Food processing plants demand the highest hygiene standards. The Flyability ELIOS 3 inspects mixing tanks, silos, brew kettles and process vessels without human entry – no contamination risk, HACCP-compliant documentation, and no production interruption. Since 2017.
Food processing operations are subject to one of the most demanding hygiene regimes in industry. The EU Food Hygiene Regulation (EC) No. 852/2004, IFS Food and FSSC 22000 standards, as well as the operational HACCP (Hazard Analysis and Critical Control Points) concept define clear requirements for every object, tool and person that comes into contact with product-contact areas.
A drone deployment in a food processing facility must fully meet these requirements. The key points:
Foreign body prevention: Loose parts, screws, coating abrasion or lubricants must not enter product-contact areas. Before deployment, the ELIOS 3 is checked for loose parts and damage. A written checklist protocol documents the condition before and after each mission.
Cleaning and disinfection: The drone is cleaned with food-approved cleaning agents. In operations with disinfection requirements (e.g. dairies, breweries), additional disinfection is performed.
HACCP documentation: The drone deployment – particularly in CCP-relevant areas (Critical Control Points) – is documented in the facility’s HACCP plan and hygiene protocols.
The food industry operates a wide variety of vessels, silos and process equipment that must be regularly checked for internal condition. Kopterflug inspects:
Breweries are a particularly illustrative example of the requirements for drone deployments in the food industry. Modern breweries operate fermentation tanks with volumes of 500 to 10,000 hectolitres – cylindroconical unitanks made of stainless steel or historic wooden cask vessels. These vessels are inspected by drone after the regular cleaning cycle (CIP – Cleaning in Place) for their internal condition before being refilled.
Typical inspection findings in brewery tanks:
Historic wooden and concrete vessels (lager cellars, stoneware storage silos) can be inspected by drone for cracks, leaching and hygienic condition – conventional confined space entry methods are difficult in these often low-ceilinged and narrow spaces.
In hop silos and malt stores, particular caution applies due to dust explosion risk (Ex Zone 21 for malt dust). Gas measurement and dust concentration measurement before deployment are mandatory here.
Compliance with hygiene standards begins before the deployment day and ends with HACCP-compliant documentation:
Yes. The ELIOS 3 deployment follows a defined hygiene protocol: the drone is cleaned with food-approved agents before each mission. A written foreign body checklist documents the drone’s condition before and after the flight. The entire deployment is documented in a format suitable for IFS Food and FSSC 22000 audits. The inspection takes place exclusively in emptied, cleaned vessels – never during active production.
Before every deployment, the ELIOS 3 undergoes a systematic completeness check: all parts, screws and components are inspected for secure attachment and damage. Any loose or damaged elements would halt the mission. After the flight, the same check is repeated. Both checks are documented in a written protocol that becomes part of the HACCP documentation.
Typical inspection objects include: stainless steel mixing tanks and process vessels (dairies, beverage plants), grain and flour silos (mills, baking industry), brew kettles and fermentation tanks (breweries), sugar towers and crystallisers, piping bridges and transfer channels, and drying systems and exhaust ducts. The ELIOS 3 fits through openings from 50 × 50 cm.
In areas with dust explosion risk (e.g. Ex Zone 21 for grain or malt dust), gas measurement and dust concentration measurement before deployment are mandatory. The ELIOS 3 is designed for confined spaces and minimises turbulence. However, a thorough ATEX assessment must be carried out before each deployment in potentially explosive atmospheres.
The inspection report is delivered in a format compatible with IFS Food, FSSC 22000 and internal HACCP documentation. All findings are classified with photographs and action recommendations. The foreign body protocol, cleaning documentation and flight log are handed over for archiving in your quality management system.
The drone is always cleaned with food-approved agents before deployment. Additional disinfection is performed when required by the facility operator – for example in dairies, breweries or other operations with specific disinfection protocols. The cleaning and disinfection procedure is coordinated with the facility’s quality assurance team in advance.
Typical findings include: weld seam corrosion, coating damage (epoxy, phenol linings), dead-space areas with insufficient CIP effectiveness, deposits and discolouration, condition of fittings (agitators, spray balls, sensors), and general internal wall condition. All findings are documented in 4K with precise position reference.
A single vessel inspection typically takes 15–45 minutes depending on size and complexity. Multiple vessels can be inspected in a single day. The overall time saving compared to conventional confined space entry methods is significant – no scaffolding, no PPE donning procedures, no complex safety chain required.
Do you need HACCP-compliant drone inspection in your food processing facility? Describe your operations and the vessels to be inspected – we will develop a tailored, hygiene-compliant inspection concept.