Plant Cleaning and Sanitation to Control Listeria

Plant Cleaning and Sanitation to Control Listeria
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Plant Cleaning and Sanitation to Control Listeria Goal = Training for all people who conduct cleaning and sanitizing tasks. This lesson will be most effective if followed by hands-on training. It is important to demonstrate the proper use of cleaning equipment and the proper sequence for cleaning and sanitizing. This can best be accomplished by actually demonstrating the procedures you use to employees in the location(s) where they are conducted. Prior to conducting the training it is important to review your current cleaning and sanitizing procedures for each area of the plant. Any modifications or updates should be made before training so that employees will learn the proper procedures. If there is a dedicated cleaning and sanitizing crew for the whole plant they would be trained in all procedures. If workers in specific areas of the plant clean and sanitize at the end of the day they need to be trained on those procedures they are responsible for. The specific procedures that need to be covered in this training, at a minimum, are the ones described in the Year 2 Listeria control plan. Separate training may need to be conducted for employees in raw areas and employees in finished product areas.

Plant Cleaning & Sanitizing Training Program for Listeria Control
May 15, 2002 What is it? Listeria are invisible bacteria (germs) that can cause illness. When people eat foods that contain one type, Listeria monocytogenes, it can cause: miscarriage in pregnant women brain infection and blood poisoning in babies, elderly people, and people with a weakened immune system. Briefly remind this group of employees what Listeria is. Points to emphasize: It is a type of bacteria that is too small to see without a microscope. It is found everywhere in the environment; including soil, water, animals, birds, people and even fish. Emphasize that even though you can’t see it you have to assume that it is there unless the item has just been properly cleaned and sanitized. Certain types of Listeria can cause people to get sick and other types don’t. One type, Listeria monocytogenes, can cause very severe illness and even death. Lm can cause pregnant women to lose their babies by miscarriage or the babies can be born with serious illness when the infection is transferred from the mother to the baby. It can also cause serious infection in people who are susceptible such as senior citizens and people with medical conditions that weaken their immune system such as people who have cancer or who are undergoing radiation or chemotherapy, diabetics, people with HIV etc. Remind employees that current regulatory policy is zero tolerance. If Listeria monocytogenes is found in finished products they would have to be recalled from customers. This is very expensive and affects your company’s reputation. Some companies have gone out of business after a recall and all employees lost their jobs.

May 15, 2002 Where is it? Listeria can enter the plant on Employee’s shoes and clothing Carts, boxes, pallets Raw seafood In the plant Listeria can live on Floors and drains Scrap or trash barrels Equipment like hoppers, augers, or slicers Any surface that is not properly cleaned and sanitized Describe where we find Listeria in plants. Give specific examples for your plant that emphasize the potential problem areas where Listeria has been found or might be expected to be found. Don’t forget to include employees and the things that they touch. Explain that you can expect to find Listeria on floors and in drains. Plants with more drains and a wet environment have more places for Listeria to live and grow in. Give examples of the types of equipment (slicers, conveyors, hollow rollers, tubs, totes, carts and racks, pallets etc.) where Listeria can live and could eventually end up contaminating finished products. Emphasize that since you can assume that the floor is contaminated with Listeria, special attention needs to be paid to the wheels of carts, smoker racks etc. and people’s shoes all of which can transfer Listeria from one part of the plant to another. Also note that various other items such as scrap or trash barrels, pallets etc. and anything that comes from outside the plant can bring in Listeria. These items must not enter the areas where exposed finished product is handled without cleaning and sanitizing them first or taking other precautions.

Special Cleaning is Essential to Control Listeria
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Special Cleaning is Essential to Control Listeria Listeria may grow in a microscopic biofilm if your plant is not adequately cleaned and sanitized on a regular basis. Listeria in biofilms can be protected from the effects of cleaners and sanitizers. You must use the right detergent, sanitizer, and procedure to eliminate Listeria. Even individuals with no understanding of microorganisms seem to grasp the concept of biofilms when explained in simple terms. This is a protective covering that the bacteria produce to protect themselves and secure their food and water supply. Try to help employees visualize an invisible layer of bacteria interlocked with grape-vine like tendrils. It takes extra effort and special cleaning agents and sanitizer to effectively eliminate Listeria when a biofilm is formed. You may want to emphasize that is why this training is being held to be sure that the proper cleaners, sanitizers and procedures are used to eliminate this bacteria.

General Cleaning & Sanitizing Procedure
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 General Cleaning & Sanitizing Procedure Step 1 – Remove all exposed products Step 2 – Dry clean/sweep area Step 3 – Wet area to be cleaned Step 4 – Clean and scrub area Step 5 – Rinse Step 6 – Sanitize Step 7 – Air dry/Store properly The purpose of this slide is to review general cleaning and sanitizing procedures before getting into specific procedures for various types of equipment and areas of the plant. This basic procedure includes 7 steps instead of 5 to help you make several points. The steps that are added are: the removal of all exposed products; dry cleaning, sweeping and removal of all garbage and packaging material before wet cleaning begins; and proper storage of all items, utensils, equipment etc. after cleaning and sanitizing is completed. A series of slides follows to allow you to make each of these points and discuss how each step should be conducted in your plant.

Step 1 – Remove exposed finished products
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Step 1 – Remove exposed finished products Explain why it is important that all exposed products and especially finished products be removed before cleaning and sanitizing begins. If you start to spray dirty equipment, floors etc while finished product is exposed (not in a sealed container or package) it could become contaminated with Listeria. When you spray and/or scrub dirty equipment, floors etc., bacteria like Listeria can become airborne in water droplets that can settle onto product and contaminate it. This mistake has been observed in many plants. Develop alternatives in workers daily schedules if necessary before conducting this training to prevent this from happening in the slicing, packing or picking rooms where exposed finished product is handled and may become contaminated.

May 15, 2002 Step 2 – Dry clean & sweep area Remove garbage, food debris & other waste Step 2 – The area to be cleaned must be scraped or swept first to remove food and other debris. All garbage, cardboard, packaging material and other extraneous items should be removed before wet cleaning begins. This will help make cleaning easier and make sure that anything that can’t be effectively cleaned and sanitized is removed before cleaning begins. Removing all debris and garbage also makes it easier to get to cracks, crevices, and niches that can harbor Listeria when you are cleaning and sanitizing the area.

Step 3 – Wet down area to be cleaned
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Step 3 – Wet down area to be cleaned Step 3 – Floors, walls and equipment should be wet down before cleaning. Describe how this is done in your plant. For example use a hose with a low pressure nozzle. Surfaces need to be wet before cleaning starts to help loosen dirt, fish oil, scales or other debris before applying detergent.

Step 4(a) – Apply detergent
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Step 4(a) – Apply detergent Step 4 – Apply detergents. This slide should be used to describe your plant’s procedures for the application of detergents with sprayers, manual applications or any other method that you use. The next slide can be used to describe procedures for using foam applicators. Describe what detergents are used in the plant. Describe why these products are especially needed for your type of plant. Describe how to mix your detergent properly and/or which pre-mixed dispenser to use. Tell employees how long the detergent should sit on the surface to be cleaned before they start scrubbing. Use the guidelines from the manufacturer of the detergent that you use to determine the appropriate amount of time that the detergent should remain on various pieces of equipment before scrubbing. Describe any special detergents such as de-greasers that are used in specific areas and how and when they should be used.

Applying Detergent with Foamers
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Applying Detergent with Foamers This slide is included for you to describe the use of foam applicators in your plant. Describe the applicator equipment, where foam applicators are used in the plant and how and when to use them properly. Courtesy Hydro Systems Company

Step 4(b)- Scrub area vigorously
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Step 4(b)- Scrub area vigorously Make the point that detergent alone can’t do the job. It takes a lot of good old fashioned elbow grease and scrubbing to get things clean. This is especially important in fish and meat plants where scales, protein, fish oil etc. can be difficult to remove, especially if the surface has dried out or been exposed to heat (gets cooked onto the surface). Make the point that scrubbing properly with the proper detergent is the single most important step in the whole cleaning and sanitizing procedure. Emphasize the type of equipment like brushes, green scouring pads etc. that should be used for scrubbing in your plant. Describe the color coding system for cleaning brushes & pads if you use one. Describe any special tools that you use for specific equipment or areas of the plant. Re-emphasize that scrubbing or cleaning tools used in raw areas of the plant should NEVER be used in finished product areas. Make the point that all surfaces need to be scrubbed including corners, seams, underneath tables etc.

May 15, 2002 Step 5 - Rinse Step 5. Rinse to remove detergent and any remaining dirt and debris. Describe how to rinse properly (including in the sink for utensils and portable items). Use low pressure if possible.

May 15, 2002 Step 6 - Sanitize Step 6. Sanitize – Describe how this is different from cleaning. This step is to apply a chemical to kill any remaining bacteria. Emphasize how if a surface is not clean sanitizers cannot do their job – killing bacteria – because the sanitizer will not be able to reach bacteria “hiding” under dirt or pieces of food stuck to a surface. Also note that it is particularly hard for sanitizer to reach Listeria when they are living in a biofilm and that is why special sanitizers are used and/or they are rotated every week, month etc.

Be sure to use the right amount of Sanitizer: Use Test Strips
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Be sure to use the right amount of Sanitizer: Use Test Strips Use this slide to explain why you need to use the right amount of sanitizer and follow the procedure for mixing or selecting the right sanitizer applicator. One concept to emphasize is: If the sanitizer is too weak all bacteria especially resistant ones like Listeria won’t be killed. If the sanitizer is too strong it can damage equipment, contaminate products, and even cause your skin to break out in a rash. Regulations also require that the right concentration be used. The concept that if a little bit is good – then more must be better- definitely does not apply to sanitizers. Demonstrate with test strips used in your plant how to test sanitizer strength. If you use more than one type of sanitizer be sure to explain how to read the test strip label to be sure that you use the right test strips for the sanitizer being used.

Step 7– Air Dry/Store Properly
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Step 7– Air Dry/Store Properly Step 7 – Describe how drying with a cloth, sponge etc can re-contaminate a clean surface and how improper storage can cause re-contamination. In other words all of your hard work up to this point is for nothing. It’s important to explain where and how specific items are to be stored properly for air drying. For example, one common problem is that wet tubs, totes, pans etc. are nested after cleaning and sanitizing. A film of water – which is a great environment for Listeria to live and grow- is formed between each pan or tote. Totes etc. should be stacked so that there is no nesting until they are dry. When they are completely dry they can be nested for storage if necessary.

May 15, 2002 Cleaning Tips NEVER use high pressure hoses to clean drains, minimize use elsewhere NEVER use compressed air to clean equipment NEVER start cleaning & sanitizing if there is any exposed product in the entire area NEVER do a wet mid-shift cleaning NEVER stack or nest tubs, totes, pans etc. after they are cleaned and sanitized NEVER let water spray on cleaned & sanitized surfaces such as those close to the floor while cleaning It’s important to review each of these items on the List of things that will Never be done in your plant. Explain that drains are where you expect Listeria to end up. If you use high pressure you will create small water droplets that could have Listeria and spread them throughout the plant and possibly create many new niches where it can grow and multiply – making your efforts to find and eliminate it much more difficult. Explain how compressed air lines and filters that are moist can be perfect places for Listeria to live and grow. When you spray the air you can contaminate products. Explain your company policy about mid-shift (lunch break) clean-ups. Describe what employees should do and what not to do before they leave and when they return. It is desirable to have employees remove debris and food particles and wipe down their work area with sanitizer before breaks instead of a mid-shift wet clean up. Caution against splashing water off of the floor or any unsanitized surface onto other equipment, especially if previously cleaned. Cleaning crews can sweep the floor during production but should not wash down with a hose until after production is completed. Mid-shift cleaning should be avoided.

Cleaning Tools May 15, 2002 Never mix uses. For example, never: Use floor brooms/floor squeegees on tables Use pads or brushes used for cleaning garbage barrels on packing tables Use the same brush to clean floor drains on any food contact surface. Use brushes, pads, brooms or squeegees in raw product area and then in finished product areas Clean & Sanitize all brooms, brushes and pads every day, after plant is cleaned. Store cleaning aids properly Determine if color-coding or other system is needed to segregate cleaning utensils and explain the appropriate colors that are to be used. Review procedures for cleaning and storing cleaning aids (off the floor so they dry). Wiping cloths should not be used. Discourage the use of sponges – require nearly daily replacement if used.

Listeria Control & Prevention
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Listeria Control & Prevention Use a schedule to rotate sanitizers Use “Special” aggressive Cleaning & Sanitizing procedures when testing shows a Listeria “hot spot” Monitor and test to determine the effectiveness of sanitation controls Use this slide to describe any special procedures that you use for Listeria control. Describe how often sanitizers will be rotated and how cleaning crew will be told when to use the new sanitizer and how to use it including mixing or dispensing it properly and testing it to determine that the concentration is correct. Develop and describe your “aggressive” procedure when a Listeria “hot spot” is identified by test results. This might include using different cleaners and/or sanitizers, completely dissassembling equipment, soaking items overnight in sanitizer or even heat sterilization. Finally, describe your testing program and how that is being used to monitor the effectiveness of your cleaning and sanitizing procedures. Let employees know that this is serious and the company is spending money on testing to be sure that cleaning and sanitizing is effective and that Listeria is being eliminated.

Plant Procedures for Cleaning and Sanitizing
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Plant Procedures for Cleaning and Sanitizing BEGIN DEMONSTRATIONS of specific procedures used in your plant. This is where you teach your employees by actually doing each procedure in the location where it is conducted. This will be the most effective way to train those responsible for these daily activities. You need to think through how to do this in the most practical and effective way. These demonstrations could be conducted all at once at the end of the day by actually doing the cleanup or you may want to demonstrate one or two procedures each day for as many consecutive days as you need to cover them all. Be sure to keep a record of when each part of the training is completed to be sure that all procedures have been covered and all of the appropriate employees have been trained. You need to think through how to best accomplish these demonstrations. You might want to review each of the procedures in the next 7 slides in the slide show presentation, but they are somewhat wordy and may get tedious. If you choose this approach you may want to go through the next 7 slides quickly, and then go out into the plant and conduct the demonstrations in each appropriate area. An alternative approach would be to stop the slide show here, print out a copy of each of the next 7 slides along with your written procedures and give them to employees as handouts to follow while you are conducting the demonstrations. Food Safety is Everyone’s Job!

Slicing & Packing (Finished Product) Areas End of Day Clean-up
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Slicing & Packing (Finished Product) Areas End of Day Clean-up Remove garbage/food waste, clean tables & other surfaces sweep floors. 3) Wet all surfaces with water. 4) Apply detergent to all surfaces 5). Scrub all surfaces with brushes or pads 6). Rinse and inspect for cleanliness Remove & store all exposed products 7). Apply sanitizer 8). Store equipment properly to air dry 9). Remove standing water from floors 10). Wash cleaning tools, sanitize & store Demonstrate how to do a complete end of the day cleaning and sanitizing for each of your finished product areas. Include procedures for all stationary objects such as tables, floors and walls, conveyors etc. Note that not just tabletops need cleaning but also under the lip, undersides and table legs. Footrests can be moved to a corner of the room used for cleaning assorted non-food contact objects. This makes for more consistent cleaning and provides easier access under tables. Stress mats should be cleaned and moved so that the floor beneath them can be effectively cleaned and sanitized. Don’t forget to sanitize stress mats after cleaning because they have been frequently identified as a harborage site for Listeria. Some objects, like paper towel dispensers and electrical equipment, may need to be moistened with detergent by hand and not sprayed with foam or wetted with a hose. Caution employees to never spray drains under high pressure or even the floor after other surfaces have been cleaned.

Slicers & other Equipment End of Day or After Use Cleaning
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Slicers & other Equipment End of Day or After Use Cleaning 1) Remove food scraps and other waste 2) Dis-assemble equipment 3) Remove food scraps and debris 4). Wet equipment and parts 5). Apply detergent and soak 6). Scrub all surfaces with brushes or pads 7) Rinse and inspect for cleanliness 8). Apply sanitizer (soak parts in sanitizer) 9) Store properly and air dry 10). Wash cleaning tools, sanitize and store Demonstrate the procedure(s) that should be used for all equipment such as slicers, conveyors, vacuum packing machines, scales etc in the finished product area(s). This should include how to completely disassemble equipment for daily cleaning, what cleaning tools, detergents and sanitizers to use and how to store all cleaned and sanitized parts properly to air dry.

May 15, 2002 Knives, Trays, Pans & other Utensils End of Day or After Use Clean-up Use procedure for 2 or 3 compartment sink 1) Fill sink compartment with warm water & detergent 2) Make sanitizer solution and check with test strips 2) Scrape/clean to remove food debris 3) Soak as necessary 4) Scrub all surfaces with brush or pad 5) Rinse and inspect for cleanliness 6) Immerse, spray or flood with sanitizer 7) Store properly on racks, shelves or hooks & air dry Demonstrate how to properly clean and sanitize portable items such as utensils, trays, pans, knives etc. in a 2 or 3 compartment sink. The three steps of detergent cleaning, rinsing thoroughly, and wetting with sanitizer are necessary to kill Listeria. Clean things that routinely touch product (trays, knives, pans etc.) first, then finish with gloves and aprons or other items. Give employees a detailed procedure for mixing detergent for use in soak/dip tanks. Apply sanitizer to articles placed in a cleaned and sanitized sink or similar basin. Caution employees to use gloves when hand scrubbing with detergent. Show what articles are sanitized by dipping them in a tub (or 3rd basin of 3-compartment sink) or how to apply the sanitizer with a spray. Drying racks or additional wall hooks may be needed if articles do not dry overnight.

Storage Coolers Daily and End of Week Clean-up
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Storage Coolers Daily and End of Week Clean-up Daily – Remove debris/trash & standing water Visually inspect for: proper product storage, no condensate or drip, no cross contamination Weekly – Remove all products Remove trash & standing water and sweep Wet all surfaces Apply detergent to all surfaces including ceiling 5. Scrub with brushes and floor broom 6. Rinse and inspect for cleanliness 7. Apply sanitizer to all surfaces Demonstrate your procedures for both daily cleanup of coolers as well as the complete weekly wet cleaning and sanitizing procedure. Employees should know that contamination in cold damp coolers is one of the common sources of L.m. in many food plants. The amount of time spent scrubbing can decline after the first 2-3 thorough cleanings. Management will let employees know when and if to reduce scrubbing. Caution against using floor brooms on ceiling or walls.

Raw Product Areas End of Day Clean-up
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Raw Product Areas End of Day Clean-up 1). Never use cleaning tools from finished product areas. 2). Remove & store all raw or in-process products 3). Remove garbage/food waste, clean tables & other surfaces & sweep floors. 4) Wet all surfaces with water. 5) Apply detergent to all surfaces 6). Scrub all surfaces with brushes or pads 7). Rinse and inspect for cleanliness 8). Apply sanitizer 9). Store equipment properly to air dry 10). Remove standing water from floors 11). Wash cleaning tools, sanitize & store. Demonstrate the specific procedures for floors, walls, tables, conveyors etc. in the raw product area as well as equipment such as skinners, tubs, totes, brine tanks, and any portable items that are cleaned in a 2 or 3 compartment sink. If the same cleanup crew is responsible for both the finished product and raw product areas you may just need to explain the differences between these two areas. If the same crew cleans both areas they should be careful not to track Listeria from the raw area into the finished product area. If the raw area is cleaned first, the crew should change aprons, gloves, boots etc before cleaning the finished product area. If the finished product area is cleaned first this may not be necessary before moving to the raw area since it is likely to be more heavily contaminated. Emphasize importance of never using the same cleaning tools used in the raw area to clean in the finished product area.

Drains -Daily Clean-up
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Drains -Daily Clean-up Move equipment or food contact surfaces that could get contaminated or use a splash guard Remove drain cover Rinse with low pressure hose Apply foam or detergent solution Scrub with designated brush (1/4 inch smaller than drain opening) Flood with sanitizer Insert bactericidal ring if used Replace drain cover Clean drain brush and store in sanitizer Demonstrate your procedure for cleaning drains. Explain how to clean as well as when to clean. Determining “when” to clean drains may be dependent on where the drain is. For example are drains cleaned after the rest of the room is cleaned and sanitized or before? If drains are cleaned after the room is cleaned and sanitized, special precautions may be needed to ensure that equipment or surfaces are not re-contaminated during drain cleaning. In some cases it may be necessary to clean drains before the rest of the area is cleaned as well as after cleaning is complete. Be sure to emphasize again that high pressure is never used in drains. Also emphasize what special cleaning tools are used for drains and how and where they should be stored to ensure that they are not used to clean other items or areas.

Special Cleaning and Sanitizing Procedures for:
Plant Cleaning & Sanitizing Training Program for Listeria Control May 15, 2002 Special Cleaning and Sanitizing Procedures for: Smoking Racks Totes and tubs Plastic pallets Carts, dollies and pallet jacks Rubber aprons and boots Boot dips This slide is a reminder to demonstrate how to clean and sanitize any other items for which you might have special procedures. Be sure to demonstrate how to clean and sanitize smoking racks, tubs and totes, plastic pallets, and carts and dollies properly as well as how to store them properly after they are cleaned. All of these portable items have been found to harbor Listeria and are likely to be one of the most important ways that Listeria is moved from one area of the plant to another. It is very important to carefully clean and sanitize the wheels of any rolling conveyance in the plant on a regular (at least daily) basis. You should also demonstrate the proper procedures for cleaning, sanitizing and storage of rubber aprons, gloves and boots. If you use footbaths or boot dips you also need to demonstrate how they should be maintained during the day and cleaned and sanitized at the end of the day.

May 15, 2002 Safe Food Depends on You If We All Work Together We Can Provide Safe Food for Our Customers

May 15, 2002 Credits This training program was developed as part of a project entitled “Control Strategies for Listeria monocytogenes in Food Processing Environments” funded under the National Food Safety Initiative in 2000 by the Cooperative State Research Education and Extension Services of USDA Project No Lots of hard work was contributed by: Cornell University New York Sea Grant University of Delaware Sea Grant College University of Maryland Sea Grant VPI Sea Grant Extension LSU Cooperative Extension National Food Processors Association National Fisheries Institute

Plant Cleaning and Sanitation to Control Listeria

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