cleaning & sanitizing for food plants. effective cleaning 2 introduction all equipment must be...
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Effective Cleaning 2
Introduction
All equipment must be cleaned and sanitized prior to use and following any pause in use that could result in contamination.
Specific procedures (SOPs) for cleaning & sanitizing each piece of equipment are available to the operator
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Definition of Cleaning
- the complete removal of food soil using appropriate detergent chemicals under recommended conditions.
- a process which will remove soil and prevent accumulation of food residue which may decompose or support the growth of disease-causing organism or the production of toxins.
Definition of Sanitizing
- Reducing of microorganisms on surface to safe level
- A process which destroys disease causing organism which may be present on equipment and utensils after cleaning
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Sterilize : statistical destruction and removal of all living organisms.
Disinfect : to inanimate objects and the destruction of all vegetative cells (not spores).
Sanitize refers to the reduction of microorganisms to levels considered safe from a public health viewpoint.
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Food Soil
Food soil : unwanted matter on food-contact
surfaces. visible or invisible.
The primary source:
- food product being handled. - minerals from water residue - residues from cleaning compounds- Microbiological bio-films
Food Soils Classification:
Soluble in water
(sugars, some starches, most salt)Soluble in acid
(limestones,most mineral deposits)Soluble in alkali
(protein, fat emulsions)Soluble in water, alkali or acid
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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.
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Surface Deposit
SolubilityEase of
RemovalHeat-Induced
Reactions
Sugar Water soluble Easy Caramelization
Fat Alkali soluble Difficult Polymerization
Protein Alkali soluble Very Difficult Denaturation
StarchWater soluble, Alkali soluble
Easy to Moderately Easy
Interactions with other constituents
Monovalent SaltsWater soluble; Acid soluble
Easy to Difficult Generally not significant
Polyvalent Salts Acid soluble DifficultInteraction with other constituents
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Main purposes of cleaning
Remove soils that harbor microorganisms and provide nutrients for their growth
Prevent the transfer of ingredients from different batches of products
Eliminate soils that affect efficiency of heat transfer
Prolong equipment life by removing potentially corrosive materials
Facilitate preventive maintenance
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Cleanup steps
Pre-rinse Removes gross soils (reduces need for chemicals)
Wash Removes most bacteria by chemicals, heat, agitation
Post-rinse Removes most bacteria and soil loosened by washing
Sanitize Ensures that equipment doesn’t
contaminate incoming product Doesn’t compensate for poor wash
“You can’t sanitize dirt!”
WaterWater comprises approximately 95-99%
of cleaning and sanitizing solutions.
Functions:carry the detergent or the sanitizer to the
surface; carry soils or contamination from the
surface.
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Water must be potable and pathogen-free.
Suspended matter must be kept at minimum level
Soluble iron and Manganese salt less than 0.3 ppm
Never used HARD WATER
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Alkaline-based Detergents
- Sodium Hydroxide Sodium
- Hydroxide/Hypochlorite Solutions Acid-based Detergents
- Phosphoric Acid
- Nitric Acid Additives
- Surfactants
- Chelating Agents
- Emulsifiers
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Cleaning Detergent
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Cleaner selection
Factors to be considered when selecting cleaning chemicals
Nature of soil Organic / protein / petroleum-based / inorganic
(scale or oxide) Nature of surface to which soil is attached
Stainless steel / aluminum / rubber / plastics Quality of water available
Use potable water Hardness (Ca / Mg) will affect performance
Remember
acid cleaners dissolve alkaline soils (minerals)
alkaline cleaners dissolve acid soils and food wastes
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Cleaning methods
1. Manual Taking equipment apart & using brushes
2. Cleaning-Out-of-Place (COP) Taking equipment apart and using tank for
soaking
3. Cleaning-In-Place (CIP) Using circulating solution without taking
equipment apart
4. Pressure spraying Using high or low pressure
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Manual cleaning
Uses lower concentrations of chemicalsCleaners are formulated for safe useBrushes are used to apply physical
energyVery labor intensiveComplete cleaning may be difficult if
physical energy is not consistent
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Cleaning out of Place (COP)
Requires little labor Good penetration during soaking Needs good arrangement of parts and agitation
to work effectively Cleaner needs to be selected because of long
soaking time
Cleaning in Place (CIP)
CIP is used to clean tanks, piping and even workspaces between production batches by automatically recirculating detergent and rinse solutions.
The washing process consists of several cycles in which rinsing material is recycled through the vessels, pumps, valves and other process equipment in the flow system.
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Clean-In-Place (CIP) Benefits
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Reduced Water UsageReduced Sanitizer ConsumptionReduced Operating CostsReduced Wastewater CostsIncreased Efficiency - Reduced Cycle
TimesIncrease Available Process Time
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Pressure spraying
Effective for cleaning large areasE.g. floors, walls, irregular areasFoaming cleaners on walls
Temperature is reduced on contactPhysical energy varies with proximity
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Effective cleaning
Procedures include:Contacting the soilAllowing sufficient contact time to reactMaintaining temperatureProviding sufficient energy
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Mechanism of cleaning
Detergent is dissolved in waterSolution is applied to surface to separate
soilWater soluble soils are dissolved in waterCleaner allows water close contact to
surfaceCleaner then loosens soil by reducing its
attraction to surface
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Mechanism of cleaning (2)
Soil separation is helped by physical action Scrubbing / turbulent flow / pressure spray
Soil dispersion begins Soluble soils remain in cleaning solution Clumps of insoluble soil are broken down Fats & strong alkalis create a soluble soap
Cleaner and dispersed soil are removed Surface is rinsed with potable water to remove
cleaning solution
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Cleaner performance
Four factors for cleaner effectivenessTime
15+ minTemperature
60-70C (140-160F) preferredConcentration of cleaner
Recommended by manufacturerPhysical energy
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Cleaning Variables
TemperatureTime
Concentration Velocity
Concentration
Temperature
Time TimeTemperature
ConcentrationVelocity
Velocity
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Purpose of sanitizing
Last step in cleanup processRequires proper cleaning of surface first
Remove oil / biofilm / cleaner residueReduces microorganisms on previously
cleaned surface free of pathogens
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Ideal sanitizer
Has a rapid kill and wide spectrum of kill Exhibits good environmental resistance
Not adversely affected by poor water quality or residues
Effective over wide pH range Non-toxic to humans Non-corrosive to surfaces under all conditions Freely soluble Good shelf life
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Effective sanitizing
Use at recommended concentration More can cause corrosion
pH of sanitizer is formulated for best action Kill increases with temperature
Stability can decline
Time of exposure varies Must be capable of 99.999% kill in 30 sec Contact time of 2 min is common
Residual soil affects performance of oxidizers
Sanitizing Agents
Physical Sanitation Alkaline-Based Sanitizers
Chlorine
Quaternary Ammonium Acid-Based Sanitizers
- Hydrogn Peroxide
- Peroxyacetic Acid (PAA)
- Anionic Acids Iodophores
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General types of sanitization
Thermal Sanitization
- hot water or steam for a specified temperature and contact time.
Chemical Sanitization
- the use of an approved chemical sanitizer at a specified concentration and contact time.
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Proper operation & cleanup
Promptly rinse equipment after use with cool to warm water
Properly maintain equipmentSeals and gaskets
Keep work area cleanReduces amount of difficult cleaning
Follow predetermined schedulesUse chemicals for intended use /
concentration
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Portable equipment
Store properly when not in useKeep from splashing / dust
Re-sanitize before next useClean and sanitize if brought out of
storage
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Equipment cleanup procedures
Remove all product and debris from equipment
Have sufficient room between walls / equipment to allow for cleaning
Have sufficient space underneath equipment for cleaning or seal
Disassemble equipment as necessary: Remove / replace shields Clean horizontal debris catchers Remove / replace product contact surfaces
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Equipment for cleanup
Washing equipment considerations include: High pressure systems
Central / portable
Mixing valves (steam + cold water) or hot water systems Raise temperature for cleaning
Proportioning pumps / venturi-metering / foamers
Minimize water use to limit sewer loads
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Manual cleaning
Completely disassemble equipmentRinse manuallyBrush with cleaning solutionRinseSanitize
Before reassemblyJust before processing
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Remember!
Remove all productClean up first using scrapers / broomsThen clean thoroughly, paying close
attention to product contact surfacesSanitize clean area so that it doesn’t
contaminate new product