Advanced Cleaning and Sanitation for the Produce Industry

Advanced Cleaning and Sanitation for the Produce Industry
Ian S. Bessell – Director of Business Development
Phillip Ellis – Southeast Technical Representative
FAFP Educational Luncheon
November 21, 2013
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
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Who Do We Work With?
Customer base includes leading food and beverage producers
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Birko 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
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QUESTION
What is the purpose of
cleaning and sanitation?
Cleaning and sanitation is not just about cleaning the
food processing surfaces, it is also about creating a
sanitary environment in which to process food and
protecting that environment during processing
operations.
Effective sanitation is the cornerstone of quality
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The Food Safety Equation
REPEATABLE FOOD SAFETY RESULTS
TRAINED
EMPLOYEES
GMPs/GAPs
SANITARY
EQUIPMENT
DESIGN
VALIDATED & VERIFIED
PROCESSES
SANITARY
FACILITY
DESIGN
HACCP
CONTINUOUS IMPROVEMENT PROCESS
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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
Bankruptcy
Incarceration
Death
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Jensen Farms
Environmental Assessment Findings
•
•
•
1. Facility Design
– Refrigeration unit drain line, allowed for water to pool on the packing facility floor in
areas adjacent to packing facility equipment, may have extended and spread the
pathogen to food contact surfaces.
– Packing facility floor was constructed in a manner that was not easily cleanable.
Specifically, the trench drain was not accessible for adequate cleaning and may have
served as a harborage site for Lm or contributed to the growth, or spread of the
pathogen.
2. Equipment Design
– Packing equipment, including equipment used to wash and dry the cantaloupe, did
not lend itself to be easily or routinely cleaned and sanitized.
– Several areas on both the washing and drying equipment appeared to be
uncleanable, and dirt and product buildup was visible on some areas of the
equipment, even after it had been disassembled, cleaned, and sanitized.
– Corrosion was also visible on parts of the equipment.
From: FDA Environmental Assessment: Factors Potentially Contributing to the Contamination of Fresh Whole Cantaloupe Implicated in a Multi-State
Outbreak of Listeriosis (October 19, 2011) http://www.fda.gov/Food/FoodSafety/FoodborneIllness/ucm276247.htm
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Cleaning and Sanitation
in produce It isn’t Rocket
Science, is it?
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Various Material Used
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Process often introduces water
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Harvest, Transport & Cooling
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Facility Design presents some
unique challenges
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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?
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How do you clean this?
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Complex Product Mixes
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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?
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Sanitary Design –Cleanable to a
Microbiological Level
Food facilities and equipment must be constructed and be maintainable to ensure that they can be
effectively and efficiently cleaned and sanitized over their life. The removal of all food materials is
critical. This means preventing bacterial ingress, survival, growth, and reproduction. This includes
product and non-product contact surfaces.
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Not all repairs are “good” repairs
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Passive Control
Active Control
Magnetic Lock
RTE Area
Cross Traffic Aisle
From This
Design
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Access Control Card Reader
To This More
Sanitary Design
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Pooling water
From This
Poor repairs
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Design
To This More
Sanitary Design
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Gaps
No threshold or seal
Threshold fully embedded in caulk
From This To This
More
Design
Sanitary Design
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Adequate Equipment Spacing—
360° Access
From This
Design
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More
Sanitary Design
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From This
Design
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To This More
Sanitary Design
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Problem Areas
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Design Issues – Catch Points
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Problem Areas
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Policies to Defend the Perimeter
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Zones of Control
Cleanroom
Trash
Raw
Welfare
Cleanroom
First Aid
Sanitation
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Zones of Control
Your goal is a logical process flow
with strict zones of control
Cleanroom
Raw
Processing
Cleanroom
Secondary
Cook/Chill
Cleanroom Packaging
Cleanroom
Raw
Welfare
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Office
RTE
Welfare
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Preventing Cross Contamination
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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
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Protecting the Sanitary Space
Boot Scrubbers and Hand Washing Stations
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Question
WHAT ARE THE ACTUAL
STEPS IN THE CLEANING
CYCLE IN A PRODUCE
FACILITY?
THEY ARE THE SAME BASIC STEPS AS
ANY OTHER TYPE OF FOOD FACILITY
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Pre-Sanitation
• Pre-sanitation task completed consistently
(floors swept, equipment covered, materials
removed, etc.)
• Equipment disassembled to proper level to
provide accessibility
• Dry clean completed
Hollow member + cracked weld
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Dry Cleanup
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Dry Cleanup
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Pre-Rinse
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Pre-Rinse
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• Rinse until visually free of soils
• Use lowest effective pressure to minimize aerosols and condensation
• Lower pressure reduces risk of cross-contamination and machine
damage
Multiple lap joints
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• Order of applications (necessary to reduce cross-contamination
potential)
– Wall/floors then equipment
– Avoid drying of chemicals
• Mechanical action
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Detergent Application
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Detergent Application
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Hand Scrub All Equipment
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Hand Scrub All Equipment
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Post Rinse and Inspect
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Manual Cleaning Failure
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Post Rinse and Inspect
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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
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QUESTION
What are we doing
during sanitation
• Remove Soil
• Kill Bacteria
• Remove Biofilm
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Sanitizers
Effective Cleaning is 99% of the sanitation job. The
remaining 1% is the job of sanitizers
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Sanitizers
Produce Bacteria
• Listeria spp.
• Salmonella spp.
• Escherichia coli
Organic vs. Conventional Process and Product will
impact choice of sanitizers
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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 & condensate
pans
• Specialty products required to inhibit
or prevent the formation of biofilm in
previously cleaned drain pans – Quat
Blocks
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BIOFILM
BIOFILM
http://www.hygiena.net/images/biofilm-diagram.gif
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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”.
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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
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Drain Foamer
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Sterilex Drain Program
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The Future - What's 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
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Beyond Chemistry
The Role of Equipment & Technology
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
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Putting it All Together
Birko’s Integrated Approach to Produce Safety
The Birko Shield Food
Safety Assessment
• On site evaluation
• Process Chemicals
• Interventions &
Application Equipment
• Cleaning and Sanitation
• Process
Environment Protection
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Discussion and Questions
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