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Development of a Sanitat ion Program

Chapter 8

DeveloPment of a Sanitation Program

The SaniTaTion ProceSS1.0

1.1 Wet cleaning

1.2 Dry cleaning

1.3 Managing clean out-of-Place (coP) Programs

1.4 Managing clean-in-Place (ciP) Programs

DeveloPing a SaniTaTion PrograM2.0

2.1 Dairies

2.2 Fruit and vegetable Processors

2.3 Beverage Processors

2.4 low-Moisture Food Processing

2.5 Meat Production Facilities

2.6 ready-to-eat Production Facilities

DocuMenTing a SaniTaTion PrograM3.0

3.1 SSoPs (Sanitation Standard operating Procedures)

3.2 Sanitation Matrix

3.3 Monitoring the Sanitation Program

3.4 Training

DeveloPing veriFicaTion anD valiDaTion ProceDureS4.0

4.1 Strategic Sampling

4.2 Sampling Methods

SaniTaTion ForM TeMPlaTeS5.0

SourceS oF inForMaTion6.0

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the sanitation program is an important prerequisite program. effective prerequisite programs form the foundation of any HaCCP system.

an effective sanitation program:

• Preventspestinfestation;

• Reducesthepotentialforcross-contamination;

• Minimizesthechanceforinjury;and

• Helpscreateamorepleasantworkenvironment.

Should office toilets be included in a sanitation program?

Itdepends.Ifofficeareatoiletsareavailabletoprocessingpersonnel,orifprocessingareatoiletsareaccessibletoofficepersonnel,theprocessormustdeterminehowtocontrolhazards.this might require including toilets in the Sanitation Standard operating Procedures (SSoP).

1.0 tHe Sanitation ProCeSSCleaning procedures in modern food facilities vary greatly. Such procedures depend on the product, process and equipment used.

for example, the type of cleaning needed in a facility producing ready-to-eatmeatsmightdifferverymuchfromaflourmill’scleaningrequirements.Similarly,theprocessinaready-to-eatproductfacilitycoulddifferfromaplantwhoseproductsarecookedimmediatelybeforebeingeaten.

Sanitationoffood-contactsurfacesisusuallydoneinthefollowingorder:

1. Scrapeallloosedebrisandfoodparticlesfromsurface;

2. Cleansurfaceusingsometypeofcleaningmethod(wetordry);

3. Sanitizeusinganeffectiveandapprovedsanitizer(wetcleaningonly);

4. Rinse(wherenecessary);and

5. Cover or protect the cleaned equipment.

Cleaning means to remove physical contaminants such as soil, food and dirt particles.

Sanitizing refers to reducing disease-causing organisms to safe levels.

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Letutensilsorotherequipmentairdryaftersanitizing,andthencoverthem.Rememberthattoweldryingcanre-contaminatethecleanedandsanitizedsurface.Alsorememberthatunprotectedstoragewheresplashingoccurscanalsore-contaminatesurfaces.

1.1 Wet CleaningThemaincleaningmethodusedinmostfoodprocessingfacilitiesiswetcleaning.Thisinvolvesusingaliquid(mostoftenwater)andsomeformofagitation(scrubbingorscraping)toremovesoil.

Toolssuchasbrushes,highpressurepumps,airorsteamareusedinwetcleaning.

Generally,wetcleaningisrecommendedtogetridofstickyresiduescontaining allergens.

Wet cleaning has several steps:

1. Flush or rinse excess soil (dirt, debris, or other unwanted material) with water.Thefirststepistoremovevisiblesoil. Mostcleanersaren’tdesignedtoworkwithlargeamountsof surface contamination.

2. Use the right cleaner and procedure for each surface. the chemical supplier can help you choose the cleaning chemicals, procedures and tools needed for each process. Keep in mind that agitation(suchasmanualscrubbing)mightalsobeneeded.

3. Rinse the cleaner from the equipment with water.

4. Sanitize areas that are hard to reach once reassembled.

5. Reassemble the equipment.

6. Sanitize the assembled equipment parts.

7. If necessary, rinse the sanitizer off with clean water. Some sanitizers,atspecificconcentrations,canbeleftonwithoutrinsing.

8. Dry the equipment. equipment is usually air dried.

9. Cover or protect the equipment from re-contamination.

Once the equipment is washed, sanitized and rinsed (where necessary), keep equipment free from re-contamination.

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Makesurethatallcleaningtools:

• arerugged;

• madefromnon-absorbentmaterial;

• donotretainsoil;and

• dryquickly.

Cleanandsanitizealltoolswhenfinishedcleaning.Donotusebroomsorbrushesinwetcleaningoperationsbecausetheypromotemicrobialgrowth.

Occupational Health and Safety and Chemical Hazards

Amajorissuefacingallfacilitiesisthepotentialforreactionsbetweencleaningproducts.Somehighlyreactivechemicals,likebleach,willproducetoxicfumeswhenincontactwithothercleaners.Thisoftenhappenswhenanacidcleanerismixedwithabaseorcausticcleaner.

Whenusing,storingormixingchemicals,alwayslookatthechemical’sMaterial Safety Data Sheet.Ifyouhavedoubtsabouthowtousechemicals,orneedinformationonpossiblechemicalsreactions, askthechemicalsupplier.

Beforeusingbleachofanyconcentration,rinsethearea.Drainor clean equipment completely of all residual soils, cleaners and chemicals.Neverusebleachinaconfinedspace.Alwaysmakesurethere is adequate ventilation.

1.2 Dry CleaningNotalloperationscanbewetcleaned.Inbakeries,flourmills,dry-blendingfacilitiesandsimilaroperations,microorganismsareoflessconcernthanmoulds,insects,rodentsandforeignobjects.Inthesefacilities,clean-upcrewsusebrooms,brushes,shovelsandvacuumsystemstoremovewasteandspills.

Unlikewetcleaning,drycleaningdoesnotuseastep-by-stepprocedure.Indrycleaning,themethodistostarthighandworkdown.

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Usedrycleaningonlywhentherearenosticky,glutinousallergenresidues.Rememberthatallergenscaneasilybecomeairborne,especiallyinfacilitieswithacommonairsupply.Drycleaninginsuchfacilitiescoulddrawallergensintotheairsupplysystemandcontaminatenon-allergenicproducts.Useavacuumcleanertodomost of the cleaning.

1.3ManagingCleanOut-of-Place(COP)ProgramsMostfacilitieswillhavesomekindofCleanOut-of-Place(COP)equipment.COPequipmentincludesitemsthathavetobemanuallycleanedandsanitized.ExamplesofCOPequipmentincluderemovablepiping,fittings,gaskets,valves,pumpsandproducthandlingutensils.

COPcanoccurinvariousways.Cleaningknivesinasinkisoneexample. another CoP method is chemical agitation cleaning in specializedtanks(e.g.dishwashers).

When developing CoP protocols and procedures, pay attention to areas underneathandaroundpipegaskets.Alsowatchforanyothersmallcavities,gaps,nichesandharbouragepoints(placeswherepestscanhide).Residueandbacteriacangatherintheseareas.

HerearesometipstomakeCOPsystemsmoreeffective:

• Try to do all COP tasks in a prescribed order. Chances ofcross-contaminationfromunsanitizedtosanitarysurfaces,oroverspray,aremorelikelywhensanitationteammembersperform different activities.

• Look into using basket, tote or pail washers. often facilitieswillusemanysmallcontainersinprocessoperations.Washingmanycontainersatonce,inalargerwashingsystem,decreasestheriskofcross-contamination.Thiscanalsoreducetheamountofstaffneededforthejob.

• Consider having COP operations done on production floors.Membersofthesanitationcrewcanworkdirectlyonthefloorortemporarytables.Beforeputtingtheseinplace,it’simportanttolookattheimpactsuchprocedurescanhaveonprocessflow.Alsolookathowtheyaffectcontaminationcontrols.

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• Use racks or COP tanks to hold parts and utensils while they are cleaned.PlacetheremovedpartseitheronarackforcleaningorinaCOPcirculationtank.Thenmakesuretheyarecleanedusinghotwater,achemicalsolutionandsomeformofagitation.

• Make sure tools and equipment aren’t sources of contamination.Besuretochooserugged,easy-dryingcleaningbrushesmadefromnon-absorbentmaterials.

• Colour coding or labeling brushes and cleaning utensils as food-contact and allergen surfaces can reduce contamination. Separating utensils used in different areas ofthefacility(e.g.barn,killfloorandprocessingareas)helpsreducecross-contamination.

1.4ManagingClean-in-Place(CIP)ProgramsClean-in-place(CIP)sanitizingcleanstheinsidesurfacesofpipes andtanksofliquid.Italsocleanssemi-liquidprocessingequipment.

CIPusuallyinvolvesforcingdetergentthroughequipmentwithasprayorsprayballs.Theseremovesoilthroughagitation.AnotherCIPmethoduseswaterspraytopushbrushesthroughpipestocleanandremovedebris.

CIPsystemscanusecomputerizedcontrols.Thesecanmonitorandcontroltheflow,mixing,temperature,timeanddetergent.CIPmightalso use manual methods to control pumps, spray systems and the addition of chemicals.

RememberthatCIPsystemsarelimited.BeforedesigningaCIPsystem,assesstheproductionprocessthoroughly.Determinewhat willworkbestforeachoperation.

Some guidelines for developing a CiP system include:

• Linescarryingcleaningchemicalshouldhaveshouldhavepermanent,easy-to-take-apartfittings;

• Pipelinesshouldberigid,supportedandself-draining;

• CIPpipelinesandtanksshouldbedesignedwithaccesspointsorviewingwindows.Thishelpsduringinspection;

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• Useanairbreaktopreventcross-connectionsbetweencleaningsolutionsandproductwater.Anotherchoiceistouseanapprovedback-flowpreventiondevice;

• Followtheoriginalmanufacturer’sspecificationsforflowrate,timeandtemperature.Followtheseguidelinesforcleaningandsanitizingsolutionstrengthsaswell;and

• BuildCIPpipesandtanksfrom‘foodgrade’material.

Designingtanksandpipesystemsarebothimportanttostopthe build-upofsoil.Italsomakescleaningandsanitizingeasier.

For more information about sanitary design, see Chapter 4: Developing a Premises Program.

Figure 1: How Joints, Cracks, or Crevices in Tanks and Pipes Reduce or Limit Operation of CIP Systems

When designing the sanitation program for CiP equipment, include the followinginformation:

• Equipmentandutensilstobecleaned;

• AccuratecircuitdiagramsoftheCIPsystem;

• Installationinstructions;

• Dutiesofthepersonresponsible;and

• Methodsforcheckingtheconcentrationandeffectiveness of chemicals.

an effective cleaning program should clean equipment, not damage it.Manyfacilitiesusetraditional’greenscrubbingpads’forcleaningequipment.Remember,greenpadsareVERYabrasiveandcandamageequipment.Instead,use‘whitepads.’Thesemaycostlessandhavealessabrasivesurface.

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2.0 DeveloPing a Sanitation ProgramRemembertheseimportanttipswhendevelopingthesanitationprogram:

• Makethoroughcleaningandrinsingpartofthedailycleaningschedule;

• Makesanitizingaroundfloordrainspartofthedailycleaningschedule;

• Usesanitizerringsindrainsandcoolingunits;

• Followthemanufacturer’sinstructionswhenusingcleaningchemicals;and

• Talktothechemicalsuppliertolearnaboutthesanitizerandhowtouseitinthefacility.

For examples of Cleaning Schedules, see Forms E.1.1 and E.1.2.

Figure2outlinesthedevelopmentofasanitationprogramandwouldbeusedbyproductionandmaintenancestaff.Followthisstep-by-stepguidealongwithatrainingandcommunicationprogram.

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Figure 2: How to Set Up a Cleaning Schedule

How to Set Up a Cleaning Schedule

Step 3

Step 4

Step 5

Step 6

Step 7

Display the schedule in a visible place for all staff to read. Laminating or covering the notice in plastic will protect it.

Step 1

At the top, write down the room to be dealt with (If necessary, use more than one sheet per room or area).

Step 2

In the ‘Item’ column, list all the items or equipment that require cleaning in that area (e.g. walls, doors, floors, mixer, etc.)If several items have the same cleaning requirements and procedures, group them together in one box.

For each item or area that is listed, write down:• The job title of the person responsible for performing the activity (e.g night janitor);• The method of cleaning to be used;• The name and description of the cleaning products to be used, and tin what concentrations; and• How frequently the item or area needs cleaning.

Repeat the process for each room or area.

Write the information in Steps 1 through 3 on an easy-to-readCleaning Schedule. This chart will include ‘Items and Area to BeCleaned’ and ‘Method of Cleaning.’ It also includes an area forthe person responsible to initial when the job is finished. Common formats are a weekly, monthly, or daily schedule,depending on the activities and who does them.

Make sure all staff know their cleaning responsibilities. Ensure they are trained in procedures for using various chemicals in the facility.

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Whendevelopinganyformofsanitationprogram,keepinmind:

• Diseasecausingmicroorganismscanbefoundonalmostanysurface in a facility including:

• Floors

• Drains

• Overheadbeamsandpipes

• Equipmentsurfaces

• Inspect‘deadspots’onandaroundequipment.Ifmaterialcangetin,contaminantscangetout;

• Cleanandinspectmorefrequentlyinstorageareaswithhigherhumidityandheat.Heatandhumidityallowmicrobesandpeststoflourish;

• Checkforbitsoffoodleftinsideemptybinsandcontainersthatcanattractpests;

• Inspectforcondensation,whichisapotentialsourceofproductcontamination;

• Schedulecleaningwithroutinemaintenanceactivities.Equipmentdisassembledformaintenancecanbecleanedatthesametime;

• Displaycleaningandsanitationinstructionsinareaswhereproductionormaintenanceactivitieshappen;

• Encouragestaffto‘CleanAsYouGo.’Thisreducescontamination,shortensclean-uptimeanddecreasespestactivities;

• DONOTuseuntreated,re-circulatedwater.Makesurethatallwaterusedforsanitationisdrinkable.MakesurethatitmeetstherequirementsofHealthCanada’s“GuidelinesforDrinkingWaterQuality;”

• Ensureallwastematerialdisposalroutesareshortanddirect;and

• Createaverificationsystemtocheckonthesepoints.Theresultsmaynotalwaysdistinguishbetweenmicroorganismsandorganics(e.g.inATPtesting).However,resultsshouldindicatewhensurfacesarenotclean.

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2.1 DairiesTasteisakeyqualityindicatorformilk.Onecauseofoff-flavourinmilkismicrobialcontaminationduetopoorsanitation,cooling,and/orrotation.ContaminationiseffectivelycontrolledbyusingSOPs(Standard operating Procedures) and SSoPs (Standard Sanitation operating Procedures).

When developing a sanitation program for a dairy facility, consider the following:

Freshsoil(dirt,debris,orotherunwantedmaterial)ona•coldsurfaceiseasiertoremovethandriedorbaked-oncontaminants;

Whiteorgreyishmaterialsonthesurfaceofequipmentmaybe•milkorwaterstone(calciumorlime).Thismayrequiredifferentcleaningmaterials;and

Reducetheuseofhotwatertolimitbakingsoilontoequipment.•

ManydairyfacilitiesuseClean-in-place(CIP)systemsforvatsandpipingsystems.Whendevelopingtheprogramwiththeengineeringstaff:

• KeepthetemperatureofthecleaningsolutionlowenoughtoensurethattheCIPdoesnotbakeonsoils.Thisincreasescleaningtimeandtheneedforcleaningcompound;

• Setrinsewatertemperaturetoavoidwaterstone(calciumorlime)depositsontheequipment;and

• Payspecialattentiontothetypeandstyleofspraydevicesused.Makesuretheymeettherequirementsofthecleaningprogram.

2.2FruitandVegetableProcessorsFruitsandvegetablesareofteneatenwithoutcookingorfurtherpreparationandbecauseofthistheyrequireextracaution.

Manymicroorganismscansurviveandgrowonfruitsandvegetables.Allproduceprocessingfacilities(fromfresh-cuttopackaging)shouldusethewetcleaningmethod.Thisshouldbethemainmethodofcleaning equipment and facilities.

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When developing a sanitation program in a produce facility:

• Separateanyunacceptableorreturnedgoodsfromproduction,shippingorgeneralstorageareas.Thesegoodscanbeinfestedandcanthenleadtocontaminationofgoodproduct;

• Removeasmuchdirtandmudaspracticalfromfreshproducebeforeitreachespackingfacilitiesorareas;

• Makesureallpackagingisundamagedandfreeofcontamination;and

• Protectunused,cleaned,andnewpackingcontainersfromcontamination during storage.

2.3 Beverage ProcessorsMostbacteriaarenotaconcernforthebeverageindustry.Thisisbecauserawmaterials,processingtechniquesandthefinalproductusuallydon’tsupportbacteriagrowth.However,yeast,mouldandcertaintypesofbacteriathatcancausedisease,maystillbeaprobleminbeverageprocessingplants.

Inadairyorbeveragefacility,CIPisthemostcommoncleaningprocess. When deciding on methods for removing soiling material from conveyorsystems,rememberthat:

• Mostsoilswillbespilledproduct,greaseandfilingsfromcontainers;and

• Foamcleaningwithhighpressurerinsesworkbest.

Researchhasshownthatbiofilms(slimylayersthatdevelopwhenbacteriaattachtoequipmentorsurfaces)cangrowinsidecoolingtowers.Theycanalsogrowinsideandoutsidewarmersandpasteurizersandinsidecoolers.Theuseofcleanerscontainingquaternaryammoniumwillhelpstoptheformationofthesefilms.

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2.4Low-MoistureFoodProcessingThemostcommonlow-moisturefoodprocessingfacilitiesincludebakeries,nut,seed,pasta,candyandsnackfoodfacilities.Theseproductstendtocontainlittlewaterandthereforedon’tgenerallysupportmicrobialgrowth.Thebiggestconcerntheseoperationsistheabsorptionofunnecessarymoisturethatmayleadtomouldgrowth.

Drycleaningisbestinalowmoisturefoodprocessingenvironment.Usebrushes,broomsanddustpanstoremoveheavydebris.

Whendevelopingthesanitationprogramforalowmoisturefacility,ensurethatsomecleaningisdoneduringoperationtohelpkeepthefacility tidy.

Thetwomostcommonmethodsofdrycleaningarevacuumcleaningandcompressedair.Vacuumcleaningisthebestequipmentcleaningmethodinmanyareas,because:

• It’sagoodwaytoremovelightormoderatedebris;

• Itreducesdust,whichreducescross-contaminationwithairborneparticles;and

• Vacuumscomeinmanysizesthatsuittheuniqueneed of a facility.

Beawarethatpoorlymaintainedvacuumsystemscantransportdustoverlargeareas,whichwillincreasethelikelihoodofcontaminationfrom air particles.

Compressed air is also a common method for cleaning equipment inlow-moistureenvironments.It’sgoodforremovingdebrisfromequipmentandalsoaneasywaytocleanhard-to-reachareas.

Followthesetipswhendevelopingacompressedairsanitationprogram:

• Filtercompressedair;

• Uselowvolumeandpressurewhenworkingwithcompressedair;and

• Controldustinstorageandhandlingareas.

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2.5 meat Production facilitiesMeatandmeatproductsaremorelikelytobeaffectedbymicrobialgrowth.ThisisbecauseoftheirneutralpHandhighproteincontent.

the sanitation program in facilities that handle meat products must pay specialattentiontothecontrolofbacterialgrowth.Theprogrammustalsopreventcross-contaminationofthefinishedproduct.

Itisimportanttoplaceinedibleproductindesignatedtubsoringuttanksandtophysicallyseparatethemfromedibleproduct.

Inediblewasteshouldbestoredinaseparateroom.Ensurethatinedibleproductisneverplacedinbinsorcontainersthatwillatanytimeholdedibleproduct.

It’simportanttomakesurethatthesanitationscheduleincludesnon-processingrooms.Itmustalsoincludefacilityareasthataren’tcleanedevery day. examples of these areas include:

• Smokehouses

• Coolers

• Coolingunits

• Screens

• Waterstoragefacilities

• Spicerooms

• Storageareas

• Deliveryvehicles

Theseareasmaynotalwaysbecheckedonpre-ops.Therefore,cleaningstaffneedtounderstandtheschedule.Theymustknowwhentoaskapre-opverifiertoinspectcertainareasforcleanliness.

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2.6Ready-to-EatProductionFacilitiesReady-to-eatproductsarenotcookedbeforebeingeaten,sothesanitation program for these producers must:

• Controlphysicalcontamination;

• Controlchemicalcontamination;

• Addressbacterialgrowth,and

• Preventcross-contaminationofthefinishedproduct.

Control of Listeria Monocytogenes

Listeria monocytogenesisanexampleofapathogenthatgrowseasilyundernormalstorageconditionsandcancontinuetogrowwhentheproduct is refrigerated.

Listeria monocytogenescansurvivewithorwithoutoxygenandisfoundinmanyfoodprocessingplants.Itcangrowincool,dampareas(such as those found in any processing area), in coolers or on the slaughterfloor.

SanitationisthekeytocontrollingandeliminatingListeria monocytogenes. Pay special attention to:

• Equipment

• Floors

• Walls

• Lightfixtures

• Coolingunits

• Ceilingsandoverheadstructures

• Floordrains

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3.0 DoCumenting a Sanitation ProgramSanitation program documents are important for three reasons:

• Theydemonstrateduediligence;

• Theyallowathirdpartyauditthefacilityonbehalfofcustomers;and

• Documentationofthesanitationprogramisaregulatoryrequirement.

the current trade environment demands that manufacturers prove due diligence in all activities. Documentation encourages employees toperformallkeyactivities.

Foranyfoodsafetyprogramtobeauditable,themanufacturermustdocumentwhattheydo.It’simportantthattheyprovetheiractivitiesarefollowingthestatedmethods.Thisisshownthroughdocumentation.

the sanitation programiskeytofoodsafetyproduction.Becauseofthis,auditorswilllikelycheckthesanitationprogramintheirassessments.

Thelawrequiresmanyfoodproductionfacilitiestohavedocumentedprerequisiteprograms.Thisisrequiredby:

• TheFoodSafetyEnhancementProgram(FSEP),through theCanadianFoodInspectionAgency(CFIA);

• TheMeatFacilityStandards(MFS);and

• Otherregulatorystandards.

Rememberthatdocumentationimprovestheprobabilityoflongtermsuccess.

Toanauditor,ifit’snotinwriting,itwasn’tdone.

Everythingintheprogramshouldbedocumented.Thisincludes:

• Training

• Dilutionrates

• Pre-opinspectionfindings

Thefacilityshouldbeabletoshowthatthesanitationprogramsupportsall other prerequisite programs.

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three formats commonly used to document sanitation program requirements are:

• SanitationStandardOperatingProcedures(SSOPs);

• Matrixorschedules;and

• AcombinationofmatrixandSSOPs.

3.1 SSoPs (Sanitation Standard operating Procedures)SanitationStandardOperatingProcedures(SSOPs)areusuallywrittenin an essay or report form.

Writeouteachcleaningproceduresothataneworuntrainedemployeewillbeabletofollowtheinstructions.Theymustknowexactlywhattodo.Theseemployeesmustknowwhat,when,andhowtodothejob.

AtypicalSSOPwillincludeadescriptionoftheactivitytobedone.Itwillalsoinclude:

• Informationaboutthechemical(s)tobeused–includingconcentration and procedures for using them, and any personal protectiveequipment(PPE)needed;

• Detailedstep-by-stepprocessinstructions–includingalistofsanitationequipmenttobeused,andinstructionsontakingequipment apart.

Be sure to document:

• Sanitationprocesstobeused(COPorCIP);

• Cleaningandsanitizinginstructions;

• Temperatureofwater;

• Waterpressureneeded;

• Reassemblyinstructions;

• Frequencythatthisactivitymustbeperformed;

• Documentnameofwherecompletionoftheactivityisrecorded;

• Jobtitleoftheperson(s)responsiblefortheactivity;

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• JobtitleofthesupervisororpersonwhowillmonitorandsupervisetheSSOP;

• JobtitlesofpersonneltosignoffanddatethedocumentaftertheSSOPisacceptedoraltered;and

• Pre-opinspectionorverificationinstructions.*

*These instructions should include the title and name of the person who will perform the pre-op inspection or verification of the SSOP. They should also include documents where results are to be recorded. They must state deviation procedures to follow if situations change.

WhenatypicalSSOPiscompleted,apersonshouldbeabletofillineachspaceofthefollowingSanitationMatrix.

Sanitation activities

VerificationProcedures

Deviation Procedures

Who

What/How

Frequency/When

records

For another example of how to document sanitation procedures, see Form E.1.3: Cleaning Procedure Sheet.

3.2 Sanitation matrixLikethesanitationprogram,thesanitationmatrixaddressesaprocessingfacility’suniqueneeds.

Therequiredinformationshouldbecompletelycontainedwithinthematrix.Itshouldalsobeeasytounderstand.

Therearevariouswaystodevelopasanitationmatrix.Somerecommended columns to include are:

• Room,area,equipment;

• Listoftoolsandequipmentneeded;

• Frequency(daily,monthly,yearlyorasneeded);

• Thepersonresponsible(anddesignatedalternate);

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• Chemicalsused;

• Appropriatechemicalinstructions(includingmixinginstructions,concentration,temperatureandcontacttimes);

• Cleaningmethodtobeused(manual,automatic,foam,etc.);

• Specificsanitationprocedures;

• Disassemblyinstructionswhererequired;and

• Sign-offrecord,orassociatedrecord.

It‘simportanttomakesurethatthematrixiscompletedbyrelatingitto

• Training

• Verification

• DeviationSSOPs

3.3 monitoring the Sanitation ProgramAswithanyprerequisiteprogram,developamethodtomonitorhowthesanitationprogramisworking.

these procedures can include:

• Checkingtheconcentrationsofthecleanersandsanitizerswhileinuse;

• Checkingthetemperatureofthewaterduringcleaningataregularfrequency;and

• ObservingsanitationemployeesduringcleaningtomakesurethatSSOPsarefollowedcorrectly.

See Form E.1.4: Daily Sanitation Report.

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3.4 trainingIt’simportantthatstaffunderstandchemicalusageandsanitationpolicies.Thisreducesthepossibilityofaccidentalcontaminationoffoodproducts.

Staffshouldunderstandwrittensanitationprocedures.Pestcontrolandsanitation in a HaCCP facility requires extensive documentation. train employeestomaintainrecordstheyareresponsiblefor.

Sanitationstaffneedtoknowthefollowing:

• Whysanitationisimportanttothefacility’sfoodsafetysystem;

• Differentkindsofdirtandhowtoremoveeachtype;

• Howtousethetoolsnecessarytocleanthefacility;

• Howeachcleaningchemicalworks;

• Skillsneededtouseeachchemical;

• Skillstomakesurethatallproceduresarecomplete;and

• Documentation.

Remember,thecostoftrainingemployeesissmallcomparedtothecosts that arise from poor sanitation. Such costs include:

• Productlineshutdowns;

• Reducedshelflife;

• Productrecalls;

• Damagetothebrand;and

• Consumercomplaintsorlawsuits.

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4.0 DeveloPing verifiCation anD valiDation ProCeDureSEnvironmentalswabbing(swabbingequipmentandsurfacesinfoodproductionareas)ortestingisthemostcommonwaytocheckasanitation program.

these procedures are not developed to determine if the product should bereleased.Instead,theyaredevelopedtomonitorwhethercurrentsystemcontrolsareworking.

Generally,thesetestsaredoneonbothfood-contactandnon-foodcontactsurfaces.Theyarepartofdailypre-operationalactivities.Theseproceduresneedtobedocumentedwithinthesanitationprogram.

4.1 Strategic SamplingPre-operationalswabbingwillhelpidentifytroublespots.Theseswabsprovidebaselineinformationthatafacilityusestodecidewhetheritscontrolofmicrobesisgettingbetterorworse.

Manyfacilitiesdeveloptheirverificationproceduresaroundtroublespots.Locationstosampleinthefacilitywilldependon:

• Thelayoutofthefacility;

• Thekindofproductbeingmanufactured;and

• Thetypeofprocessinglinetheproductisbeingrunon.

Onproductionlineequipmenttakesamplesfromthefollowingtwoareas:

• Food-contactsurfaces–whereproductcomesdirectlyintocontactwiththesurface;and

• Non-foodcontactsurfaces–wherecontaminantscouldmovefromandcomeintocontactwithfood-contactareas.

Don’tjustlookatequipmentandsurfaces.Allenvironmentalsamplingsystems should include some form of air sampling. microorganisms existintheairaspassengersondustparticles.They’realsofoundincondensation droplets and exist as individual organisms.

In-plantsamplingsitesshouldincludehotspots(checkairaswellasequipment/surfaces).Theyshouldalsoincludeunusuallocationssuchaspostersorsigns.Thesamplingshouldchangetonewlocationsfromtime-to-time.

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4.2 Sampling methodsVariousmethodsareavailableforenvironmentaltesting.Theseinclude:

• Rapidmicrobialtestingtechniques;

• Standardmicrobiologicaltesting;and

• Allergenresiduetesting.

ATP Testing Methods

ATP(AdenosineTriphospate)testingisusuallydonewithspecificATPequipment.

Ingeneral,ATPtakeslittletimeorworktoprepare.Thetestingunitsrequire appropriate training to use properly.

ATPtestsprovideinstantfeedbackonhowthecleaningprogramisworking.Theyareconsideredtobe‘real-time’becausetheresultsareavailableinaminuteortwoandnotdayslateraswithmicrobialtesting.

ATPtestingdoesnotrequirealaboratoryatthefacilityorsendingsamplestoathirdpartylab.

ATPswabsareoftenusedtoassessmicrobesandallergens.Thisprocessissometimesunabletoprovidetheexactamountorleveloforganicmaterialorallergenspresentonasurface.However,ithelpsfinetuneandcorrecttheprogram.

InadditiontoATPtesting,it’simportanttooccasionallydoafullmicrobiologicalanalysesorallergenassessmentofafacilityenvironments.

Microbiological Testing Methods

Thereareavarietyofrapidmicrobialtestingmethodsavailable.ThesemaynotbeasfastasATPtesting,buttheycanassessthecleanlinessof the facility.

Resultsofmicrobialtestingcanserveasusefulguidelines.However,interpretingresultsbasedonabsolutenumberscanbemisleading.Sometimes this is even counterproductive. Certain conditions (such as fattyfilms)canmakethesebacterialcountsinaccurate.

See Form E.1.5: Microbial Swab Record.

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Allergen Testing Methods

Therearefewapprovedmethodstotestforthepresenceofallergenproteins.

ManufacturersmayuseallergenspecificswabbingkitssuchasELISA(EnzymeLinkedImmunosorbentAssay),whichdetectallergenicproteins.

Aconcernwithallergenproteintestkitsisthattheydon’trecognizedenatured proteins. these proteins may cause a reaction in sensitive individuals.

DNA Testing Method

PolymeraseChainReaction(PCR)isoneofthenewermethodsofallergenandmicrobialtesting.PCRtestsfortheDNAassociatedwiththe material of interest.

Themaindisadvantageofthismethodisthatitdoesn’ttestforproteins. instead it tests for Dna. this means that a positive allergen PCr test may result in a negative eliSa or atP result.

Further,apositivemicrobiologicaltestmayendupscanningasnegative.Thisisbecauseoftheextremesensitivityofthistesting.ThePCRmethodcanfinddeadanddamagedcellsaswellaslivingmicrobes.Asaresult,mostmanufacturershavedecidednottousePCRtesting at this time.

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5.0 Sanitation form temPlateSe1.1 Cleaning Schedule (option 1)

e1.2 Cleaning Schedule (option 2)

e1.3 Cleaning Procedure Sheet

e1.4 Daily Sanitation report

E1.5 MicrobialSwabRecord

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6.0 SourCeS of information1. AmericanInstituteofBaking(2000)Food Processing Sanitation/Hygiene

Correspondence Course.

2. Stier,RichardF.andCramer,Mike.PROCESS CONTROL - Top Tips toMake Your CIP and COP Systems Work For YouFoodSafetyMagazine(October/November2005).

3. Campbell,Brian.TESTING - Is Your Plant As Clean As It Looks? foodSafetyMagazine(April/May2005).

4. Stier, richard. university of florida, institute of food and agriculturalSciences Basic Elements of Equipment Cleaning and Sanitizing in FoodProcessing and Handling Operations.

5. Schmidt, ronald H. university of florida, institute of food andagricultural Sciences Basic Elements of Equipment Cleaning andSanitizing in Food Processing and Handling Operations.

6. AlbertaFoodProcessorsAssociationFoodSafetyCounselingProgram(2001) Sanitation and Pest Control Workshop Participant Manual.

7. ArizonaDepartmentofHealthServices,DivisionofPublicHealthServices(2004) Food Equipment Cleaning and Sanitizing.

8. FoodSafetyPackFoodSafetyTeamofWyreBoroughCouncil’senvironmental Health Services unit (august 2004).

9. SaferFood,BetterBusiness.FoodStandardsAgency,EU(January2006).

10. Canadian food inspection System Code of Hygienic Practice forCommercial Prepackaged and Non-Prepackaged Water, first edition,aPPenDiCeS. http://www.cfis.agr.ca/english/regcode/bw/bw_apdx_e.shtml#aPPenDiX3.

11. FoodandAgriculturalOrganizationoftheUnitedNationsandWorldHealthOrganization(2003)Codex Alimentarius – Food Hygiene BasicTexts third edition.

12. u.S. food and Drug administration Center for food Safety and appliednutrition Guide to Minimize Microbial Food Safety Hazards for FreshFruits and Vegetables Food Safety http://www.foodsafety.gov/~dms/prodguid.html#vii.

13. ENVIRONMENTALAUDIT–WheretosampletoensureproductsafetyQC Quarterly (may 1999).

14. Flickinger,Bruce.What’s Your Sanitation Strategy? food QualityMagazine(October1995).

15. Kramer David n. myths Cleaning, Sanitation, and Disinfection. Dairy,Food, and Environmental SanitationVol.12,No.8.Pages507-509(July1992).

chapter 8file/chapter_08-sanitation.pdf · 8-2 development of a sanitation program let utensils or...

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