Sanitation and GMP Controls for Listeria. Listeria Controls Sanitation, Good Manufacturing Practices, and Employee Training Programs are the key elements.

Sanitation and GMP Controls for

Listeria

Listeria Controls

Sanitation, Good Manufacturing Practices, and Employee Training Programs are the key elements of an effective Listeria control program!!!!

There are no “magic bullets” for Listeria control

Sanitation & GMP controls provide a series of hurdles that prevent or minimize contamination

Sanitation Goals

Minimize contamination coming into plant

Prevent cross contamination by people, products and equipment in the plant

Eliminate in-plant niches and contamination sources where and when they are found

Prevent contamination of finished products during processing and packaging

Start by Evaluating:

1. The potential for cross contamination associated with your plant ‘s:

Process & Product FlowDesign & Layout of operationsMovement of people and equipment

2. Where there are potential niches for Lm to establish itself in your plant

3. How effective are Routine and Intensive Cleaning & Sanitizing procedures

4. Employee hygiene & food handling practices

Evaluate Design & Layout of Processing Operations

How Linear is Your Product Flow ?

Is there adequate separation of raw products & processes from finished products & processes?

Process Flow

Receive Product

Cook

Cool

Pick tail meat

Weigh

Package

Chill

Pack

Finished Product Storage

How Is Your Plant “Zoned”?Establish successively cleaner processing zones

“Dirty Zone” – Where raw product is handled. E.g. receiving, storage, cooking

“In-Process Zone” – Intermediate steps in the process. Crawfish picking

“Clean Zone”–Where finished product is handled, processed and packaged. E.g. weighing, vacuum packing, chilling

Evaluate the location of all processing steps Raw or semi-processed products handled in the “dirty” side of the plant must be separated from locations where finished products are handled or processed in the “clean” side of the plant.

Where do Process Steps Occur

In the Plant ?

Evaluate Traffic Flow: Movement of People & Equipment

Prohibit entry of people, equipment, packaging etc. into finished product areas from outside the plant.

Control movement of equipment and people between raw and finished product areas

Assign equipment, people & cleaning tools to finished product areas only

Control Strategy Options: People

Discourage traffic between finished product (“clean”) areas & raw product (“dirty”) areas.

Require all employees (including supervisors, office workers, management, delivery people & visitors) to wash hands & change outer garments before entering the plant.

Do Not Enter

Control Strategy Options: People … continued

Restrict movement of employees and visitors from raw product or “dirty” areas to finished product or “clean” areas.

When this is not possible, minimize traffic to the extent possible and use strict controls (wash hands, change outer garment, use footbaths etc.) before entering finished product handling areas.

Before You Go Through this Door

Control Strategy Options: People

Require employees to use dedicated & easy to clean footwear in the plant.

Require the use of a foot bath or chemical foam barrier when moving from “dirty” to “clean” areas.

Control Strategy Options: Equipment

Prohibit movement of equipment between finished product (“clean”) areas & raw product (“dirty”) areas.

Wherever possible use designated items like containers, utensils, tools, trash barrels etc. in finished product areas and don’t move them

to other areas of the plant.

Control Strategy Options: Equipment -continued

Separate operations physically if possible or separate by timing the movement of product to prevent cross contamination

Processing

Room

Cook

Room

Chute

Training and Monitoring

1. Develop and finalize new procedures and policies as necessary.

2. Assign supervisors, team leaders etc. to monitor performance and ensure that new procedures or policies are implemented properly.

3. Implement a system to reward or recognize compliance and/or penalize for non compliance

4. Train employees to ensure that they understand what is expected, why it’s important, and what impact/consequences their performance will have.

Find and Eliminate Listeria monocytogenes (Lm) Niches

Niches are places in the plant where Lm persists and grows over time.

Niches can occur anywhere there are cracks and crevices that can accumulate bacteria, water, & nutrients (food debris) and are hard to reach with cleaning tools & sanitizer.

Lm can form biofilms in these niches that protect it from the environment.

Find and Eliminate Listeria monocytogenes (Lm) Niches

Normal cleaning and sanitation procedures may not be effective when Lm has colonized a niche.

During operation, Lm can work its way out of a niche and contaminate equipment & products as they move downstream in the process.

Bacteria like Listeria can form a biofilm to protect themselves

Potential Reservoirs or Niches of Lm

Floors & Floor Mats Drains

Cleaning Tools Blowers & Chillers

Other Potential Sources of Lm

Baskets Chutes Counters Scales Packaging

Equipment On/Off Switches Rubber seals on

doors

Trash/waste receptacles

Floors with standing H2O

Condensate traps Ice makers Underneath Cleaning

table

Sanitation Procedures

Routine Cleaning & Sanitation Procedures are essential to eliminate new day-to-day Listeria contamination that continually comes into the plant with product, people, supplies, and/or equipment.

Intensive Cleaning & Sanitizing Procedures are used to eliminate Listeria monocytogenes niches where and when they are found.

General Cleaning and Sanitizing Procedures

Step 1 – Remove exposed products

Step 2 – Dry clean & sweep areaRemove garbage, food debris & other waste

Step 3–Wet down area to be cleaned

Step 4(a) – Apply detergent

Applying Detergent with Foamers

Courtesy Hydro Systems Company

Step 4(b)- Scrub area vigorously

Be sure to use the right amount of Sanitizer:

Use Test Strips

Areas to be Sanitized with Quats or Peracid Sanitizers

Drains Daily

Floors Daily

Waste containers Daily

Walls Weekly/monthly

Condensate drip pans

Weekly

HVAC Weekly/monthly

Coolers* Weekly/monthly

Freezers* Semi-annually* Chlorine may be more effective than Quats if the temperature is low

Step 7– Air Dry/Store Properly

Cleaning Tips – Sanitation Don’ts

DO NOT use high pressure hoses to clean drains, minimize use elsewhere

DO NOT use compressed air to clean equipment

DO NOT start cleaning & sanitizing if there is any exposed product in the entire area

DO NOT do a wet mid-shift cleaningDO NOT stack or nest tubs, totes, pans etc.

after they are cleaned and sanitizedDO NOT let water spray on cleaned & sanitized

surfaces such as those close to the floor while cleaning

Cleaning Tools

Designate cleaning tools for a specific purpose. For example, never:Use floor brooms/floor squeegees on tablesUse pads or brushes used for cleaning garbage

barrels on packing tablesUse the same brush to clean floor drains on any

food contact surface. Use brushes, pads, brooms or squeegees in raw

product area and then in finished product areas

Clean & Sanitize all brooms, brushes and pads every day, after plant is cleaned.

Store all cleaning aids properly

Plant Procedures for Cleaning and Sanitizing

Plant Procedures for Cleaning and Sanitizing

Food Safety is Everyone’s Job!Food Safety is Everyone’s Job!

Sanitation Procedures: Drains

Drains are likely to be the most highly contaminated area of the plant

An inadequate drainage system with frequent backups is a critical problem. If a backup occurs production must stop. All exposed product should be removed. The drain should be cleared, cleaned with caustic, rinsed & sanitized before starting production. Never use high pressure to unclog a drain

Consider the location and type of each drain when determining what procedure to use

Drains -Daily Clean-up

1. Move equipment or food contact surfaces that could get contaminated or use a splash guard

2. Remove drain cover 3. Rinse with low pressure hose4. Apply foam or detergent solution5. Scrub with designated brush (1/4 inch

smaller than drain opening)6. Rinse with low pressure hose7. Flood with sanitizer8. Insert bactericidal ring if used9. Replace drain cover10. Clean drain brush and store in sanitizer

Raw Product AreasEnd of Day Clean-up1) Remove & store all raw or in-process

products 2) Remove garbage/food waste, clean tables

& other surfaces & sweep floors.3) Wet all surfaces with water 4) Apply detergent to all surfaces5) Scrub all surfaces with brushes or pads6) Rinse and inspect for cleanliness7) Apply sanitizer8) Store equipment properly to air dry9) Remove standing water from floors10) Wash cleaning tools, sanitize & store

Finished Product Areas - End of Day Clean-up

1) Never use cleaning tools from raw product areas

2) Remove & store all exposed products 3) Remove garbage/food waste, clean tables

& other surfaces sweep floors.3) Wet all surfaces with water. 4) Apply detergent to all surfaces5) Scrub all surfaces with brushes or pads6) Rinse and inspect for cleanliness7) Apply sanitizer8) Store equipment properly to air dry9) Remove standing water from floors

10) Wash cleaning tools, sanitize & store

1) Never use cleaning tools from raw product areas

2) Remove & store all exposed products 3) Remove garbage/food waste, clean tables

& other surfaces sweep floors.3) Wet all surfaces with water. 4) Apply detergent to all surfaces5) Scrub all surfaces with brushes or pads6) Rinse and inspect for cleanliness7) Apply sanitizer8) Store equipment properly to air dry9) Remove standing water from floors

10) Wash cleaning tools, sanitize & store

Trays, Pans & other UtensilsEnd of Day or After Use Clean-up

1) Fill sink compartment with warm water & detergent2) Make sanitizer solution and check with test strips 2) Scrape/clean to remove food debris 3) Soak as necessary4) Scrub all surfaces with brush or pad5) Rinse and inspect for cleanliness6) Immerse, spray or flood with sanitizer7) Store properly on racks, shelves or hooks & air dry

Storage CoolersDaily and End of Week Clean-up

Daily – Remove debris/trash & standing water Visually inspect for proper product storage, no condensate or drip, no cross contamination

Weekly – 1. Remove all products2. Remove trash & standing water and sweep3. Wet all surfaces4. Apply detergent to all surfaces including ceiling5. Scrub with brushes and floor broom6. Rinse and inspect for cleanliness7. Apply sanitizer to all surfaces

You May Need Special Cleaning and Sanitizing Procedures for:

Floor Mats Totes and tubs Colanders Aprons and boots Boot dips

Sanitation Implementation

Consistency & attention to details is critical

Assign reliable dedicated employees to cleaning and sanitation tasks and train them

Seek expert assistance as necessary to ensure that effective chemicals, procedures and delivery systems are being used and monitored properly

Assign reliable supervisory level personnel to routinely monitor cleaning crew performance and proper use of chemicals and cleaning tools

Good Personal Hygiene Practices For ALL Employees Include

Good Personal Habits Proper Clothing Good Health Hand Washing Handling Products

Properly

Make sure Employees Keep Themselves Clean

Bathe or shower daily

Keep fingernails clean and trimmed at all times

Implement, Monitor and Enforce Policies that Ensure that Employees:

Keep their hands away from their mouth, nose, arms or other body parts when working.

Do not eat, drink, or smoke in the food handling areas.

Train and monitor employees to ensure that they never touch dirty objects and then touch food products while working unless they properly wash their hands or at a minimum change their gloves.

Dress Properly for Work

Require all employees to wear clean, washable outer garments or uniforms.

Require employees to wear hairnets, caps, or other suitable covering to confine hair.

Supervisors & management should set an example

Do not allow employees to wear fingernail polish or jewelry when preparing or handling food.

Implement procedures to ensure employees keep shoes or boots

clean.

ALL Employees Should Come to Work in Good Health

Require any illness to be reported to a supervisor and have ill employees avoid contact with food, food contact surfaces and utensils.

Gloves shall be worn to touch food and food contact surfaces when an employee has any cuts, sores, rashes, casts, or wears nail polish, artificial nails or jewelry.

How to Wash Your Hands

1. Wet hands with warm water; 2. Use ample liquid soap from a

dispenser;3. Lather exposed arms and hands for

20 seconds by vigorously rubbing;4. Thoroughly rinse hands in warm

water;5. Use foot operated faucets to

prevent re-contamination of hands;6. Dry hands thoroughly and properly

dispose of paper towels;7. Dip hands in sanitizing solution; and8. Do not touch unsanitary objects.

When to Wash Your Hands

Before starting work After using the

bathroom After leaving the

work area Before returning to

the work area

When To Wash Your Hands continued

After touching bare human body parts;

After coughing, sneezing, using a handkerchief, or disposable tissue;

After handling soiled equipment; Immediately before handling food During food handling as often as

necessary; and

After other activities that may require it.

Don’t Allow Poor Food Handling Practices

Make sure all equipment is clean before it is used

Don’t let employees bring personal items to work

Never putting finished product back onto a packing line if it dropped onto the floor or touched something dirty

This training program was developed as part of a project entitled “Control Strategies for Listeria monocytogenes in Food Processing Environments” funded under the National Food Safety Initiative in 2000 by the Cooperative State Research Education and Extension Services of USDA Project No. 00-51110-9768.

Lots of hard work was contributed by:

Cornell University Virginia Sea Grant

New York Sea Grant LSU Cooperative Extension

Delaware Sea Grant National Fisheries Institute

Maryland Sea Grant National Food Processors Assoc.

Credits