cleaning sanitizing
TRANSCRIPT
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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.
Get Back to the Basics
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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
Get Back to the Basics
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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!