Master Program of Cleaning and Sanitizing

BY SARAT ROY

EMAMI-PANTNAGAR

Very poor Quality Audit score in case of cleaning & sanitizing Throughout all Emami units.

Major gaps observed - There is no prerequisite program for master cleaning & sanitization

Objective: The methods of cleaning and sanitizing, the types of chemicals used, the frequency of cleaning activities, and the control of microbes must all be done expertly to protect our finished products from contamination issue.

Why special focus on cleaning & sanitizing !!!

3S is the part of

5S (technique applied for Good House Keeping)

3S

The First “S"

1S Activities Indicators of success

Seiri (sorting/ segregation)

- Sort though- Identify what is needed and

discard the unnecessary items.

- Productive area saving

The Second “S"

2S Activities Indicators of success

Seiton (arrangement)

- Set item in order by creating place for everything and put everything in its place

- Keep accessibility- Labeling

- Time saved in searching and returning

The Third “S"

3S Activities Indicators of success

Seiso (shine/ cleanliness)

- Eliminate dirt and foreign matter

- Reduction in m/c downtime- Increased life of m/c parts- Reduction of no. of accidents- Reduction of rejection/rework- Higher productivity- Healthy environment

Deep cleaning

Removing physical contaminants such as soil, unwanted

materials, dirt particles & waste materials from surface by rinsing

and washing through the use of physical and chemical action.

Cleaning removes 90-99% of the bacteria, but thousands of

bacteria may still be present.

Cleaning

Types of cleaners

Alkaline: CAUSTIC SODA

Anionic / Nonionic : TEEPOL

StandardSolution in master plan

StandardQuantity in master plan

Frequency

Used in present time

Area Quantity use

Colin Daily Max Glass

Teepol Not mentioned

Daily Teepol 1Cap /1 ltr.

Lyzol 1 capful/4 ltr. water

Daily Lyzol Admin & Quality

Phenyl 2 capful/5 Ltr.water

Daily Max Total area

Area Process

Admin Firsty cleaninig with the washing powder (like (active wheel ),then sanitizing with Lyzol.

Quality Firsty cleaninig with the like (active wheel ,then sanitizing with Lyzol.

Mfg Firsty cleaninig with the Teepol & ditergent powder like (active wheel ).

Pkg Firsty cleaninig with the ditergent powder (active wheel),then sanitizing with phenyl.

How cleaning agent work?

Cleaning agent having surfactant reduce the surface tension of water

The surfactant's water-hating end is attracted to the oil in the soil. At the same time, the water-loving end is attracted to the water molecules.

The droplets of oil, surrounded by the detergent molecules form an emulsion in the water and are able to be washed away.

Caustic Soda

Conditions to apply ? • 1% solution• Temp 50-60oC• Contact time: 20 minutes

How it works? It can dissolve grease, oils , fats and protein based deposits.

Suitable use for?SS equipments cleaning,Plastic drum & crate, Drain cleaning,

Teepol

Active ingredients:

Sod. Benzene Sulphonate, Alcohol ether sulphate

Concentration: 1%

Used for: Equipment, floor, glassware cleaning

Sanitizing - “Treating a cleaned surface to destroy and reduce the microorganism to a safe level”

Types of sanitizers:

Heat

Chlorine

VU

IPA

Lysol

Phenyl

For any chemical disinfection:

(1) Must first satisfy the disinfectant demand

(2) Must then establish a disinfectant residual

(3) Must maintain the concentration & contact time effectively

Heat

Dry heat kills the organisms by destructive oxidation of essential cell constituents.Conditions: temp 160 °C for 60 mins.Dry heat is employed for glassware, metal instruments which are not spoiled by high temperatures.

Moist heat kills the organisms by coagulating and denaturing their enzymes and structural protein.Conditions: temp 121 °C for 15 mins.Moist heat is used for the sterilization of culture media where steam can penetrate.

Moist heat is more effective than dry heat

Chlorine

Chlorine is available in several forms calcium hypochlorite (solid) sodium hypochlorite (solution)

◦ In water, chlorine forms hypochlorous acid (HOCl) and hypochlorite anion (OCl-)

◦ HOCl is 80 to 100 times more potent germicide than the hypochlorite ion (OCl-)

Best practice for water disinfection:

6-8 mg/L Free Chlorine Residual for 2 Hours Min contact time.

UV Treatment

UV range = ~100 to 400 nm

Germicidal Wavelength

s

UV dose of 30,000 microwatt-seconds/cm2 at the end of 8,000 hours of use

Efficiency highly dependent on water quality ( must be free of suspended solids to form scale on UV tube)

UV Treatment mechanism

Primary mechanism is absorption of UV by the DNA, and disruption of the chemical bases.

Renders the cell unable to reproduce their DNA, and, therefore, cannot grow.

At least a three-log (99.9%) reduction in bacteria, yeast and viruses

70% IPA- Disinfectant

Isopropyl alcohol ( Isopropanol ) can be considered as a

disinfectant as well as an antiseptic, antimicrobial agents

that destroy microorganisms on living tissue. IPA affects the

outer cell membrane of bacteria by making the lipids in the

membrane soluble to water. This solubility causes the cell

membrane to lose its structure, allowing alcohol into the cell

where it denatures proteins. The denatured proteins become

coagulated.

Disinfectant: Destroy pathogenic microorganism (E.Coli-

diaria, Salmonellae-typhoid).

70% IPA- Disinfectant

Why 70% IPA better than 100%? 100% IPA causes protein to coagulate instantly. The

coagulated proteins create a hardened protein wall around the cell, protecting the interior. With the inside of the cell protected, the organism is not killed but remains dormant.

70% IPA is combined with 30% water. This dilution allows protein coagulation to occur gradually as the organism absorbs the alcohol at a slower rate. The microorganism is slowly overcome and dies.

Lysol - Disinfectant

The active ingredient in of the Lysol is Benzalkonium Chloride ( cationic surface acting agent )

Suitable for floor cleaning and disinfecting ( 7% in water )

Phenyl - Disinfectant

It is a mixture of phenols and cresols, used as a disinfectant.

Spectrum of action – gram positive, gram-negative bacteria. No activity against viruses, fungi and spores.

Mode of Action It acts by rupture of cell membranes and denaturation of cellular constituents.

Indications · Disinfectant for floors, washbasins, drain etc.· Waste disinfection – infective wastes such as urine.

Fumigation

Formaldehyde is active against bacteria, fungi and many viruses and spores. It acts by protein denaturation and reacting with the amine group in the cells, thus acting as a cytotoxic agent.

Formaline is a commercially available as a 40% solution of formaldehyde vapour in water. When it is heated, formaldehyde vapour is generated. Fumigation is most effective above a temperature of 20 C and relative humidity of 65%. Mixing formaline and water with potassium permanganate crystals is not recommended (This can result in a violent reaction if the correct relative concentrations of the two components are not used )

Use 100 ml formaline plus 900 ml water per 1000 ft3 of space. The door should be locked for 12hrs.

Fumigation is a hazardous operation, and it should be performed with extra care

Air filters fundamentals

Air filters (Mechanical) are used to remove air born contaminations

Pre-filtersEfficiency: 99 % down to 5 microns ( 5 to 7 Layers of high density poly ethylene mesh)

Fine filtersEfficiency: 99 % down to 3 microns(Non woven synthetic media sandwiched between 2 layers of HDPE Mesh)

High – Efficiency Particulate Air filter ( HEPA ) The filter has a minimum efficiency of 99.97 % when tested with an

aerosol of essentially mono dispersed 0.3 µm challenge aerosol.

Dettol antiseptic are insoluble in water, it produces a white - coloured milky emulsion of oil droplets when diluted ( 2% ) with water during use in cuts, wounds.

The active ingredient in Dettol is chloroxylenol (C8H9ClO)

Dettol - Antiseptic

The main differences between antiseptics and disinfectants are that disinfectants are used primarily to sanitize objects, and antiseptics are used on human skin. They both act as antimicrobials that kills the microbes that cause infection

Personal Hygiene

Sanitization of equipments & vessels of NRO ( R&D ref )

Manufacturing section-

Splash hot LLP (80°C) through the walls and drain through the filter after two circulation.

Transfer 1 ltr. IPA into the mixer and actives blender and closed for 1hrs.

Drain out IPA, allow the odor to get off, by keeping the vessels open for some time.

Sanitization of equipments & vessels of ZB and MPB ( R&D ref )

Manufacturing section-

Clean the batch mixing using a steam inject for melting and removing The product.

Heat about 30kg LLP in the melting kettle to about 75 to 80°C and circulate it in all other vessel by transfer line.

Splash 3 ltr IPA into the mixer and actives blender and closed for 1hrs.

Drain out IPA, allow the odor to get off, by keeping the vessels open for some time.

Sanitization of equipments & vessels of BPAC ( R&D ref )

Clean the batch mixer using a steam injects for

melting and removing the product adhered to the walls

and blades of the mixer.

Fill the melting kettle with DM water and heat to 75 to

80°C circulate it in all other vessel by transfer line and

drain. Repeat the process using fresh hot DM water.

Then using 3ltr IPA and Close the lid for 1 hr then

drain out, allow the odor to get off, by keeping the

vessels open for some time.

Manufacturing section-

CIP

Clean in Place means cleaning and sanitizing the manufacturing system without dismantling the connected pipelines, vessels, valves, filters etc.

Sequence of CIP operation:1. Heat caustic solution ( 1% in water) upto 80C in

steam jacketed vessel.2. Circulate the hot caustic solution min 30mins

then drain.3. Rinse by water. 4. Circulate citric acid solution ( 1% in water) for

30mins then drain.5. Check pH ( std 7 ).

Frequency: once per 6 months

Pest control

Target Pest Recommended chemicals

Service frequency

Crawling insects Deltamethrin, Allethrin, Kerosene, Imidacloprid, Polybutene glue, Bromadiolone

MonthlyWeekly

LizardWeekly

CockroachWeekly

Rat

* No Pest control activity is allowed inside process area

To prevent flies, air curtains and insect light traps to be installed suitably

Key Learning

SOP of cleaning and sanitization should be justified by basic chemistry and applied uniformly as a benchmark.

Effectiveness of cleaning & sanitization depends on a) maturity level, b) eye level and c) interest level of HK zone owner.

GHK evaluation to be done based on1. Sub-zones and overall Plant 2. Snap shot3. Chemical compliance as specified4. Frequency compliance as specified5. Micro testing result monitoring6. Score as per 1s/ 2s/ 3s/ 4s/ 5s std

Thanks