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Key Terms
Cleaning Removal of Visible physical dirt and stains. A clean surface is defined as being
free from soil (e.g. food residues), free from bad odours, be non-greasy to the
touch and have no visible oxidation (e.g. rust).
Disinfection : The process of killing pathogenic bacteria , but not spores and all viruses by
99.999% during a time frame greater than 5 but less than 10 mins. Commonly brought
about by heat or application of chemicals. Disinfectants have a higher level of germ kill
capability for pathogenic bacteria as compared to sanitizers.
There is also a risk of biofilms forming on factory and food preparation surfaces if these
programs are inadequate. Biofilms are complex aggregations of microorganisms and
other materials which enhance survival and growth of microorganisms; once formed
they are very difficult to remove.
The safety of staff must be considered when developing these programs, including the safe
use of chemicals and hot water, and reducing manual labour.
Cleaning prior to sanitizing is recommended as it increases
the effectiveness of the sanitizing step.
What Should be Cleaned and Sanitized?
• All surfaces that may contact the food product, such as utensils, knives,
tables, cutting boards, conveyor belts, ice makers, ice storage bins, hands,
gloves, and aprons. Surfaces that do not directly contact the product such
as walls, ceilings, floors and drains have a profound effect on environment.
• Food Transportation Unit: This includes vehicles, aircraft, ships, containers, boxes,
bulk tanks, trailers and any other transportation unit used to transport food.
• "Potentially Hazardous Food" means any food in a form or state which is capable
of supporting the growth of pathogenic microorganisms or the production of
toxins. Example for such foods involve meat, poultry, seafood, milk and its
products.
Contact time
Detergent concentration
Chemical action
Time
Science behind cleaning
Different types of soil
– Oily & Fatty soils, Proteinaceous soils, Carbohydrate soils
Use of water or any other agent to remove small particles missed in the dry
cleaning step and prepares (wet) surfaces for cleaning application.
Product processed
Point in processing environment
Interior or exterior of equipment
. Residence time
Temperature
What is soil?
Soil is any unwanted matter on the surface of an object that one desires to be
clean. It is undesirable foreign matter on surfaces. In general a heterogeneous
mixture of many substances. Special care must be taken to ensure that all soil is
removed and that it is not redeposited on the substrate.
- Physical properties
- Chemical properties
Characteristics of Food Soils
• Soil may be classified as visible and invisible, the latter category being primarily
microorganisms, such as bacteria, yeasts, and molds.
• Some food soils can be dissolved in water such as simple carbohydrates (sugars),
some simple mineral salts (NaCl), and some starches. There are also food soils that
dissolve in alkali, like proteins, starches associated with proteins or fats, and
bacterial films (biofilms). There are food soils that dissolve in acid, like hard water
hardness salts (calcium and magnesium salts), and more complex mineral films,
including iron and manganese deposits. Some also that dissolve with surfactants,
which include fats, oils and greases, many food residues, inert soils such as sand,
clay, or fine metals, and some biofilms
Cleaning Process
– Primary step
• removal of soil from substrates
– Secondary step
• stabilisation of dispersed or dissolved soil in the wash liquor to
prevent re-deposition (long term effect)
• Detergents react with soils to change their chemistry so they will dissolve
into the water and be carried away.
Detergents
Solvent cleaners
Abrasive cleaners
Acid cleaners
Cleaning Agents - Detergents
Detergents - A detergent is a surfactant or a mixture of surfactants with "cleaning
properties in dilute solutions." These substances are usually
alkylbenzenesulfonates, a family of compounds that are similar to soap but are
more soluble in hard water.
Detergents contain surfactants ( surface acting agents ) that reduce surface tension
between soil and surface so that soil can be penetrated and removed. Types of
detergents
• General Purpose (GP)
• Alkaline
• Chlorinated ( Chlorinated alkaline);
• Acid
• Enzymes
• General purpose detergents are mildly alkaline and used to clean up fresh soil from
floors , walls , ceilings, equipment, utensils, etc .
• Acid detergents remove inorganic mineral deposits (scale) and stains such as those
associated with hard water.
• Emzymes are specific to a given soil type. These detergents are tailored for protein,
oil or carbohydrate based oils. Carbohydrate soils mostly occur where breading,
batters or starches are used.
Acid cleaners
Used on mineral deposits eg. Scale
Used in ware-washing machines , steam tables,
Used for rust stains and tarnish on copper and brass.
Abrasive cleaners –
Contain a scouring agent like silica that help to remove hard – to – remove
soil.
Often used on floors or to remove baked on food in pots and pans.
Effectiveness of detergents depends upon
For an effective detergent and soil cleaning effectiveness will depend upon
several basic factors
– Contact time
– Temperature
– Physical disruption ( scrubbing) and
– Water chemistry
For certain applications such as smoke houses, highly caustic detergent or alkali
(Caustic soda) is heated to 180degree F or hotter. The conditions chemically alter
and disperse soils such that denatured food residues are not likely to develop.
Water Chemistry – Final rinsing with water to drain the soil, nature, source and type of
water used effects the method of cleaning and sanitation.
STEP – 4 – Post Rinse
• During post rinse – water is used to remove detergent and loosen soil
from food contact surfaces.
• All the detergents must be removed in order for the sanitizing agent to be
effective.
STEP – 5 - Application of a sanitizer
After the food contact surfaces are cleaned, they must be sanitized to eliminate or
atleast suppress potentially harmful bacteria. Many type of chemical sanitizers are
available. They may or may not require rising before the start of processing,
depending upon sanitizer concentration. All sanitizers must be legally approved and
used only as per the MSDS (Material safety Data Sheet) provided by the chemical
manufacturer.
Application method
While using sanitizer a recommended dosage and application method of proportioners
and applicators must be used. These proportioners and applicators can be installed
in-line, on-line or at a separate stations.
A range of procedures can be used from manual mixing to fully automated system may
be applied.
Sufficient contact time and coverage is sometimes best assured by the use of sanitizers
dip tanks for utensils and equipment parts.
Sinks and cleaning sanitations can be applied with protioning devices that mix and
deliver sanitizers in the prescribed concentration
Bulk containers or reservoir fitted with auto dosers which minimize maintenance, control
of chemicals usage and may reduce monitoring.
For control of common soil microorganisms, such as Listeria and E.coli footbaths are
frequently used as a part of plant sanitation program.
An ‘Ideal’ Sanitizer
– Acceptable toxicity
– Wide, non-selective spectrum
– Rapid action
– Reasonably soil tolerant
– Non corrosive
– Compatible with cleaning materials
– Useable in ambient conditions
– Easily measured and monitored
– Free rinsing
– Non-toxic to the environment
– Cost effective & safe to handle.
Sanitizers concentration commonly used in Food Plants
* The higher end of the listed range indicates the maximum concentration
permitted without a required rinse ( surface must drain)
# Includes mix of oxychloro compounds
Source 21 CFR 187.1010
Types of Sanitizers
Chlorine Sanitizers
Unfortunately no deal sanitizer exists for every requirement.
Chlorine sanitizers
Chlorine and products that produce chlorine comprise the largest and most common
group of food plant sanitizing agents. Chlorine sanitizers are effective against a
wide range of bacteria and molds. They work well at cool temperatures and
tolerate hard water. They are also relatively inexpensive. Household bleach is a
solution of sodium hypochlorite, a common form of chlorine.
Chlorine exists in more that one chemical state when dissolved in water. The
effectiveness of chlorine sanitizers is proportional to the hypochlorous acid in
solution; the most effective chemical form of chlorine.
Chlorine dioxide : - Chlorine di-oxide does not form hypochlorous acid but dissolves in
water to produce a solution possessing strong oxidizing properties, It can be more
effective that chlorine in terms of ability to kill or reduce bacteria and retains some
anti microbial function in the presence of organic soils. It is particularly useful for
destroying bacteria bio-films. It is also less corrosive to stainless steel and less pH
sensitive than chlorine.
Limitations
• Quats exhibit selective to different types of microorganisms they kill.
• On shifting from other sanitizers to Quats, there may be chance incident of
establishment of coliform or spoilage organisms in the environment, which may
then transfer to the products.
• These may exhibit effective results when altered with other sanitizers one or two
times a week.
• If detergents are not thoroughly rinsed from surfaces prior to applying quats or the
sanitizer will be chemically neutralized.
Iodine based sanitizers
• Iodoine based sanitizers, know as Iodophors are formulated with other
compounds to enhance their effectiveness They offer desirable features in a
sanitizer. They kill most types of micro organisms including yeast and molds even at
low concentrations.
• They tolerate moderate contamination with organic soils and less corrosive and pH
sensitive than chlorine and are more stable during storage and use. They are less
irritating to skin than chlorine and often selected for hand dips.
• Iodophors have an amber to light brown colour when properly diluted which can
be useful for monitoring since colour indicates the presence of active iodine. Test
strips are available for more precise monitoring.
The Carboxylic acid sanitizers, commonly known as fatty acid sanitizers, these are
generally more effective than acid – anoinic against a range of microorganisms types.
Peroxyacetic acid are produced by combining hydrogen peroxide and acetic acid. This
sanitizers is highly effective against most microorganisms of concern, especially in
biofilms which would otherwise protect bacteria. They are fast acting even at low
temperatures, tolerate some organic soil and degrade to form environmentally safe
products.
Other sanitizing agents include ozone, ultraviolet light and hot water. Ozone is an
unstable oxidizing gas that must be generated on-site, contributing to its relatively
high cost. It is a more aggressive sanitizer than chlorine but requires careful
monitoring to prevent the release of excessive levels of the toxic gas.
Ozone, like chlorine, is dissipated when in contact with organic soils. It can be injected
into water system, as an alternative to chlorine gas, to make it safe for processing.
Ultraviolet ( UV ) irradiation is sometime used for treating water, air or surface that
can be positioned in close proximity to UV generating lamps. Ultraviolet does not
penetrate cloudy liquids or below to surfaces of films or solids.
It has no residual activity and cannot be pumped or applied onto equipment like most
chemical sanitizers.
Sanitizers - sanitizing methods
Spray Sanitizing Use of spray to sanitize equipment surfaces
CIP Sanitizing Sanitizing by circulation of the chemical agent inside pipeline and
equipment.
Immersion / COP Sanitizing equipment by immersion in a tank of sanitizing solution
Sanitizing
Fogging Fogging the chemical agent to sanitize the air and surfaces in a room.
Chlorine All food contact surfaces, sprays, CIP, fogging
Mixed Halogens All food contact surfaces, CIP, spray sanitizing
Iodine All food contact surfaces, spray, CIP, approved as hand dips.
Peracetic Acid All food contact surfaces, CIP, especially cold temperatures and Carbon
di oxides environments.
Acid Anionics All food contact surfaces, CIP, spray, combined with sanitize and acid
rinse step into one.
QUATS All food contact surfaces, mostly used for environmental control: walls,
drain and tiles
Cleaning methods in Food industry
•Immersion cleaning
•COP
•CIP
Manual Scrubbing -
Single disc w/water tank e.g. Stripping coated
floorings
Automatic Scrubbing –
Machine scrub/dry floor in one operation. Cleaning of
medium to large areas.
•Use of high foaming solution to increase the retention time on the vertical
surfaces
•Gels are used to further increase over foam the retention time on the
vertical surface
H20
30 - 50 psi
Advantages of Foam Cleaning Process
• Manual or Automated
• Use of Brooms/ Shovels
• Use of automated Vaccum cleaners
• Process used where wet cleaning is not possible
• Areas manufacturing water sensitive products
Immersion Cleaning
• This is the type of cleaning in which the parts to be cleaned are placed in the
cleaning solutions to come in contact with the entire surface of the parts.
• Immersion cleaning is preferred for parts that must be placed in baskets and for
processes requiring a long soaking time because of the type of contamination to be
removed or the shape of the parts to be cleaned.
It is the most effective method, even if not the fastest one, and can be used with any
type of cleaner for any process, heated or at room temperature. Immersion
washers can be portable or stationary; single or multi-compartment; and are
available with a variety of options, controls and valve configurations including CIP
capability. The important aspects during design of immersion washer should be
Automated controls:
- Contact Time
- Temperature
COP Mechanical Action (agitation)
Combination
Mechanical cleaning - CIP
Cleaning in place can be described as the cleaning of equipment and vessels at the
same place without movement of them to a different place. The cleaning agents
can be transferred to the vessel or equipment types either thorough fixed piping or
flexible hoses. The CIP process can consist of the following elements:
• Supply pump
• Return pump
• Heat exchanger with Black/Plant steam supply
• Chemical tanks i.e Acid, Alkali tanks
• Supply Pressure gauge or transmitter
• Supply temperature sensors
• Conductivity meter with sensor
C.I.P. Basic Requirements
Mechanical cleaning – High Pressure cleaning
Visual test
General appearance
Microbiological test
contact agar method
swab/rinse method
rapid hygiene test.
Verification of cleaning and sanitation methods
Monitoring to assure a clean and sanitary processing environment processing is required
regulation. Various methods are used by different organizations to verify
effectiveness of cleaning and sanitation programms.
2. Contact plate – Contact plates contain agar which has a convex surface. These plates
are pressed against the surface of equipment then incubated. Examination of the
plate will give an organism count and individual colonies can be lifted from the plate
and identified.
The surface of the equipment touched by the contact plate must be cleaned of any agar
residue. This method is used for verifying periodic effectiveness of cleaning and
sanitizing plant surfaces. The test procedure is very simple and requires no
additional special equipment and little training. Most contact plates are simply
touched to the surfaces to be tested then covered with a protective cap.
3. Swabbing - A sterile cotton or calcium alginate swab is wetted in sterile buffer, saline
solution, or broth and rubbed over a measured portion of the surface of the
sanitized equipment. The swab is then either streaked across an agar plate or
placed into a sterile broth tube.
The plate or tube is incubated for the appropriate length of time. Examination of the
plate will give an organism count and the individual colonies can be lifted from the
plate and identified. Tubes are examined for turbidity. This is a pass / fail test.
Swabbing is very useful for irregular surfaces or curved equipment
5. Final Rinse Test: Water of known microbiological quality and volume is rinsed
through the equipment. The water is recovered and filtered via membrane
filtration technique. The membrane is placed onto a plate and incubated.
Examination of the plate will give an organism count and individual organisms can
be identified. Note that rinse water analysis may not detect the presence of biofilm
on equipment surfaces.
Cleaning & Sanitation – Microbiological Aspect
• Microbes need Water and Food for growth.
• Most of food products are high in water activity.
• Food product contact surfaces may harbor microbes and provide the shield to
exterior factors.
• Bacteria take exponential route for the growth and one bacteria doubles in average
20 minutes.
• A non-clean, improperly clean surface may create a risk to food product and its user.
• Critical for surfaces, coming in direct contact with food.
• A suitable disinfectant should have
• Broad Spectrum for killing microbes (viz. all groups – Bacteria, Yeasts,
Molds, Viruses etc., Gm+ve & Gm-ve etc.)
• Should be sporicidal if required
• Rinse free or easy to rinse
• Should not affect MOC
• Safe and easy to use
• Detergent-disinfectant can provide cleaning and sanitation simultaneously, thus
saves water, energy, time and manpower
Monitoring steps in the cleaning program should include:
• Visual inspection post cleaning to ensure any visible food residues have been
removed
• Temperature checks for water and chemical solutions (using a calibrated
thermometer or temperature recorder) to ensure they are within the ranges
specified in the Standard Operating Procedures (SOP)
• Concentrations of detergents and sanitizers are within the ranges specified in the
SOP
• Timing devices used to ensure adequate contact times are operating correctly
• Records are checked against procedures outlined in the SOP.
The schedules should define when and how different items and areas should be
cleaned and who to do the cleaning.
• What is to be cleaned
• Who is to clean it
• When it is to be cleaned
• How it is to be cleaned
• The time necessary to clean it
• The chemicals used
• Materials and equipment to be used
• The cleaning standard required
• The precaution to be taken
• The protective clothing to be worn
• Who is responsible for checking and recording that it has been cleaned.
END OF PRESENTATION