Case Study UV-C Technology Revolutionizes Hygiene Standards in Meat Processing
As one of the largest slaughterhouses in Germany, SIMON-Fleisch GmbH faces the daily challenge of combining the highest hygiene standards with responsible use of resources. Until 2021, the required hygiene levels were ensured through energy-intensive hot water sterilization, extensive use of chemical disinfectants and time-consuming intermediate cleaning processes.
At a company of this scale, these conventional methods resulted in significant personnel, material and energy costs. In addition, they posed risks to employee safety and could interfere with stable production workflows.
With the introduction of modern UV-C disinfection systems from Hoenle AG, the Wittlich-based company was able to successfully overcome these challenges. The installed conveyor belt and knife sterilization systems operate temperature-neutral, chemical-free and continuously during ongoing production.
They achieve a 99.99% reduction of microorganisms, significantly reduce electricity and water consumption and noticeably improve occupational safety — all without disrupting production processes.
High Energy and Chemical Consumption in Disinfection: SIMON-Fleisch Adopts UV-C Technology for Safety, Efficiency and Sustainability
UV-C Conveyor Belt and Knife Disinfection with a 99.99% Inactivation Rate
“Ensuring consistent hygiene throughout the production process used to require enormous effort. Frequent intermediate cleaning steps, high energy consumption and the use of chemicals were part of our daily routine.” – reports Tim Reuland, Head of Quality Management at SIMON-Fleisch GmbH.
“With the systems from Hoenle UV Disinfection, we were able to significantly reduce these burdens across the entire production process while simultaneously increasing our safety standards.”
UV-C Technology Supports Strict Internal Hygiene Standards and Ensures Product Safety
With an annual production capacity of around 100,000 tons of meat, SIMON-Fleisch GmbH requires the strictest hygiene controls, not only to comply with legal regulations but often exceeding them. The management team recognizes that food safety beyond statutory requirements forms the foundation of the company’s success. This commitment is reflected in their openness to innovative technologies that improve both production processes and product quality while ensuring higher safety standards.
At the same time, growing consumer awareness and stricter requirements from retailers and authorities have driven continuous evaluation and improvement of production processes. Against this backdrop, SIMON-Fleisch sought solutions that were not only more reliable but also more economical and safer.
The choice ultimately fell on Hoenle AG’s UV-C technology, which enables continuous disinfection without chemicals, water or heat. In 2021, the first UV-C conveyor belt disinfection systems were installed in the cutting department. In 2023, the implementation continued with MD3S knife sterilizers in the slaughtering area to further ensure compliance with internal hygiene standards, which go well beyond legal requirements.
From Hot Water and Chemicals to Continuous UV-C Disinfection
Before the introduction of the MD3S knife sterilizers, sterilization in meat production was a labor- and resource-intensive process. Conveyor belts were cleaned only at scheduled times, using large amounts of chemicals. Intermediate cleanings during shifts were unavoidable, as otherwise the microbial load on surfaces posed a risk to food safety. These production interruptions were not only time-consuming but also generated significant costs and required high material and personnel input.
For knives, which are indispensable in the slaughtering process, hot water sterilization was previously used. While this was an established method, it had several disadvantages. Energy and water consumption were extremely high, the knife cleaning systems required intensive maintenance and employee safety was compromised due to the risk of scalding and escaping steam. Additionally, the steam could enter production areas, creating an additional hygiene risk.
UV-C Technology Secures Work Processes, Protects Employees and Saves Resources
With the commissioning of the first conveyor belt sterilizers in 2021, SIMON-Fleisch GmbH successfully stabilized its internal hygiene chain.
“For us, it is crucial that cleanliness and process reliability no longer depend on interruptions or manual interventions. Our UV-C systems enable a stable, predictable production flow — and with significantly fewer resources.” – explains Lars Zigann, Sales Manager at Hoenle Disinfection.
Downtime for intermediate cleaning has been completely eliminated, making production processes more efficient and predictable. In 2023, the MD3S knife sterilizers were installed in the slaughtering area, fully replacing the previous hot water sterilization method. This has led to significant reductions in energy and water consumption, lower maintenance costs and improved employee safety, as there is no longer any risk of scalding or exposure to steam. The integrated rinse cycle eliminates the need for manual washing, saving time and increasing operational efficiency.
Notably, the systems achieve a 99.99% microbial reduction, ensuring a high level of safety even against pathogens that may be resistant to conventional methods. Operating contactless and temperature-neutral, the UV-C technology provides a decisive advantage in sensitive production processes. The positive effects are reflected not only in enhanced food safety but also in operational cost savings, as reduced consumption of chemicals, energy and water supports sustainable and cost-effective business operations.
Close Coordination and Reliable Service Ensure Hygiene and Smooth Production
The successful collaboration between SIMON-Fleisch GmbH and Hoenle Disinfection is based not only on the quality of the products but also on the partnership-oriented approach of both companies. From the very beginning, great importance was placed on close coordination with the responsible teams in Wittlich. Through multiple on-site visits and a comprehensive analysis of the production environment, tailor-made solutions were developed specifically for SIMON-Fleisch.
“The consulting was transparent, professional, and practical, allowing us to make the decision to implement the systems on a solid foundation. Even during ongoing operations, the team at Hoenle Disinfection Austria has impressed us with their reliable service,” says Tim Reuland.
Scheduled maintenance appointments are reliably adhered to, and reference measuring devices are available for individual process and system checks. This form of after-sales support ensures that the systems always operate at optimal performance, potential production interruptions are minimized or avoided entirely, and, above all, the strict hygiene requirements are consistently met.
The collaboration between the two companies will soon continue with new projects at various locations. The planned introduction of systems for air circulation and evaporator disinfection will further strengthen the hygiene chain at SIMON-Fleisch GmbH. These new systems will enable even more comprehensive coverage of production areas and contribute to securing the company’s high hygiene standards over the long term.
“For us, this represents a consistent entrepreneurial advancement of our hygiene strategy — delivering even greater safety, resource efficiency and sustainable business practices,” explains Tim Reuland.
For Hoenle Disinfection, as part of the Hoenle Group, these projects reaffirm its commitment to setting new standards in the food industry as an innovative company. Together with SIMON-Fleisch GmbH, the latest UV-C technologies demonstrate that they not only address current challenges but also provide solutions for future requirements.
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