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Contents
What is sanitation?
Introduction
Common pathogens
Sanitizers for meat and poultry plants
Cleaning practices for meat and poultry plants
Sanitation procedures
S.R.Swaminathan (BTF 06‐027)
What is sanitation?
The word sanitation comes from the latin word sanitas , which
means “health”. In the food industry , sanitation means creating
and maintaining hygienic and healthful conditions. Scientific
principles are used by healthy food handlers in a hygienic
environment to produce wholesome food. Sanitation can reduce
the growth of microorganisms on equipment and dirt on food.
This can reduce contamination of food by microorganisms that
cause foodborne illness and food spoilage.
Sanitation is more than cleanliness. Food or equipment can be
free of visible dirt and still be contaminated with
microorganisms or chemicals that can cause illness or food
spoilage. Sanitary principles also apply to waste disposal and
can help reduce pollution and improve ecological balance.
Introduction
Meal and poultry are perishable foods (i.e., they spoil quickly),
and the meat discolors easily. Poor sanitation allows microbes to
cause even more damage to the flavor and color of meat. A good
sanitation program reduces color changes and spoilage and
increase the shelf life of meat and poultry.
In the meat and poultry industry, sanitation begins with the live
animal or bird and continues until the food product is served.
Management should plan, enforce, and supervise the sanitation
program thoroughly. The person in charge of the program
should report to top management and make sure that the facility
and food products are sanitary. Trained staff should clean and
inspect the plant and equipment and be responsible for keeping
it clean.
S.R.Swaminathan (BTF 06‐027)
Common pathogens
Meat and poultry products cause about 23% of foodborne illness
outbreaks. They are associated with 5 to 10 % of deaths caused
by foodborne disease. Pathogens associated with meat and
poultry are listeria monocytogenes, E.coli, salmonella spp., and
campylobacter spp.
Listeria monocytogenes is often found on retail cuts of fresh
poultry and red meats. It is often found around wet areas and
cleaning equipments, such as floors, drains, wash areas, ceiling
condensation, mop and sponges, brine chillers, and at peeler
stations. Refrigeration at 4 to 5°C (a common storage
temperature) does not stop this pathogen from growing.
Possible ways to control include antimicrobial agents, colder
storage (<2°C), making products with lower water activity or
pH, or pasteurization products after processing. On of the best
ways to control pathogens is by preventing cross‐contamination.
Sanitizers for meat and poultry plants
Sanitizers work only on clean surfaces, i.e., after all dirt is
removed. Soil that can prevent the sanitizer from working
properly include fats, meat juices, blood grease, oil, and mineral
buildup. Microbes can grow under and inside soil and can hold
food and water that allow microbes to grow. Chemical sanitizers
cannot destroy micoorganisms in or under soil deposits.
i) Steam
Steam is not a good sanitizer. Many operators think that
water vapor is steam and do not expose the equipment to
S.R.Swaminathan (BTF 06‐027)
enough steam to sanitize it. Workers should not use steam
to sanitize refrigerated areas because it cause
condensation and wastes energy. Steam also does not
sanitize conveyors properly.
ii) Chemical sanitizers
Chlorine is the most important compound for disinfecting,
sterilizing, and sanitizing equipment, utensils, and water.
Meat and poultry operations most often use these chlorine
compounds:
Sodium and calcium hypochlorite: these cost more than
plain chlorine, but are easier to apply.
Liquid chlorine: this chlorinates processing and cooling
waters and prevents bacterial slimes.
Active iodide solutions can also sanitize. Iodophors are
very stable, have a much longer shelf life than
hypochlorites, and work at low concentrations. These
sanitizing compounds are easy to measure and dispense,
and penetrate dirt well. They prevent films and spotting
because of their acidity. The temperature of the sanitizing
solution should be below 48°C.
Quaternary ammonium compounds work well on floors,
walls, equipment, and furnishings in meat and poultry
plants. The “quats” work well on porous surface because
they penetrate well. Quats form a film on surfaces which
inhibitd bacterial growth. Sanitizers and compounds that
contain an acid and a quat sanitizer work best for
controlling l.monocytogenes and mold. Sanitarians may
use quats temporarily when they find mold buildup.
Acid sanitizers combine rinsing and sanitizing steps. Acid
neutralizes the excess alkali from the cleaning residues,
prevents alkaline deposits from forming, and sanitizes.
S.R.Swaminathan (BTF 06‐027)
S.R.Swaminathan (BTF 06‐027)
plant. This portable equipment can be utilized for cleaning
parts of equipment and building surfaces and is especially
effective for conveyors and processing equipment when
soaking operations are impractical and hand brushing is
difficult and labor intensive.
iii) Foam cleaning
Foam is particularly beneficial in cleaning large surface
areas of meat and poultry plants and is frequently used to
clean transportation equipment exteriors, ceilings, walls,
piping, belts, and storage containers. Portable foam
equipment is similar in size and cost to portable high
pressure units. Centralized foam cleaning applies cleaning
compounds by the same desirable features as a centralized
system.
iv) Gel cleaning
This equipment is similar to high pressure units, except
that the cleaning compound is applied as a gel rather than
as a high pressure spray. Gel is especially effective for
cleaning packaging equipment because it clings to the
surfaces for subsequent soil removal. Equipment cost is
similar to that of portable high pressure units.
v) Combination centralized high pressure, low volume and
foam cleaning
This system is the same as centralized high pressure
except that foam can also be applied through the
equipment. This method offers the most flexibility because
foam can be used on large surface areas, and high pressure
can be applied to belts, conveyors, and hard to reach areas
in a meat and poultry plant. Equipment costs for this
system range from $15,000 to over $150000, depending on
size.
S.R.Swaminathan (BTF 06‐027)
vi) Cleaning in place (CIP)
With this closed system, a recalculating cleaning solution is
applied by installed nozzles, which automatically clean,
rinse and sanitize equipment. The use of CIP system in the
meat and poultry industry is limited. This equipment is
expensive and lacks effectiveness in heavily soiled areas.
CIP cleaning has some application in vacuum thawing
chambers, pumping and brine circulation lines, preblend/
batch silos, and edible and inedible fat rendering systems.
The motor and drive components are mounted on a base
plate. As the shackles pass between two rotating brushes
they are cleaned. The brushes can be lifted above the rail
when not in use.
Sanitation procedures
Detailed cleaning operations should be written and posted in the
plant . documentation of procedures is beneficial when
supervision changes are made and for training of new
employees. As mechanization increases , cleaning methods
become correspondingly more detailed and complicated. Prior
to adopting a cleaning procedure, it is essential to become
familiar with the operation of all production and cleaning
equipment. In addition to providing the necessary information,
this can lead to improvements in methods that are used or
should be incorporated.
The following are examples of cleaning procedure that could be
used for distinct operations and areas in a plant. These examples
are only guidelines. Every cleaning application should be
adapted to the prevailing conditions. Although this step will not
be mentioned, hoses and other equipment should be returned to
their proper locations after cleanup.
S.R.Swaminathan (BTF 06‐027)
1. Livestock and poultry trucks
Frequency : after each load has been hauled
1.Scrape remove all manure that has accumulated from the
premises.
2.Completely remove all manure, mud, and other debris,
completely disinfecting with a quaternary ammonium
2. Slaughter area
Frequency : daily. Debris should be periodically removed
during the production shift
1.Briefly pre rinse all soiled areas with 50 to 55°C water
2.Apply an alkaline cleaner using foam system to all
framwork, undersides, and other difficult to reach areas.
3.Allow 5 to 20 mins and rinse well.
4.Apply white edible oil to surface subject to rust
corrosion.
5.Clean specialized equipment according to manufacture
advice.
3. Poultry mechanical eviscerators
Frequency : daily. A continuous or intermittent sanitizer
spray should be provided to reduce contamination
1.Frequently clean up all large pieces.
2.Prerinse with 50°C water.
3.Apply alkaline cleaner
4.Allow 10 to 20 mins.
5.Rinse well with water.
6.Apply 200 ppm cl
S.R.Swaminathan (BTF 06‐027)
4. Poultry pickers
Frequency : daily
1.Prerinse with 50°C water.
2.Apply a heavy‐duty alkaline cleaner through shower
cabinets or tank.
3.Exposure for 20 mins.
4.Rinse well.
5. Receiving & shipping area
Frequency : daily
1.Cover electrical lines, scales and exposed products.
2.Rinse the walls and floors with 50 °C
3.Apply acid cleaning.
4.Wait for 20 mins.
5.Remove, clean, and replace drain covers in the proper
position after rinse‐down.
6. Storage cooler
Frequency : weekly
1.Clean each section, when empty.
2.Rinse thoroughly with 55°C with a reliable floor cleaner.
3.Work on debris.
4.Squeegee the floor where water has accumulated to
prevent it from freezing.
S.R.Swaminathan (BTF 06‐027)