BCFPA SANITATION ISSUES in the PLANT ENVIRONMENT

Whydo it?Sanitation Program Why do it? Sanitation Program A.Purpose of Sanitation –Safety -Product -Employee -Environment –Quality - Shelf Life -Consumer Acceptance -Sales/ Profits B.Food Microbiology –Pathogens/Spoilage –Growth –Sources –Controls

Why do it? Why do it? Because if you don’t, this could be Your Plant!

Mass Produced Foods Today, the food plant worker touches the lives of MILLIONS of people. Small Serving local market (100’s of people) Quick turnover 1900’s Food Plant Modern Food Plant Large Serving the World (Millions of people) Long distribution times

Sanitation “All precautions and measures which are necessary in the production, processing, storage and distribution, in order to assure an unobjectionable, sound and palatable product which is fit for human consumption” 1st Priority - Management Commitment NOT limited to Cleaning and Sanitizing

Cost of Sanitation Not just Cleaners and Sanitizers –Time –Tools –Training GMP –Building design –Pest control –Personnel hygiene –Equipment design

Sanitation It’s the LAW –GMP’s: Safety, Wholesome, Sanitary It’s Good Business –Profits and Growth Failure –Customer Dissatisfaction –Lost of Reputation –Law suits, $’s - Legal Fees, Fines –Criminal Actions - Jail –Plant Closed

Current Issues In Sanitation Health and Safety Control – Process and Costs Validation - Feedback Resources - Tools New Technology

Health Employees and Customers Food Borne Illness Allergens Cross Contamination

Safety Employees and Customers Allocation systems – reduce interaction with concentrated chemicals Protect against Contamination by Cleaners, Sanitizers Environmental impact – effluent concerns

Control & Validation Sanitation - Only One Part GMP – SSOP - HACCP Everyone’s Job Producer Processor Storage Distribution Preparer

Control - Plan Make a Plan –Written Procedures –Effective - Results & Cost –Safety Orientated –Practical –Specific –Posted Current –Feedback –Continuous Improvement and Innovation –Up-dated Regularly

Control - Training How –Based on Written Procedures –Specific –Stress Safety Why? –Food Safety and Quality –Microbial Control –Reinforcement

Control - Monitor All Aspects Must be Measured Detergent consumption Create a Daily Sanitation Log Monitor – 4 Factors –Concentration –Temperature –Time –Mechanical Force

Need: Sanitation Daily Log Record all daily sanitation challenges & exceptions: —Time allotted for C&S —Absenteeism & replacement workers —Water Temperature, Pressure & Volume —Chemicals Used & Concentrations - both detergents and sanitizers —Equipment issues and repairs - both C&S and manufacturing equipment Record anything and everything that may have impacted C&S

Validation HACCP External audits Performance Incentives Pre Operational All aspects must be monitored – know where to exert effort

Validation - Results –A.Visual - Immediate –B.Microbiological Pre-Operational –Swabs (I.D. problem area/ location) –Bioluminescence/ ATP Product –Fresh –Aged C.Organoleptic Fresh Aged D.Performance Monitoring CIP Monitoring E.Customer Acceptance Complaints Sales

Validation Rapid Methods Bioluminescence –Total ATP - Hygiene –Rapid - Real Time Data Trending Software Allergen Control Water testing “Fire Fly” Enzyme

Resources Required Commitment – look at sanitation as method to gain control and help deal with challenges Management – understand from the top down the need for change Monitoring Support to maintain changes

Resources - The Basics Time to clean – minimum time for sanitation that is non-negotiable Trained employees Tools to clean – foam, sanitize, scrub, rinse Proper chemicals available Supervision Ability to monitor program

Methods of Cleaning Manual: Sink, Bucket & Brush –Limited Temperature and Cleaner Activity Foams/Gels & Thin Films –Extended Contact Time –Increased Cleaner Activity –Fast

Methods of Cleaning Cont… Mechanical –High Pressure Rinse Assist Manual/Foam Methods –Spray Washers –COP Tanks –CIP - Clean In Place

Buildings and Facilities Buildings and Facilities How do bugs get in and move around? Adequate Space for Sanitary Storage Permits Control of Potential Risks Process Flow – Raw to Cooked Landscaping - Weeds, Grass, Neighbors Pest Control Ventilation- –Adequate and Protected

Buildings and Facilities Buildings and Facilities Con’t Water - Potable, Adequate, Protected Toilet Facilities Hand Washing Signs - Precautions, Policies Wastes - Rubbish, Effluent

EQUIPMENT Cleanable - Seams, Welds, Materials Self Draining Prevents Adulteration - Lubricants, Fuel, Metal Fragments, Contaminated Water Maintenance personnel / tools Controls and Monitoring Devices Proper Ventilation Compressed Gases - Food Quality

New Technologies Beverage CIP trends Conveyor lubrication Water conservation Effluent ATP

Beverage CIP Trends 5 Step – Hot Sanitize (185F for 20 min) hours total 5 Step – Cold Sani – 2 hours total 3 Step – Hot clean and sterilize – minutes total 3 Step cold – clean and sani in one step daily (45-60 minutes total), full clean 1x weekly

Lubrication Traditionally used fatty acid Synthetic lubricant development Dry lubricant –No water used – dry floor leads to less micro (listeria), less effluent, less wear and tear on equipment, no drip pans

Utilities / Effluent New detergent formulations leading to reduced operating costs and faster turn around –Reduced rinse times –Excelerate – ½ alkalinity and 1/3 sodium than traditional chlorinated alkalines –Enzyme cleaners - Solodigm –Phosphorous content reduction –Reduced temperature cleaning

The Sanitation Process “Deadly Results” –Consumer: People DIE –Business: Lost Sales / Costly Recalls –You: Plant Closes Everyone’s Job - 100% Commitment –Safe / Quality Foods –Safe Environment for: Food Production / Worker / The Environment -“Earth” Make The Right Choice