Sanitation 101
Presented By:
Terry Lum
November 8th, 2005
Terry’s Bio
• BSc. Biochemistry, UBC
• 7 years with Foremost Foods
• 1 year with Labatt's
• 5 years Ecolab Account Manager, Food
& Beverage Division.
Topics of Discussion
A.
B.
C.
D.
E.
Why Sanitation?
Consumers View of Quality.
Microorganisms.
What is Sanitation, Cleaning and Sanitizing?
Six Steps to Total Sanitation
1. PREPARATION
2. PRERINSE
3. APPLY CLEANER
4. RINSE
5. INSPECT
6. SANITIZE
F. Validation
1. Visual
2. Microbial
3. Rapid Method
G. Cleaning Utensils
A. WHY Sanitation ?
• SAFETY
–
–
–
Consumer
Employee
Environment
• QUALITY
–
–
–
–
Fresh / Wholesome
Shelf life
Consumer Acceptance
Sales / Profits
B. Consumers View of Quality
•
•
•
Safety
Long Shelf life
Desirable
“Sensory Attributes”
•
•
•
•
Value
Nutrition
Defect Free
Consistent
C. Microorganisms
• What are Microorganisms?
– The term microorganism, meaning small living thing, is
used to describe the forms of life we cannot see with
the naked eye. Bacteria, yeast’s and molds are types of
microorganisms.
– THEY ARE EVERYWHERE!
– The enemies are groups of microorganisms called
PATHOGENS are disease causing organisms. They can
make you sick and kill you.
– SPOILAGE bacteria, which cause food spoilage.
Microorganisms
continued…
• Conditions for Growth of Microorganisms:
– Food, Water and Time.
– If there is a source of food, water, efficient time and
temperature is favorable. This will result in the growth
of microorganisms. Flume water is a perfect conveyor
of food = Starch!
– With all these elements in place, microorganisms will
grow at a very fast rate.
Microorganisms
continued…
Reproduction
Binary Fission
1→ 2 → 4 → 8 → 16 → 32 → 64 → 128…Millions
Microorganisms
continued…
• Where an area of your plant contains food and water, and
cannot be effectively cleaned and sanitized in a reasonable
time. This creates what is known as a growth niche.
• Such Growth Niche Locations are:
– Ledges
– equipment seams
– cracks in floors and walls
– absorbent materials
– under equipment, flumes, cutters, belts
– Drains, gutters, troughs.
Biofilms
• Mass with
Protective
Film (Slime)
• Traps
Nutrients
and Bacteria
• Bacterial
Attachment
• Prevents Anti-Microbial Action
• Effective Cleaning Required
Microorganisms
continued…
• Other Sources of Microorganisms:
–
–
–
–
–
–
–
–
–
raw materials and ingredients
employee’s gmp, handwashing, footware
packaging materials
wet product residue on the floor
non product contact surfaces
floor mat’s
buttons and switches
door knobs
rodents and pests
D. What is Sanitation,
Cleaning and
Sanitizing?
• Sanitation:
– Is the creation and maintenance of conditions favorable
to good health. This involves both actions of cleaning
and sanitizing.
• Cleaning:
– Cleaning is the elimination of visible and invisible soil
from the food processing environment.
• Sanitizing:
– The act of reducing the number of microorganisms to
safe levels on clean surfaces.
E. Six Steps to Total Sanitation
1.
2.
3.
4.
5.
6.
PREPARATION
PRERINSE
APPLY CLEANER
RINSE
INSPECT
SANITIZE
1. PREPARATION
• REMOVE ALL
PACKAGING
MATERIALS
• REMOVE ALL RAW
MATERIALS
• GATHER ALL OF THE
NECESSARY SUPPLIES
INCLUDING ALL PPE
(Rubber boots, rubber
gloves, apron, eye
protection, etc.)
2. PRERINSE
• RINSE FROM TOP DOWN.
• PURPOSE IS TO
REMOVE HEAVY
SOIL - NOT CLEAN
3. APPLY CLEANER
• CLEANER MAY BE
FOAMED, SPRAYED, OR
BRUSHED ON.
• WHEN FOAMING,
ALWAYS START AT THE
BOTTOM AND WORK UP
• NEVER ALLOW CLEANER
TO DRY BEFORE RINSING.
APPLY CLEANER AGAIN
IF THIS OCCURS.
APPLY CLEANER
• Clean and Scrub Equipment:
– when applying detergent cover
every square inch
– some pieces of equipment may
require extra scrubbing
– clean in direction of flow
– do one piece at a time
CHOOSING THE RIGHT CLEANERS
Four Factors
I.
II.
III.
IV.
Nature of the Soil
Role of Water
Surface to be Cleaned
Methods of Application
I. Nature of Soils
• Visible
– Solution: The Right Cleaner
• Invisible (microorganisms)
– Solution: The Right Sanitizer
Food Industry
Classification of Soils
•
•
•
•
Fat
Protein
Carbohydrates
Mineral Salts
Fats
• Emulsification: Surfactant
• Disporsion: Alkali
• Saponification: Strong Alkali
Fat Removal
100
90
80
70
60
% 50
40
30
20
10
0
C 20
F 68°
Water
Cleaner
32.5
90.5°
45
57.5
113°
135.5°
Temperature
70
158°
Protein
• Alkaline or Acid
– Dissolve proteins
• Oxidizing Agent
– Hydrolyze proteins
• Enzyme (protease)
– Catalyst to hydrolyze proteins
Solubility of Protein
Alkaline
Only
Chlorinated
Alkaline
Carbohydrates
• Sugars
– Soluble in warm water
• Starches
– Alkaline or acid cleaner
– Enzyme (Amylase)
Mineral Salts
• From food and water supplies
Build-up is referred to as “stone”
– Milk-stone, beer-stone
• Phosphates and polymers form soluble
complexes
• Chelates, the strongest, form soluble
complexes
II. Role of Water-Hardness
• The most important chemical property of water
• Temporary hardness
–
–
–
Calcium of magnesium bicarbonate
Precipitates upon heating
Precipitates with alkali
• Permanent hardness
–
–
–
•
•
Calcium or magnesium chlorides or sulfates
Stable when heated
Precipitates with alkali
Hardness forms scale or leaves films
Municipal water in BC is generally soft.
Cleaning Solution
Detergent
1%
Water
99%
pH SCALE
•
•
•
•
STRONG
•
ACIDS
•
|---------------|----------------|
0
7
14
NEUTRAL
(EG. WATER)
STRONG
ALKALIS
7 is 1 activity=>10=>100=>1000=>10,000=>100,000=>1,000,000
• 14 is=>10,000,000times the Activity WOW!
III. Surface or Material to
be Cleaned
•
•
•
•
•
•
Stainless Steel Preferred
Aluminum
Copper and brass
Mild steel
Nonmetallic surfaces
Nature of surface
– Smoothness
– Corrosion
IV. Methods of
Application
• Manual: Sink,
Bucket & Brush
– Limited Temperature and
Cleaner Activity
• Foams/Gels &
Thin Films
– Extended Contact Time
– Increased Cleaner Activity
– Fast
Methods of
Application
Cont…
• Mechanical
– High Pressure Rinse
• Assist Manual/Foam
Methods
–
–
–
Spray Washers
COP Tanks
CIP - Clean In Place
Methods of Application
Typical Cleaning Solutions
Manual/Hand
Temperature
pH
(Maximum)
Foam
4 - 10.5
120° F
High Foam
Spray
3 - 10.5
120° F
Moderate Foam
Foam/Viscous
Solutions
Mechanical
2 - 11.5
Ambient
1 - 13
180° F
High - Moderate
Foam
Low - Defoamed
The 4 x 4 Formula
• 1. Pre-Rinse
• 2. Wash - Remove Soil
•
•
•
•
Concentration
Temperature
Time
Mechanical Force
• 3. Rinse
• 4. Sanitize
• Kill Microorganisms
Four
Factors
in
Cleaning
FACTOR
•
•
•
•
Concentration-pH
Temperature
Time
Mechanical Force
Concentration
pH
Temperature
Mechanical
Force
Time
MANUAL
2-10.5
120ºF max
Costly
High
MECHANICAL
1.0-12.5
140º-180ºF
Variable
Low
4. RINSE
• ALWAYS START
AT THE TOP AND
WORK DOWN.
• YOU ARE TRYING
TO REMOVE ALL
SOIL NOW
5. INSPECT
• ALWAYS INSPECT
YOUR WORK!
• CORRECT ANY
PROBLEMS AT THE
TIME YOU FIND
THEM
6. SANITIZE
• APPLY SANITIZER
TO ALL FOOD
CONTACT
SURFACES AND
MOST NON-FOOD
CONTACT
SURFACES
Why Should Cleaning & Sanitizing
Be Carried Out As Two Steps?
• The presence of any residual soil can
chemically or physically impair the
efficacy of sanitizers
• Soil may shield microorganisms from
the necessary direct contact with the
sanitizers
F. Validation
1.
2.
3.
Visual
Microbial
Rapid Method
Validation - Visual
• Immediate
• Often Over Looked
• Aids
– Flashlights
– Spot Lights
– Black Lights
Validation - Microbial
• Pre-Operational
– Swabs
– Rinse Samples
• Final Product
– Fresh
– Aged
• After the Fact
– 24-36 Hours
– 7-10 Days
Validation
- Rapid Methods
• Enzyme / DNA
Analysis
• Bioluminescence
– Total ATP - Hygiene
– Rapid - Real Time
“Fire Fly” Enzyme
What is ATP?
Adenosine Triphosphate
The “energy currency” molecule of all living organisms
+
Firefly enzyme
Principals of ATP Measurement
ATP + Luciferase
Luciferase - ATP
Luciferase - ATP
Firefly Luciferin
Light
Instrument Reading = Light = ATP = Soil Load
G. Cleaning Utensils
• One of the critical elements in this
program is the proper selection, use and
care of cleaning utensils, such as cleaning
brushes and containers. The segregation
of these utensils is to avoid cross
contamination. Separate utensils used for
food and non-food contact surfaces by
color-coded program.
¾ WHITE – Food contact surfaces
¾ RED – Raw
¾ BLUE – Floor
¾ BLACK - Drain
Color-Coded
Brushes
Tank & Vat
Valve & Pipe
Drain
Questions???