Contamination Control in the Food Industry

Visit our food industry focus site at www.foodprocessingvacuum.com

Industrial Cleaning Best Practices

Contamination Control in the Food Industry

Presenter:

Kim Kanis, Senior District Manager, Nilfisk CFM

2011

Overview

• Why Clean?

• A Common Enemy: Contamination

• Cleaning Methods: – Pros and Cons– Preferred Methods– Dry Cleaning Techniques

• HEPA-Filtered Industrial Vacuums

• Combustible Dust in the Food Industry


Contamination Control – Why Clean?

• GMPs

• HACCP

• Product Safety

• Product Quality

• Company Reputation

• Cost of Recalls

• Cost of Lawsuits


Contamination Control – Why Clean?

• The CDC estimates 76 million cases of foodborne disease occur each year in the United States, responsible for 325,000 hospitalizations and 5,000 deaths.

• Financial: the average food/beverage recall is $10 million.**Deloitte, GMA and FMI study, 2009.


Contamination Control - Threats

• Bacteria and viruses

• Parasites

• Allergens

• Rodents/pests

• Mold, toxins, and contaminants


Contamination Control


“We Live in a Microbial World”

The consequences of failure to attain adequate control of airborne microbial contamination can result in product spoilage and/or a foodborne disease hazard. Airborne bacteria counts will normally be greatest in dusty environments and can range as high as 10,000 organisms per cubic meter.

Source: Sanitation in Food Processing - Second Edition

Cleaning Methods

• Controlled Wet - minimal wet cleaning methods used as needed

• Wet - wet cleaning methods used for all standard cleaning procedures

• Dry - dry cleaning methods used for all standard cleaning procedures


Cleaning Methods


Dry Cleaning: The Preferred Method

Although microorganisms survive, they cannot grow in dry foods or in their equipment soils. To introduce water in any form into such a process is to court disaster. Therefore, for routine cleanup of dry food lines use only procedures such as vacuuming, wiping with clean cloths, brushing or scraping.

Source: Principles of Food Processing Sanitation

Dry Cleaning - Methods

• Brooms/Mops• Compressed Air• Shop-Style Vacuums• Central Vacuum System• HEPA Vacuums


Cleaning Methods - Tips

• Work from top down• Vacuum, brush or shovel to remove fines and dust• Use a scraper to remove excessive product buildup• Vacuum, brush or wipe to remove fines created by

scraping• If possible, integrate industrial vacuum into process to

collect excess dust during production run, packaging, etc.

• Sanitize as needed• Compressed air should not be used to substitute a

vacuum cleaner, brush or broom


Cleaning Methods

Dust removal is accomplished by use of:

1. Vacuum Cleaners

2. Brooms and Brushes

3. Compressed Air

These are given in order of preference. The vacuum cleaner must be used whenever possible. Compressed air should be used only where a vacuum and brushes will not reach.Source: AIB - Basic Food Plant Sanitation Manual


Brooms and Mops

Pros• Ease-of-use• Readily available• Inexpensive

Cons• Not effective for fine powder collection• Can disturb and spread dust, bacteria, allergens & insects• Limited to floor cleaning• Must be regularly cleaned and zoned for some areas• Mops introduce water and can leave residue• Cleaning water can become a source of contamination if not

changed frequently• Mops must be cleaned, dried and stored properly


Compressed Air

Pros• Ease-of-use• Useful in tight areasCons• Distributes contaminants in

compressed air system• Spreads fine dust, bacteria

and allergens everywhere• Does not remove fine dust• Blows dust into hard-to-reach

areas


Compressed air just moves dust from point a to point b; it does not eliminate the dust

Shop-Style Vacuums

Pros• Ease of use• Many are designed for wet and dry collection• Can be used to clean a variety of areas• InexpensiveCons• Not effective for fine powder collection,

bacteria, or allergen control• Motor burn-up (not cost-effective)• Many do not hold up well in industrial

environments• Loud• Static electricity build-up


Source: http://jc-coleman.com/shopvac-meltdown/

Central Vacuum Systems

Pros• Convenient to use• Powerful• Continuous-duty capabilities• Large collection capacity• Ideal for multiple operator use

Cons• System failure can leave many people without a way to clean• System cannot be used outside of immediate area• Piping can become blocked and/or contaminated• Cannot collect liquid; mold build-up in pipes• Can be expensive


HEPA-filtered Vacuums

Pros• Ease-of-use• Multi-stage filtration / HEPA

filtration captures bacteria• Multiple filter options • Many are designed for wet and

dry collection• Can be used to clean a variety

of areas (general maintenance and specialized applications)

• Many have unique filter loading indicators and filter cleaning options


Manual filter shaker removes caked on dust; maintaining performance

Nomex® filters and high-temp wands withstand hot ovens to remove crumbs, etc.


Pros• Continuous-duty

capabilities

• Multiple construction material choices

• Multiple vacuum performance choices including portable units and central systems


•Portable

•Wet/Dry

•Stainless Steel

•Three-Phase

•Pneumatic

•Drum-top

•EXP


Cons• Initial Cost• Problems can arise if dry-only HEPA vacuums are used

for wet collection• Some require filter changes between wet and dry use• Not all vacuums are created equal



Accessories• Food-grade• Color-coded• Wall/Overhead• Floor • High-temperature• Stainless• Bulk collection• Micro tools• Anti-static


HEPA-filtered VacuumsNot just for general maintenance…


Industrial vacuum decreases product loss by collecting pistachios that fell during transport from silo to plant.

Industrial vacuum removes excess product and fine dust from production line; can be integrated into line for continuous processing

Quickly collect bulk materials

Combustible Dust

• Food Industry is particularly under the microscope• OSHA NEP raises the issue of using “properly-equipped”

industrial vacuums as defined by NFPA 654.• Classed materials may require an “explosion-proof”

vacuum, as determined by Authorities Having Jurisdiction (AHJ, eg. building inspector, fire marshall, insurance agent).

• Often, a standard, non-EXP industrial vacuum cleaner is suitable for collecting “combustible dusts.”

• Remember, it is up to the AHJ to determine if your work area or facility is classified hazardous, which then determines the type of equipment you should use.

• Shop-style vacuums can add to the risk!



Air-operated Explosion Proof

Air-operated, Pneumatic Vacuums

• Powered by compressed air (Venturi principle)• No electrical components• No moving parts• Use when electricity is prohibited or unavailable

• Intrinsically Safe• Meet the requirements for use in Class II areas• Made of non-sparking materials• Conductive accessories• Grounded

Explosion-Proof Vacuums


• Certified as “Explosion Proof” by NRTL– CSA, UL, ETL– EXP rated TEFC motors– EXP rated sealed switches/connections– Internally/externally grounded (filters, body, tank, wheels,

etc.)– Conductive hose and accessories

• Beware of posers!– Some companies offer “dressed up” models with antistatic

accessories

• Remember, investing in the proper equipment is only one part of the equation. Inspect your facility to ensure you have proper safety measures in place, including Explosion Prevention (NFPA 69) and Deflagration Venting devices (NFPA 68).

Approved for use in Class I, Group D and Class II, Groups E, F & G

Resources

AIB ResourcesGeneral Websitewww.aibonline.org

Food Plant Sanitation Workshops https://secure.aibonline.org/php/ecomm-catalog.php?catalogNbr=392

FDA ResourcesAvoid a Recallhttp://www.fda.gov/Safety/Recalls/IndustryGuidance/default.htm

Federal Food Safetyhttp://www.foodsafety.gov/

Other Resources

Combustible Dust NEP:

www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=DIRECTIVES&p_id=3830

Nilfisk CFM Food Industry Focus Sitewww.foodprocessingvacuum.com


Contamination Control in the Food Industry

Technology

food industry focus

cleaning methods dry

contamination cleaning

cleaning methods dust

wet wet cleaning methods

floor cleaning

cleaning methods tips

residue cleaning water