Sanitation for Dry Operations

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Sanitation for Dry Operations

• Jeffrey Brusseau
• Wesmar Company

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Questions we need to ask

• The 4 Ws
• Why?-Food processing operations conducted in an
  always dry environment can be a threat to food
  safety. Pests,dust,and soil all contribute to the
  potential growth of bacteria.
• What-cleaning and sanitizing of food
  contact/potential food contact surfaces.

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Federal Guidelines

• To assure food has been prepared, packed and held
  under sanitary conditions, The Federal Food, Drug
  and Cosmetic Act of the Food and Drug
  Administration (FDA) states the following
• "Sec. 402. A food shall be deemed to be
  adulterated . . . (a) (3) if it consists in whole
  or in part of any filthy, putrid, or decomposed
  substance, or if it is otherwise unfit for food
  or (4) if it has been prepared, packed, or held
  under unsanitary conditions whereby it may have
  become contaminated with filth, or whereby it may
  have been rendered injurious to health ..."

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What are sensitive areas?

• Where-near water sensitive equipment,metal
  detectors, electronics, scales, packaging areas,
  finished product storage areas.
• Or in locations where high water activity may be
  contributing to bacteria growth due to high
  condensationpoor air evacuation can travel
  bacteria throughout plant.
• When-according to master cleaning schedule.

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Trends in process design

• Another interesting trend in plant renovations
  over the past two to three years has been dry
  clean-up.
• We have been pushed in a few plants to dry out
  the packaging area, says John Gunst, packaging
  engineering manager of Power Engineers, Boise,
  Idaho, identifying dairy and frozen food
  processors among those clamoring for dry
  cleaning. The processors want no drains or
  sloped floors in order to avoid any possibility
  of introducing listeria or other microbes that
  could grow in drains. The goal is not to spill
  anything and to use as little water as possible
  in that area of the plant.
• When we do find water, we mop it up right away,
  one plant manager notes. We want no place for
  the bacteria to grow. You dont want hub drains
  in the floor or moisture-laden areas that will
  support bad bugs. Food Processing.com

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Issues of dry cleaning

• Dry cleaning a plant poses a bigger challenge.
  Air-hose blowing, though still common, poses risk
  of spreading allergens, and the better plant
  programs have ceased the practice. A peanut chunk
  can be propelled half way across a plant by an
  air-hose blast. A vacuum, on the other hand,
  removes it.
• In dry cleaning plant areas that contain one or
  more allergens, great care must be taken to
  control and contain allergen-laden dust and
  debris. Distributing allergens during brushing,
  wiping, sweeping or compressed-air cleaning can
  make a bad situation worse. This results in food
  quality and safety problems and increased
  sanitation costs associated with recleaning the
  allergen-contaminated areas.
• Food Processing.com 2006

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Possible methods for dry cleaning

• Air Pushing or Pulling?
• To blow soil could mean issues with
  allergens,re-depositing soil on other surfaces
  which were already cleaned.
• Are there micron filters on the air lines? Has
  the air compressor been tested for moisture?
• Wesmar once took a sample of water from an air
  compressor at a dairy plant,had the sample plated
  for TPC,the bacteria count was extremely high!
• It is common to re-contaminate the area with
  dirty air.

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• Or Pulling.
• Vacuums may be effective but can be an easy place
  for bacteria to flourish if the vacuums are not
  cleaned and sanitized regularly.
• The hoses and wands must be sanitary to touch
  food contact surfaces.
• Sweeping floors thoroughly.

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Minimal use of water in dry cleaning

• What if you cannot use water,but have grease,or
  other food buildup?
• Use spray bottle application of appropriate
  detergent.
• Clean with clean towels.
• Rinse towels in warm water.
• Use towels to remove all detergent residue.

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Final steps before processing

• Apply sanitizer to surfaces.
• It may be helpful to use an ATP device to verify
  cleanliness of surfaces.
• Allow to dry as per the label instructions.
• It may be important to use lint free towels in
  this method.

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In summary

• Are your dry process or storage areas as clean as
  they can be?
• Bacteria is nearly invisible. For food safetys
  sake,be sure youre looking at all potential
  areas, including drains and other places where
  biofilms may reside. Look for places that bugs
  can grow and spray them, wipe them, vacuum them!

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• Any Questions??