Principles of Cleaning and Sanitation

Transcription

Principles of Cleaning and Sanitation
Elis Owens Ph.D. – Senior Chemist/Microbiologist
PRODUCE SAFETY WORKSHOP
UC DAVIS – November 2014
Outline
• Who is Birko
• Principles of Cleaning and Sanitation
Selecting the right Chemistry
Chemistry/Sanitizer Rotation
Application Options
Sanitary Design
Floors and Drains
Property of Birko Corporation
November
2014
Copyright 2011 Birko.
All rights reserved.
The Birko Story
60 Years of Success
• Founded in 1953, Birko is a 3rd generation family-owned
manufacturer of cleaning and process chemistry for food
producers
• Chad Equipment, LLC, a Birko company, is a leading supplier of
equipment for pathogen intervention and chemical handling
• PMA Gold Circle Member
• ColoradoBIZ Magazine Top
Manufacturing Company 2013
October
18,reserved.
2013
All rights
Who Do We Work With?
Customer base includes leading food and beverage producers
November
2014
Birko – CHAD Capabilities
• Over 250 specialized products including cleaners, sanitizers,
process chemistry and direct food contact antimicrobials
• Products suitable for use with natural and organic labels
• Committed to research, development and innovation with strong
collaboration with leading universities
• 20+ patents related to food safety, and process chemistry and
equipment
• Only chemical manufacturer involved in original HACCP
legislation
• All technical reps are HACCP certified
November
2014
Our Approach to Food Safety
MULTIPLE-HURDLE INTERVENTION STEPS
• Effective Cleaning & Sanitation Products and Procedures
• Specialized Equipment for Chemical Control and application
• Antimicrobial Interventions or Pathogen Reduction
Treatments Products Applied at Key Steps in the Production
Process
• Implementation of Technology to Control and Capture Data
November
2014
The Challenge
What are your day to day challenges or what
keeps you up at night related to sanitation?
• Sanitation vs. Production
• Knowledge
• Resources
• We’ve never done it before
November
2014
World-Class Food Safety
Eight Imperatives of Food Safety
1. Employee Safety & Training
2. Consistent, Predictable, Safe, Food Production
3. Commitment to a Formal Continuous Improvement Process
4. Sustainable & Responsible
5. Effective Cost Management
6. Partnering with Industry Leaders (Customers & Vendors)
7. Third Party Verified
8. Documented Implementation & Execution Plan
November
2014
KPIs that Sanitation Influences
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Food Safety
Cost Management
Process Efficiencies
Yield Enhancement
Utilities Efficiencies
Chemistry & Food Safety Enhancements
November
2014
SAFETY FOR EMPLOYEES
Everybody goes home not to the hospital
• CHEMICAL HAZZARDS
• EQUIPMENT HAZZARDS
• SLIP & FALL HAZZARDS
November
2014
CHEMICAL HAZZARDS
• Heavy soil loadings require strong chemicals!
• Chemical damage to the body starts by
(1) Skin contact
(2) Absorption through the skin (HF, DMSO)
(3) Inhalation
(4) Eye contact
(5) Ingestion
• Make sure that Safety Data Sheets (SDS) are available to all employees
• Learn about the products and risks – train team members
November
2014
CHEMICAL HAZZARDS
• Appropriate PPE (Personal Protective Equipment)
• Gloves
• Safety Glasses
• Goggles
• Face Shield
• Boots
• Rain suit
• Label all containers used to hold or carry chemicals
• Never return chemicals to the drum after they have been
dispensed
November
2014
Mixing Incompatibles
November
2014
EQUIPMENT and SLIP & FALL
LOCK OUT TAG OUT
• De-energize, lock & tag out all energy sources on
processing equipment
– Electrical, hydraulic, pneumatic and water/chemical
• Use waterproof covers on moisture sensitive equipment.
SLIP & FALL
• Equipment is not a ladder
• Provide and train employees in use of ladders, catwalks
etc
• Fall protection as a last resort where needed
November
2014
QUESTION
What is the purpose
of cleaning and
sanitation?
November
2014
The “Why?” of Sanitation
Prevents Foodborne Illness
• Regulations tell us we have to - FSMA, FDA etc.
• Risk Management Issue
• Product Liability
• Personal Liability
• Brand Reputation
Effective sanitation is the cornerstone of quality
November
2014
Consequences
• E. coli O157:H7 at Jack in the Box 1993
• 4 Children die, >700 gravely ill
Listeria outbreak 2011/12
• Est. 38 adult deaths
• 146 sickened in 28 states
Litigation
Bankruptcy
Incarceration
Fatalities
Copyright 2011 Birko. All rights reserved.
QUESTION
What are we doing
during sanitation
• Remove Soil
• Kill Bacteria
• Remove Biofilm
November
2014
SOIL
• Definition:
• Any substance that is found on a surface but is not an
intended part of that surface and therefore is unwanted;
• Any substance that is suspended in air and may deposit on a
surface but is not intended to be present there
• Synonyms: Dirt, Contamination, Biofilm
• Produce Plant Soils Include: Dust, mud, grime, manure, mineral
deposits, protein, carbohydrates, rust
• SOIL harbors, and provides food for, microorganisms
November
2014
BIOFILM
BIOFILM
http://www.hygiena.net/images/biofilm-diagram.gif
November
2014
BIOFILM
• Major area of concern for food processors especially
for ready to eat items in wet processing areas
• Typically resistant to conventional cleaning and
sanitation processes
• Frequent culprit where persistent bacterial
contamination is a problem
• Very common in drains
• Specialty products required for removal
November
2014
QUESTION
What are the prerequisites for an
effective sanitation
program
November
2014
Prerequisites
TO CLEAN SUCCESSFULLY YOU NEED:
• Knowledgeable Supervision & Management Commitment
• A Cleanable Plant and Cleanable Equipment
• An Operational Cleaning and Sanitation Program
• Adequate Supply of Potable Hot Water Suitable, Functioning
Sanitation Equipment
• Effective Cleaning Chemicals and Sanitizers
• Adequate Numbers of Trained Personnel
• Ongoing Employee Training in Sanitation and Safety
November
2014
SUPERVISION & MANAGEMENT
• Cleaning is a Key Management Responsibility
• Teamwork is key & needs to involve:
• Management
• Sanitation Department
• Maintenance Department
• QA/QC
• Production
All departments and personnel must understand and believe
in the importance of effective cleaning and sanitation
November
2014
CLEANABILITY
November
2014
10 Principles of Sanitary Design
i.
Cleanable to a microbiological level
ii.
Made of compatible materials
iii. Accessible for inspection, maintenance, cleaning
and sanitation
iv. No product or liquid collection
v.
Hollow areas should be hermetically sealed
November
2014
10 Principles of Sanitary Design
vi. No niches
vii. Sanitary operational performance
viii. Hygienic design of maintenance enclosures
ix. Hygienic compatibility with other plant
systems
x. Validated cleaning and sanitizing protocols
November
2014
CLEANABILITY
• Materials of construction
Stainless Steel and some plastics
Aluminum and other soft metals
Wood other porous materials
A
B
C
November
2014
CLEANABILITY
• Methods of Construction
Open Hollow Legs
Cracks, Narrow Gaps, Overlapping joints
Unsanitary Welds
• Any area that is hidden and or hard to clean
can be come a harborage area
November
2014
Unsanitary Examples
November
2014
Passivation
• Pretreatment to protect stainless steel
surfaces
• Clean surfaces to remove soils or
manufacturing residues
• Use a nitric acid based cleaner to form
protective oxide film
• Birko acid/alkaline conversion coating
(passivation plus)
November
2014
Facility Design
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Solid cleanable floors sloped toward drains
Drains preferable located away from walls
Sanitary joint between floors and walls
Cooler condensate does not drain to floor
Harborage area on door thresholds
Cracked and broken epoxy floor coatings
November
2014
DOCUMENTED PROGRAM
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Sanitation Plan
What you clean
When you clean it - Frequency
How you clean it
– Disassembly (?), Products, Dilution rates
• Verification
• Sanitation step = product, ppm, contact time
November
2014
CRITICAL CONTROL POINTS
Any point in the operation where product contamination could occur:
• All Food Contact Surfaces
• All Processing Equipment
• Cleaning and Sanitation Challenges:
• Drains– Floors – Conveyor Belts
• Ventilators - Cracks, Crevices
• Joints
• Coolers – Track Work
ESTABLISH A PLAN (SSOP) AND STICK TO IT!
November
2014
CLEANING FREQUENCY
DAILY
• All Food Contact Surfaces
• All Hand-Held Equipment
• All Processing Equipment
• Raw Product Storage
November
2014
CLEANING FREQUENCY
DAILY Continued
• Floors, Walls, Ceilings
• Rest Rooms - Supplied with hand soap, hand
sanitizers etc
• Lunch Rooms
• Locker Rooms
• Shipping and Receiving Docks
November
2014
CLEANING FREQUENCY
WEEKLY
• Floors and Drains
• Non Food Contact Equipment
• Racks and Shelving, Door gaskets, and hardware
• Coolers (esp. cooling units!)
• Tires and Wheels – hand trucks, pallet jacks,
fork lifts, racks, etc.
November
2014
CLEANING FREQUENCY
• MONTHLY – Packaging Storage Areas
• PERIODIC ON-SHIFT CLEANING (per SSOP)
• Key parts of system my require continuous
cleaning or spot cleaning during breaks and lunch
periods
• SEMI-ANNUALLY or Annually
• Harvest Equipment
• Freezers & Coolers
November
2014
Water Quality Considerations
• Water needs to be potable
• Water Chemistry can have a profound effect on cleaning!
• Plant water should be analyzed for:
• Hardness - both Ca & Mg – reacts form soap scums
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Silicates – avoid acid cleaners will leave a white film
•
Iron
• Some water conditioning may be required
• Water Chemistry can vary seasonally & by source
• Retest or review annually
November
2014
Temperature and Pressure
• 130F to 140F adequate for most cleaning applications
• Check temperature at point-of-delivery
• Hot, hot is not better! Excessively hot water can cook
proteinacious material on to surfaces
• New technologies make maintaining a consistent supply of hot
water, simple and efficient
• Sufficient pressure to dislodge gross soils
• Sufficient pressure to support the number of hoses in use
• Above 160 psi pressure will atomize material into the air
November
2014
Sanitation Equipment
• Sprayers and Hoses
• Plant pressure should be sufficient
•
<160 psi to avoid atomization
• Temperature Setting optimum
= 130°F to 140°F
• Adjustable spray pattern
• Water saving designs
• Pressure Washers for field
November
2014
Equipment – Foamers
• Portable
• Wall-Mounted
• Centralized Systems
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High Efficiency
Reduce Water Use
Reduce Chemical Use
Speed Up Cleaning Process
Save Labor
November
2014
Automated CIP Systems
November
2014
CHEMISTRY
Cleaning Agents
• Acid Cleaners
• Alkaline Cleaners
• Non-Caustic Cleaners
• Chlorinated Caustic Cleaners
• Neutral Cleaners
• Solvent-Based Cleaners
• Displacement cleaners
• Combination Cleaners (Blend On-Site)
November
2014
Selecting Cleaners
• Soil to be removed
• Substrate
 Stainless steel
 Softer metals
 Plastics or synthetic
 Porous materials
• Water and Waste Water Considerations
November
2014
Cautionary Notes
• Aluminium, Brass & Soft Metals or Galvanized
¤ Avoid Sodium & Potassium hydroxides
¤ Avoid sodium hypochlorite bleach
• Acid will strip the galvanized coating from sheet metal
• Acids will etch concrete floors
• Solvents may damage plastics
• Peroxide bleaches vs. Chlorine Bleaches
• Waste water sodium/salt issues
November
2014
Mechanisms of Cleaning
Primary
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Hydrolysis
Dissolution
Displacement/Dispersion
Emulsification
Supplemental
• Peptizing
• Chelation
• Buffering
(For detail, please see Appendix)
November
2014
Detergent Components
• Surfactants and Wetting Agents – aid soil
penetration, emulsification
• Builders – improve surfactant performance by
lessening water hardness (chelators)
• Solvents – help dissolve or disperse fatty soils
• Corrosion Inhibitors – protect substrate surfaces
from adverse effects of acidic, caustic and
chlorinated cleaning compounds
November
2014
Surfactants
Surfactants Reduce Surface To Promote Wetting and
Emulsion Formation
Water + Oil  Oil Globules in Water (2 Phases)
Water + Oil + Surfactant  Emulsion
http://www.silviamar.com/Documents/s
oap.htm
November
2014
Non-Traditional Cleaning
• Acid First No Rinse Cleaning
 Combination organic/mineral soil
Acid cleaning softens the mineral matrix
Follow immediately with alkaline cleaner
Rapid pH shift prevents scale from
hardening and allows alkaline cleaner to
remove the soil
November
2014
On Site Blending
B.O.S.S. - Blend on Site System
Custom Formulas and Controlled Use
• Concentrated products = enhanced functionality, reduced costs
• Computer controlled mixing, allocation and dispensing
• PIN controlled allocation – prevents over or under usage
• Real time usage, inventory and cost reporting
• Upload, collate and report data from multiple plants
November
2014
Question
WHAT ARE THE
ACTUAL STEPS IN
THE CLEANING
CYCLE
November
2014
CLEANING PROCESS
Dry Clean-Up / Dry Pick-Up (“Rough clean”)
Remove all product and packaging materials
Sweep, scrape, scoop all gross soil
Pre-Rinse / Rough Down Rinse / Wash Down
Can we reuse water from e.g. flumes for this
Top to bottom
Perimeter toward the center
Inspect – is area ready for foaming
November
2014
Cleaning Process
Chemical Cleaning
Foaming application
Hand Scrub
Rinsing - removes the cleaning chemicals before they dry
Inspection of cleaned surfaces – re-clean if needed
Sanitizing
Application of an approved compound to kill
bacteria
November
2014
CIP Cleaning
• CIP (Clean-In-Place) – applicable to juice producers
• Enclosed tanks and pipe work are cleaned using the
system’s own circulating pumps or an external CIP
system.
• Low-foaming cleaners and sanitizers are used
• Follows the same general steps outlined above
• The CIP process may be fully automated on larger
systems
November
2014
Situations to avoid
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Use of high pressure water, air - aerosols
Inattention to door seals, gaskets, o-rings
Standing water or drain backups
Hollow rollers, crannies, nooks
Mops and foam pads (any multiple use cleaning aids)
Porous surfaces that can soak up liquids
Joints, “sandwiches” on equipment
Spaces inaccessible to sanitation procedures
Inattention to ventilation systems
Excessive humidity
November
2014
Manual Cleaning Failure
November
2014
Sanitizers
Effective Cleaning is 99% of the sanitation job. The
remaining 1% is the job of sanitizers
November
2014
Sanitizers
Produce Bacteria
• Listeria spp.
• Salmonella spp.
• Escherichia coli
Organic vs. Conventional Process and Product will
impact choice of sanitizers
November
2014
TERMINOLOGY
Sanitizers and Sanitizing
Sanitizers are not disinfectants.
• Sanitizers kill most bacteria present
(5 Log Reduction = 105 down to 1)
• Post Rinse sanitizers – used on food contact
surfaces without a subsequent rinse
• Disinfectants kill nearly all bacteria present
(6 Log Reduction = 106 down to 1)
• Sterilization kills ALL bacteria present
November
2014
Hard Surface Sanitizers
• Chlorine / Sodium Hypochlorite
• Quaternary Ammonium Compounds (“Quats”)
• Iodophors
• Peroxyacetic Acid (“PAA”)
• PAA now approved at up to 500ppm post rinse
• Acidified Sodium Chlorite (ASC)/Chlorine Dioxide
• Hot Water/Steam – knife pots
November
2014
Hot Water Knife Sterilizers
November
2014
New Sanitizer Trends
• Ozone
• Electrolyzed Water – generating chlorine bleach in situ
• Silver/Citric Acid combinations
• Chloramine chemistry
• Organic acid surfactant blends
November
2014
Use Precautions
•
Sanitizers should be precisely mixed to an
application concentration to meet predetermined
requirements as defined in your SSOPs
• Under-mixing or over-mixing can be problematic
•
Sanitizers are applied after the cleaning rinse
step, usually with a low-pressure spray
applicator. All surfaces of equipment and
environmental surfaces to be sanitized are wetted
• Contact Time!
November
2014
Use Precautions
• “Post-Rinse Sanitizers” are allowed to remain on
equipment and other surfaces without rinsing.
• The label will specify a minimum amount time
necessary for sanitizing.
• Visibly wet sanitizer remaining on food contact
surfaces may require removal prior to the shift start
• Rotate Sanitizers – Quat to PAA, Quat to NaOCl,
weekly, every other night
November
2014
Verification of Cleaning
• Visual Inspection – is it clean
• Pre-Operational Testing
• Sanitation can be confirmed through
the use of pH test strips, ATP
(Adenosine Triphosphate) test swabs
or rapid bacterial test equipment.
• Other confirmation test protocols may
be included in a good sanitation
program
November
2014
Biofilms
Before Treatment
• Bacteria attach themselves to
surfaces in moist, temperaturepermissive environments and
begin forming colonies.
• As these colonies grow they
produce a protective, adhering
matrix which may repel cleaning
chemicals and sanitizers
After Treatment
November
2014
Biofilms
• Biofilms are a leading source of bacteria in the food plant
environment because of the presence of moisture
• Many of the problem bacteria such as Listeria and
Salmonella readily produce biofilm protected colonies
• Not removing the biofilm means that colonies continue to
produce more bacteria, releasing them into the plant
• “Most general cleaning and sanitation products will not
penetrate or detach the sturdy polysaccharide biofilm
matrix”.
November
2014
Biofilms – Sterilex Products
• The only EPA-approved biofilm
remover
• Removes E. Coli, Salmonella,
Listeria and other problem organic
contaminants
• Used as a weekly “shock treatment”
in drains and troughs or plant
surfaces
Drain Foamer
November
2014
Sterilex Drain Program
November
2014
Drains – Additional Points
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Clean without contaminating the plant
Don’t clean during production
Clean early in sanitation program
Avoid aerosols
Separate tools for drain cleaning
Designated personnel who clean drains and
then change gloves/rain suits before other
tasks
November
2014
Field/Harvest Operations
Many Challenges
• Uncontained environment – exposed to the elements
• Wild flora and fauna
• Limited sanitary facilities – bathrooms and hand
washing facilities
• Materials not amenable to cleaning
• Temporary transient labor pool not invested in
sanitation program
• TIME – Do I Harvest or Do I Clean?
November
2014
High Risk Areas
November
2014
Suggested Solutions
• Provide hand and equipment washing facilities
• Supervise their use especially after bathroom use
• Mandate cleaning between lots/field areas
• Power Wash and Sanitize harvest equipment
between lots/fields and nightly
• Use off season to deep clean equipment
November
2014
Chemistry Considerations
• Non-stainless steel, soft metal and porous surfaces
• Paint, seal or replace where possible
• Mild non-caustic detergents
• Cleaning is key as proper sanitation may be difficult
• Peracetic acid as principle sanitizer
• Fogging an option of the off season
November
2014
PACKING SHEDS
Many Challenges – Similar to Field
• Relatively Uncontained Environment – open barn
with roof but no side walls
• Not built with sanitation in mind
• Pest Control – insects, birds rodent vectors
• Limited sanitary facilities – bathrooms and hand
washing facilities
• Materials not amenable to cleaning
• Temporary transient labor pool not invested in
sanitation program
• TIME – Do I Harvest or Do I Clean?
November
2014
PACKING SHEDS
Suggested Solutions – short term
• Pest Control – repel, barriers, traps
• Provide hand and equipment washing facilities
• Supervise their use especially after bathroom use
• Mandate cleaning between lots
• Develop appropriate SSOPs and use them between
lots/fields and nightly
• Use off season to deep clean
• Protect packaging materials from contamination
November
2014
PACKING SHEDS
Suggested Solutions – Long Term
• Remodel or rebuild with a sanitation focus
• Eliminate hard to clean or porous materials
• Build in pest control pest exclusion strategies
• Use off season to deep clean
November
2014
PACKING SHEDS
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Non-stainless steel, soft metal and porous surfaces
Paint, seal or replace where possible
Mild non-caustic detergents
Cleaning is key as proper sanitation may be difficult
Peracetic acid as principle sanitizer
Fogging an option of the off season
November
2014
COLD STORAGE ROOMS
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Not built with sanitation in mind
Frequently full of produce
Cold moist environment – Listeria friendly
•Not built
with sanitation
in mindvectors
Pest Control
– insects,
birds rodent
Storage bins and fork lifts bring contamination
in to the environment
• Cooling equipment hard to clean.
November
2014
COLD STORAGE ROOMS
November
2014
Look for hidden areas
November
2014
Protecting the Sanitary Space
• Isolate the work area and
keep it sanitary
• Entryway Foamers
• Helps to clean boots, truck
tires and fork lift wheels
• Typically apply a quat foam
• Combine with floor powder
(not sanitizing but helps
control soil and inhibit
bacterial growth
Hallway Foamer
November
2014
Protecting the Sanitary Space
Boot Scrubbers and Hand Washing Stations
November
2014
Air Treatment
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Coils and cooling units
Air Filtration
UV Treatment
Aerocide
November
2014
Low Tech Options
• Soap and antibacterial handosaps
– Triclosan, Quat, Iodophor, CHG
• Gloves – wash with soap and water
• Hand and Glove dips also for tools
– Chlorine 100 – 200ppm
– Quat 200ppm
• Spray had and tool sanitizers alcohol/quat
November
2014
Continuous Sanitation
• Sanitizing belt sprays
• PAA or Chlorine
• Spray on Conveyor return
• Help keep conveyors clean
• Prevent cross contamination
• Reduce conveyor snot
November
2014
Continuous Santiation
• Drain Rings and Condensate tray quat blocks
• Continuos slow release of sanitizer to inhibit
bacteria
• On going trash, and debris pick up during
production
• Train and Monitor – what they do can be
deadly
November
2014
Preventing Cross Contamination
November
2014
Whats Changing
Food Safety
• FSMA, Emerging Pathogens, Traceability
Regulatory Changes
• Federal Rules: OSHA, EPA, National Organic Program
• State Level: California Prop 65, clean air and water rules
Environmental/Sustainability Concerns
• Water quality and conservation
• Reduction of sodium chloride and TDS in process effluent
Customer Demands
• Reduce sanitation costs
• Increased emphasis on fresh cut ready to eat value added items
November
2014
Discussion and Questions
www.birkocorp.com
Produce Cleaning and Sanitation (reference)
Hydrolysis
“Breaks compounds apart by reaction
with water”
• Caustics and acids with extreme pH
• Extreme pH can be corrosive to soft metals
(brass, galvanized surfaces)
November
2014
– Dissolution
“Dissolving soil from a substrate into a liquid to
form a solution.”
• Dissolving the soil through whichever
means works best - water, solvents, like or
opposite pH).
• An example of dissolution is removing
hard water scale with acid. The calcium
does not change, just dissolves.
November
2014
–
Displacement/Dispersion
“Penetrates between the soil and substrate and lifts the
soil off suspending it in water”
• Alkaline, non-caustic products use
displacement by suspending the soil in
solution.
• Frequently employ peroxide chemistry to lift soils
from the surface
• Dispersing agents keep the soil in suspension to
aid rinsing
November
2014
– Emulsification
“Dispersing oil in water”
• Surfactants (detergents) pull greasy, oily soils
into water and keeps them there
– Peptization (opposite = “flocculation”)
“Breaks soils into smaller pieces.”
• Necessary in recycled solutions to keep
soil from re-depositing on the surface.
• Phosphates help peptize soil.
November
2014
– Chelation/Sequestration
• Chelators complex metal ions (EDTA,
heptonate, phosphonates)
• Help to mitigate the effect of hard water on
cleaning chemicals
– pH Buffering
“Stabilize the pH of cleaning solutions by
neutralizing any added acid or alkali.”
• Holds the pH where you want it to be.
• Extends the effective life of cleaning solutions
November
2014
– Dry Pick-Up
• Gets all large scrap material off tables, belts
and floors
• Squeegees and shovels are used to collect
material and place it in “inedible” barrels.
November
2014
– Wash Down
• Water sprayers are used to remove material
from all surfaces and move it to a collection
point.
• Excessively hot water can cook residues onto
equipment surfaces.
• Our target water pressure is <160 psi.
November
2014
– Wash Down
• Work systematically from top-to-bottom and
from the perimeter of the room toward a drain
or central collection point.
• Squeegees and shovels, identified for cleaning
purposes only, are used to pick up larger
deposits to facilitate floor rinsing.
• All troughs and drains are to be cleared for the
next step.
• Visual inspection confirms that this
step has been completed satisfactorily.
November
2014
– AVOIDING CROSS CONTAMINATION
DRAINS
• Clean drains before cleaning the rest of the room
• Drain cleaning can create aerosols that can recontaminate previously cleaned surfaces
AIR HANDLING SYSTEMS
• Very efficient at spreading contamination
around your plant
• Cooling coils and air ducts need to be cleaned
periodically
November
2014
– Cleaning
• Chemicals are selected for the specific
soil, soil adhesion and substrate to be
cleaned:
– Alkaline Cleaners > pH 9 for fats and
some proteins
– Acid Cleaners < pH 2 for mineral
deposits and some proteins; have some
antimicrobial effect
November
2014
– Cleaning
• Chemicals are selected for the specific
soil, soil adhesion and substrate to be
cleaned:
– Neutral Cleaners for hand scrubbing and
for sensitive surfaces and equipment
– Solvent-Based Cleaners for fats, oils
and greases
November
2014
– Cleaning
• Cleaning chemicals should always be mixed
according to manufacturer’s directions
• Under-mixing may result in an ineffective
and inadequate cleaning job
• Over-mixing can be dangerous to worker
health and is a waste of chemical
November
2014
– Cleaning
• Your chemical supplier is always the best source
of information on the selection of the proper
chemical for a specific job.
• OSHA requires that plants have an MSDS
(Material Safety Data Sheet) for each
chemical,
readily accessible to all employees
November
2014
– Cleaning Chemical Application
Many chemical cleaning agents are formulated with
a foaming agent for this step.
• Foam additives allow the chemical to cling to
the surface being cleaned and keep it from
drying out before it has time to work.
• A variety of industrial foaming equipment
is available.
November
2014
– Cleaning
• Foamed chemicals are applied with moderate
pressure and allowed a sufficient time to work
before being thoroughly rinsed off. Some
light pressure washing is possible with a foamer.
• Refoaming and hand scrubbing of some surfaces
may be necessary to remove soil buildup and
to clean hard-to-reach areas and intricate
equipment.
November
2014
– Cleaning
• A dry surface must be re-foamed before rinsing.
• Rinse from the top down and from the room
perimeter to the drain. Foam should not be
visible when thoroughly rinsed.
• Visually inspect cleaned surfaces and repeat
the cleaning step where soil remains.
November
2014
– Sanitizers and Sanitizing:
Chlorine
– Approved for all food contact surfaces
Mode of Action:
– Oxidation of cellular constituents
– Most effective at low pH
Advantages:
– An inexpensive sanitizer
– Kills a wide range of bacteria
November
2014
Chlorine
Disadvantages:
– Efficacy degraded by organic matter
– Corrosive to metals (including stainless steel)
– Poor penetration
– Temperature volatile
– No residual effect
Common Uses:
– 200 ppm as a post-rinse sanitizer
November
2014
Quaternary Ammonia Compounds, “Quats”
Mode of Action:
– Penetrates cell membranes and inhibits
cellular enzymes
Advantages:
– Exhibit good penetration and surfactency
– Effective across a broad ph range (pH 2 – 10)
– Form a bacteriostatic film
continued
November
2014
Advantages:
– Stable with some organic matter
– Active at elevated temperatures
(180°F to 200°F)
– Relatively non-corrosive and non-irritating
Disadvantages:
– Forms a film on equipment
– Can irritate skin at higher concentrations
>1000ppm
November
2014
Common Uses:
– 1000 ppm to disinfect floors and drains
– 200 ppm for food contact surfaces
November
2014
Iodine-Based Sanitizers
Mode of Action:
– Causes oxidation of cellular constituents
– Most effective at low pH
Advantages:
– Kills a wide range of bacteria
– Good residual protection
– More effective on viruses than other sanitizers
(continued)
November
2014
Advantages: (continued)
– Non-irritating to skin
– Prevents accumulation of mineral deposits
Disadvantages:
– Can stain at very high concentrations
– Costs more than Chlorine
– Vaporizes at 43°C (110°F)
November
2014
Common Uses:
– 25 ppm as a post-rinse and hand sanitizer
– 150 ppm as a disinfectant wash for boots and
other non-food contact surfaces
November
2014
Peroxyacetic Acid Sanitizers
– Approved for all food-contact surfaces
Mode of Action:
– Causes oxidation of cellular constituents
Advantages:
– Antimicrobial activity over a wide range of
temperatures
– Effective on biofilms and spores
– Tolerant of organic matter
– Environmentally benign residue
November
2014
Disadvantages:
– Mildly corrosive at use concentrations
– Concentrated product requires appropriate PPE
– Product and constituents have low PEL
(Permissible Exposure Limit) necessitating
appropriate ventilation
November
2014
Common Uses:
– Suitable as a sanitizer in CIP applications
– Appropriate as a “Day” sanitizer for belts –
150 ppm maximum
– Highly effective sanitizer between 85 – 200 ppm
November
2014
www.birkocorp.com

Principles of Cleaning and Sanitation

Transcription

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