CLEANING, HYGIENE AND SANITIZING OPERATIONS
Introduction
Drinking, eating, washing, excreting – these are things we
do every day of our lives. But the way we do them can have a major impact on
our health. Good hygiene practices are an essential part of daily life and we
all need to understand what hygiene means, why it’s important for our health
and wellbeing, and how we can change our behaviour to safeguard our health.
Promoting good hygiene in your community and educating people in ways to protect
themselves and their families from ill health is one of the most important
aspects of your work.
Hygiene - a set of preventive measures for good health - has
become an essential part of our lives. Today it seems natural to wash our
hands, vaccinate our children or drink safe water, but it hasn't always been
so. The concept of hygiene, closely linked to popular beliefs and to customs as
well as to scientific and medical knowledge, has evolved. The history of
hygiene can be divided into two main phases separated by the biological
revolution, when micro-organisms and their role in diseases were discovered.
Beyond this dividing line, hygiene became a scientific discipline supported by
irrefutable observations. Many misconceptions were swept aside to make way for
practices which play a large part in extending our life expectancy.
Importance
Why Clean?
Effective cleaning of
equipment in the food processing industry reduces chances for contamination of
food during preparation, processing, storage and serving. The first step in the
practical application of a sanitation program is to render the surface clean.
This will reduce to a degree the number of microorganisms present and eliminate
one essential need for life - "food". The surviving microorganisms
will be left unfed, unprotected and highly susceptible to final disinfecting
and sanitizing treatment. Cleaning minimizes attraction of other lower forms of
life, increases life of equipment, improves employees morale and efficiency and
is important for aesthetic considerations.
Why disinfect or sanitize?
The primary reason
for the application of effective sanitizing procedures is to reduce those
disease organisms which may be present on equipment or utensils after cleaning
to a safe level as may be judged by public health requirements, and thus
prevent the transfer of such organisms to the ultimate consumer.
In addition,
sanitizing procedures may prevent spoilage of foods. The existence of any
microbe in a food environment must be strictly controlled. The so-called
harmless microbe under the proper conditions can become a nuisance. Food can
become contaminated, reproduce to sufficient numbers to cause off-colours,
off-odours and off-flavours. Unsightly growth often results in waste and loss
of precious dollars. Many kinds of bacteria can cause slime formation on meats,
poultry, fish and similar edibles.
Difference between cleaning and sanitizing
Cleaning
is the process of removing food and other types of soil from a surface, such as
a dish, glass, or cutting board. Cleaning is accomplished using a cleaning
agent that removes food, soil, rust stains, minerals, or other deposits. The
right cleaning agent must be selected because not all can be used on
food-contact surfaces. (A food-contact surface is defined as a surface of
equipment or utensil with which food normally comes into contact or a surface
of equipment or a utensil from which food may drain, drip, or splash into a
food or onto a surface normally in contact with food.)
Sanitizing
is the process of reducing the number of microorganisms that are on a properly
cleaned surface to a safe level. A safe level is defined as a 99.999% reduction
of the number of disease microorganisms that are of public health importance.
Sanitizing is accomplished by using heat, radiation, or chemicals. Unless
the item to be sanitized is effectively cleaned, it is impossible to obtain
close contact between the sanitizer and the surface to the sanitized.
Also, some chemical sanitizers, such as chlorine and iodine, react with
organic matter and so will be less effective when the surface is not properly
cleaned.
Cleaning
means the removal of dirt, food residue,
and any other materials from a surface, utensil, or equipment using detergents
or other cleaning aids and either mechanical or detergent scrubbing actions,
followed by rinsing.
Sanitizing
means the application of a chemical or heat to a clean surface that will kill microorganisms.
The definitions section of the GMP regulation states that: Sanitize means to adequately treat food-contact surfaces by a process
that is effective in destroying vegetative cells of microorganisms of public
health significance, and in substantially reducing numbers of other undesirable microorganisms, but without adversely
affecting the product or its safety for the consumer.
Disinfecting is a
process that Kills disease causing germs on surfaces. This process is
accomplished with germicides or physical agents such as high heat. Most
surfaces need to be cleaned, some need to be sanitized and very few need to be
disinfected.
Principles of cleaning
Effective cleaning and sanitization of food contact surfaces
of equipment and utensils serve two primary purposes:
1. Reduces
chances for contaminating safe food during processing, preparation, storage and
service by physically removing soil, bacteria and other microorganisms; and
2. Minimizes
the chances of transmitting disease organisms to the consumer by achieving
bacteriologically safe eating utensils.
There are five basic principles of cleaning that must be
used in conjunction with each other:
- TIME
- TEMPERATURE
- MECHANICAL ACTION
- CHEMICAL ACTION
-
PROCEDURES
These five must be carefully balanced in order to accomplish
the stated job most efficiently and most economically. Should any of the five
basics be decreased in strength, one of the others will have to be increased in
order to accomplish the job. It is critical for operators to maintain the
proper balance of the basics.
A specific cleaning compound should be selected for its
special cleaning properties. Also, a compound that is effective for one
application may be ineffective for other uses. In addition to being effective
and compatible with its intended use, a cleaning compound should fit the needs
of the establishment.
There are
few principles that should be following for good practice:
·
All food contact surfaces must be cleaned and
sanitized after every use, when there is service interruption during which
contamination is possible or at regularly scheduled intervals if the surfaces
are in constant use.
·
A specific cleaning compound should be selected
for its special cleaning properties. A compound that is effective for one
application may be ineffective for other uses.
·
In addition to being effective and compatible
with its intended use, a cleaning compound should fit the needs of the
establishment.
·
Worn and pitted porcelain, rusty metals, or
seriously soiled floors can be effectively cleaned with abrasives. Abrasives
should be used cautiously in a foodservice facility. Because they can mar a
smooth surface, they should be used sparingly on food contact surfaces.
·
If soil is attached so firmly to a surface that
alkaline or acidic cleaners will not be effective, a cleaner containing a
scouring agent, usually finely ground feldspar or silica, is used to attack the
soil.
·
If not continuous, cleaning must at least be
performed at regular and frequent intervals so that a consistently good quality
of product is maintained.
·
Food residues may be dry particulate, dried-on,
cooked-on, sticky, fatty or slimy. Such residues may be best removed by
physical means or by the use of hot or cold water supplemented with detergents.
Cleaning steps
There are eight basic steps for manual cleaning and
sanitizing of a typical food-service facility:
1. Clean
sinks and work surfaces before each use.
2. Scrape
heavy soil deposits and pre-soak to reduce gross deposits that contribute to
deactivation of the cleaning com-pound. Sort items to be cleaned, and pre-soak
silverware and other utensils in a solution designated for that purpose.
3. Wash
items in the first sink in a clean detergent solution at approximately.
4. Wipe
all non-food contact surfaces.
5. Periodically
wring out cloths used for wiping down stationary equipment and surfaces in a
sanitizing solution. Keep them separate from other wiping cloths.
6. Air-dry
all cleaned parts before reassembling.
7. Clean
stationary items that are designed to have a detergent and sanitising solution
pumped through-out according to the manufacturer’s instructions. High-pressure,
low-volume cleaning equipment can be used for cleaning, and spray devices can
be used for sanitizing. For sanitizing, spray for 2 to 3 minutes with
double-strength solution of the sanitizer.
8. Any
wooden cutting boards should be scrubbed with a nontoxic detergent solution and
stiff-bristled nylon brush (or a high-pressure, low-volume cleaning wand).
Also, a sanitizing solution should be applied after every use. As wooden
cutting boards reflect wear from cuts and scars, they should be replaced with
polyethylene boards. Wooden cutting boards should not be submerged in a
sanitizing solution.
Cleaning frequency
The frequency of cleaning and sanitization is determined
by the types of activities conducted in any given area. Qualified personnel
should visually monitor each area routinely. Cleaning and sanitizing schedules
can be adjusted and remedial action can be taken as needed.
Cleaning Frequency
a)
Tableware shall be washed, rinsed, and sanitized after each use.
b) To
prevent cross-contamination, kitchenware and food-contact surfaces of equipment
shall be washed, rinsed, and sanitized after each use and following any
interruption of operations during which time contamination may have occurred.
c) Where
equipment and utensils are used for the preparation of potentially hazardous
foods on a continuous or production-line basis, utensils and the food-contact
surfaces of equipment shall be washed, rinsed and sanitized at intervals
throughout the day on a schedule subject to the approval of the regulatory
authority. This schedule shall be based
on food temperature, type of food, and amount of food particle accumulation.
d) The
food-contact surfaces of grills, griddles, and similar cooking devices and the
cavities and door seals of microwave ovens shall be cleaned at least once a day
except that this shall not apply to hot oil cooking equipment and hot oil
filtering systems. The food-contact
surfaces of all cooking equipment shall be kept free of encrusted grease deposits
and other accumulated soil.
e) Non-food-contact surfaces of equipment shall
be cleaned as often as is necessary to keep the equipment free of accumulation
of dust, dirt, food particles, and other debris.
All equipment
should have a regular cleaning and sanitization schedule. The frequency should
be determined based on several factors:
·
Product vulnerability to contamination
·
Type of equipment used
·
Difficulty in removing product from the equipment
·
Whether continuous process batching is being performed
Waste Disposal Area
Provisions
should be made for regular and timely removal and disposal of waste out of the
proximity of finished products, components, and manufacturing areas to minimize
the risk of microbial contamination.
·
Refuse for disposal in designated containers using plastic
liners.
·
Construct containers so that they are leak-proof and
rustproof, and cover whenever possible.
·
Empty refuse containers at a minimum of once daily and clean
it when necessary prior to reuse.
·
Clean spills immediately and remove debris from the
manufacturing areas.
·
Use disposable towels and discard immediately after single
use. Do not use rags.
·
Isolate waste disposal areas from manufacturing, and
routinely clean and sanitize to minimize odours.
·
Dispose of product or process waste in accordance with
current government regulations.
·
All hazardous waste, including spills, should be handled per
the facility hazardous waste management plan.
Cleaning equipment and supplies
Store
cleaning equipment and supplies properly in a clean area. Maintain the supply area
in an orderly manner. Separate supplies and equipment for lavatory cleaning
from other cleaning supplies.
Walls, ceilings, pipes, and
fixtures
Clean
and/or sanitize on a scheduled basis (for example, monthly, quarterly or more frequently,
if needed). Vacuum to remove loose material.
Floors
Clean
floors on a scheduled basis, to include the following
·
Vacuum and/or sweep frequently.
·
Minimize airborne dust during clean up.
·
Wet mop or machine scrub on a predetermined schedule,
Sanitize as appropriate.
·
Promptly clean up spills of raw materials, product or packaging
components.
The factors that affect cleaning efficiency and frequency
1.
Type of Soil to be removed
2. Water
quality.
3. Water
Temperature
4. Contact
Time
5.
Water Velocity
6. Sequestering
Agent
7.
Concentration of the detergent
Type of Soil to
be removed
Food Deposits:
Fat & Grease – Alkaline detergent
Protein & Blood – Alkaline detergents and Enzyme
detergents
Sugar & Carbohydrates – Water
Minerals
Deposits, rust – Acid detergents
Soils contains microorganism such as bacteria, viruses,
yeasts and moulds thus the use of sanitizer is recommended. By identifying the
type of soil involved, we can easily determine the type of detergent suitable
to remove the soil effectively and economically.
Water Quality
Water is the main component in cleaning materials. Water
use must be potable (safe to drink) Water must not be hard water as it reduces
the effectiveness of detergents and leaves scale deposits on the surface of
equipment. Hard Water: Water with high mineral content. Soft water: water with low mineral content. Hard water
does not pose any harm to one’s health but poses serious problems in industrial
setting.
Water
Temperature
Depends on the type of detergent:
Heat stable type – Between 54°C – 71°C
Cold water type – Tap water temperature
Temperature of water needs to be hot enough to decrease
the strength of the bonds that hold soil to the surface being cleaned. However
it should not be too hot such that the soil gets baked onto the equipment
surface. At higher temperature of the
water, the effectiveness of cleaning will be high.
Water Velocity
The velocity of the cleaning solution helps in removing
soil from food surfaces.
The importance of the velocity cleaning solution
decreases as the effectiveness of the detergent increases.
Contact Time
Cleaning efficiency increases with longer contact time
between the cleaning solution and the surface to be cleaned.
The amount of scrubbing necessary to remove soil
decreases with increase contact time between the cleaning solution and the
surface to be cleaned.
Sequestering
Agent or Chelating Agent: It is an
inorganic ingredient blended with detergent to prevent the precipitation of
unstable salts (Calcium and Magnesium Ions) that leads to the formation of
scale (or deposits). Helps softened hard water so that it is suitable to be used
for cleaning. In another word we can say Sequestering agents or Chelating
agents remove a metal ion from a solution system by forming a complex ion that
does not have the chemical reactions of the ion that is removed. Sequestering agents
or Chelating agents are used to eliminate water hardness and heavy metals, such
as iron and copper which can affect the scouring process.
Concentration of
the detergent
Increase the concentration of the detergent increases the
efficiency of soil removal from the equipment surface. However, beyond a
certain limit, the higher the concentration neither increase nor decrease
cleaning efficiency. Follow the recommended usage of detergent provided by the
manufacturer.
Types of Cleaning
Agents
Not all cleaning agents can be safely used on food-contact
surfaces. Examples of those that should not be used include: glass cleaners,
some metal cleaners, tub and tile cleaners. The label should indicate if the
product can be used on a food-contact surface.
Secondly, the ideal cleaning agent must be selected to make
cleaning easy. Cleaning agents are divided into four categories:
•Detergents --
All detergents contain surfactants that reduce surface tensions between the
soil and the surface, so the detergent can penetrate quickly and soften the
soil. Examples include Dawn and Joy dishwashing detergent and automatic
dishwasher detergents.
•Solvent cleaners
-- Often called degreasers, solvent cleaners are alkaline detergents that
contain a grease-dissolving agent. These cleaners work well in areas where
grease has been burned on. Examples include Fantastic.
•Acid cleaners --
Use on mineral deposits and other soils alkaline cleaners cannot remove, these
cleaners are often used to remove scale in warewashing machines and steam
tables.
•Abrasive cleaners
-- Use these cleaners to remove heavy accumulations of soil often found in
small areas. The abrasive action is provided by small mineral or metal
particles, fine steel wool, copper, or nylon particles. Some abrasive cleaners
also disinfect. Examples include Ajax and Comet.
Principle of sanitation
1. Washing
equipment and utensils until visibly clean does not complete the process. A
sanitization step must also be completed.
2. Proper
sanitisers must be use.
3. No
rinsing or any other cleaning process should take place after the sanitizing
process.
4. Equipment
and utensils must be air dried only.
5. Swabbing
can be utilised when the sanitising solution is twice the strength required.
6. Thermometers
and test kits are required to ensure the sanitation status.
7. Before
returning to work every one should wash their hands .
8. Any
spilled materials or products must not be returned to the production area.
9. Waste
materials must be placed in containers (with tight-fitting covers) suitable for
disposal.
10. Each
employee is required to keep the immediate work area clean and tidy.
11. Tobacco
use is forbidden, except in designated areas.
12. Spitting
is prohibited anywhere in the area.
Factors affecting sanitation
The primary reason for the application of effective
sanitizing procedures is to destroy those disease organisms which may be
present on equipment or utensils after cleaning, and thus prevent the transfer
of such organisms to the ultimate consumer. In addition, sanitizing procedures
may prevent spoilage of foods or prevent the interference of microorganisms in
various industrial processes which depend on pure cultures.
There are two generally accepted methods of
providing for the final sanitization of a utensil after effective removal of
soil, heat and chemical.
A. Hot
water - an effective, non-selective sanitization method for food-contact
surfaces; however, spores may remain alive even after an hour of boiling
temperatures. The microbial action is thought to be the coagulation of some
protein molecules in the cell. The use of hot water has several advantages in
that it is readily available, inexpensive and nontoxic. Sanitizing can be
accomplished by either pumping the water through assembled equipment or
immersing equipment into the water. When pumping it through equipment, the
temperature should be maintained to at least 171°F. (77°C) for at least 5
minutes as checked at the outlet end of the equipment. When immersing
equipment, the water should be maintained at a temperature of a least 171°F (77 °C) or above for 30
seconds.
B. Steam
is an excellent agent for treating food equipment. Treatment on heavily
contaminated surfaces may cake on the organic residues and prevent lethal heat
to penetrate to the microorganism. Steam flow in cabinets should be maintained
long enough to keep the thermometer reading above 171°F (77°C) for at least 15
minutes or above 200°F. For at least 5
minutes. When steam is used on assembled equipment, the temperature should be
maintained at 200. For at least 5 minutes as checked at the
outlet end of the assembled equipment.
Chemical sanitizers
The use of chemicals is the most common method
for killing food poisoning bacteria however, heat can also be used. Food businesses
must make sure that any sanitizer used is ‘food grade’ – safe for food contact surfaces.
The table below lists examples of common sanitizers.
Chemical sanitizers are generally
chlorine-based or ammonium-based compounds. Products suitable for using in food
businesses are available from commercial chemical suppliers and retailers. Only
use chemical sanitizers that are designed for using in food premises. Some
sanitizers require residues to be rinsed off food contact surfaces after use.
Dilution rates, contact times and safety instructions vary from product to
product. When using and storing chemicals (including bleach), always follow the
manufacturer’s instructions. Items that can fit in the sink can be washed and
cleaned in the left-hand bowl. They can then be immersed in a chemical sanitizer
solution in the right hand bowl.
Chemicals used in sanitising
Hypochlorite
Effectiveness, low cost and ease of
manufacturing make hypochlorites the most widely used sanitizers. Sodium
hypochlorite is the most common compound and is an ideal sanitizer, as it is a
strong oxidizer. Hypochlorite cause broad microbial mortality by damaging the
outer membrane, likely producing a loss of permeability control and
eventualities of the cell.
Chlorine Dioxide
This inorganic compound is a broad sanitizer
effective against bacteria, fungi and viruses. Chlorine dioxide is an oxidizer
that reacts with the proteins and fatty acids within the cell membrane, resulting
in loss of permeability control and disruption of protein synthesis.
Iodophor
These compounds are less active than
hypochlorites but are effective sanitizers and disinfectants. Iodophors attach
to the sulphurs of proteins such as cysteine, causing inactivation and cell
wall damage.
Sanitizing Food Contact Surfaces
Sanitizing is a procedure to treat
food-contact surfaces that destroys most disease producing bacteria and
viruses, substantially reduces the number of other undesirable organisms, and
does not adversely affect the product or its safety for the consumer.
Sanitizing can be done with heat or with chemicals.
Sanitizing does not affect bacterial
spores—that is beyond the capability of the process. A sanitizer will not
sterilize a food-contact surface or a water system. Sterilization refers to the
statistical destruction and removal of all living organisms, including spores.
The official definition of sanitizing for food product contact surfaces is a
process which reduces the contamination level by 99.999% (5 logs) in 30 sec.
Disinfectants are stronger chemicals that produce a much larger reduction of
microorganisms. They are generally not used in food applications.
Dishwasher
To sanitise effectively with a dishwasher:
·
Use the correct type of detergent or sanitizer,
·
Use the hottest rinse cycle available (economy
cycle on a domestic dishwasher is not adequate),
·
Look over equipment and utensils when removing
them from the dishwasher to check they are clean,
·
Clean the dishwasher so there is no build-up
of food residues, and
·
Regularly maintain and service the dishwasher
according to the manufacturer’s instructions.
A hand sanitizer or hand antiseptic is
a supplement or alternative to hand washing with soap and water. Various
preparations are available, including gel, foam, and liquid solutions.
Food contact surface is
the surface of equipment and utensils with which food normally comes into
contact and those surfaces from which food may drain, drip or splash back onto
surfaces normally in contact with food.
Definitions for Terms
1.
Acidity
-- the degree or measure of the amount of acid in a solution or substance;
measurement can be expressed in parts per million, percentage, or pounds or
grains per gallon.
2.
Acids
-- they are chemicals that form hydrogen ions in solution giving a pH less than
7.
3.
Acids,
strong -- they are substances that release high concentrations of hydrogen
ions in a solution giving a very low pH. Examples include muriatic and sulphuric
acids.
4.
Acids,
weak -- they release moderate to low concentrations of hydrogen ions in a
solution, giving a moderately low pH.
Examples include organic acids, such as lactic and acetic acids.
5.
Alkalinity
-- the degree or measure of the amount of alkali in a solution or substance.
6.
Alkalis
-- they are chemicals that release an excess of hydroxyl ions in a solution
giving a pH of greater than 7.
7.
Alkalis
strong, -- they are substances that release high concentrations of hydroxyl
ions in solution giving a very high pH.
Examples include caustic soda and caustic potash.
8.
Alkalis,
weak -- they release moderate to low concentrations of hydroxyl ions giving
moderately high pH values. An example is
sodium bicarbonate.
9.
Antiseptic
-- an agent used against sepsis or putrefaction in connection with human beings
or animals.
10. Automated Cleaning (CIP):
Clean-in-place: Cleaning internal surfaces of production equipment without
disassembly.
11. Bactericide -- an agent that causes the
death of a specific group of microorganisms.
12. Bacteriostat -- an agent that prevents
the growth of a specific group of microorganisms but does not necessarily kill
them.
13.
Buffer
- any material that moderates the intensity of an acid or alkali in solution
without reducing the quantity of acidity or alkalinity.
14.
Chelation
- The action of an organic compound attaching itself to the water hardness
Particles and
inactivates them so they will not combine with other material in the water and
precipitate out. A substance that removes a metal ion from a solution system by
forming a complex ion that does not have the chemical reactions of the ion that
is removed can be a chelating or a complexing agent.
15.
Corrosion-resistant
materials - Materials that are capable of maintaining their original
surface characteristics under prolonged use, including the expected food
contact and the normal use of cleaning compounds and sanitizing solutions.
16.
Disinfectant
-- an agent that is applied to inanimate objects; it does not necessarily
kill all organisms.
17.
Dispersion
-- the action of breaking up of mass into fine particles, which are then
suspended and flushed off the surface and/or equipment.
18.
Dissolving
-- refers to the mixing of a liquid and a solid to produce a homogeneous solution.
19.
Easily
cleanable -- surfaces must be readily accessible and made of such materials
and finish and so constructed these chemical residues may be effectively
removed by the cleaning process.
20.
Emulsification
-- the action of breaking up fats and oils into very small particles which are
uniformly mixed in a water solution, preventing the clumping or clustering of
the particles; in a stable emulsion the oil particles are suspended for a long
period of time.
21.
Germicide
- an agent that destroys microorganisms.
22.
Peptizing
- the physical formation of colloidal solutions from soils which may be only
partially soluble; this action is similar to dispersion but is particularly
applicable to protein soils.
23.
pH - It is a measure of the activity of the
(solvated) hydrogen ion. pH, which measures the hydrogen ion
concentration, is closely related to, and is often written as, pH.
24.
pH
scale – it measures how acidic or basic a substance is. The pH
scale ranges from 0 to 14. A pH of 7 is neutral. A pH
less than 7 is acidic. A pH greater than 7 is basic.
25.
Rinsing
-- condition of a solution or suspension which enables it to be flushed from a
surface easily and completely; action occurs by reducing the surface tension of
the water being used.
26. Sanitization -- the process of reducing
microbiological contamination to a level that is acceptable to local health
regulations.
27.
Sanitizer
-- an agent that reduces the microbiological contamination to levels conforming
to local health regulations.
28.
Saponification
-- a chemical reaction of esters into acids or alcohols by the action of
alkalis or acids; use of alkalis with animal or vegetable fats results in soap.
29.
Sequestration
-- the chemical action resulting in the binding of a metal ion in solution with
the formation of a soluble and stable complex; when the activity is performed
to control water hardness with formation of a typical organic ring structure,
the action is termed "chelation."
30. Sterilization -- the process of
destroying all microorganisms.
31.
Surfactant
-- a chemical product whose molecules are able to modify the properties of an
interface, e.g. liquid/liquid, liquid/air by lowering (reducing) the surface
tension, allowing water to contact all surfaces. The four major types of surfactants used in
detergents are: anionic, cationic, non-ionic,
and amphoteric.
32.
Suspension
-- the action which keeps insoluble particles uniformly distributed in a
solution, preventing them from settling and forming deposits and making it
easier to flush them from equipment.
33.
Water
hardness -- relates to water
containing mineral constituents which form insoluble products, resulting in
poor lathering of soap; principally caused by salts of calcium, magnesium, and
iron.
34.
Water
softening -- the process of removing the calcium and magnesium salts,
preventing the precipitation of insoluble carbonates and hydroxides.
References: Principles of Food
Sanitation (Fifth Edition) Norman G. Marriott and Robert B. Gravani, NSW Food
Authority, http://www.foodsafetymagazine.com