science based sanitation best practices · choosing the right cleaner effect soil type chemistry...

Science Based Sanitation Best Practices

Jeremy Adler

Sr. Technical Support Coordinator

LISTERIA RECOVERY IN PLANT ENVIRONMENTS

Plant Conditions Listeria recovery

Above average sanitization + excellent or moderate environmental control program

6.8%

Below average sanitization and slight or no environmental control program

27.5%

Walker et al. J. Food Protect. 1991

MAGIC

MIRACLEin a DRUM

or

LISTERIA CONTROL IS NOT . . .

RocketScience

CONTROL REQUIRES DOING THE RIGHT

THING EVERY TIME

FOUR TENETS OF LISTERIA PREVENTION & CONTROL

BUT, WE CAN HELP

CONTROL LISTERIA!

WE CANNOT COMPLETELY ELIMINATE LISTERIA . . .

LISTERIA CONTROL & PREVENTION Prevent Entry

Control incoming contamination

– Employees, Equipment, Ingredients, Packaging

Prevent Growth Remove growth nutrients; water & soil

– Keep it dry, Keep it cold, Use sanitizers

Eliminate Harborage SitesEliminate niches/harborages

– Sanitary equipment design & maintenance– Regular, effective & thorough C&S

Prevent Spread Control vectors (stop transmission)

– Employees, forklifts, cleaning tools, floor scrubbers, pests, water, air, etc.

PREVENT ENTRYCONTROL INCOMING CONTAMINATION

• Movement of people, equipment, materials, etc., needs to be monitored, controlled and restricted

• Zoning and traffic patterns

PREVENT ENTRYSOLUTIONS

• Environment Care Program

– Floor & Drain Management

– Doorway Sanitation

– Floor Sanitizers

– Hard Surfaces

– Cooler and Freezer Care

• Personal Hygiene Program

– One Step Disinfectant

– Cleaner-Sanitizers

– Boot Washers & Sanitizers

– Hand-care Solutions

PREVENT GROWTHIDENTIFY & EXECUTE APPROPRIATE CLEANING & SANITIZING PROGRAMS

CLEANING:

• Match the cleaner to the nature of the SOIL

• Match the cleaner to the WATER properties

• Optimize compatibility with the SURFACE

• Be appropriate for the METHOD of application

• Meet ENVIRONMENTAL guidelines

Clean surface,

ready to

sanitize


DRY CLEANING:

• Match the cleaner to the nature of the SOIL

• Optimize compatibility with the SURFACE

• Use appropriate METHODS for the application

• Meet ENVIRONMENTAL guidelines

Clean surface,

ready to

sanitize


SANITIZERS:

Sanitizer ConcentrationLog

Reduction

Chlorine 100 ppm >5

QAC 200 ppm >5

Iodophor 25 ppm >5

Fatty Acid 1oz/6gal >5

Acid Anionic 200 ppm >5

Peracid 1 oz/4 gal >5

Mixed

Peracid1 oz/6 gal >5

A.O.A.C. Germicidal Sanitizer Method - 25oC

For application claims and use instructions please refer to the product label

FLOOD SANITIZE TO ENSURE THOROUGH COVERAGERECOMMEND USING A CENTRAL SANITIZER SYSTEM

ELIMINATE HARBORAGE SITESPOOR SANITARY DESIGN AND MAINTENANCE WILL NEGATE THE BEST

CLEANING PROGRAM

TYPICAL HARBORAGE SITES INCLUDE:

Hollow rollers

Bad gaskets, bad welds

Sprockets & gears

Materials of different kinds

bolted together

Difficult to clean scrapper

blades

Conveyor wear strips & guides

KEEP IN MIND THE RIGHT “TOOL” FOR THE JOB

ELIMINATE HARBORAGE SITES

DON’T CREATE HARBORAGE SITES WITH INCORRECT CHEMISTRY CHOICES

Typical causes of cross-contamination include:

Humans

High pressure rinsing during production

Leaks

Failure to follow GMP processes

Cleaning tools & equipment (floor

scrubbers, mop buckets, etc.)

PREVENT SPREAD &

CROSS-CONTAMINATIONYOU CAN NOT ELIMINATE LISTERIA; THEREFORE, IT IS EXTREMELY

IMPORTANT YOU PREVENT ANY KIND OF CROSS-CONTAMINATION TO

PREVENT AND CONTROL LISTERIA

PREVENT SPREAD &

CROSS-CONTAMINATION

Deeper Dive into Cleaning & Sanitizing

FOUR FACTORS OF CLEANING

• Chemistry (type & concentration)- Proper detergent and concentration

for the job

• Temperature- Necessary for proper cleaning

performance (within a range)

• Time- To complete all necessary cleaning

procedures and pre-op

• Mechanical Force- Scrubbing, brushing, boosted water,

CIP, COP

TEMPERATURE – INITIAL HOT WATER RINSEFatty soils require temp & detergent for effective removal

RINSE WATER HOSE TEMPS

• Optimum rinse hose temperature is 130-140˚F, at the hose nozzle, for effective removal of animal fats

• >140˚F will start to bake soils on to surfaces causing build-ups and potential biofilms and can cause increased condensation

• 130-140˚F is also the optimum temperature for most detergents to perform - need hot water through foam cleaning

• Up to 10˚F temperature drop from point of heating to rinse hose nozzles

• Water temperatures at nozzle should be verified and monitored nightly and recorded on log sheet for historical reference

MECHANICAL – CENTRAL WATER SUPPLY

– Low Pressure: 40 – 100 psi (primarily scale cleaning)

– Boosted (Med Pressure): 100 – 250 psi (Optimum for short cleaning window)

– High Pressure: 250 – 1,000 psi (not recommended)*Some organizations may call >400 high pressure, but you MUST be careful

MECHANICAL – MANUAL CLEANING

FOAM SPRAY HAND WASH

pH range: 2-12

Rinse: 120-140°F

Foam and spray: Ambient temperature

Hand wash: Ambient – 120°F

CHOOSING THE RIGHT CLEANER

EFFECT

SOIL TYPE

CHEMISTRY

Fats & Oils Carbohydrates Proteins Minerals

Dissolve Liquefy Hydrolyze Disperse Emulsify

Rinse

Alkaline Acid Oxidizer Enzyme Solvent Surfactant

• Everything must be covered

• Belts should be running

• Work bottom to top when foaming

• Sanitary design is both friend and foe

CHEMISTRY – COVERAGE!

TIME

• Chemistry (type & concentration)- Proper detergent and concentration

for the job

• Temperature- Necessary for proper cleaning

performance (within a range)

• Time- To complete all necessary cleaning

procedures and pre-op

• Mechanical Force- Scrubbing, brushing, boosted water,

CIP, COP

FOUR FACTORS OF SANITIZING

• Chemistry (type & concentration)- Proper sanitizer and concentration for

the job

• Water quality, material compatibility, label claims

• Temperature- Necessary for proper performance

(within a range)

• Time- Allow enough time to perform “kill”

• Coverage- Complete coverage of surface areas to

reduce micro levels

Coverage

ChemistryTemp

Time

Sanitizing Program

Coverage! Coverage! Coverage! Coverage!

WHAT A SANITIZER IS/DOES• Reduce microbial contamination to a safe

level

• Two Types:- No rinse food contact surface sanitizer

• Approved for incidental food contact

• Must be adequately drained from the surface

- Non-food contact surface sanitizer

• Usage restrictions:- Only prepare in potable water

- Do not reuse for sanitizing (prepare fresh)

- Use the accurate concentration• Below = Questionable efficacy

• Above = Violate regulatory approvals

A Sanitizer

Does NotSterilize

&

Disinfect

DoesReduce

contamination to

safe level

&

Surface sanitizer

kills 5 logs in 30

seconds at 25 C

DIRECTIONS FOR USE:It is a violation of Federal law to use this product in a manner

inconsistent with its labeling.

A World of Food SolutionsOSI Group, LLC.

World Headquarters | Aurora, Illinois, USA630.851.6600 | www.osigroup.com1

Assessing and Controlling

Microbial Risk Through Periodic

Equipment Cleaning

Presented by:

James T DavisCorporate Sanitation Manager

OSI Group

May 9th, 2018

A World of Food Solutions

Overview

Key Definitions

Food Safety Hazards

Periodic Equipment Cleaning Program

Brief Note on Heat Treatment


Key Definitions

1.) What is RISK?

Chance of injury, damage or loss; dangerous chance or hazard


Key Definitions

2.) What is a NICHE?

An area or point on a piece of equipment or infrastructure that has the

potential to harbor food particulate and/or microorganisms

Example: Mounting plate on forming machine


Key Definitions

3.) What is HYGIENIC DESIGN of equipment?

The state in which equipment is engineered to optimize product quality, food

safety and operational efficiency through the elimination of niche or harborage

areas and ease of cleanability.

Listeria present in a hairline scratch of the surface of

stainless steel

Key Point: Microorganisms are very

small and have the potential to reside in

“niche” areas in equipment – hygienic

design is key to eliminate these areas!!


Key Definitions

4.) What is PERIODIC EQUIPMENT CLEANING (PEC)?

A preventative measure by which processing equipment is disassembled and

cleaned beyond normal daily sanitation requirements to address identified

risks in hygienic design to remove food particulate and microorganisms in

niche areas


Food Safety - Hazards

Three types of hazards associated with equipment, relevant to equipment design:

1) Biological

- L. monocytogenes, E. coli, Salmonella, etc

- Pathogenic vs. Non-Pathogenic

2) Chemical

- Allergens, processing chemicals, etc

3) Physical

- Metal, wood, plastic, etc


Periodic Equipment Cleaning (PEC) Program

Steps of PEC Program Development

1.) Perform an equipment hygienic design risk assessment

2.) Identify gaps and add to master sanitation schedule (MSS)

3.) Implement PEC to address noted deficiencies/gaps

4.) Validate PEC tasks and frequency


Step 1: Assessing Risk

What are factors pertinent in determining risk?

1.) Product factors

2.) Process/Operational factors

3.) Equipment design factors



Examples To Use When Assessing Risk

2017 3-A Workshop (PRODUCT RISK) – Hygienic Design Risks (Source: 3-A.org)

Source: http://www.3-a.org/Portals/57/Documents/Annual%20Meeting%20Presentations/2017/May%201%20Basics/May1_Basics_03_Workshop%201%20Risks.pdf?ver=2017-05-08-

103056-857

Key Point: Understand what

risk level is your product!

RTE > Raw

Exposed RTE > Cook-In-Bag

http://www.3-a.org/Portals/57/Documents/Annual Meeting Presentations/2017/May 1 Basics/May1_Basics_03_Workshop 1 Risks.pdf?ver=2017-05-08-103056-857



1. Cleanable to a microbiological level

2. Made of compatible materials

3. Access for inspection, maintenance, cleaning and sanitation

4. No product or liquid collection

5. Hollow areas should be hermetically sealed

6. No Niches

7. Sanitary operational performance

8. Hygienic design of maintenance enclosures

9. Hygienic compatibility with other plant systems

10.Validate cleaning and sanitizing protocols

North American Meat Institute – 10 Principles of

Sanitary Design (EQUIPMENT RISK)



Example: Quantifying Risk Using the NAMI Sanitary Design

Checklist and Guidance

Determine equipment design and acceptability from industry guidance

Source: https://www.meatinstitute.org/ht/a/GetDocumentAction/i/97261



Example: Quantifying Risk Using the NAMI Sanitary Design

Checklist and Guidance

Assign a score to a specific equipment design using document guidance


Step 1: Assessing RiskExample: Quantifying Risk Using the NAMI Sanitary Design Checklist and Guidance

Set design acceptability rating by risk level type or when action is needed

Example Requirement

a.) High Risk Level (A) ≥ 90%

b.) Moderate Risk Level (B) ≥ 80%

c.) Low Risk Level (C) ≥ 70%

OR

Example Requirement

a.) High Risk Level requires redesign or action for all “Unacceptable” or “Marginal” items

b.) Moderate Risk may require redesign or action (validate and monitor)

c.) Low Risk Level may require action (validate)

OR

????



Number Zone (s) Risk

Microbial

Risk

Chemical

Risk

Foreign

Material Risk

1 2 High Y Y

2 2 High Y YInsert Plugs

Pressed connection producing

uncleanable seam;

incompatible synthetic

material cracking under

normal use

Item Sanitary Design Issue

Covers

Bolted/gasketed connections

producing uncleanable seam;

evidence of frayed gasket

Microbial Intervention?

(Yes/No)

Yes

Yes Disassembled & Cook Weekly Replace *See Photos Below

*See Photos Below

Current Intervention Recommendations/WOs Comments

Disassembled & Cook Weekly

Replace during inspection if

compromised

Example:


Step 2: Identify Gaps and List in MSS

Gaps are identified sanitary design constraints from step 1

Example Gaps List:


Step 3: Implement PEC – Example PEC

Remove all belt supports and guides

Remove modular plastic belt

Remove all stand-off mounted items

Remove all bearings, pillow blocks, fasteners

Remove all adjustment arms

Remove spray devices (or caps when not in

use)

Remove all sprockets and rollers from shaft(s)

**All disassembled pieces placed in COP

tank - 160°F for 30 minutes with chemical

WEEKLY REQUIREMENT


Step 3: Implement PEC – Example PEC

Key Points• All removed parts and pieces MUST be disassembled as far as possible

• Inspect for damage while disassembled

• Take “BEFORE” cleaning and “AFTER” cleaning swabs (TPC/APC, Environmental)


Step 4: Validate PEC Tasks and Frequency

Goal: Determine efficacy of PEC cleaning process AND the longest period of time that the

selected equipment can go between deep cleaning cycles while maintaining hygienic conditions

Determine Efficacy of Cleaning Process (“AFTER” PEC)

1.) Utilize organoleptic methods (sight, touch, feel) to determine cleaning effectiveness upon completion –

similar to existing pre-op standards

2.) Utilize swabbing (TPC/APC, Environmental, ATP) post-sanitation

Determine Frequency of Cleaning Process (“BEFORE” PEC)

1.) Utilize swabbing (TPC/APC, Environmental, ATP) after disassembly but PRIOR to any cleaning

2.) Visual inspection for soil load



Key to Remember!!

“Before” swabs are used to validate & verify frequency of PEC

“BEFORE” SWAB FAILURES MEANS YOUR FREQUENCY IS INADEQUATE

“After” swabs are used to validate & verify cleaning effectiveness

“AFTER” SWAB FAILURES MEANS YOUR CLEANING IS INADEQUATE

You NEED to take both!

**Visual inspection SHOULD also be used during this time



Key Points

• Set limits for acceptability

• Examples:

• APC: ≤ 100 CFU

• Listeria: Negative

• Determine what frequency should

be based on data

• Example

• Week of failure point (APC)

minus 1 week

• All PEC tasks should have a

validated frequency


Brief Note on Heat Treatment & PEC

1.) Heat treatment can be utilized in combination with deep teardown events to

enhance the hygienic conditions of the equipment or component in question.

2.) Several options available for heat treatment

A. Batch Smokehouse/Oven

B. COP Tank

C. Tent Steaming

3.) Important Factors

A. Time (Target minimum 30 minutes – Need to VALIDATE!)

B. Temperature (165-185°F – Need to VALIDATE!)

C. Humidity (Saturated steam/heat!)

D. Disassembly (More disassembly = less heat penetration needed)


Brief Note on Heat Treatment & PEC

Use of steaming may reduce frequency of extensive teardowns (PEC

events) for complex equipment

Time efficiency

Limitations of heat intervention

Does NOT replace extensive teardown (PEC events) but compliments

Soils still present in niche areas!


Questions or Comments?

Thank You!

James T DavisCorporate Sanitation Manager

OSI Group

[email protected]