1. Cleaning & Sanitizing for Food Plants

2. Effective Cleaning 2 Introduction All equipment must be cleaned and sanitized prior to use and following any pause in use that could result in contamination. Specific procedures (SOPs) for cleaning & sanitizing each piece of equipment are available to the operator

3. Effective Cleaning 3 Definition of Cleaning - the complete removal of food soil using appropriate detergent chemicals under recommended conditions. - a process which will remove soil and prevent accumulation of food residue which may decompose or support the growth of disease-causing organism or the production of toxins.

4. Definition of Sanitizing - Reducing of microorganisms on surface to safe level - A process which destroys disease causing organism which may be present on equipment and utensils after cleaning 22 Dec 07Effective Cleaning 4

5. Sterilize : statistical destruction and removal of all living organisms. Disinfect : to inanimate objects and the destruction of all vegetative cells (not spores). Sanitize refers to the reduction of microorganisms to levels considered safe from a public health viewpoint. 22 Dec 07Effective Cleaning 5

6. 6 Food Soil Food soil : unwanted matter on food-contact surfaces. visible or invisible. The primary source: - food product being handled. - minerals from water residue - residues from cleaning compounds - Microbiological bio-films

7. Food Soils Classification: Soluble in water (sugars, some starches, most salt) Soluble in acid (limestones,most mineral deposits) Soluble in alkali (protein, fat emulsions) Soluble in water, alkali or acid 22 Dec 07Effective Cleaning 7

8. Many complex films contain: combinations of food components, surface oil or dust, insoluble cleaner components, and insoluble hard-water salts. These films vary in their solubility properties depending upon such factors as heat effect, age, dryness, time, etc. 22 Dec 07Effective Cleaning 8

9. Surface Deposit Solubility Ease of Removal Heat-Induced Reactions SugarWater solubleEasyCaramelization FatAlkali solubleDifficultPolymerization ProteinAlkali solubleVery DifficultDenaturation Starch Water soluble, Alkali soluble Easy to Moderately Easy Interactions with other constituents Monovalent Salts Water soluble; Acid soluble Easy to DifficultGenerally not significant Polyvalent SaltsAcid solubleDifficult Interaction with other constituents Effective Cleaning 9

10. Biofilm Effective Cleaning 10

11. Effective Cleaning 11 Main purposes of cleaning Remove soils that harbor microorganisms and provide nutrients for their growth Prevent the transfer of ingredients from different batches of products Eliminate soils that affect efficiency of heat transfer Prolong equipment life by removing potentially corrosive materials Facilitate preventive maintenance

12. Effective Cleaning 12 Cleanup steps Pre-rinse Removes gross soils (reduces need for chemicals) Wash Removes most bacteria by chemicals, heat, agitation Post-rinse Removes most bacteria and soil loosened by washing Sanitize Ensures that equipment doesn’t contaminate incoming product Doesn’t compensate for poor wash “You can’t sanitize dirt!”

13. Water Water comprises approximately 95-99% of cleaning and sanitizing solutions. Functions: carry the detergent or the sanitizer to the surface; carry soils or contamination from the surface. 22 Dec 07Effective Cleaning 13

14. Water must be potable and pathogen- free. Suspended matter must be kept at minimum level Soluble iron and Manganese salt less than 0.3 ppm Never used HARD WATER 22 Dec 07Effective Cleaning 14

15. Alkaline-based Detergents - Sodium Hydroxide Sodium - Hydroxide/Hypochlorite Solutions Acid-based Detergents - Phosphoric Acid - Nitric Acid Additives - Surfactants - Chelating Agents - Emulsifiers 22 Dec 07Effective Cleaning 15 Cleaning Detergent

16. Effective Cleaning 16 Cleaner selection Factors to be considered when selecting cleaning chemicals Nature of soil Organic / protein / petroleum-based / inorganic (scale or oxide) Nature of surface to which soil is attached Stainless steel / aluminum / rubber / plastics Quality of water available Use potable water Hardness (Ca / Mg) will affect performance

17. Remember acid cleaners dissolve alkaline soils (minerals) alkaline cleaners dissolve acid soils and food wastes Effective Cleaning 17

18. Effective Cleaning 18 Cleaning methods 1. Manual Taking equipment apart & using brushes 2. Cleaning-Out-of-Place (COP) Taking equipment apart and using tank for soaking 3. Cleaning-In-Place (CIP) Using circulating solution without taking equipment apart 4. Pressure spraying Using high or low pressure

19. 22 Dec 07Effective Cleaning 19 Manual cleaning Uses lower concentrations of chemicals Cleaners are formulated for safe use Brushes are used to apply physical energy Very labor intensive Complete cleaning may be difficult if physical energy is not consistent

20. 22 Dec 07Effective Cleaning 20 Cleaning out of Place (COP) Requires little labor Good penetration during soaking Needs good arrangement of parts and agitation to work effectively Cleaner needs to be selected because of long soaking time

21. Cleaning in Place (CIP) CIP is used to clean tanks, piping and even workspaces between production batches by automatically recirculating detergent and rinse solutions. The washing process consists of several cycles in which rinsing material is recycled through the vessels, pumps, valves and other process equipment in the flow system. 22 Dec 07Effective Cleaning 21

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23. Clean-In-Place (CIP) Benefits 22 Dec 07Effective Cleaning 23 Reduced Water Usage Reduced Sanitizer Consumption Reduced Operating Costs Reduced Wastewater Costs Increased Efficiency - Reduced Cycle Times Increase Available Process Time

24. 22 Dec 07Effective Cleaning 24 Pressure spraying Effective for cleaning large areas E.g. floors, walls, irregular areas Foaming cleaners on walls Temperature is reduced on contact Physical energy varies with proximity

25. 22 Dec 07Effective Cleaning 25 Effective cleaning Procedures include: Contacting the soil Allowing sufficient contact time to react Maintaining temperature Providing sufficient energy

26. 22 Dec 07Effective Cleaning 26 Mechanism of cleaning Detergent is dissolved in water Solution is applied to surface to separate soil Water soluble soils are dissolved in water Cleaner allows water close contact to surface Cleaner then loosens soil by reducing its attraction to surface

27. 22 Dec 07Effective Cleaning 27 Mechanism of cleaning (2) Soil separation is helped by physical action Scrubbing / turbulent flow / pressure spray Soil dispersion begins Soluble soils remain in cleaning solution Clumps of insoluble soil are broken down Fats & strong alkalis create a soluble soap Cleaner and dispersed soil are removed Surface is rinsed with potable water to remove cleaning solution

28. 22 Dec 07Effective Cleaning 28 Cleaner performance Four factors for cleaner effectiveness Time 15+ min Temperature 60-70  C (140-160  F) preferred Concentration of cleaner Recommended by manufacturer Physical energy

29. 22 Dec 07Effective Cleaning 29 Cleaning Variables TemperatureTime Concentration Velocity Concentration Temperature Time Temperature Concentration Velocity

30. Effective Cleaning 30 Purpose of sanitizing Last step in cleanup process Requires proper cleaning of surface first Remove oil / biofilm / cleaner residue Reduces microorganisms on previously cleaned surface free of pathogens

31. Effective Cleaning 31 Ideal sanitizer Has a rapid kill and wide spectrum of kill Exhibits good environmental resistance Not adversely affected by poor water quality or residues Effective over wide pH range Non-toxic to humans Non-corrosive to surfaces under all conditions Freely soluble Good shelf life

32. Effective Cleaning 32 Effective sanitizing Use at recommended concentration More can cause corrosion pH of sanitizer is formulated for best action Kill increases with temperature Stability can decline Time of exposure varies Must be capable of 99.999% kill in 30 sec Contact time of 2 min is common Residual soil affects performance of oxidizers

33. Sanitizing Agents Physical Sanitation Alkaline-Based Sanitizers Chlorine Quaternary Ammonium Acid-Based Sanitizers - Hydrogn Peroxide - Peroxyacetic Acid (PAA) - Anionic Acids Iodophores 22 Dec 07Effective Cleaning 33

34. General types of sanitization Thermal Sanitization - hot water or steam for a specified temperature and contact time. Chemical Sanitization - the use of an approved chemical sanitizer at a specified concentration and contact time. 22 Dec 07Effective Cleaning 34

35. Effective Cleaning 35 Proper operation & cleanup Promptly rinse equipment after use with cool to warm water Properly maintain equipment Seals and gaskets Keep work area clean Reduces amount of difficult cleaning Follow predetermined schedules Use chemicals for intended use / concentration

36. Effective Cleaning 36 Portable equipment Store properly when not in use Keep from splashing / dust Re-sanitize before next use Clean and sanitize if brought out of storage

37. Effective Cleaning 37 Equipment cleanup procedures Remove all product and debris from equipment Have sufficient room between walls / equipment to allow for cleaning Have sufficient space underneath equipment for cleaning or seal Disassemble equipment as necessary: Remove / replace shields Clean horizontal debris catchers Remove / replace product contact surfaces

38. Effective Cleaning 38 Equipment for cleanup Washing equipment considerations include: High pressure systems Central / portable Mixing valves (steam + cold water) or hot water systems Raise temperature for cleaning Proportioning pumps / venturi-metering / foamers Minimize water use to limit sewer loads

39. Effective Cleaning 39 Manual cleaning Completely disassemble equipment Rinse manually Brush with cleaning solution Rinse Sanitize Before reassembly Just before processing

40. Effective Cleaning 40 Remember! Remove all product Clean up first using scrapers / brooms Then clean thoroughly, paying close attention to product contact surfaces Sanitize clean area so that it doesn’t contaminate new product

41. THANK YOU 22 Dec 07Effective Cleaning 41