Food-Safe Robots: Transforming Food Processing with Hygienic Automation

Food-safe robots, also known as hygienic robots or washdown robots, are revolutionizing how food is handled in manufacturing, hospitality, and healthcare settings. These robots are engineered with food-grade materials, smooth surfaces, and sealed designs that withstand rigorous cleaning, allowing them to operate in direct contact with food without harboring bacteria.

Industry adoption is accelerating: the global food robotics market is projected to reach $4 billion by 2028 (10.2% CAGR) amid labor shortages and high sanitation standards. In the United States, interest is surging in FDA-compliant automation and robotic food handling to boost safety and efficiency. Executives in food processing, food service, and healthcare are looking to these hygienic robots as a solution to contamination risks, throughput bottlenecks, and workforce challenges.

Key Applications Across Food Industry Segments

Food-safe robots are being deployed in diverse sectors of food production and service, handling tasks that once relied on manual labor. Key applications include:

• Meat & Poultry Processing: Robots carve and cut meats, debone poultry or fish, and perform butchery tasks in cold, wet environments. Primary processing of raw, unpackaged foods now often uses food-grade robots designed to withstand protein residues and sanitizing agents. This reduces human contact with raw product and maintains hygiene.

  
  

• Dairy, Bakery & Prepared Foods: Robots handle sticky or wet products like cheeses and dough, assist in tasks like icing cakes or slicing bread, and load ingredients into trays. Stäubli’s HE-series robots, for example, are used to customize meals and handle baked goods in high-speed lines.

  
  

• Produce Handling: Robotic pick-and-place systems with soft grippers sort fruits and vegetables. Robots minimize bruising and perform quality checks, improving throughput and reducing contamination.

  
  

• Packaging & Palletizing: Washdown-rated robots package goods and palletize beverages. ABB’s IRB 360 FlexPicker and Yaskawa’s MPL-series robots operate faster than human workers and are widely used in secondary processing.

• Food Service & Healthcare: Food-safe robots are emerging in restaurant kitchens and hospital food services, assembling salads, cooking, or delivering meals. In healthcare, they reduce contamination risks, especially for vulnerable patients. FDA-compliant robotic kitchen assistants manage prep tasks while adhering to food safety protocols.

Leading Manufacturers and Hygienic Robot Models

Several top manufacturers offer hygienic, food-safe robots tailored for the food and beverage industry:

• Stäubli: Their HE (Humid Environment) robots, like the TX2-60 HE and TS2 HE SCARA, feature stainless-steel surfaces, sealed housings, and food-grade lubricants. These are benchmark models for hygienic food-safe automation.

• ABB: Offers food-grade variants of IRB 360 “FlexPicker” and IRB 660 palletizers with IP69K-rated models. These robots use food-safe paint and gaskets.

• FANUC: Provides white epoxy-coated robots with USDA and FDA compliance. Models like LR Mate and M-430iA use food-safe grease and are sealed to IP67/IP69K standards.

• Yaskawa Motoman: Their HD series, including HD7 and HD8, meet EHEDG and ISO 14159 standards. Collaborative robots in the HC series also carry food-grade certifications.

• KUKA: Offers Hygienic Oil (HO) and Hygienic Machine (HM) robots. The KR Delta HM, for instance, meets FDA, EHEDG, and German LFGB standards.

Food Safety Protective Covers

In environments where full washdown-rated robots may not be feasible or cost-effective, food safety protective covers play a vital role in maintaining hygiene. These custom-fit covers are designed to shield robots and automation equipment from direct contact with food, water, or cleaning chemicals. Typically made from FDA-approved polyurethane, PTFE, or other non-porous, antimicrobial materials, these covers can be easily removed, cleaned, and sanitized. Protective covers are especially useful in facilities with variable sanitation needs or where retrofitting existing robots for full food contact is impractical. They also provide an additional layer of defense against dust, debris, and microbial buildup in splash zones. Companies like Roboworld and QSR Automations offer robotic protective sleeves and barrier systems that are NSF/ANSI-compliant, supporting safe operations in critical food zones. While not a substitute for hygienic robot design, these accessories extend the flexibility of robotic deployments in semi-clean or transitional environments.

U.S. Food Safety Regulations and Standards for Robotics

Adopting food-safe robots requires compliance with U.S. food safety standards:

• FDA Regulations: Food-safe robots use FDA-approved materials and lubricants that meet 21 CFR. Robots must be non-toxic, non-absorbent, and chemical resistant.

• NSF/ANSI 169: This standard ensures robotics meet sanitation requirements for both food and splash zones. Robots like Doosan’s E-series cobot are certified under NSF/ANSI 169.

• ISO 14159: Addresses hygienic design for machinery, ensuring equipment can be cleaned thoroughly and won’t become a contamination source.

• EHEDG Guidelines: Provide design best practices for cleanable food equipment. Stäubli and other manufacturers build robots aligning with EHEDG principles.

• Other Standards: 3-A Sanitary Standards (dairy), BISSC (bakery), and IP ratings (IP67, IP69K) are also important. High IP ratings ensure robots can be cleaned to sanitation SOPs.

Cost Considerations for Food-Safe Robotic Systems

Food-safe robots typically carry a premium but offer strong long-term ROI. Key cost factors include:

• Base Unit Price: Robots range from $20,000 to $100,000+, with food-grade versions adding 10–30% to the cost.

  
  

• Integration Costs: Turnkey systems, including tooling, safety enclosures, vision, and programming, can range from $100,000 to $300,000+. Simple bakery tasks may cost under $50,000 all-in.

• ROI and Labor Savings: Robots operating 24/7 can replace multiple shifts of labor. Many companies see ROI in 1–3 years. Avoiding a single contamination event can offset initial costs.

• Used Options: Refurbished food-grade robots are sometimes available at 50% of new cost. Leasing or modular setups can reduce capital burden.

Benefits: Hygiene, Throughput, and Labor Optimization

Deploying food-safe robots provides:

• Reduced Contamination Risk: Robots minimize human contact, localize contamination risk, and clean more easily. Unlike humans, they never forget to wash their hands.

• Improved Throughput: Robots work 24/7 with consistent quality. They improve packaging accuracy, reduce rework, and prevent bottlenecks.

• Labor and Ergonomics: Robots take on dirty, dangerous, or dull jobs, reducing injuries. Workers can be reassigned to supervisory or quality roles. In healthcare and hospitality, food-safe robots automate prep and delivery.

Conclusion: A New Era of Hygienic Automation

Food-safe robots have matured into robust, regulation-compliant, and cost-effective tools. With FDA-compliant automation and food-grade robotics from trusted brands, manufacturers and service providers are improving food safety, meeting labor challenges, and boosting efficiency. In today’s competitive landscape, food-safe robots are no longer a luxury—they are a necessity for future-ready food and hospitality operations.