[From the Board] Sanitation: The Front Line of the Food Industry

Microbial issues of concern in food processing facilities usually fall into two categories: shortened shelf life due to product spoilage or pathogen contamination. Solving problems of a microbial nature means critically examining practices during operations and third-shift sanitation. Some areas more commonly scrutinized are employee hygiene procedures, plant design and maintenance, equipment design and maintenance, monitoring traffic patterns and examining air flow patterns. While these endeavors can result in better control of a persistent problem, consideration of fundamental practices such as cleaning and sanitizing procedures can sometimes be more fruitful.

BEFORE STARTING. There are several aspects to consider when reviewing a company’s sanitation program. A quality cleaning and sanitizing program must have detailed cleaning procedures for all product contact surfaces such as equipment and utensils and non-product contact areas such as walls, overhead structures and refrigeration units. Procedures must define cleaning frequency and the type of cleaning required, whether clean-in-place (CIP), clean-out-of-place (COP) or manual cleaning. Finally, thorough coverage of an EPA-registered food contact sanitizer at approved use concentration must be ensured.

Consideration of cleaner selection must involve an understanding water quality, the nature of soil, the surface to be cleaned and the application method. As water makes up approximately 95-99 percent of cleaning and sanitizing solutions, the quality of this ingredient should be carefully monitored. Water pH, hardness and impurities all play a role in determining efficacy of a given product. Excessively hard water results in increased detergent consumption and also promotes scale deposits and precipitates. Water usually ranges from pH 6.5 to 8.5. Most detergents and sanitizers will function within this range, but effectiveness may diminish where highly acidic or alkaline water is used.

Soil in the food processing environment can exist in two forms: visible or invisible. Invisible soils include microorganisms, such as bacteria, yeast and mold. Visible soils contain the major constituents of foods, namely fats, proteins, carbohydrates and can also include insoluble mineral salts. Soils encountered in food processing can vary widely in composition and no single detergent is capable of removing all types. The properties of soils encountered in the processing environment should be well understood to facilitate selection of an appropriate detergent. For example, soils that are predominantly protein-based will require an alkaline detergent for effective removal.

Appropriate application of cleaning compounds may also be a consideration when reviewing microbial problems. In some situations manual, or hand cleaning, is the most effective means of soil removal, while in others CIP or COP will yield best results. While stainless steel is the preferred material for food contact surfaces in many industries, other materials such as aluminum and plastics also may be used. Incorrect detergent usage may result in degradation of surfaces that are more difficult to clean.

APPLYING SANITIZERS. Once visible soil is removed, surfaces must be sanitized using thermal or chemical means to minimize microbial contamination risks. With chemical sanitization, use only EPA-registered products. Just as cleaners, soil types and cleaning methods vary, so too do sanitizing methods, types of microbial contaminants and sanitizers. To maximize effectiveness of a sanitizer concentration, temperature of application, contact time, pH and water quality must be considered.

Sanitizers act by reducing microbial contaminants on inanimate surfaces, but those surfaces must be adequately cleaned and rinsed. Soil can chemically inactivate a sanitizer as well as offer a physical barrier to protect microbial cells. To achieve maximum efficacy a sanitizer must act on a clean, well-rinsed surface and operate within the optimum pH range of the specific sanitizer. The exposure time and concentration should be carefully monitored and applied according to the EPA-registered label.

CONCLUSION. Industry food safety programs have evolved considerably over the past few decades and will continue to develop as technology improves and microbial ecology is better understood. As a result of improvements, some food products have superior shelf life while others have reduced or eliminated pathogen contamination risks. While numerous improvements in plant and equipment design, employee practices and product formulation have facilitated progress in the food industry, commencing a production shift with a clean and sanitized work environment makes the task of producing wholesome food considerably easier.

The author is director of microbiology for Ecolab in St. Paul, Minn., and is a member of QA’s Advisory Board.