[box type=”shadow” ]Manufacturing facilities are governed by Standard Operating Processes which define the extent of cleaning required for a contamination-free production facility ensuring safety and quality of product. Investments in cleaning products and process are defined accordingly. A large part of the unorganised sector, even today follows methods which ensure no food safety. Clean India Journal attempts to summarise the areas that require cleaning in food processing to ascertain the kind of cleaning products that go into maintaining standards, safety and quality of food products.[/box]
In India, the food sector has emerged as a high-growth and high-profit sector due to its immense potential for value addition, particularly within the food processing industry. Currently valued at US$ 39.71 billion, it is expected to grow at a CAGR of 11% to US$65.4 billion by 2018. Food and grocery account for around 31% of India’s consumption basket.
The Indian food processing industry accounts for 32 per cent of the country’s total food market, one of the largest industries in India and is ranked fifth in terms of production, consumption, export and expected growth. It contributes around 14% of manufacturing Gross Domestic Product (GDP), 13% of India’s exports and six per cent of total industrial investment. Indian food service industry is expected to reach US$ 78 billion by 2018.
Food processing industry covers a wide range of products fruit and vegetables; meat and poultry; milk and milk products, alcoholic beverages, fisheries, plantation, grain processing and other consumer product groups like namkeen, confectionery, chocolates and cocoa products, Soya-based products, mineral water, high protein foods and many others. While leading manufacturers have the SOPs in place to meet the food safety regulations, there are a large number of food processors who are yet to follow the rules of laid down. Some of these products, like namkeen, are manufactured on a large scale and yet the cleaning processes are rudimentary and involve no auditing to ensure food safety.
Investing in quality cleaning machines is all about investing value retention, safety and efficiency in any manufacturing facility. Food industry needs to follow cleaning processes in the production unit and there are specific cleaning products that can be used to ensure food safety.
Cleaning in food plants
• Gross Clean/Preparation
• Pre-rinse
• Detergent application
• Post-rinsing
• Disinfection
• Terminal rinsing
Once a cleaning procedure has been established, it is essential that it is validated. Is the procedure as documented capable of controlling the identified hazards? This may include bacterial pathogens or allergens. The method of validating a cleaning procedure is as follows:
• Document the cleaning procedure as it actually exists done on the job and in conjunction with those who perform the cleaning.
• Identify the general and specific hazards of concern, e.g. pathogens, allergens, etc.
• Identify the monitoring program, e.g. visual, ATP, chemical testing, etc.
• Conduct the cleaning program as documented a number of times and follow up with the monitoring checks.
• Confirm that the procedure as documented is capable of meeting the monitoring criteria.
• If the procedure is not capable, modify the cleaning method or correct the issue.
• Repeat the above process until the documented cleaning procedure is confirmed as capable of meeting the standard (verified) and approve the procedure.
• Conduct training of employees against the procedure and implement the monitoring program.
• Retain full records of the above data and process including your conclusions.
Monitoring the cleaning process
A typical monitoring program may include one or more of the following:
• Visual inspection
• Microbiological testing
• Rapid testing
Wet and Dry Cleaning
Cleaning essentially involves dry cleaning and wet cleaning in the food processing unit. Even though there are best of the cleaning chemicals and detergents and water, dry cleaning is the best solution in case of cleaning that equipment that handles production of dry goods. For example, in a unit handling chocolate or peanut butter, if water is used as a cleaning agent, it would end up in a big mess and could ruin the machinery too.
Many a time, brushing and scraping manually are resorted to in the dry cleaning techniques, however these methods are time consuming and does not yield effectively clean results. The main flaw with this method is that it does not agitate the surface, which is fundamental to getting deep within the surface, including any pores and crevices. A process that combines an approach of washing, scrubbing, steaming and drying food processing equipment and surfaces is ideal. These steps allow for not only sterilisation (if steam temperature is high enough) but also a mechanical agitation, which helps with the removal of food residue, dirt and grime.
For tough-to-reach spots, many food processors rely on compressed air, which is just blowing powder and debris from one place to another. To remove food residue from both reachable and hard to reach areas effectively, industrial vacuums with HEPA filters are used. In order to remove stubborn soils or greasy particles, dry vapour steam equipment could be used. Besides the production lines, dry vapour is also used in the packaging machinery and conveyor belts.
Dry steam cleaning processes, significantly reduce the risk of residue build-up or the occurrence of moist/wet floors, which could lead to slips and falls. Following, these basic steps, the machinery is sprayed with sanitizers to complete the cleaning process.
Dry cleaning procedures can be applied to floors, walls, containers, installations, etc. For example, filling stations or even during goods handling, there is a lot of spillage that needs to be cleaned quickly. Industrial vacuums with high suction power and good filters are suitable to clean this area of the food processing unit.
Vacuums again are used to clean ovens. Many cleaning equipment manufacturers have come up with special nozzles that are heat resistant enabling cleaning when the oven is hot.
Similarly, in the production line, another technology that is more prominently used abroad includes the ice blasting machines which take care of residues like carbon, grease, starch, etc. This can also be used in the mixing plants, tanks, furnaces and handling systems.
Sweepers again are part of dry cleaning which can be used in the shop floor and also in the surrounding area cleaning.
High pressure jets, part of wet cleaning, are used commonly to remove fat or grease deposits also for foaming structure within the production unit. The hot and cold water option in the high-pressure jets enables all-round cleanliness and hygiene.
Other common wet cleaning products include vacuums, scrubber dryers, single disc machines.
Traditionally, cleaning used to be done either before production or after, and if it occurred during production hours, machines were turned off for cleaning. Cleaning in place or inline cleaning systems are now being used extensively for interior cleaning of pipes, vessels, tankers, heat exchanges, fillers and other enclosed process systems. This method allows processing equipment to be steamed, vacuumed and removed of any waste in one go, without having to stop. This greatly reduces the risk of contamination further down the production line. Surfaces receive a deep clean while production is occurring rather than a wipe down at the end. It also reduces resources, labour and downtime. Other cleaning processes include chiller and heat exchanger tube cleaning machinery and others.
Detergents, Disinfectants
The official definition (Association of Official Analytical Chemists) of sanitizing for food product contact surfaces is a process which reduces the contamination level by 99.999% (5 logs) in 30 sec.
The official definition for non-product contact surfaces requires a contamination reduction of 99.9% (3 logs). The standard test organisms used are Staphylococcus aureus and Escherichia coli.
General types of sanitization include the following:
• Thermal Sanitization involves the use of hot water or steam for a specified temperature and contact time.
• Chemical Sanitization involves the use of an approved chemical sanitizer at a specified concentration and contact time.
Detergents are normally used to remove soils, while sanitizers which contain both detergents and disinfectants which are used to kill microbes without employing a soil removal action.
Water comprises approximately 95-99% of cleaning and sanitizing solutions. Water functions to do the following:
• carry the detergent or the sanitizer to the surface
• carry soils or contamination from the surface.
The primary source of soil is from the food product being handled. However, minerals from water residue and residues from cleaning compounds contribute to films left on surfaces. Microbiological biofilms also contribute to the soil build-up on surfaces. Since soils vary widely in composition, no one detergent is capable of removing all types. 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.
The rule of thumb is that acid cleaners dissolve alkaline soils (minerals) and alkaline cleaners dissolve acid soils and food wastes. Improper use of detergents can actually “set” soils, making them more difficult to remove (e.g., acid cleaners can precipitate protein). Many films and biofilms require more sophisticated cleaners that are amended with oxidizing agents (such as chlorinated detergents) for removal.
Cleaning and disinfection may in some cases be combined into one operation using a sanitizer which has the action of both a detergent and a disinfectant. However, it is believed that the two-stage approach is more consistent and effective than the single stage sanitizer approach. It is important that non-scented chemicals are used in food operations due to the risk of taint.
Detergents can be significant contributors to the waste discharge (effluent). Of primary concern is pH. Many publicly owned treatment works limit effluent pH to the range of 5 to 8.5. So, it is recommended that in applications where highly alkaline cleaners are used, the effluent be mixed with rinse water (or some other method be used) to reduce the pH. Recycling of caustic soda cleaners is also becoming a common practice in larger operations.
The process of cleaning could be rather simple but the choice of cleaning chemicals, sanitizers, equipment and even tools is complex and requires knowledge of each product and its reaction with the soil. The is a vast subject and this article has put together basics in cleaning in a food unit.
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Hygiene Practices
Facilities required in the processing room:
• A changing room where clothing and shoes that are not worn for work can be stored.
• Separate hand-washing facilities for staff, with soap, clean water, nail brushes and clean towels or hot-air hand dryers. Handwashing facilities should not be used for washing equipment.
• Toilets, which should be separated from the processing room by two doors or located in a nearby building.
• First aid materials.
• Protective aprons or coats washed regularly, hats/hairnets, and if necessary, gloves and shoes/boots.
• Cleaning chemicals, stored away from the processing room.
Personal hygiene:
• Wear a hat/hairnet that completely covers the hair. Do not comb your hair in a processing room or storeroom.
• Cover all cuts, burns, sores and abrasions with a clean, waterproof dressing.
• Do not smoke or eat in any room where there is open food because bacteria can be transferred from the mouth to the food.
• Do not spit in a processing room or storeroom.
• Wash hands and wrists thoroughly with soap after using the toilet, eating, smoking, coughing, blowing your nose, combing your hair, handling waste food, rubbish or cleaning chemicals. Dry them on a clean towel before handling food again.
• Keep finger nails cut short.
• Do not wear perfume or nail varnish as these can contaminate products.
• Do not handle any food if you have sores, boils, septic spots, a bad cold, chest infection, sore throat or a stomach upset. Report any of these to the manager and do alternative work.
• Do not cough or sneeze over food.
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Cleaning:
• Clean the processing room, toilets and washing facilities, and storerooms every day.
• Use the correct chemicals to clean equipment, make sure there are no food residues and rinse the equipment with clean water of drinking quality.
• Make sure all cleaning cloths are washed and boiled each day. Do not hang them on equipment, products or window ledges to dry.
• Clean as you go -do not leave dirty equipment until the end of the day before cleaning it.
• Keep the outside area around the processing room clean and tidy, keep grass cut short.
Sanitation:
• Put all wastes into bins that are not used for anything else. Empty the bins periodically during the day away from the processing site.
• Prevent all animals from entering the processing area or storerooms.
• Visitors should only enter the processing room wearing protective clothing and under supervision.
• Keep food covered wherever possible.
• Keep all food, tools and equipment off the floor.
• Store ingredients in sealed containers.
• Do not use broken or dirty equipment.
• Report any signs of insects, rodents or birds to the manager.
Safe clothing and work practices:
• Wear shoes that protect your feet from falling objects.
• Do not wear any loose clothing or jewelry that could get caught in running machines. Wear overalls.
• Prevent staff from running inside a building.
• Do not allow customers, children or animals into the processing room.
• Immediately clean up any water, oil or grease on the floor using sawdust, sand, husks etc.
• Cover burning electrical equipment with a damp cloth or sand. Never use water to put out flames.
• Shield gas burners from direct sunlight because the flames can become invisible.
• Do not put cleaning chemicals into old food containers.
• Have a first aid box containing sterilized dressings, cotton wool, adhesive plasters and bandages.
Operating machinery:
• Ensure that only trained staff enter the premises or operate machines.
• Do not allow staff to start a machine unless they know how to stop it. Only one person should operate a machine at any one time.
• Make the layout of machinery logical, and leave sufficient space around it so that there are few chances for operators to get in each others way.
• Do not try to attract operators’ attention by touching or calling them from behind if they are using a machine. Always speak to them from the front, or wait until they have finished what they are doing.
• Train staff to be familiar with potential hazards (e.g. potentially dangerous machines), and what they should do in case of an accident. Use charts hung on the wall near to each machine to show safety precautions.
• Ensure that guards are fitted and in place over any moving parts of a machine and alert staff to machines that appear to be standing still when running at high speed.
• Never allow staff to clean, adjust or lean over moving machinery and do not allow them to leave a running machine un-attended.
• Encourage operators to report any loose parts on a machine.
• Do not allow staff to work with equipment that is defective. Put a note on any machine that is under repair saying ‘DO NOT TOUCH’.
• Do not allow anyone to touch inside electric equipment while it is connected.
• Regularly check the cords of electrical appliances to ensure that outside covers are not broken and wires are not exposed.
Compiled from various sources
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