Total Construction. 

“It quickly becomes an operational issue if the drainage isn’t right, and it’s not an easy fix.” 

When it comes to addressing the issue, Blythman’s advice is simple. – prevention is the best solution, which requires the correct planning. 

“The key is designing systems that can handle the waste properly,” said Blythman.

“You also need to focus on prevention and ensure that operational staff  clean up as much solid material before the floor is washed down.

“A lot of the time, people don’t realise the importance of adequate drain sizes and traps.

“Ultimately, a lot of these issues come down to production priorities. Many facilities are focused on the speed and output of production, not on how to effectively handle waste, water, and drainage systems. It’s tough to change these mindsets.”

Drainage: a key component of meat production

Australia’s meat processing sector is one of the largest in the world, with millions of cattle and sheep processed each year. 

Water plays a key role in cleaning, cooling, and processing meat. However, its use also generates waste, blood, fat, tissues, and other by-products that must be effectively managed. Without proper drainage, these waste products can quickly become a health and safety risk. As well as cause delays in production.

“Meat cuts are often washed down the drain and end up in the DAF plant, or blocking the drains which is not ideal,” said Blythman. 

“With that happening you could end up needing a larger DAF, which is extra cost, however if the right processes are implemented in clean up regimes, issues can be avoided. These things aren’t always taken into consideration when planning the facility.” 

If drainage systems are poorly designed or maintained, wastewater can accumulate, creating a breeding ground for harmful bacteria, including Salmonella, Listeria, and E. coli. 

Such contaminants can spread to meat products, production surfaces, and equipment, jeopardising both food safety and the facility’s reputation. As the global demand for safe and high-quality Australian produce grows, maintaining effective drainage systems is critical to meeting both domestic and international standards.

One way Total Construction helps clients mitigate these risks is with a propriety drain tray, designed to easily capture and remove meat cuts before they enter the drainage system and potentially cause damage. 

“We implemented a custom drain catch system for one client, which is designed to catch solid waste before it goes into the bucket trap. It’s essentially a large tray that can be lifted out for cleaning,” said Blythman.

“This allows staff to see when the drain is getting clogged, rather than waiting for it to fully block within the bucket trap. While it’s still in its trial phase, it’s already showing positive results.”

“Another problem is that companies often opt for cheaper drainage solutions, like smaller drains, because they’re cheaper upfront,” said Tony Tate, general manager, Food & Beverage Division, Total Construction. 

“But this often leads to more maintenance and bigger costs down the line. If we can implement pre-emptive solutions, like catchment trays or better waste management systems, it will save them money over time.”

Food safety risks

Food safety in Australia is governed by strict regulations to ensure the hygiene of meat products. However, even the most stringent protocols can be undermined by inadequate drainage. 

Wastewater that isn’t properly channelled can result in contamination, potentially causing costly product recalls, foodborne illness outbreaks, or loss of consumer trust.

Improper wastewater management is a contributor to contamination in meat processing facilities. When wastewater pools on the production floor, it can become a source of contamination, posing risks to both consumers and workers. 

The failure to maintain a functional drainage system is a failure in hygiene, with direct consequences for public health.

Downtime and reduced productivity

“Some industries, like chicken processing, have learned from past mistakes,” said Tate.

“They’ve invested in stronger, more durable drainage systems and trained their staff to handle waste disposal more carefully. However, some new operators skip staff training and don’t emphasise proper waste management practices.”

In addition to the direct costs of downtime, poor drainage also creates indirect financial risks. 

“Many facilities underestimate the costs and time required to plan and implement proper drainage systems. The pressure to get the plant running quickly often leads them to prioritise production over proper drainage,” said Blythman. 

“However, getting the drainage right from the start can prevent much larger and more costly issues later on.”

Meanwhile, contaminated production zones may require decontamination, further halting operations. A well-maintained drainage system ensures that production continues smoothly and safely, minimising both operational disruptions and associated costs.

Another way meat production can help mitigate the risks associated with the incorrect disposal of off-cuts is through leaning into a circular-economy approach. 

“Pet food companies are always looking for more meat off-cuts to use in their products,” said Blythman. 

“So, producers are able to turn a waste stream into added value if they do it correctly.” 

Managing wastewater 

Australia’s meat production industry operates in a water-scarce environment, with many facilities located in regions that face water resource challenges. 

As businesses face increasing pressure to reduce their environmental impact, managing wastewater effectively is a key component of sustainability.

“One of the biggest overlooked costs is effluent charges. Facilities are often billed based on how much waste goes down the drains,” said Tate.

“The more waste, the higher the charges. This ties back to good manufacturing practices, which should aim to keep waste out of the drains in the first place. If you can reduce the amount of waste, you’ll save on chemicals and plant maintenance in the long term.”

Improperly treated wastewater can contaminate local waterways, contributing to nutrient overload, algae blooms, and the decline of aquatic ecosystems. 

Meat processing facilities that fail to treat wastewater properly risk not only environmental damage but also legal and reputational consequences. 

Many facilities have already adopted advanced wastewater treatment systems, including biological filtration and membrane filtration, to ensure compliance with environmental regulations and reduce their ecological footprint.

As consumer demand for sustainable and safe meat production continues to rise, facilities that invest in effective drainage infrastructure will not only meet regulatory requirements but also enhance their competitiveness in the global market.

The future of Australia’s meat industry depends on its ability to operate efficiently, safely, and sustainably. Correct drainage is a fundamental part of that success, ensuring that Australian meat continues to meet the highest standards of quality and safety for years to come. 

Feature from Food & Beverage Magazine.