Cleaning Sanitizing

7/30/2019 Cleaning Sanitizing

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Cleaning & Sanitizing To ControlMicroorganisms

Tom BouffordSeptember 30, 2009

Back To The Basics


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Discussion Topics

\ General cleaning considerations Causes of product Issues and Back To The Basics Steps in developing a cleaning program

Master Sanitation Program

Cleaning procedures Soil types Soil removal detergents Four Factors of Cleaning

\ Methods of wet and dry cleaning

\ Sanitizing\ Validation & Verification


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NO perfect and easy

solution to consistentproduct quality & safety

\ No Miracle in a drum

\ No Silver bullet

\

Not even irradiation is aperfect solution

MiracleIn ADrum


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Need:

Problems may not be prevented / resolved

solely by a new piece of equipment

\ Good Sanitary Design

\ Proper Operation

\ Effective Sanitation

\ Proper Maintenance


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Microbial Contamination Control

\Prevent Entry

Must control incoming contamination Employees, Ingredients, Packaging

\Prevent Growth Keep it dry, Keep it cold, Keep it Clean and use Sanitizers

\Prevent Establishment Eliminate Niches/ Harborages

Sanitary design & maintenance

\Prevent spread

Control Vectors

Stop means of transmission

Requires multiple interventions


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Causes of product quality & safety issues

#1 Human error(Training, Supervision, Accountability)

2. Poor equipment sanitary design and maintenance

3. Inadequate Cleaning & Sanitizing(often relates back to #1 & #2)

4. Ingredients / Raw Materials (relates back to #1 - #3, just at a different location)

Get Back to the Basics


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Microbial Control

\ 99% of microbiological problemsare sanitation related problems.



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SANITATION DEFINED

\ Cleaning Technologies / Methods

\ Sanitizing Technologies / Methods

\

People / Training / Practices\ Sanitary Design & Maintenance

Sanitation


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Improve Product Safety

\ Effective & regular sanitation program Cleant Sanitizet Verify

\ Sanitary equipment design & preventativemaintenance

\ GMPs - hygiene practices, traffic control, facilities& equipment

\ Verification - monitor results & document

\ Communicate & respond to all employees

\ Training / Education

\ Participation, Accountabil ity & Commitment Management Supervisors All Employees



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First Step: Requirements for developing

an effective sanitation program

\ Review Equipment Construction, Composition & Maintenance Follow Manufacturers Recommendations / Warranty How is the equipment designed to be cleaned?

\ Knowledge of Type & Nature ofSoil and Microorganisms of Concern

\ Adequate Quality Water Supply Water Chemistry, Volume, Pressure, Temperature

\ Knowledge of Cleaners & Sanitizers

\ Proper Application Equipment

\ Understanding of 4 Factors of Cleaning

Time, Temperature, Concentration, Mechanical Action\ Understanding Environmental Issues

\ Trained, Responsible & Properly Supervised Personnel


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Next Step:

Make sure you have and are following these:

\ Master Sanitation Program Critical foundation of all sanitation programs Scheduled routine cleaning and preventative maintenance

\

Written cleaning procedures\ Sanitation Standard Operating Procedures - ( SSOPs )


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Example: Master Sanitation Schedule


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Example: Daily Cleaning Procedure

Questar CAF

Questar CAF


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Plant: Date:

Processing Area: Revision Date:

Equipment:

Cleaning Frequency:

Task Description

Chemicals

Required

Chemicals

Used

Cleaning

Equipment

Completion

Check L istI. Preparation:

1.

2.

II. Pre-Rinse

3.

III. Application of Cleaning Chemicals

4.5.

6.

7.

8.

IV. Post Rinse:

9.

V. Inspection of Equipment10.

11.

VI. Sanitizer Application12.

Approved by: _____________________

Date: _____________________

Example: Sanitation SOP (SSOP)


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Cleaning


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Microbial control programs require

effective cleaning and sanitizing

\ Cleaning Process of removing soil (food residue, microbes, etc.)

\

Sanitizing Process that destroys microorganisms after cleaning Also acts as a final additional rinse to physically remove allergens


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Why should cleaning & sanitizing

be carried out as two steps ?

\ Soil may chemically inactivate the sanitizer

\ Soil may physically shield microorganisms from thenecessary direct contact with the sanitizer.

The presence of any residual soil can chemically orphysically impair the efficacy of sanitizers.


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BasicsWhat is Cleaning?

\ Food product residue\ Water components\ Airborne contamination\Transient soil from workers\ Detergent ingredients\

Microorganisms

Removal of all unwanted material on a surface.


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What is soil &

how do we classify it in the food industry?

Organics

Protein

Fat

Carbohydrates

Inorganics

Mineral salts

Soils generally are not a pure composition,but a mixture of all of these.


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Soil Classification - Solubility

\ Water Soluble Salts & Sugars

\ Water Insoluble Alkali Soluble

Fats & Oils, Complex Carbohydrates Alkali / Oxidizer (Chlorine) Soluble

Protein Acid Soluble

Inorganics/ Minerals

Complex Carbohydrates

Heat Denatured Protein

\ Water Insoluble & Acid / Alkali Insoluble Fiber (Cellulose), Carbon, Titanium dioxide (TiO2)


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Soil removal

- Detergents


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Basics: what is cleaning?

Four Phases ofWet Cleaning:

\ Soil penetration - Surface wetting

\

Soil dispersion\ Soil suspension

\ Prevent re-deposition of removed soil


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How do we most efficiently &

effectively clean and remove all of these typicalfood soil components?

\ Using a builtdetergent!


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Detergent builders

\ Alkaline builders (alkaline detergents)

\ Acid builders (acid detergents)

\ Surfactants

\ Oxidizing agents, e.g. chlorine

\ Enzymes

\ Water conditioners

Substances that increase cleaning power of water


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Formulated / built detergents

\ Handle variety of soils Soils generally are not a pure composition

\ Handle various water conditions

\ Clean with less caustic Lower alkalinity Lower pH Less rinsing needed to bring to neutral

\ Better at biofilm removal (Antoniou & Frank. 2005. J FP 68(2):277-281)

Optimized chemistry = Cleaning efficiency & efficacy


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Soil Removal(Detergent components & what works best)

\ Fat / Oil / GreaseTemperature - Important in removal of all soils,

but especially with fats & oils. Surfactants Alkaline

Solvents

\ Protein Alkaline Chlorine & Other Oxidizing Agents Protease Enzymes

Possible Protein Film - Bluing


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Soil Removal(Detergent components & what works best)

\ Carbohydrates Simple Sugars

Water

Complex Carbohydrates (e.g. Starches)

Alkaline Some acids depending on conditions, e.g. sulfamic acid

\ Inorganics - Minerals Acids Chelators & other water conditioners


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Concentration

Temperature

Time

Mechanical Force

Four Factors of Cleaning = Clean


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Cleaning Methods

e.g. Manual cleaning

Time

Mechanical Force

Temperature

Concentration

Cleaning element ratios depend on the cleaning method

e.g. Foam c leaning e.g. Soak cleaninge.g. CIP cleaning


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Cleaning Basics

\ Best results All cleaning factors are optimum for the

specific method of cleaning.

\ One factor missing, eg. Temperature

Chemical concentration, mechanical, ortime must be increased substantially

\Two factors missing, eg. temperature& mechanical force

Effective cleaning is very difficult toachieve unless soil is very light!


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Poor sanitary design and maintenance

will negate the best cleaning program!


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Cleanable Design ?

\ We cant expect chemistry alone to EFFECTIVELY

clean soil loads or locations like these!


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Cleanable

Design ?

\ Eqiupment has to

been cleanable withreadily available tools

and within the time

allotted !


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z

How do you cleanthese areas and

keep them from

becoming a sourceof contamination ?

CleanableDesign ?

\ Dissimilar materials

bolted together


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Scraper Bar Cannot be or isnt removed

for daily cleaning


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Eliminate Hollow Rollers Install Solid Rollers


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Accessible !

\ To assure cleanabili ty andallow appropriate inspection,areas must be accessible.

If you cant see it, or cant reach it,it probably does not get clean.


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Cleaning

Methods


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WET cleaning vs. DRY cleaning

\ Distinctly different - each have unique issues

\ Same Goal - clean equipment

\ Same Problem - sanitation verification

Key Points:\ Keep dry areas dry!

\ Controlled wet cleaning in both

wet and dry facilities.


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Self draining

\ Remove water quickly and thoroughly dry

7 f ff i WET i i


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7 steps of effective WET sanitation

\Secure equipment and Dry Clean

\Pre-rinse

\Soap and Scrub

\

Rinse and Inspect\Assemble & Prepare for Pre-Op

\Pre-Op Inspection & Cleaning Verification

\Sanitize EPA Registered Food Contact Surface Sanitizer

P id P N E i t


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Provide Proper Necessary Equipment

Cl i T l


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Cleaning Tools

Make sure cleaning tools

do not become a source ofcontamination!

No wood brushes No brushes having natural

fibers or steel bristles No sponges or porous

cleaning devices

Cl i T l


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Cleaning Tools

Clean, sanitize, air dry & store properlyOr discard after each use, e.g. green pads.

Make sure it is clear


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Make sure it is clear

what should be used where.

Isolate tools used in raw/ pre-cooked areas from cooked areas!

Wet cleaning methods


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Wet cleaning methods

Manual Cleaning


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Manual Cleaning

\ High Physical Action

\ Good For Small Areas

\ Labor Intensive

Bucket & Brush

Foam Cleaning


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Foam Cleaning

\ Generally used where CIPis not practical Exterior of equipment Environmental cleaning

\ Foam application equipmentmust be adjusted properly Foam consistency not too wet or too dry

\ Potential shortcomings: Dries in 5-10 min and can be hard to remove

If foam dries it is not free rinsing

Future Greater use of


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Benefits:

Future Greater use of

automated cleaning

\ Reduce time of cleaning

\ Control / reduce cost of cleaningImprove efficacy of cleaningImprove consistency of cleaning

\ Eliminate human error factor! Improves and helps ensure the consistency of

cleaning!

Clean Out Of Place (COP)


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Clean - Out Of - Place (COP)

\ Disassemble equipment

\ Place parts in COP tank

\ Run wash cycle

\ Reduces human error

Semi-automated - the Washing Machine

Effectiveness of COP tank cleaning


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COP = More consistent effective cleaning!

Effectiveness of COP tank cleaning

In plant evaluation results:

\ Processed food plant installed COP tank for parts cleaning.

\ Shelf-life target: Line 1 - No COP tank 67.3%

Line 2 - COP tank used 98.9%

COP Concerns


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COP Concerns

\ Must avoid flow restrictions Proper parts baskets Proper tank sizing

Equipment must fit in tank

\ Need to overflow tank to prevent re-deposition of soil that isremoved.

Disassemble all parts before putting


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Disassemble all parts before putting

in COP tank

Ensure that the COP tank is


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Ensure that the COP tank is

sized properly

Provide proper storage for parts


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Provide proper storage for parts

Store clean parts so that they stay clean!


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Store clean parts so that they stay clean!

Clean - In - Place (CIP)


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Clean In Place (CIP)

\Equipment is designed to beCIP cleaned.

\Equipment is notdisassembled duringcleaning.

\Effective, repeatable cleaning& sanitizing

\Reduces human error

Fully automated cleaning & sanitizing

CIP cleaning pipe lines


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g pp

\ Flow rates critical for effectiveness < 5 ft. / second = Laminar Flow

> 5 ft. / second = Turbulent Flow

\ Pipe size vs. flow rate 1.0= 10 GPM 2.5= 69 GPM

1.5= 23 GPM 3.0= 101 GPM 2.0= 43 GPM 4.0= 184 GPM

CIP cleaning Tanks & Vessels


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CIP cleaning Tanks & Vessels

Spray Ball Sizing & Maintenance

Routine Inspection &


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p

Maintenance Neglected

Spray Ball Maintenance

Monitor Performance


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\ Automatic Monitoring Time Temperature Concentration Flow Rate Volume

\ Verify the record & assessneed for corrective action

Dry Cleaning: 101


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Dry Cleaning: 101

\Basic Rule of Thumb: If the environment is dry, keep it dry.

\ Ifany moisture is introduced into or forms in a dry area atany time, having a method that quickly and thoroughlyremoves/dries this moisture is an absolute necessity.

7 steps of effective DRY sanitation


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\Sanitation preparation

\Secure & disassemble equipment\Dry clean

(any isolated wet clean ensure completely dry before returning

\

Detail clean Work top down\Post inspection & reclean

\Pre-op Inspection, cleaning verification & reassembly

\Sanitize Non-aqueous EPA registered food contact surfacesanitizer

Dry Cleaning Methods


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\ Sweeping

\ Brushing / Scraping

\ Vacuuming

\ Blowing Compressed air

\ Blasting -Not recommended

blows soil around, notcontained and captured.

Examples of Blast Technologies


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\ Soda Blast Sodium bicarbonate

\ ExaStrip SensiClean Calcium carbonate

\ Dry Ice Blast Cold J et Dry ice pellet

Cleaning capabilities of Blast Technologies


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\ Soda Blast Hard inelastic soils

\ ExaStrip SensiClean Hard inelastic soils

\ Dry Ice Blast Hard inelastic soils Soils that freeze harden

Overall conclusions


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regarding blast cleaning

\ High upfront equipment costs

\ Excellent on hard tenacious inelastic soils

\ Less effective on some soft or elastic soils

\ Point of site cleaning limitations what you can see and reach

\ Significant environmental impact - Soil transport to other

surfaces

\ Post-blast cleanup required

\ Need for an attached vacuum system

Low Pressure Steam - AmeriVap


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\ Benefits Moderate capital cost Allows for use of wet chemistry High temperature - sanitizing No dust No media

\ Limitations Steam vapor Residual water Adequate electrical supply May not work on some soils


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Sanitizing

Effective cleaning MUST precede sanitizing


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Concentration

Temperature

Time

Mechanical Force

\ Sanitizing is not a substitute for good housekeeping andthorough cleaning!

United States


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Environmental Protection Agency

\ FIFRAFederal Insecticide, Fungicideand Rodenticide Act

\ 40 CFR 180.940

\ Antimicrobial efficacy data\ Product chemistry

\ Toxicology data

\

Label & technical literature

Antimicrobial division & sanitizer registration


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EPA Reg. No. 1677-58

Sanitizing Food Contact Surfaces


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Be sure to read the label carefully and


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DIRECTIONS FOR USE:

It is a violation of Federal law to use this product in

a manner inconsistent with its labeling.

follow the Directions For Use!

Ensure correct sanitizer concentration


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Critical for:\ Efficacy

\ Compliance with the law

Document & record results

Final step:


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Wet areas - flood sanitizing

\ Flood Sanitize Using aCentral Sanitizer System Ensures complete surface coverage

\ Last thing to be done Everyone out of the room. No other activity going on in the room. Leave sanitized equipment alone!

Final Step:


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Dry areas - sanitizing

\ Eco-Wipe FCS EPA-registered quat/alcohol based ready-to-use sanitizing wipes

\ RTU Surface Sanitizer EPA-registered, ready-to-use quat/alcohol sanitizing and disinfecting

solution

\ Sani-Step EPA-registered, solid, granular quaternary floor sanitizer

Disposable Hard Surface Sanitizing Towel


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\ QAC + Alcohol

RTU SURFACE SANITIZER


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\ Ready To Use\ No-rinse food contact surface sanitizer

\ QAC + Alcohol

SANI-STEP


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\ Granulated QAC non-foodcontact surface sanitizer floor treatment

\ EPA Registered

\ Listeria andSalmonellaefficacy claims

Steps to Insure Quality/Safety


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\ Personal Hygiene GMPs Uniforms & Footwear Hand Washing and Sanitizing Proper glove use

Cleaning and sanitizing efficacy


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validation & verification

\ Validation Microbiological

\ Verification

Sensory Microbiological ATP

Cleaning Verification


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Black Light Protein Stain

Visual / Sensory

\ Immediate\ Often over looked

\ Aids

Flashlights Spot lights Black lights Soil identification test kit

\ Sensitivity?

Cleaning Verification


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Microbiological

\ Specific pathogen testing\ Aerobic plate count


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ATP

\ Real time results Make immediate decisions Take proper corrective action

\ More sensitive than visual

\ Ensure Proper Effective

Cleaning Program Proper product selection Proper product use Minimize areas omitted ID problem areas equipment

design & maintenanceTraining/ monitoring employees

Proactive Construction Program


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\ Develop a Formal Program: Implement construction SOP GMP training of contractors and their employees Isolate area Reroute traffic

Record what happened & when in daily log Extraordinary deep cleaning and sanitizing

3 Cs of cleaning = Microbial control

B k T Th B i


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Back To The Basics

\ Correct Correct Chemicals Four Factors of Cleaning Correct Method of Application Correct Employee Practices

\ Complete

Every square inch of all surfaces Cleanable equipment - Good sanitary design & Maintenance

\ Consistent Done correct and complete consistently each and every time!

\ s = SANITIZE EPA Reg. Food Contact Surface Sanitizer

What you can do immediately


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\ Look at your entire process with a critical eye: Know where microorganisms are introduced

Reassess the cleanability of equipment Ensure proper routine maintenance

Select proper detergents and sanitizers based on the facilities needs Validate and verify effectiveness of cleaning and sanitizing program


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Thank You!

Cleaning Sanitizing

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