Food Processing Cleaning & Sanitation PDF

FSC60504 FOOD PROCESSING TOPIC 4: CLEANING & SANITATION DR LEONG SZE YING SCHOOL OF BIOSCIENCES 1 [email protected]  Detergent-sanitizers Procedures Clean-in –place (CIP) Proper storage Pest control Topic 4:...

FSC60504 FOOD PROCESSING TOPIC 4: CLEANING & SANITATION DR LEONG SZE YING SCHOOL OF BIOSCIENCES 1 [email protected]  Detergent-sanitizers Procedures Clean-in –place (CIP) Proper storage Pest control Topic 4: Cleaning & Sanitation Learning Outcome: Apply the principles and practices of cleaning and sanitation in food processing Detergents Sanitizers Detergent-sanitizers Procedures Clean-in-place (CIP) Proper storage 2 Pest control WHY CLEANING AND SANITATION IS IMPORTANT? Hygiene considerations are of utmost importance in food manufacturing process An integral part of food production The ability of equipment to produce high-quality foods depends significantly on hygienic conditions The intensity of the necessary cleaning and sanitation procedures depends on the previous soiling or fouling phenomena: how dirty the equipment is Source of contamination comes from: Dirty raw material Foreign bodies Dirty production equipment 3 WHY CLEANING AND SANITATION IS IMPORTANT? Refers to the unwanted deposition of material from a product stream on a surface as a result of processing 4  GOALS OF CLEANING AND SANITATION Raw materials Foreign bodies Dirty production (fluid & solid) equipment Fluid: screening (e.g., Rely on mechanical Scheduled daily at inlet pipes), separation process cleaning to ensure filtering (with and free of soil, without filter aids), pathogenic adsorption (e.g., on microorganisms, food activated carbon), spoiling and centrifugation microorganisms, and are used detergents and/or Solids: settling, disinfectant agents screening, and sorting Addition of Carryover dirt is not antifouling treatment acceptable (e.g. passivation) 5  GOALS OF CLEANING AND SANITATION Raw materials Foreign bodies Dirty production (fluid & solid) equipment Fluid: screening (e.g., Rely on mechanical Scheduled daily at inlet pipes), separation process cleaning to ensure filtering (with and free of soil, without filter aids), pathogenic adsorption (e.g., on microorganisms, food activated carbon), spoiling and centrifugation microorganisms, and are used detergents and/or Solids: settling, disinfectant agents screening, and sorting Addition of Carryover dirt is not antifouling treatment acceptable (e.g. passivation) 6 TYPICAL COMPONENTS IN FOULED LAYERS FOR FOOD PROCESSING EQUIPMENT 7  CLEANING & SANITATION PROCEDURE The cleaning and sanitation procedure consists of a series of cleaning cycles with alternate composition of the medium used Water  Detergent  Water  Sterilising chemicals  Water 8  (1) WATER The water’s surface tension is too high Water as part of cleaning solutions function as: Solvent for the chemicals Transport medium Transmitter of thermal and chemical energy 9 http://www.lorchem.com/pages.php?id=63  (2) DETERGENTS Water only The detergent choice depends on: The chemical and physical composition of the soil (low or high viscosity, solid, non-fat, water/alkali or acid soluble, etc.) to be removed from the equipment Not all the different types of chemicals available for cleaning are Water+detergent: Reduced equally suited surface tension Acids for mineral deposits An alkaline medium for organic or protein-containing substances In food production: the soil are, in most cases, not exclusively mineral or Water+concentrated organic Different types of chemicals are used The chemical conversion of the deposits to be removed from the surfaces Complete moistening, reduction of the surface should be achieved 10 tension and optimum Interactions with the deposits >> between the deposits with the solid surface cleaning  (3) CLEANING CHEMICALS: SINGLE CHEMICALS AND FORMULATED PRODUCTS Sold in various physical forms Powder or liquid concentrate Pure substance or complex mixtures of several substances The mixed products can be: Fully formulated products Component products made up of a basic substances and ingredient concentrates as a second component Categorised as: Acid cleaners Alkaline cleaners Enzyme cleaners Solvent based (but nonfood grade) Try to look for examples (commercial cleaning chemical 11 products) for each cleaner type  (3) CLEANING CHEMICALS: SINGLE CHEMICALS AND FORMULATED PRODUCTS Alkaline cleaners Acid cleaners Alkalis chemically react with vegetable and animal Principle: Insoluble deposit  water soluble salts fats  causes saponification of the fat (thus, Acids chemically react with mineral (limescale) usually act as degreasers and deep cleaners) and oxidised (rust) soiling The soap produced by this reaction promotes the The soiling (dirt) is converted by a chemical effect of the surfactants in the cleaning agent reaction into water-soluble salts and gases Alkaline-based agents also enable strongly Used for residues such as: adhering/bonding dirt to be removed more easily Beer stone-deposit (created by proteins, hop resins because they swell up and Ca-oxalate) The effect of alkaline-based agents on dirt and Milk stone: consist mainly of tricalcium phosphate grease is also very dependent on the influence of May contain: Strong acids, inhibitors, disperging the electrical charges existing between the dirt agents, nonionogenic surfactants/tensides particles and the surface  May contain: Strong/weak alkalies, complexing Acids can severely damage materials (limestone, agents, tensides, stabilisers, oxidisers, corrosion metal) inhibitors, solubilisers May be irritant, caustic or toxic 12 May be irritant or caustic effect  (3) CLEANING CHEMICALS: SINGLE CHEMICALS AND FORMULATED PRODUCTS Alkaline cleaners Acid cleaners Alkalis chemically react with vegetable and animal Principle: Insoluble deposit  water soluble salts fats  causes saponification of the fat (thus, Acids chemically react with mineral (limescale) usually act as degreasers and deep cleaners) and oxidised (rust) soiling The soap produced by this reaction promotes the The soiling (dirt) is converted by a chemical effect of the surfactants in the cleaning agent reaction into water-soluble salts and gases Alkaline-based agents also enable strongly Used for residues such as: adhering/bonding dirt to be removed more easily Beer stone-deposit (created by proteins, hop resins because they swell up and Ca-oxalate) The effect of alkaline-based agents on dirt and Milk stone: consist mainly of tricalcium phosphate grease is also very dependent on the influence of May contain: Strong acids, inhibitors, disperging the electrical charges existing between the dirt agents, nonionogenic surfactants/tensides particles and the surface  May contain: Strong/weak alkalies, complexing Acids can severely damage materials (limestone, agents, tensides, stabilisers, oxidisers, corrosion metal) inhibitors, solubilisers May be irritant, caustic or toxic 13 May be irritant or caustic effect  (3) CLEANING CHEMICALS: SINGLE CHEMICALS AND FORMULATED PRODUCTS Enzymatic cleaners used to: Protect industry material Minimise the use of cleaning chemicals Example: (proteases) Savinase and Properase https://www.novozymes.com/en/products/animal- protein/savinase https://patents.google.com/patent/WO2003018734A1/en https://patents.google.com/patent/US20180042253A1/en The use of enzymes Savinase® and Properase 1600 L® on encrusted fouling deposits produced during heating of milk. Pretreatment of the 14 deposits for 15 min in nitric acid 0.5%, 65◦C  (4) SANITISERS Aiming to reduce the number of living microorganisms through: Thermal deactivation Chemical sanitising For food equipment Radiation Sanitisers for use in combination with thermal deactivation: Halogens: active chlorine compounds Surface-active agents Other components: Peroxides (hydrogen peroxide, peracetic acid) Formaldehyde Ethylene oxide Monobrome acetic acid esters Ozone 15 Labile germizide (P-propiolatone)  CLEANING TECHNIQUES/PROCEDURES (A) Open Cleaning Techniques Suited for external surfaces, large storage tanks, transport tanks, and machine parts with complicated design High labour involvement through one of the following: COP: Cleaning-out-of-place CHP: Central high-pressure cleaning CLP: Central low-pressure cleaning CFS: Central foaming system (B) Closed Cleaning Techniques Cleaning-in-place (CIP) systems Single use CIP system 16 Multiuse/Reuse CIP system  CLEANING TECHNIQUES/PROCEDURES Single use CIP system: The cleaning/detergent solutions are used only once; recovered and stored in the reuse CIP system Example of a standard cleaning program for one tank cleaning covers a 20-min program sequence: Three pre-rinses of 20 sec with intervals of 40 sec each Dosage of cleaning media and injection of steam A water circuit and injection of organic acid to lower the pH value to 5 to 4.5 for about 3 min Examples of cleaning media: An alkaline cleaning medium; dosage 0.65% A product with a number of emulsifying, surface-active and antifoam substances; dosage 0.08% A liquid chloric cleaning medium; dosage 0.15% 17  CLEANING TECHNIQUES/PROCEDURES Single use CIP system: The cleaning/detergent solutions are used only once; recovered and stored in the reuse CIP system 18  CLEANING TECHNIQUES/PROCEDURES Reuse CIP system: The cleaning/detergent solutions are reused The essential components of a CIP plant for a reuse system: Lye and acid tanks Freshwater tank Return water tank, if required A heating system A pressure and return pumps The piping system of a cleaning plant is fixed in the plant and equipped with remote controlled valves and measuring devices The cleaning liquid is conveyed from the cleaning plant through the production plant, plant section, or machines to be cleaned 19  CLEANING TECHNIQUES/PROCEDURES Reuse CIP system: The cleaning/detergent solutions are reused  The automatic mode of the Reuse CIP system comprised of: 1. Pre-rinse operations 2. Detergent recirculation 3. Intermediate rinse 4. Acid recirculation (if necessary) 5. Sterilant recirculation 6. Hot water sterilisation 7. Final water rinse20 CLEANING TECHNIQUES/PROCEDURES https://www.haskell.com/insights/methods-to-achieve- 21 sustainable-clean-in-place/ PROPER STORAGE OF FOOD AND CHEMICAL AGENTS Foods received into the food warehouse for handling or storage must be placed in a manner that will: Facilitate cleaning Facilitate implementation of insect, rodent, and other sanitary controls Maintain product wholesomeness Adopt and implement effective procedures to provide stock rotation – e.g. date code is visible Separate the storage of food, raw material from the chemical agents – e.g. safety symbols, ventilated, spill containment, secure storage, in original containers, equip with PPE 22  PEST CONTROL No pests shall be allowed in any area of a food plant Pest infestation results in product adulteration, which can lead to product loss, possible recall or regulatory control action, and potential loss of business.....this is serious!!!! 23 PESTS OF CONCERN TO FOOD PROCESSING PLANTS  Insects They can carry many disease-causing organisms About 90% of complaints against food establishments are for rodents and that  Rodents about 90% of those are for mice. - Cause economic loss - Carriers of disease They carry disease-causing organisms  Birds such as Salmonella and fungi 24  Inspection and Reports: Ideally weekly Treatment Materials: Applied by licensed party PEST Habitat Elimination: The first line of defence against pests in the perimeter of the plant CONTROL MEASURE Exclusion: To exclude pests: deny access to food, warmth, moisture, and shelter Sanitation: Regular cleaning to prevent the attraction, breeding, or infestation of pests Extermination: Install insect light traps (electrocutors), bait stations, pheromone traps, catch-all traps, and bird-control 25 devices