BCFPABCFPA

SANITATION ISSUES SANITATION ISSUES in the PLANT in the PLANT

ENVIRONMENTENVIRONMENT

WhyWhy do it?do it? Sanitation ProgramSanitation Program

A. Purpose of Sanitation– Safety - Product

- Employee- Environment

– Quality - Shelf Life - Consumer Acceptance

- Sales/ Profits

B. Food Microbiology– Pathogens/Spoilage– Growth– Sources– Controls

WhyWhy do it? do it? Because if you don’t, this could be Your Plant!

Mass Produced FoodsMass Produced FoodsToday, the food plant worker touches the lives of MILLIONS of people.

• Small• Serving local market (100’s of people)• Quick turnover

1900’s Food Plant Modern Food Plant

• Large• Serving the World (Millions of people)

• Long distribution times

SanitationSanitation• “All precautions and measures which are

necessary in the production, processing, storage and distribution, in order to assure an unobjectionable, sound and palatable product which is fit for human consumption”

• 1st Priority - Management Commitment

• NOT limited to Cleaning and Sanitizing

Cost Cost of Sanitationof Sanitation• Not just Cleaners and Sanitizers

– Time– Tools– Training

• GMP– Building design– Pest control– Personnel hygiene– Equipment design

SanitationSanitation• It’s the LAW

– GMP’s: Safety, Wholesome, Sanitary

• It’s Good Business– Profits and Growth

• Failure– Customer Dissatisfaction– Lost of Reputation– Law suits, $’s - Legal Fees, Fines

– Criminal Actions - Jail

– Plant Closed

Current Issues In SanitationCurrent Issues In Sanitation

• Health and Safety

• Control – Process and Costs

• Validation - Feedback

• Resources - Tools

• New Technology

HealthHealth• Employees and Customers

• Food Borne Illness

• Allergens

• Cross Contamination

SafetySafety

• Employees and Customers• Allocation systems – reduce

interaction with concentrated chemicals

• Protect against Contamination by Cleaners, Sanitizers

• Environmental impact – effluent concerns

Control & ValidationControl & Validation

• Sanitation - Only One Part• GMP – SSOP - HACCP

Everyone’s JobEveryone’s Job

Producer Processor Storage

DistributionPreparer

Control - PlanControl - Plan• Make a Plan

– Written Procedures

– Effective - Results & Cost

– Safety Orientated

– Practical

– Specific

– Posted

• Current– Feedback

– Continuous Improvementand Innovation

– Up-dated Regularly

Control - TrainingControl - Training• How

– Based on Written Procedures– Specific– Stress Safety

• Why?– Food Safety and Quality– Microbial Control– Reinforcement

Control - MonitorControl - Monitor• All Aspects Must be Measured• Detergent consumption

• Create a Daily Sanitation Log• Monitor – 4 Factors

– Concentration– Temperature– Time– Mechanical Force

Need:Need:Sanitation Daily LogSanitation Daily Log

• Record all daily sanitation challenges & exceptions:

— Time allotted for C&S

— Absenteeism & replacement workers

— Water Temperature, Pressure & Volume

— Chemicals Used & Concentrations

- both detergents and sanitizers

— Equipment issues and repairs

- both C&S and manufacturing equipment

Record anything and everything thatmay have impacted C&S

ValidationValidation

• HACCP

• External audits

• Performance Incentives

• Pre Operational

• All aspects must be monitored – know where to exert effort

Validation - ResultsValidation - Results

– A. Visual - Immediate

– B.Microbiological• Pre-Operational

– Swabs (I.D. problem area/ location)

– Bioluminescence/ ATP

• Product– Fresh– Aged

C. Organoleptic • Fresh

• Aged

D. Performance Monitoring• CIP Monitoring

E. Customer Acceptance• Complaints• Sales

ValidationValidationRapid MethodsRapid Methods

• Bioluminescence– Total ATP - Hygiene– Rapid - Real Time

• Data Trending Software

• Allergen Control• Water testing

“Fire Fly” Enzyme

Resources RequiredResources Required

• Commitment – look at sanitation as method to gain control and help deal with challenges

• Management – understand from the top down the need for change

• Monitoring

• Support to maintain changes

Resources - The BasicsResources - The Basics

• Time to clean – minimum time for sanitation that is non-negotiable

• Trained employees• Tools to clean – foam, sanitize,

scrub, rinse• Proper chemicals available• Supervision• Ability to monitor program

Methods of CleaningMethods of Cleaning

• Manual: Sink,Bucket & Brush– Limited Temperature and

Cleaner Activity

• Foams/Gels & Thin Films– Extended Contact Time

– Increased Cleaner Activity

– Fast

Methods of CleaningMethods of CleaningCont…Cont…

• Mechanical– High Pressure Rinse

• Assist Manual/Foam Methods

– Spray Washers– COP Tanks– CIP - Clean In Place

Buildings and FacilitiesBuildings and FacilitiesHow do bugs get in and move around?

• Adequate Space for Sanitary Storage

• Permits Control of Potential Risks

• Process Flow – Raw to Cooked

• Landscaping - Weeds, Grass, Neighbors

• Pest Control• Ventilation-

– Adequate and Protected

Buildings and FacilitiesBuildings and Facilities Con’t

• Water - Potable, Adequate, Protected

• Toilet Facilities

• Hand Washing

• Signs - Precautions, Policies

• Wastes - Rubbish, Effluent

EQUIPMENTEQUIPMENT

• Cleanable - Seams, Welds, Materials• Self Draining• Prevents Adulteration - Lubricants, Fuel,

Metal Fragments, Contaminated Water• Maintenance personnel / tools• Controls and Monitoring Devices• Proper Ventilation• Compressed Gases - Food Quality

New TechnologiesNew Technologies

• Beverage CIP trends

• Conveyor lubrication

• Water conservation

• Effluent

• ATP

Beverage CIP TrendsBeverage CIP Trends

• 5 Step – Hot Sanitize (185F for 20 min) 2.5-3 hours total

• 5 Step – Cold Sani – 2 hours total• 3 Step – Hot clean and sterilize – 60-

90 minutes total• 3 Step cold – clean and sani in one

step daily (45-60 minutes total), full clean 1x weekly

LubricationLubrication• Traditionally used fatty acid

• Synthetic lubricant development

• Dry lubricant– No water used – dry floor leads to less

micro (listeria), less effluent, less wear and tear on equipment, no drip pans

Utilities / EffluentUtilities / Effluent

• New detergent formulations leading to reduced operating costs and faster turn around– Reduced rinse times– Excelerate – ½ alkalinity and 1/3 sodium than

traditional chlorinated alkalines– Enzyme cleaners - Solodigm– Phosphorous content reduction– Reduced temperature cleaning

The Sanitation ProcessThe Sanitation Process

• “Deadly Results”– Consumer: People DIE– Business: Lost Sales / Costly Recalls– You: Plant Closes

• Everyone’s Job - 100% Commitment– Safe / Quality Foods– Safe Environment for:

• Food Production / Worker / The Environment -“Earth”

Make The Right ChoiceMake The Right Choice