Multivariate Analysis (Minitab)

Wet Clean Methods
Manual and COP

AGENDA
Goals & Reality

Pre-Requisites For Cleaning
The Basics
Wet Sanitation Methods
Operational Sanitation
2
GOALS & REALITY
GOALS OF AN EFFECTIVE
SANITATION PROGRAM
Safety
– Consumer
– Employee
– Environment
Quality
– Fresh / wholesome
– Shelf life
– Consumer acceptance
– Sales / profits
4
REALITY
Clean vs. Dirty

– “Clean is not a natural state. Dirty is a natural state – everything moves to dirty.”
– Need regular and consistent cleaning
New vs. Old
– “Nothing stays new”
– Need regular maintenance or replacement!
5
PRE-REQUISITES FOR CLEANING
PRE-REQUISITES FOR CLEANING
Pre-requisites
for Cleaning
Master Sanitation
Master Sanitation Program / PM Program Program /
– Scheduled routine cleaning and preventative maintenance PM Program
Hazard Control Plan (such as HACCP) Hazardous

Control Plan
Sanitation Standard Operating Procedures (SSOPs) Sanitation Standard
Operating Procedures
Operator training (SSOP)
Personal Protective Equipment (PPE) Operator Training
Cleaning tools and equipment Personal Protective
Equipment (PPE)
Production equipment inspection
Cleaning tools
and equipment
Production equipment
inspection
7
OPERATOR TRAINING
Pre-requisites
for Cleaning
Master Sanitation
Safe usage and storage of Program /
equipment and chemicals PM Program
SSOPs Hazardous
Control Plan
– Understandable
Sanitation Standard
– Practical Operating Procedures
– Documented (SSOP)
Importance of sanitation for Operator Training
food safety and quality Personal Protective

Equipment (PPE)
Cleaning tools
and equipment
inspection
8
PERSONAL PROTECTIVE
EQUIPMENT (PPE) Pre-requisites
for Cleaning
Master Sanitation
Check that appropriate Program /
personal protective PM Program
equipment is available, and Hazardous
in good condition Control Plan
Wear appropriate PPE Sanitation Standard

for the task (SSOP)
Operator Training
Personal Protective
Equipment (PPE)
Cleaning tools
and equipment
inspection
9
CLEANING TOOLS:
GATHER & INSPECT Pre-requisites
for Cleaning
Master Sanitation
Safety Program /
– Lock-out/tag-out procedures, locks, signage (LOTO) PM Program
– Plastic covers for electrical equipment Hazardous

Control Plan
Tools
Sanitation Standard
– Broom, shovel Operating Procedures
– Water hose (SSOP)
– Foam equipment Operator Training
– Squeegee Personal Protective

Equipment (PPE)
Supplies
Cleaning tools
– Bucket, soak tank and equipment
– Brushes and pads – Gather & inspect
– Brushes & pads
– Chemicals
inspection
10
CLEANING TOOLS:
BRUSHES & PADS Pre-requisites
for Cleaning
Master Sanitation
No federal or state regulations Program /
for color-coded cleaning tools PM Program
Options for color coding: Hazardous

Control Plan
WHITE
Sanitation Standard
Food contact Operating Procedures
(SSOP)
RED/ORANGE
Floors Operator Training
Personal Protective
BLACK Equipment (PPE)
Drains
Cleaning tools
YELLOW and equipment
– Gather & inspect
Non-food contact – Brushes & pads
DESIGNATED COLOR Production equipment

Allergens inspection
11
PRODUCTION EQUIPMENT
INSPECTION Pre-requisites
for Cleaning
Master Sanitation
Check for damage or broken parts Program /
PM Program
Check that all surfaces can be clean
Hazardous
Control Plan
Sanitation Standard
(SSOP)
Operator Training
Personal Protective
Equipment (PPE)
Cleaning tools
and equipment
inspection
12
THE BASICS
CLEANING METHODS
Cleaning element ratios vary and depend on the cleaning method and type of soil:
i.e., Manual Cleaning i.e., Foam Cleaning i.e., CIP Cleaning
Concentration
Temperature
Time
Mechanical Force
14
CLEANING BASICS
Best results
– All cleaning factors are optimized for the specific method of
cleaning
One factor missing

– i.e., temperature
– Chemical concentration, mechanical or time must be increased
substantially to compensate for loss of temp.
Two factors missing

– i.e., temperature and mechanical force
– Effective cleaning is very difficult to achieve unless soil is very
light
15
WET SANITATION METHODS
WET SANITATION PROCESS
1. Sanitation Prep
2. Pre-Rinse
3. Wash
1. Concentration
2. Temperature
3. Time
4. Mechanical Force
4. Rinse & Inspect
5. Remove Water & Assemble
6. Pre-Op Inspection & Verification
7. Sanitize
17
SANITATION PREP
Remove production supplies from the room
– All ingredients
– All food products
– All packaging materials
Empty garbage and scrap containers;
remove from room
Purge process lines
Empty drain baskets
Remove all equipment that cannot get wet
Lock-out tag-out equipment to be cleaned
– Follow plant procedures for LOTO
Wet Sanitation Process

Sanitation Prep Pre-Rinse Wash Rinse & Inspect Remove Water & Assemble Pre-Op Inspection & Verification Sanitize
18
SANITATION PREP
Secure and disassemble equipment

Cover all electric eyes, electronic control
equipment, adjacent production lines
Remove loose soil & debris from
equipment and floor (top to bottom)

19
PRE-RINSE
Rinse to remove visible soils with warm-hot water

o o
Recommended temperature range 120-140 F (49-60 C)
Rinse from top to bottom
Target removal of 95% of visible soil
Rinse parts and place into COP tank or bucket for cleaning

20
PRE-RINSE METHODS
Rinsing Categories
High Pressure 400 – 1,000 psi Boosted Pressure 100 – 400 psi
Advantages Advantages
– Greater impingement force – Safety
– Less water volume per user – Lower injury risk
– Less heated water – Soils do not tend to become
projectiles
Disadvantages
– Reduced risk of scatter soils (re-
– Safety contamination)
– High pressure spray has tendency to
scatter soils (re-contaminate surfaces) – Less difficult for operators
– Can turn soils into projectiles
handling
– Water from hose stations at this – Schedule 40 piping
pressure can cause injury to operators – Possible less damage to
or persons near by
sensitive equipment
– Damage to sensitive equipment
Disadvantages
– Difficult for operators to handle
– Must use Schedule 80 piping – Less impingement force
– Higher flow rates (greater water
use)
WASH
Foam
Foam & Scrub
Manual
COP
CIP

Foam
Foam & Scrub
Manual
COP
CIP 22
FOAM CLEANING
Foam thickness should be about ½-1”

Wetter foam generally better than dry foam
No advantage to using hot water for foam
Reduce contact time if foamed onto
hot surfaces

Foam
Foam & Scrub
Manual
COP
CIP 23
FOAM CLEANING METHODS
Central Foam Systems

Wall-Mounted - locally aspirated
Portable
– Pressurized
– Non-pressurized

Foam
Foam & Scrub
Manual
COP
CIP 24
FOAM AND SCRUB
Wear proper PPE

Foam walls, equipment, then floor
(Foam equipment from bottom to top)
Be sure to foam underside of equipment
Scour as necessary to remove film, fats and proteins
Do not allow soap to dry, contact time should not be longer
than 10-15 minutes
Clean drains

Foam
Foam & Scrub
Manual
COP
CIP 25
MANUAL SCRUB
Manually scrubbing may be required

to remove heavy soils
Use pads and color-coded brushes
as required
Do not place parts on the floor
Use a cart, table or mat for parts placement
Pad color is not regulated, but verify that
scouring pads (green or white or other color)
do not damage the surface

Foam
Foam & Scrub
Manual
COP
CIP 26
CLEAN OUT OF PLACE (COP)
Equipment parts washing

Thorough pre-rinse required
Be sure all parts are adequately covered
Test kit verification of concentration
Control cleaning solution temperature
to melt fats
Separate rinse and sanitize steps

Foam
Foam & Scrub
Manual
COP
CIP 27
Types of COP tanks

– Longitudinal flow (pipes)
– Side jets (parts)
– Combination
Longitudinal Flow Side Jets

Foam
Foam & Scrub
Manual
COP
CIP 28
Concerns: Proper Parts Baskets

– No flow restrictions
– Proper parts baskets
– Parts completely disassembled
– Proper tank sizing - Equipment must fit in tank
Need to overflow tank to prevent
re-deposition of soil that is removed

Foam
Foam & Scrub
Manual
COP
CIP 29
Disassemble all parts before putting Place parts in basket in an orderly fashion
in COP tank. for effective COP cleaning.

Foam
Foam & Scrub
Manual
COP
CIP 30
Ensure that the COP tank is sized properly.

Equipment must fit into the COP tank!

Foam
Foam & Scrub
Manual
COP
CIP 31
At the end of the wash cycle, overflow the COP tank to

prevent redepositing of removed soils.

Foam
Foam & Scrub
Manual
COP
CIP 32
RINSE TO REMOVE CHEMICALS AND SOIL
Rinse in the order that soap was applied – walls, floor and then equipment
Rinse from top to bottom
Avoid spraying floor once post rinse of equipment begins
APPLY SOAP RINSE

Top Start at Top
Start at Bottom Bottom

33
INSPECT TO VERIFY CLEAN - SENSORY
Verify by sight, feel and smell

– USDA standard of clean
Use flashlights and other lights
Equipment should be free of visible soil,
haze or water beads

34
RINSE & INSPECT
Surface should be free of water beads.
Cleaner 1 Cleaner 2

35
RINSE & INSPECT
Remove any protective covers and inspect. Hand clean as necessary.

36
CLEANING VERIFICATION
Use Adenosine Triphosphate (ATP)

swab analysis to verify that surface has
been effectively cleaned
of soils

37
REMOVE WATER & ASSEMBLE
Put on clean outerwear

Sanitize hands
Verify all chemical is removed (sight, pH paper)
Remove all standing water and overhead condensation
Inspect parts that will not be accessible after assembling
Sanitize inaccessible parts prior to assembling
Assemble: follow lock-out/tag-out (LOTO) procedures
Re-lubricate where needed

38
PRE-OP INSPECTION
Inspect that equipment is free of chemicals, tools and cleaning supplies

Inspect that guards are in place before starting equipment
Run equipment prior to inspecting
Complete formal pre-op inspection according to plant SSOP
Correct any deficiencies and provide feedback to sanitation operator

Sanitation Prep Pre-Rinse Wash Rinse & Inspect Remove Water & Assemble Pre-Op
Pre-Op Inspection
Inspection &
& Verification
Verification Sanitize
39
PRE-OP INSPECTION

Sanitation Prep Pre-Rinse Wash Rinse & Inspect Remove Water & Assemble Pre-Op
Pre-Op Inspection
Inspection &
& Verification
Verification Sanitize
40
SANITIZE
Verify no standing water

Flood sanitize entire processing area
– Walls, floors and equipment
– Ensure equipment is running
Apply from top to bottom
Follow label directions for EPA-registered
sanitizer application
– Correct concentration
– Correct contact time

Sanitize
41
CRITICAL
Ensure that current Good Manufacturing Practices (cGMP)
are in place after flood sanitizing so that sanitized
equipment does not become recontaminated
Once sanitized, leave the equipment and room alone
STOP any & all activity in room until production begins

Sanitize
42
WET SANITATION PROCESS
1. Sanitation Prep
2. Pre-Rinse
3. Wash
1. Concentration
2. Temperature
3. Time
4. Mechanical Force
4. Rinse & Inspect
5. Remove Water & Assemble
6. Pre-Op Inspection & Verification
7. Sanitize
43
OPERATIONAL SANITATION
OPERATIONAL SANITATION
Definition
– Sanitation conducted during production
– Intermittent removal of process scrap & debris
Why it’s necessary
– Employee Safety
– Inspection requirements
– Control bacterial levels during production
Why it can be problematic
– Potential for cross-contamination
– Increases microbial growth factors in the environment (water)
45
What can go wrong?
46
What can go wrong?
High pressure rinsing of floor during production
Excess Water Use = Aerosolization of contaminants
47
What can go wrong?
48
CLEANING DURING PRODUCTION
Best Practices
Minimize wet cleaning during production

Focus on dry cleaning opportunities:
– Intermittent removal & disposal of process scrap & debris
– Dedicated employee to cleanup of floor
Provide training & supervision about contamination risks
Use sanitizer hoses only if necessary
No use of water hoses
49
ACTION STEPS TO CONSIDER
What questions do you have about your facility’s sanitation processes?

What do you need to learn or follow up on when you go back?
How can your facility improve practices for Operational Sanitation?
Are there follow-ups you need from Ecolab?
50

Multivariate Analysis (Minitab)

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Multivariate Analysis (Minitab)

Загружено:

Авторское право:

Доступные форматы

Wet Clean Methods

Manual and COP

Goals & Reality

Clean vs. Dirty

Hazard Control Plan (such as HACCP) Hazardous

Importance of sanitation for Operator Training

food safety and quality Personal Protective

Wear appropriate PPE Sanitation Standard

– Plastic covers for electrical equipment Hazardous

– Foam equipment Operator Training

– Squeegee Personal Protective

Options for color coding: Hazardous

DESIGNATED COLOR Production equipment

i.e., Manual Cleaning i.e., Foam Cleaning i.e., CIP Cleaning

One factor missing

Two factors missing

Wet Sanitation Process

Secure and disassemble equipment

Wet Sanitation Process

Rinse to remove visible soils with warm-hot water

Wet Sanitation Process

Wet Sanitation Process

Foam thickness should be about ½-1”

Wet Sanitation Process

Central Foam Systems

Wet Sanitation Process

Wear proper PPE

Wet Sanitation Process

Manually scrubbing may be required

Wet Sanitation Process

Equipment parts washing

Wet Sanitation Process

Types of COP tanks

Longitudinal Flow Side Jets

Wet Sanitation Process

Concerns: Proper Parts Baskets

Wet Sanitation Process

Wet Sanitation Process

Ensure that the COP tank is sized properly.

Wet Sanitation Process

At the end of the wash cycle, overflow the COP tank to

Wet Sanitation Process

APPLY SOAP RINSE

Start at Bottom Bottom

Wet Sanitation Process

Verify by sight, feel and smell

Wet Sanitation Process

Surface should be free of water beads.

Wet Sanitation Process

Remove any protective covers and inspect. Hand clean as necessary.

Wet Sanitation Process

Use Adenosine Triphosphate (ATP)

Wet Sanitation Process

Put on clean outerwear

Wet Sanitation Process

Inspect that equipment is free of chemicals, tools and cleaning supplies

Wet Sanitation Process

Wet Sanitation Process

Verify no standing water

Wet Sanitation Process

Once sanitized, leave the equipment and room alone

STOP any & all activity in room until production begins

Wet Sanitation Process

Excess Water Use = Aerosolization of contaminants