Cold Chain Practices
All equipment, utensils and food contact surfaces in the processing facility should be cleaned and sanitised on a daily basis or more often if needed in order to prevent the adulteration of food products. Most firms use a sanitation standard operating procedure (SSOP), and master sanitation schedule.
SSOPs documents specific details on;
How workers are to clean and sanitise
How sanitisers are to be used and mixed
How and when tasks should be completed
How and where equipment and utensils are to be used and stored.
The SSOP or master sanitation schedule should be reviewed by management periodically and be updated if needed.
The SSOP is focused on cleaning food contact surfaces in order to properly clean and sanitise equipment, utensils and food contact surfaces. It's important that they be adequately constructed so as to be easily cleanable and maintained.
The materials used for equipment, utensils and food contact surfaces should be non-toxic, durable and non-absorbent. In addition, equipment should be designed to be accessible for cleaning and sanitising or be easily disassembled to allow for cleaning and sanitising.
An Example of a Processing Plant Environmental Master Sanitation Schedule
AreaCleaning/Sanitation MethodToolsCleaning MaterialsFrequencyWallsFoam, brush, rinseSoft nylon brush and High-Pressure Hose (when appropriate)Chlorine-Quaternary ammonium ("quat")-based cleanerOnce/Month Walls adjacent to processing equipment should be cleaned dailyCeilingFoam, brush, rinseNylon brush, high-pressure machineChlorine-quat-based cleanerOnce/MonthFloorsWash, rinseHard bristle broom (not straw), floor scrubbers, low-pressure hoseChlorine-quat-or iodine-based cleanerDailyDoorsFoam, scrub, rinseScouring pad, clothChlorine-quat-based cleanerOnce/WeekPlastic curtainsFoam, rinseFoam and RinseChlorine-quat-based cleanerOnce/WeekOverhead pipes, electrical conduits, structural beamsFoam, brushBrush, bucket, high water pressure machineChlorine-quat-based cleanerOnce/MonthHoist, overhead light fixturesWipe, cleanCleaning padWater, light detergentOnce/QuarterRefrigeration coilsRinse, sanitizeHigh-pressure hoseWater, sanitize with quatOnce/QuarterChillersScouringScouring padAcid cleanerAs Needed/AuditAir distribution filtersSoakPlastic binsChlorine-alkaline detergentOnce/QuarterDrains, trenchClean, flood, rinseSoft Nylon brush, 50-gallon containerChlorine-alkaline detergent, quat or iodine-based sanitizerDailyGridsBrush, rinseNylon brush, high water pressure machineChlorine-alkaline detergentDailyWaste, dumpster areasFoam, brush, rinseNylon brush, high water pressure machineHeavy-duty chlorine-based cleanerDailyEmployee break rooms/bathroomsWash, rinseNylon brush, sanitary brushesChlorine-based soap or quatFrequently throughout the dayMaintenance areasScrub, rinseNylon brushDegreasing agentOnce/Month
Including as part of the sanitation schedule the name of the employee (and alternate when a primary employee is absent) responsible for the activity, the equipment to be cleaned and how to disassemble it, the frequency of cleaning, procedures for cleaning (including type and concentration of cleaning compound and sanitiser), time and temperature requirements, cleaning solution flow rate (pressure) if applicable, and the name of an employee responsible for verifying the program effectiveness by inspection
Cleaning the condenser unit, drip pans, and hoses of refrigerators
Keeping cold storage as dry as possible
After cleaning and sanitising, visually inspecting the area cleaned for product residue and conducting routine microbiological tests (conventional or rapid microbiological methods, such as total count or bioluminescence) to verify the effectiveness of the cleaning and sanitising program
When reassembling sanitised equipment, placing the equipment parts on a sanitary mat and not on the floor
Cleaning and sanitising all processing equipment, facility utilities (e.g., air system, water system), and food-contact surfaces after maintenance work and prior to use in production
Cleaning and sanitising processing equipment and food-contact surfaces between the processing of different commodities, if appropriate based on risk
Avoiding cleaning and sanitising equipment during processing operations to prevent contamination
Minimising splashing during the cleaning of floor drains by using an appropriate brush, such as a ¼ inch smaller brush than the diameter of the drain opening, or a splash guard
For cleaning drains, we recommend using dedicated utensils (colour-coded and used for cleaning drains only) to minimise the potential for contamination. We also recommend that floor drains not be cleaned during processing operations and that the person who cleaned drains not clean fresh-cut produce food contact surfaces without changing outer garments, and washing and sanitising his or her hands.Regularly inspecting tools for cutting, slicing, and shredding for damage that could impair cleaning and sanitising them
We recommend replacing a tool if it cannot be fixed so that it can be adequately cleaned.
What's the difference between Cleaning and Sanitising?
Even though many people believe they are the same, they are really two completely separate steps in an effective operation.
Cleaning is the removal of organic material and debris from surfaces in preparation for sanitising. Cleaning involves washing and rinsing and is usually done with detergents, soap and physical scrubbing or agitation followed by a clean water rinse.
Sanitise means to treat clean food contact surfaces by a process that destroys pathogens and reduces the number of other microbes without adversely affecting product safety.
To maximise the effectiveness of cleaning and sanitising activities, there is an order of activities that should be followed:
1) any equipment that needs to be disassembled prior to cleaning should be taken apart by the properly trained individuals
2) All services should receive a pre-rinse with potable water
3) All services and equipment should be effectively cleaned using hot water, detergent, high-pressure or scrubbing as necessary
Detergent type and strength will influence the effectiveness of any cleaning program. The type of detergent used is determined by the type of soil to be removed. The temperature of the detergent solution and the exposure time are also important, as is the amount of physical scrubbing required and how well the equipment is pre-rinsed. These factors should be specified in written sanitation standard operating procedures (SSOPs) or master sanitation schedules to help ensure that they are adequately and consistently performed.
After cleaning the detergent or soap should be completely rinsed off with potable water. Next, all services should be sanitised with an approved antimicrobial agent, commonly used sanitisers include chlorine, chlorine dioxide or quaternary ammonium. It's important that the level of sanitiser used to be adequate to kill the targeted microbe which could be Salmonella, Listeria, E. coli or any other pathogen.
When using chlorine a level of 100 to a maximum of 200 parts per million (PPM) total chlorine is typically used. Personnel should follow label instructions when mixing and applying the sanitisers used.
All sanitiser levels should also be checked and recorded, consider rotating sanitisers in order to prevent the development of pathogen resistance to that sanitiser. There are also several factors to consider when choosing a sanitiser such as the type of equipment or surface to be sanitised, the temperature and contact time required by the sanitising solution, and the pH and the hardness of the water, of these factors the pH of the water is the most important.
Consult with chemical suppliers for guidance and the choice and use of detergents and sanitisers. Also, it's important to read and follow all labels of all sanitisers and detergents. All cleaning and sanitation activities should be documented in writing and reviewed by a supervisor. This provides for uniformity in these activities and allows for changes should they be needed.
Another way to check on the effectiveness of all cleaning and sanitation activities is to conduct environmental monitoring of walls, floors, ceilings, drains, chiller and storage racks. There are various types of environmental monitoring such as bacterial swabbing and the use of luminometers that use bioluminescence or light from organic matter to show whether a surface has been cleaned and sanitised properly.
Luminometers measure the amount of organic matter that may be left on food contact surfaces after cleaning and sanitising. The amount of organic matter is read as a score within a number system, this type of monitoring provides for immediate feedback and can pinpoint problem areas that need more thorough attention.
Firms may conduct these monitoring activities in-house or they may choose to hire an outside lab, outside labs should be qualified by the proper authorities in order to conduct monitoring activities. Check with local or state authorities suppliers and technical magazines for acceptable laboratories in the area.
If a firm chooses to monitor in-house, proper procedures should be followed at all times and all monitoring should be documented and verifiable. It's always recommended that whatever methods used, provide accurate results in as short a time as possible.
The proper use of all chemicals and a fresh produce processing facility should be covered in the Sanitation standard operating procedures (SSOP) or sanitation manual. The SSOP should detail what chemicals are to be used for each job, how and when they are to be mixed and applied as well as all precautions to be taken when using each chemical.
All chemicals should only be used as labelled and when safe
All chemical containers should be labelled properly
All chemicals should be stored so as they do not contaminate food, ingredients or packaging
Chemicals should not be stored on food contact surfaces and should not be stored in empty food or ingredient containers.
The label instructions for all chemicals should be followed with no hesitation to contact the supplier if there are questions.
Cleaning and sanitising Chemicals
Cleaning and sanitising chemicals may be toxic and should be stored in dry, secure, and ventilated areas away from facility traffic and processing operations. They should be handled by employees trained in the use of such chemicals.
We recommend the following practices in using cleaning and sanitizing chemicals:
Using adequate quality water for cleaning and sanitizing at temperatures appropriate for the chemicals used
Using toxic chemicals for cleaning operations in accordance with the manufacturer's instructions and in accordance with relevant Federal, State, and local government regulations
Clearly labelling toxic chemicals
Storing toxic chemicals and pesticides in a manner that protects against contamination of food, food-contact surfaces, and food-packaging materials and in accordance with relevant Federal, State, and local government regulations
Monitoring the effectiveness of cleaning and sanitizing chemicals by visual inspection and environmental testing (especially grooves and niches) for microbial growth
What is the importance of acceptable equipment construction and proper cleaning and sanitising activities?
Acceptable equipment construction, proper cleaning and sanitising activities play a key role in the control of biofilm. Have you ever heard your dentist talk about removing plaque from your teeth? Have you ever walked across a stream and slipped on slimy rocks? These are both common examples of biofilms.
What is biofilm?
Biofilm can be defined as a thin layer of bacterial cells that adhere to equipment and other services and are more resistant to common sanitisers. Various pathogens such as Listeria, Salmonella and E. coli have been shown to form biofilms that can contaminate food products during production.
Biofilms can be found on the surfaces of product lines, cutting boards, fillers, spinner baskets, stainless steel and plastic conveyor systems and any surface in constant contact with a product.
Bacteria in biofilms are hard to find using normal monitoring techniques. The control of biofilms is also very difficult, as the bacteria in biofilm acquire extreme resistance to sanitisers disinfectants and heat treatment. Because biofilms can build up over time, timely and proper cleaning and sanitising is needed to ensure that bacteria are killed in the early stages of biofilm formation. Sanitation workers should vigorously follow all cleaning steps; pre-rinse, clean, post-rinse, and sanitise every time they clean. The cleaning crews should also strictly follow the directions for the concentration, temperatures and contact times for all cleaners and sanitisers and those cleaners and sanitisers should reach all food contact surfaces.
Supervisors or a properly trained employee should conduct visual sanitation inspections after all equipment and services have been cleaned. Microbiological testing of equipment and surfaces should also be considered.
Following the firm sanitation standard operating procedures or sanitation manual is imperative for controlling biofilm formation. A firm should replace or repair any rusty, pitted or deteriorated equipment and food contact surfaces because rust and deteriorated equipment allows for the growth of bacteria. Such equipment becomes difficult to clean which leads to the formation of biofilm.
