Effective Sanitation Practices
1
Discussion Question
What is your biggest
challenge regarding
sanitation?
2
Why Is It Important to Have a
Sanitary Facility?
To control pathogens and prevent foodborne
illness
Listeria monocytogenes
Salmonella
Staphylococcus aureus
To control normal spoilage bacteria
Yeast
Molds
Others that can cause economic spoilage
and decrease shelf life
Meet customer expectations
Comply with regulatory requirements
3
Sanitary Definitions
Cleanfree of visible soil
Sanitizereduce the number of bacteria to a
safe level
Sterilizeto make free of bacteria
Contaminationthe presence of harmful
substances in food
4
Factors that Contribute to a Sanitary
Facility
Facility design
Equipment design
Good cleaning and sanitizing procedures
Good written sanitation programs and
monitoring procedures
5
Evaluating the Effectiveness of a
Sanitation Program
Microbiological testing
Adenosine triphosphate (ATP) testing
Use of sanitation records
Training
6
Sanitation Requirements
9 CFR 416Sanitation
7
Section 416.1General Rules
Each official establishment must be operated
and maintained in a manner sufficient to
prevent insanitary conditions and to ensure
that product is not adulterated.
8
SPS 9 CFR 416.2
Establishment grounds and facilities
grounds and pest control
construction
lighting
ventilation
plumbing
sewage disposal
water supply and water, ice, and solution reuse
dressing rooms/lavatories
9
SPS for Grounds and Pest Control
(416.2a)
Grounds must be maintained to prevent
conditions that
could lead to insanitary conditions
could lead to adulteration of products
interfere with inspection
10
SPS for Grounds and Pest Control
(416.2a) (cont)
Program is designed to prevent harborage
and breeding of pests.
Pest control substances must be safe and
effective.
Substances must be applied and stored to
prevent insanitary conditions.
Inspector may request written designation of
plant boundaries.
11
Grounds and Pest Control: FSIS
Verification Procedures
Perform normal operational checks
Verify that grounds are maintained with no
accumulation of trash, debris, or old
equipment
See if the pest control program is effective
Review SSOP registration, labels, and use
instructions
Ask the responsible party applying a pesticide
about its proper use
12
SPS for Construction (416.2b)
Buildings, structures, rooms, and
compartments must be sound, in good repair,
and sufficient size.
Walls, floors, and ceilings must be built of
durable materials and be cleaned and
sanitized as necessary.
13
SPS for Construction (416.2b)
(cont)
Walls, floors, ceilings, doors, windows, and
other openings must be constructed and
maintained to prevent entry of vermin (e.g.,
flies, rats, and mice).
Rooms in which edible product is processed,
handled, or stored must be separate and
distinct from inedible product areas to the
extent necessary to prevent adulteration of
product.
14
SPS for Lighting (416.2c)
Lighting of good quality and sufficient intensity
to ensure sanitary conditions is maintained
and provided in areas where
equipment and utensils are cleaned
food is processed, handled, stored, or
examined
hand-washing areas, dressing and locker
rooms, and toilets
15
SPS for Ventilation (416.2d)
Although ventilation will not be able to
completely eliminate all odors, vapors, and
condensation, it must control them as far as
necessary to prevent adulteration of product
or the creation of insanitary conditions.
16
SPS for Plumbing and Sewage
Disposal (416.2e-f)
Plumbing and sewage disposal must be
installed and maintained to
carry sufficient quantities of water to
required locations
properly convey sewage from the plant
prevent adulteration of product, water
supplies, and equipment
provide adequate floor drainage
17
SPS for Plumbing and Sewage
Disposal (416.2e-f) (cont)
Prevent back-flow conditions and cross-
contamination between piping systems that
discharge waste water or sewage and
piping systems that carry water for
processing
Prevent the backup of sewer gases
18
Plumbing and Sewage Disposal:
Plant Responsibilities
Review facilities to ensure that drainage is
adequate and does not back up on floors and
create contamination issues
Test backflow devices periodically
Ensure that water supply is potable through
testing periodically for microorganisms
Maintain documentation on file
19
SPS for Water Supply and Water, Ice, and
Solution Reuse (416.2g)
A supply of running water that complies with
the National Primary Drinking Water
Regulations (40 CFR Part 141)
20
SPS for Dressing Room/Lavatory
(416.2h)
Dressing rooms, toilet rooms, and urinals
must be
sufficient in number;
of ample size and convenient;
maintained in sanitary condition and good
repair; and
separate from rooms where products are
processed, stored, or handled.
21
SPS for Dressing Room/Lavatory
(416.2h) (cont)
Refuse receptacles must be constructed and
maintained in a manner that protects against
adulteration of product or creation of
insanitary conditions.
22
SPS for Dressing Room/Lavatory
(416.2h) (cont)
Lavatories (bak mandi) must
have running hot and cold water, soap, and
towels
be placed in or near toilet and urinal rooms
placed in the plant to ensure the
cleanliness of all persons handling product
23
SPS for Equipment and Utensils
(416.3)
Equipment and utensils must be of such
material and construction to facilitate cleaning
and be maintained in a sanitary condition.
Equipment and utensils must not be
constructed, located, or operated in ways that
prevent their inspection.
Receptacles used to store inedible products
must not create insanitary conditions.
24
SPS for Sanitary Operations (416.4)
All food and non-food contact surfaces must
be cleaned and sanitized as frequently as
necessary.
Cleaning compounds, sanitizing agents, and
processing aids must be safe and effective
under the conditions of use.
Product must be protected from adulteration
during processing, handling, storage, loading,
and unloading.
25
SPS for Sanitary Operations (416.4)
(cont)
Non-food contact surfaces of facilities, equipment,
and utensils must be cleaned and sanitized as
frequently as necessary to prevent insanitary
conditions.
During operations, product should not come into
contact with non-food contact surfaces.
Documentation substantiating the safety of a
chemicals use must be available for review.
26
SPS for Employee Hygiene (416.5)
Cleanliness
All persons must adhere to hygienic
practices while on duty to prevent
adulteration of product.
Clothing
Aprons, frocks, and other outer clothing
worn by persons who handle product must
be of material that is durable and readily
cleaned. Clean garments must be worn at
the start of each working day.
27
SPS for Employee Hygiene (416.5) (cont)
Disease control
Any person who has or appears to have an
infectious disease or an open lesion (e.g.,
boils, sores, or infected wounds) must be
excluded from any operations that could
result in product adulteration.
28
SPS for Tagging Insanitary Equipment,
Utensils, Rooms, or Compartments (416.6)
FSIS program employee will attach a U.S.
Rejected tag if any equipment, utensil, room,
or compartment is insanitary or its use could
cause adulteration of product.
Tagged equipment cannot be used until made
acceptable.
Only an FSIS program employee may remove
a U.S. Rejected tag.
29
Benefits of Sanitary Equipment
Design
Reduced maintenance costs
Less labor and chemicals for sanitation
Less down time
Fewer start-up delays
Less microbiological troubleshooting
One modeloptimized production
Minimized risk of recalls
30
Effective Sanitation
31
Controlling Microbial Hazards
L. monocytogenes understanding
the hazards, then
E. coli O157:H7 preventing entry
Salmonella points into the
Campylobacter facility and the
establishment of
Legionella niches and
harborages
32
Cleanable to a Microbiological Level
Food facilities and equipment must be constructed and be maintainable to ensure that they
can be effectively and efficiently cleaned and sanitized over their life. The removal of all food
materials is critical. This means preventing bacterial ingress, survival, growth, and
reproduction. This includes product and non-product contact surfaces.
33 33
Factors Affecting the Presence and
Concentration of Pathogens in Niches
Temperature
Moisture
Nutrients
pH
Competitive flora
34
Three Broad Sanitation Themes
Provide zones of control
Keep it cold and control moisture
Design to facilitate sanitation
Which include 11 principles
35
Theme 1: Provide Zones of Control
Create a controllable environment
Control the transfer of physical, chemical, or
microbiological hazards into your facility
Control the transfer of physical, chemical, or
microbiological hazards from one area of your
facility to another
Control post-lethality cross-contamination
36
Principle 1
Distinct hygienic zones established in the
facility
Requires a hazard analysis of your facility
and the development of a plan to reduce
the likelihood of the transfer of those
hazards into or within your facility
37
Zones of Control
Your goal is a logical process flow
with strict zones of control
Cleanroom
Cleanroom
Raw Secondary
Cook/Chill
Processing Cleanroom Packaging
Cleanroom
Raw RTE
Welfare Office Welfare
38
Principle 2
Personnel and material flows controlled to
reduce hazards
Requires establishing controls necessary to
manage the flow of people and materials
between zones
39
Passive Control
Active Control
Magnetic Lock
RTE Area
Cross Traffic Aisle Access Control Card Reader
From This To This More
Design Sanitary Design
40
Theme 2: Keep It Cold and Control Moisture
Control temperature and moisture, which both
affect the growth of microorganisms
The drier your facility, the easier it will be to
control microbial growth.
If you are designing a wet process, you
need to manage the water flows to control
the risks.
41
Principle 3
Water accumulation controlled inside facility
Requires designs that facilitate free
draining of any moisture that is introduced
into the facility environment
Pooling water is a sign of trouble
42
Pooling water
From This To This More
Poor repairs
Design Sanitary Design
43
Principle 4
Room temperature and humidity control
Requires a design that maintains the
prescribed temperature, controls
condensation, and eliminates fog during the
sanitation process
44
Principle 5
Room air flow and room air quality control
addresses airflow and air quality
Controlled pressurization and air flow
reduce infiltration of warm, humid air that can
cause condensation problems
reduce dust and dirt problems at outside
openings
allow your exhaust systems to work properly
and efficiently
BUILD IT TIGHT AND VENTILATE IT RIGHT
45
All rooms have their pressure controlled to
ensure airflow will be from more clean to less
clean areas
Cleanest Cleaner Clean
RTE Packaging Production Raw
+++ ++ +
46
Poor Ventilation Design
47 47
Good Ventilation Design
48
Typical Unit Cooler
49
Theme 3: Design to Facilitate Sanitation
Create an environment that is easy to
maintain in the required sanitary condition
Start thinking about sanitation at the
property line
Specify materials that are easy to clean
Design for the expected life-cycle of the
facility
50
Principle 6
Site elements facilitate sanitary conditions
Site design addresses the outside of your
facility.
This is your first line of defense to control
the sanitary conditions at your facility.
Proper site design reduces the risk of
contaminants entering your facility.
51
Principle 7
Building envelope facilitates sanitary
conditions
Addresses the skin of your buildingthe
building envelope. It keeps in what you
need to keep in, keeps out what you dont
want in, and allows proper transfer across
the envelope when required.
52
Gaps
No threshold or seal Threshold fully embedded in caulk
From This To This More
Design Sanitary Design
53
Principle 8
Interior spatial design promotes sanitation
Addresses the proper spatial layout of the
facility
Is there adequate space to access
equipment and building components for
sanitation and maintenance?
54
Adequate Equipment Spacing360
Access
From This To This More
Design Sanitary Design
55
Principle 9
Building components and construction
facilitate sanitary conditions
Addresses the elimination of niches and
harborages through proper specification of
materials, finishes, and sanitary design
details for the building components
56
Column spaced off of IMP
Galvanized structural steel
Sloped girts
Structural Steel Details
57
Principle 10
Utility systems designed to prevent
contamination
Addresses the elimination of niches and
harborages through proper specification of
materials, finishes, and sanitary design
details of the utility systems
58
From This To This More
Design Sanitary Design
59
Principle 11
Sanitation integrated into facility design
Addresses the need to integrate the utilities
and equipment required to support the
sanitation process into the facility design
60
Sanitation hose station
Hand wash station with floor foamer
61
Cleanable and Catwalk over Product
62
Seven Steps in a Sanitation
Program
63
64
Salt (120m, 4724 -inch)
Micro-Size
Yeast (5 m, 197 -inch)
Micron (m)
39.37 -inch
Mold spore (3 m, 118 -inch)
Listeria (0.5 m, 19.7 -inch)
0.0254 micron
1/1,000,000 meter 1/1,000,000 inch
Micro-inch(-inch)
Step 1Dry Clean
LOTO (lockout tag out), secure, and
disassemble equipment
Remove gross soils from the equipment and
floor
Remove production supplies from the room
Remove trash from the room
Empty drain baskets
65
Secure and Disassemble
66
Pre-sanitation task completed consistently
(floors swept, equipment covered, materials
removed, etc.)
Equipment disassembled to proper level to
provide accessibility
Dry clean completed
Hollow member + cracked weld
67 67
Dry Cleanup
68
Dry Cleanup
69
Step 2First Rinse
Remove remaining visible soils with hot water
(90% to 95% as a benchmark)
Gross soils prohibit effective surface cleaning
if not removed prior to detergent application
70
Pre-Rinse
Water for pre-rinse should be hot
120F to 140F: Hot enough to melt fat (if
too hot, will bake on the soil)
Use boosted pressure200 psi with 3/16
nozzle (avoid high pressure because it will
create aerosols containing bacteria)
71
Pre-Rinse
72
Pre-Rinse
73
Rinse until visually free of soils
Use lowest effective pressure to minimize aerosols and
condensation
Lower pressure reduces risk of cross-contamination and
machine damage
Multiple lap joints
74
Step 3Soap and Scour
Foam the walls, then the floor, and then the
equipment
Set contact time (i.e., 10 minutes) and do not
allow detergent to dry because this may form
a stronger soil
Scour to remove films, fats, and proteins
Clean drains prior to Step 4
75
Order of applications (necessary to reduce cross-
contamination potential)
Wall/floors then equipment
Avoid drying of chemicals
Mechanical action
76
Contact time, concentration, and mechanical action!!!
Scrub product contact surfaces daily
Scour framework weekly minimum
Chemicals are not a substitute for mechanical action
Work from walls and floor to equipment
Traps Nutrients
Bacterial Mass with Protective
Attachment Film (Slime) and Bacteria
77
Cleaning Drains
Use designated brushes
Clean with a designated employee at the end
of his/her shift, just prior to sanitizing floor
Use a chlorinated alkaline cleaner
Clean all surfaces of the drain
Sanitize with quat (800 ppm), iodine
(75 ppm), or chlorine (800 ppm)
Minimum: clean drains weekly
78
Detergent Application
79
Detergent Application
80
Hand Scrub All Equipment
81
Hand Scrub All Equipment
82
Step 4Post Rinse and Inspect
Remove chemical and soils via flood rinse
Rinse in the order the detergent was applied:
walls, then the floor, and last the equipment
Do not spray the floor once the post rinse of
the equipment begins
Use a flashlight to verify cleanliness; should
occur throughout Step 4
100% free of soils, hazes, or water beads;
verify by sight and feel
83
Post Rinse and Inspect
84
Post Rinse and Inspect
85
Step 5Remove and Assemble
Put on clean outerwear
Sanitize hands
Verify all chemicals have been removed
(sight, pH paper)
Remove all standing water and overhead
condensation
Standing water prevents sanitizer contact with
the surface
86
Step 5Remove and Assemble (cont)
Sanitize inaccessible parts prior to assembling
Pre-op inspect parts that will not be
accessible after assembling
Assemble (follow LOTO procedures)
Relubricate where needed
87
Remove and Assemble
88
Step 6Pre-op
Inspect to ensure free of chemicals, tools, and
cleaning supplies before starting the equipment,
and ensure that guards and safety mechanisms
are in place
Run equipment prior to inspecting
Complete the formal pre-op spelled out in the
plants SSOP
Correct all deficiencies and provide feedback to
the person responsible
Pre-op the facility regularly for other deficiencies
89
Facility Pre-op
90
Facility Pre-op
91
Step 7Sanitize
Make sure there is no standing water before
beginning production
Flood sanitize equipmentbottom to top (no
rinse concentration) and make sure there is no
standing sanitizer
Equipment should be run to shed the sanitizer
Foam sanitize entire processing areas wall (5 ft.
minimum) and floor (800 ppm quat minimum)
Work your way out of the room
Let air dry, squeegee pooling sanitizer
92
Periodic Sanitation/Tear Down for Access
93
Periodic Sanitation/Heat
Steaming (165F for 30 minutes)
Dry heat (165F for 4 hours)
94
Sanitation Effectiveness
Verification
Physical verification
Organoleptic (site, smell,
taste)
Step 6Pre-op
Microbiological verification
Bioluminescence/ATP (immediate results)
Aerobic plate count (results in 23 days)
Environmental monitoring (results in 35
days)
95
ATP Bioluminescense Testing
Advantages
Quick and immediate results
Measures level of sanitation by looking for
levels of ATP common in food (and
bacteria)
Can track and trend results
96
ATP Bioluminescense Testing (cont)
Disadvantages
Expensive
Does not give you the levels of bacteria on
surfaces, just food residues
97
Microbiological Testing
Results in 2448 hrs
Inexpensive
Various methods
Contact plates
Dipsticks
Petrifilm or pour plates
Air testing
98
Microbiological Testing (cont)
Establish internal microbiological standards
(10, 50, 100 cfu/square cm)
Develop a testing program and establish a
frequency of testing
Track and trend data
Critical for ready-to-eat processes (e.g.,
Listeria monocytogenes)
99
Sanitation Records
Use all sanitation records to evaluate the
effectiveness of your sanitation program:
SSOP records (pre-op, operational, and
corrective action)
ATP/microbiological test results
Track and trend results
Learn from FSIS, NRs
100
Training
Critically important
Develop specific Standard Operating
Procedures (SOPs) for cleaning and sanitizing
equipment
Involve everyone in the plant
101
Sanitation and RTE Meat and
Poultry Products
102
L. monocytogenes
103
Why the Concern?
90% of reported cases require
hospitalization
20% of cases are fatal
CDC estimates 99% of listeriosis is foodborne
0.02% of total foodborne illness, but 28% of
deaths
104
Listeria in Meat Plants (n = 41)
LOCATION % (+)
Floors 39%
Floor Drains 39%
Cleaning Aides 34%
Wash Areas 24%
Sausage 22%
Food Contact Surfaces 20%
Condensate 7%
Walls & Ceilings 5%
Compressed Air 4%
105
Focused Efforts
Traffic patternspeople and equipment
Air flow patterns
Employee hygiene and practices
Plant design and maintenance
Equipment design and maintenance
Environmental conditions
Cleaning and sanitizing
106
Focus on RTE Equipment
Slicers, dicers, and peelers
Conveyors
Loaders
Brine chill systems
Horizontal form, fill, and seal machines
107
Facility
Ceiling condition of acceptable material
Wall condition of acceptable material
Floor condition of acceptable material
Walls and floors are in good repair
Drains operate correctly
Roof condition with no leaks and cleanable
Adequate heating and cooling capabilities
108
Process Equipment
Verifiable preventative maintenance program
exists
Equipment designed for clean ability
Ladders, catwalks, and crossovers have
protective shields underneath them to protect
products and food contact surfaces
No metal-to-metal moving surfaces
109
Lead to Ineffective Sanitation
Aerosols
Spraying drains and drain components
Drains pooling/backing up
Hollow rollers, fixed sleeved assemblies, concave
surfaces
Cross traffic
Lack of accessibility
Biofilms
Idle equipment (not being used)
Standing moisture
110
Design Considerations
High-pressure water
Compressed air
Control buttons and screens
Bearings
Congestion in RTE area
Cabinets in RTE areas
Traffic patterns
GMP requirements
Sanitation process NOT documented/sequenced--
How do you sustain protocols?
111
No Niches
No lap joints
All welds are continuous, smooth, and
polished
Hermetically sealed spacers
Sleeved assemblies <1
Press fittings are not used
Fasteners not used in or above product zone
Belt supports constructed from single piece
112
Hollow Areas Hermetically Sealed
Drive sprockets and belt pulleys are solid
or sealed
Hollow tube construction fully sealed
No fastener penetrations into hollow
tubes
Threaded leg adjustorsexternal, no
penetration
Minimize plates and tagscontinuous welds
Hollow rollers are not used
113
Continuous Improvement
Traffic Patterns: (separation between raw and RTE,
separation between exposed product areas packaging)
GMPs: (is it difficult to do the wrong thing?)
Flooring: (infrastructure maintained)
Sanitary Design: (existing equipment + new)
Effective Sanitation Procedures: (daily and
periodic, limitations known and controls in place)
Assess where you for each of the categories.
114
Sanitary Design of Food
Processing Equipment
Will Reduce Risks and Improve
Food Safety
115
Resources
[Link]
Information/[Link]
[Link]
Plant_Outreach/[Link]
[Link]
[Link]
[Link]
Series-Facilities_Equipment_&_Sanitation/[Link]
[Link]
Inspection_Podcasts/[Link]
116
Development of
Standard Operating Procedures
(SOPs)
117
Purpose of SOPs
Prevent or minimize problems and possible
issues affecting food safety
Ensure the defined procedures are conducted
in a consistent manner
118
Developing SOPs
Use systematic approach in development
Determine the goal of the procedure
119
Steps in Developing SOPs
Identify the tasks
Use a team approach
Conduct analysis of tasks that are determined
to be included in procedure
Identify possible operational barriers to
procedure
120
Steps in Developing SOPs (cont)
Task analysis includes
researching regulations, guidelines, and
policies;
reviewing the operation;
identifying the steps in the procedure; and
developing a flow diagram.
121
Tools and Techniques for
Developing SOPs
Videos, photographs, etc.
On-site visual observations
Identification of past problems
A comparative analysis
122
Relevant Questions
Why is the task being done?
Who is conducting the task?
What are they doing?
What is the frequency?
What are the limits?
What are the corrective (immediate) and
preventive (long-term) measures?
123
Elements of a SOP
Steps in the procedure
Who is responsible for monitoring
Frequency
The corrective/preventive measures
Records maintained
Who approves the SOP
Reassessment
124
Development of
Sanitation Standard Operating
Procedures
(SSOPs)
125
SSOPs: Identify Reassembly
Per manufacturers instructions
Prior to slaughter
By maintenance personnel or machine
operator
126
SSOPs: Recordkeeping Procedures
SSOP on file
Daily record of findings
Corrective/preventive action records
Supporting documentation
127
Operational Sanitation Monitoring
Document actions that identify and correct
contamination
Document corrective and preventive actions
128
Modification of SSOPs
Regulatory changes
Equipment/process changes
Request for change form
Change pages included in SSOP
Changes signed and dated
129
Operational SanitationCleaning
Procedures
Clean and sanitize equipment after
contamination
Breaks and mid-shift cleanup
Between shifts
Product handling
Employee hygiene practices
130
Pre-Operational Sanitation
Monitoring
Identify responsible persons
Describe methodology used
Organoleptic procedures
Chemical monitoring
Microbiological monitoring
Surface swabs
131
Monitoring Frequency
Daily visual inspection prior to startup
Daily/weekly swabbing
Periodic checks of non-food contact areas
132
SSOP Monitoring Methodology
Inspect food contact surfaces
Check overhead areas directly over food
contact surfaces
Check areas under food contact surfaces that
may impact surfaces
*USE A FLASHLIGHT*
133
