cleaning & sanitizing for food plants. effective cleaning 2 introduction all equipment must be...

Cleaning & Sanitizing for Food Plants

Effective Cleaning 2

Introduction

All equipment must be cleaned and sanitized prior to use and following any pause in use that could result in contamination.

Specific procedures (SOPs) for cleaning & sanitizing each piece of equipment are available to the operator


Definition of Cleaning

- the complete removal of food soil using appropriate detergent chemicals under recommended conditions.

- a process which will remove soil and prevent accumulation of food residue which may decompose or support the growth of disease-causing organism or the production of toxins.

Definition of Sanitizing

- Reducing of microorganisms on surface to safe level

- A process which destroys disease causing organism which may be present on equipment and utensils after cleaning

22 Dec 07 Effective Cleaning 4

Sterilize : statistical destruction and removal of all living organisms.

Disinfect : to inanimate objects and the destruction of all vegetative cells (not spores).

Sanitize refers to the reduction of microorganisms to levels considered safe from a public health viewpoint.



Food Soil

Food soil : unwanted matter on food-contact

surfaces. visible or invisible.

The primary source:

- food product being handled. - minerals from water residue - residues from cleaning compounds- Microbiological bio-films

Food Soils Classification:

Soluble in water

(sugars, some starches, most salt)Soluble in acid

(limestones,most mineral deposits)Soluble in alkali

(protein, fat emulsions)Soluble in water, alkali or acid


Many complex films contain: combinations of food components, surface oil or dust, insoluble cleaner components, and insoluble hard-water salts.

These films vary in their solubility properties depending upon such factors as heat effect, age, dryness, time, etc.


Surface Deposit

SolubilityEase of

RemovalHeat-Induced

Reactions

Sugar Water soluble Easy Caramelization

Fat Alkali soluble Difficult Polymerization

Protein Alkali soluble Very Difficult Denaturation

StarchWater soluble, Alkali soluble

Easy to Moderately Easy

Interactions with other constituents

Monovalent SaltsWater soluble; Acid soluble

Easy to Difficult Generally not significant

Polyvalent Salts Acid soluble DifficultInteraction with other constituents


Biofilm



Main purposes of cleaning

Remove soils that harbor microorganisms and provide nutrients for their growth

Prevent the transfer of ingredients from different batches of products

Eliminate soils that affect efficiency of heat transfer

Prolong equipment life by removing potentially corrosive materials

Facilitate preventive maintenance


Cleanup steps

Pre-rinse Removes gross soils (reduces need for chemicals)

Wash Removes most bacteria by chemicals, heat, agitation

Post-rinse Removes most bacteria and soil loosened by washing

Sanitize Ensures that equipment doesn’t

contaminate incoming product Doesn’t compensate for poor wash

“You can’t sanitize dirt!”

WaterWater comprises approximately 95-99%

of cleaning and sanitizing solutions.

Functions:carry the detergent or the sanitizer to the

surface; carry soils or contamination from the

surface.


Water must be potable and pathogen-free.

Suspended matter must be kept at minimum level

Soluble iron and Manganese salt less than 0.3 ppm

Never used HARD WATER


Alkaline-based Detergents

- Sodium Hydroxide Sodium

- Hydroxide/Hypochlorite Solutions Acid-based Detergents

- Phosphoric Acid

- Nitric Acid Additives

- Surfactants

- Chelating Agents

- Emulsifiers


Cleaning Detergent


Cleaner selection

Factors to be considered when selecting cleaning chemicals

Nature of soil Organic / protein / petroleum-based / inorganic

(scale or oxide) Nature of surface to which soil is attached

Stainless steel / aluminum / rubber / plastics Quality of water available

Use potable water Hardness (Ca / Mg) will affect performance

Remember

acid cleaners dissolve alkaline soils (minerals)

alkaline cleaners dissolve acid soils and food wastes



Cleaning methods

1. Manual Taking equipment apart & using brushes

2. Cleaning-Out-of-Place (COP) Taking equipment apart and using tank for

soaking

3. Cleaning-In-Place (CIP) Using circulating solution without taking

equipment apart

4. Pressure spraying Using high or low pressure


Manual cleaning

Uses lower concentrations of chemicalsCleaners are formulated for safe useBrushes are used to apply physical

energyVery labor intensiveComplete cleaning may be difficult if

physical energy is not consistent


Cleaning out of Place (COP)

Requires little labor Good penetration during soaking Needs good arrangement of parts and agitation

to work effectively Cleaner needs to be selected because of long

soaking time

Cleaning in Place (CIP)

CIP is used to clean tanks, piping and even workspaces between production batches by automatically recirculating detergent and rinse solutions.

The washing process consists of several cycles in which rinsing material is recycled through the vessels, pumps, valves and other process equipment in the flow system.


Clean-In-Place (CIP) Benefits


Reduced Water UsageReduced Sanitizer ConsumptionReduced Operating CostsReduced Wastewater CostsIncreased Efficiency - Reduced Cycle

TimesIncrease Available Process Time


Pressure spraying

Effective for cleaning large areasE.g. floors, walls, irregular areasFoaming cleaners on walls

Temperature is reduced on contactPhysical energy varies with proximity


Effective cleaning

Procedures include:Contacting the soilAllowing sufficient contact time to reactMaintaining temperatureProviding sufficient energy


Mechanism of cleaning

Detergent is dissolved in waterSolution is applied to surface to separate

soilWater soluble soils are dissolved in waterCleaner allows water close contact to

surfaceCleaner then loosens soil by reducing its

attraction to surface


Mechanism of cleaning (2)

Soil separation is helped by physical action Scrubbing / turbulent flow / pressure spray

Soil dispersion begins Soluble soils remain in cleaning solution Clumps of insoluble soil are broken down Fats & strong alkalis create a soluble soap

Cleaner and dispersed soil are removed Surface is rinsed with potable water to remove

cleaning solution


Cleaner performance

Four factors for cleaner effectivenessTime

15+ minTemperature

60-70C (140-160F) preferredConcentration of cleaner

Recommended by manufacturerPhysical energy


Cleaning Variables

TemperatureTime

Concentration Velocity

Concentration

Temperature

Time TimeTemperature

ConcentrationVelocity

Velocity


Purpose of sanitizing

Last step in cleanup processRequires proper cleaning of surface first

Remove oil / biofilm / cleaner residueReduces microorganisms on previously

cleaned surface free of pathogens


Ideal sanitizer

Has a rapid kill and wide spectrum of kill Exhibits good environmental resistance

Not adversely affected by poor water quality or residues

Effective over wide pH range Non-toxic to humans Non-corrosive to surfaces under all conditions Freely soluble Good shelf life


Effective sanitizing

Use at recommended concentration More can cause corrosion

pH of sanitizer is formulated for best action Kill increases with temperature

Stability can decline

Time of exposure varies Must be capable of 99.999% kill in 30 sec Contact time of 2 min is common

Residual soil affects performance of oxidizers

Sanitizing Agents

Physical Sanitation Alkaline-Based Sanitizers

Chlorine

Quaternary Ammonium Acid-Based Sanitizers

- Hydrogn Peroxide

- Peroxyacetic Acid (PAA)

- Anionic Acids Iodophores


General types of sanitization

Thermal Sanitization

- hot water or steam for a specified temperature and contact time.

Chemical Sanitization

- the use of an approved chemical sanitizer at a specified concentration and contact time.



Proper operation & cleanup

Promptly rinse equipment after use with cool to warm water

Properly maintain equipmentSeals and gaskets

Keep work area cleanReduces amount of difficult cleaning

Follow predetermined schedulesUse chemicals for intended use /

concentration


Portable equipment

Store properly when not in useKeep from splashing / dust

Re-sanitize before next useClean and sanitize if brought out of

storage


Equipment cleanup procedures

Remove all product and debris from equipment

Have sufficient room between walls / equipment to allow for cleaning

Have sufficient space underneath equipment for cleaning or seal

Disassemble equipment as necessary: Remove / replace shields Clean horizontal debris catchers Remove / replace product contact surfaces


Equipment for cleanup

Washing equipment considerations include: High pressure systems

Central / portable

Mixing valves (steam + cold water) or hot water systems Raise temperature for cleaning

Proportioning pumps / venturi-metering / foamers

Minimize water use to limit sewer loads


Manual cleaning

Completely disassemble equipmentRinse manuallyBrush with cleaning solutionRinseSanitize

Before reassemblyJust before processing


Remember!

Remove all productClean up first using scrapers / broomsThen clean thoroughly, paying close

attention to product contact surfacesSanitize clean area so that it doesn’t

contaminate new product

THANK YOU


cleaning & sanitizing for food plants. effective cleaning 2 introduction all equipment must be...

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