sanitation and gmp controls for listeria
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Sanitation and GMP Controls for Listeria. Listeria Controls. Sanitation , Good Manufacturing Practices , and Employee Training Programs are the key elements of an effective Listeria control program!!!! There are no “magic bullets ” for Listeria control - PowerPoint PPT PresentationTRANSCRIPT
Sanitation and GMP Controls for
Listeria
Listeria Controls
Sanitation, Good Manufacturing Practices, and Employee Training Programs are the key elements of an effective Listeria control program!!!!
There are no “magic bullets” for Listeria controlSanitation & GMP controls provide a series of
hurdles that prevent or minimize contamination
Sanitation Goals Minimize contamination coming into plant Prevent cross contamination by people,
products and equipment in the plant Eliminate in-plant niches and contamination
sources where and when they are found Prevent contamination of finished products
during processing and packaging
Start by Evaluating: 1. The potential for cross contamination
associated with your plant ‘s:Process & Product FlowDesign & Layout of operationsMovement of people and equipment
2. Where there are potential niches for Lm to establish itself in your plant
3. How effective are Routine and Intensive Cleaning & Sanitizing procedures
4. Employee hygiene & food handling practices
Evaluate Design & Layout of Processing Operations
How Linear is Your Product Flow ?
Is there adequate separation of raw products & processes from finished products & processes?
Process FlowReceive Product
Cook
Cool
Pick tail meat
Weigh
Package
Chill
Pack
Finished Product Storage
How Is Your Plant “Zoned”?Establish successively cleaner processing zones
“Dirty Zone” – Where raw product is handled. E.g. receiving, storage, cooking
“In-Process Zone” – Intermediate steps in the process. Crawfish picking
“Clean Zone”–Where finished product is handled, processed and packaged. E.g. weighing, vacuum packing, chilling
Evaluate the location of all processing steps Raw or semi-processed products handled in the “dirty” side of the plant must be separated from locations where finished products are handled or processed in the “clean” side of the plant.
Where do Process Steps Occur
In the Plant ?
Evaluate Traffic Flow: Movement of People & Equipment
Prohibit entry of people, equipment, packaging etc. into finished product areas from outside the plant.
Control movement of equipment and people between raw and finished product areas
Assign equipment, people & cleaning tools to finished product areas only
Control Strategy Options: People
Discourage traffic between finished product (“clean”) areas & raw product (“dirty”) areas.
Require all employees (including supervisors, office workers, management, delivery people & visitors) to wash hands & change outer garments before entering the plant.
Do Not Enter
Control Strategy Options: People … continued
Restrict movement of employees and visitors from raw product or “dirty” areas to finished product or “clean” areas.
When this is not possible, minimize traffic to the extent possible and use strict controls (wash hands, change outer garment, use footbaths etc.) before entering finished product handling areas.
Before You Go Through this Door
Control Strategy Options: People
Require employees to use dedicated & easy to clean footwear in the plant.
Require the use of a foot bath or chemical foam barrier when moving from “dirty” to “clean” areas.
Control Strategy Options: Equipment
Prohibit movement of equipment between finished product (“clean”) areas & raw product (“dirty”) areas.
Wherever possible use designated items like containers, utensils, tools, trash barrels etc. in finished product areas and don’t move them
to other areas of the plant.
Control Strategy Options: Equipment -continued
Separate operations physically if possible or separate by timing the movement of product to prevent cross contamination
Processing
Room
CookRoom
Chute
Training and Monitoring1. Develop and finalize new procedures and
policies as necessary.2. Assign supervisors, team leaders etc. to monitor
performance and ensure that new procedures or policies are implemented properly.
3. Implement a system to reward or recognize compliance and/or penalize for non compliance
4. Train employees to ensure that they understand what is expected, why it’s important, and what impact/consequences their performance will have.
Find and Eliminate Listeria monocytogenes (Lm) Niches
Niches are places in the plant where Lm persists and grows over time.
Niches can occur anywhere there are cracks and crevices that can accumulate bacteria, water, & nutrients (food debris) and are hard to reach with cleaning tools & sanitizer.
Lm can form biofilms in these niches that protect it from the environment.
Find and Eliminate Listeria monocytogenes (Lm) Niches
Normal cleaning and sanitation procedures may not be effective when Lm has colonized a niche.
During operation, Lm can work its way out of a niche and contaminate equipment & products as they move downstream in the process.
Bacteria like Listeria can form a biofilm to protect themselves
Potential Reservoirs or Niches of Lm
Floors & Floor Mats Drains
Cleaning Tools Blowers & Chillers
Other Potential Sources of Lm
Baskets Chutes Counters Scales Packaging
Equipment On/Off Switches Rubber seals on
doors
Trash/waste receptacles
Floors with standing H2O
Condensate traps Ice makers Underneath Cleaning
table
Sanitation Procedures Routine Cleaning & Sanitation Procedures
are essential to eliminate new day-to-day Listeria contamination that continually comes into the plant with product, people, supplies, and/or equipment.
Intensive Cleaning & Sanitizing Procedures are used to eliminate Listeria monocytogenes niches where and when they are found.
General Cleaning and Sanitizing Procedures
Step 1 – Remove exposed products
Step 2 – Dry clean & sweep areaRemove garbage, food debris & other waste
Step 3–Wet down area to be cleaned
Step 4(a) – Apply detergent
Applying Detergent with Foamers
Courtesy Hydro Systems Company
Step 4(b)- Scrub area vigorously
Be sure to use the right amount of Sanitizer: Use Test Strips
Areas to be Sanitized with Quats or Peracid Sanitizers
Drains DailyFloors DailyWaste containers DailyWalls Weekly/monthlyCondensate drip pans
Weekly
HVAC Weekly/monthlyCoolers* Weekly/monthlyFreezers* Semi-annually* Chlorine may be more effective than Quats if the temperature is low
Step 7– Air Dry/Store Properly
Cleaning Tips – Sanitation Don’ts
DO NOT use high pressure hoses to clean drains, minimize use elsewhere
DO NOT use compressed air to clean equipment
DO NOT start cleaning & sanitizing if there is any exposed product in the entire area
DO NOT do a wet mid-shift cleaningDO NOT stack or nest tubs, totes, pans etc.
after they are cleaned and sanitizedDO NOT let water spray on cleaned &
sanitized surfaces such as those close to the floor while cleaning
Cleaning ToolsDesignate cleaning tools for a specific purpose.
For example, never:Use floor brooms/floor squeegees on tablesUse pads or brushes used for cleaning garbage
barrels on packing tablesUse the same brush to clean floor drains on any
food contact surface. Use brushes, pads, brooms or squeegees in raw
product area and then in finished product areasClean & Sanitize all brooms, brushes and pads
every day, after plant is cleaned.Store all cleaning aids properly
Plant Procedures for Cleaning and Sanitizing
Food Safety is Everyone’s Job!
Sanitation Procedures: Drains
Drains are likely to be the most highly contaminated area of the plant
An inadequate drainage system with frequent backups is a critical problem. If a backup occurs production must stop. All exposed product should be removed. The drain should be cleared, cleaned with caustic, rinsed & sanitized before starting production. Never use high pressure to unclog a drain
Consider the location and type of each drain when determining what procedure to use
Drains -Daily Clean-up1. Move equipment or food contact surfaces that
could get contaminated or use a splash guard2. Remove drain cover 3. Rinse with low pressure hose4. Apply foam or detergent solution5. Scrub with designated brush (1/4 inch smaller
than drain opening)6. Rinse with low pressure hose7. Flood with sanitizer8. Insert bactericidal ring if used9. Replace drain cover10. Clean drain brush and store in sanitizer
Raw Product AreasEnd of Day Clean-up1) Remove & store all raw or in-process
products 2) Remove garbage/food waste, clean tables &
other surfaces & sweep floors.3) Wet all surfaces with water 4) Apply detergent to all surfaces5) Scrub all surfaces with brushes or pads6) Rinse and inspect for cleanliness7) Apply sanitizer8) Store equipment properly to air dry9) Remove standing water from floors10) Wash cleaning tools, sanitize & store
Finished Product Areas - End of Day Clean-up
1) Never use cleaning tools from raw product areas
2) Remove & store all exposed products 3) Remove garbage/food waste, clean tables
& other surfaces sweep floors.3) Wet all surfaces with water. 4) Apply detergent to all surfaces5) Scrub all surfaces with brushes or pads6) Rinse and inspect for cleanliness7) Apply sanitizer8) Store equipment properly to air dry9) Remove standing water from floors10) Wash cleaning tools, sanitize & store
Trays, Pans & other UtensilsEnd of Day or After Use Clean-up
1) Fill sink compartment with warm water & detergent2) Make sanitizer solution and check with test strips 2) Scrape/clean to remove food debris 3) Soak as necessary4) Scrub all surfaces with brush or pad5) Rinse and inspect for cleanliness6) Immerse, spray or flood with sanitizer7) Store properly on racks, shelves or hooks & air dry
Storage CoolersDaily and End of Week Clean-up
Daily – Remove debris/trash & standing water Visually inspect for proper product storage, no condensate or drip, no cross contamination
Weekly – 1. Remove all products2. Remove trash & standing water and sweep3. Wet all surfaces4. Apply detergent to all surfaces including ceiling5. Scrub with brushes and floor broom6. Rinse and inspect for cleanliness7. Apply sanitizer to all surfaces
You May Need Special Cleaning and Sanitizing Procedures for:
Floor Mats Totes and tubs Colanders Aprons and boots Boot dips
Sanitation Implementation Consistency & attention to details is critical Assign reliable dedicated employees to cleaning
and sanitation tasks and train them Seek expert assistance as necessary to ensure
that effective chemicals, procedures and delivery systems are being used and monitored properly
Assign reliable supervisory level personnel to routinely monitor cleaning crew performance and proper use of chemicals and cleaning tools
Good Personal Hygiene Practices For ALL Employees Include
Good Personal Habits Proper Clothing Good Health Hand Washing Handling Products
Properly
Make sure Employees Keep Themselves Clean
Bathe or shower daily
Keep fingernails clean and trimmed at all times
Implement, Monitor and Enforce Policies that Ensure that Employees:
Keep their hands away from their mouth, nose, arms or other body parts when working.
Do not eat, drink, or smoke in the food handling areas.
Train and monitor employees to ensure that they never touch dirty objects and then touch food products while working unless they properly wash their hands or at a minimum change their gloves.
Dress Properly for WorkRequire all employees to
wear clean, washable outer garments or uniforms.
Require employees to wear hairnets, caps, or other suitable covering to confine hair.
Supervisors & management should set an example
Do not allow employees to wear fingernail polish or jewelry when preparing or handling food.
Implement procedures to ensure employees keep shoes or boots clean.
ALL Employees Should Come to Work in Good Health
Require any illness to be reported to a supervisor and have ill employees avoid contact with food, food contact surfaces and utensils.
Gloves shall be worn to touch food and food contact surfaces when an employee has any cuts, sores, rashes, casts, or wears nail polish, artificial nails or jewelry.
How to Wash Your Hands1. Wet hands with warm water; 2. Use ample liquid soap from a
dispenser;3. Lather exposed arms and hands for
20 seconds by vigorously rubbing;4. Thoroughly rinse hands in warm
water;5. Use foot operated faucets to
prevent re-contamination of hands;6. Dry hands thoroughly and properly
dispose of paper towels;7. Dip hands in sanitizing solution; and8. Do not touch unsanitary objects.
When to Wash Your Hands
Before starting work After using the
bathroom After leaving the work
area Before returning to
the work area
When To Wash Your Hands continued
After touching bare human body parts;
After coughing, sneezing, using a handkerchief, or disposable tissue;
After handling soiled equipment; Immediately before handling food During food handling as often as
necessary; and After other activities that may
require it.
Don’t Allow Poor Food Handling Practices
Make sure all equipment is clean before it is used
Don’t let employees bring personal items to work
Never putting finished product back onto a packing line if it dropped onto the floor or touched something dirty
This training program was developed as part of a project entitled “Control Strategies for Listeria monocytogenes in Food Processing Environments” funded under the National Food Safety Initiative in 2000 by the Cooperative State Research Education and Extension Services of USDA Project No. 00-51110-9768.
Lots of hard work was contributed by: Cornell University Virginia Sea Grant New York Sea Grant LSU Cooperative ExtensionDelaware Sea Grant National Fisheries Institute Maryland Sea Grant National Food Processors Assoc.
Credits