Cleaning Compounds & Sanitizers (Abu Dhabi University)

Cleaning Compounds & Sanitizers Chapter 31 – Food Safety and Management College of Health Sciences EHS310-Food Safety and Management Fall 2024-25  Outline P...

Cleaning Compounds & Sanitizers Chapter 31 – Food Safety and Management College of Health Sciences EHS310-Food Safety and Management Fall 2024-25  Outline Part II: Understanding Sanitizers Importance and methods of sanitizing. Efficacy and desired properties of sanitizers. Overview of various chemical sanitizers and their applications. Detailed Structure of the Lecture Part II: Understanding Sanitizers 1. Introduction to Sanitizing in Food Safety 2. Methods of Sanitizing 3. Efficacy of Sanitizers 4. Desired Properties of Effective Sanitizers 5. Overview of Chemical Sanitizers (Chlorine, Iodine, Quats, etc.) 6. Sanitizer Resistance and Rotation 7. Testing Sanitizer Strength 8. Best Practices for Sanitization Part II: Understanding Sanitizers  1. Introduction to Sanitizing in Food Safety Sanitizing means reducing pathogenic microorganisms to safe levels as defined by public health standards. It prevents foodborne illnesses, protecting consumer health and maintaining compliance with food safety regulations.  2. Methods of Sanitizing Thermal Radiation HHP Vacuum and Chemical steam sanitizers vacuum  2. Methods of Sanitizing Thermal Sanitization: Utilizes high temperatures (steam, hot water) to kill microorganisms. Radiation: Utilizes radiations to kill microorganisms. HHP: Applies high hydrostatic pressure to sanitize. Vacuum-Steam-Vacuum: Utilizes vacuum and steam vacuum to kill microorganisms. Chemical Sanitization: Involves the use of chemical agents like chlorine and quaternary ammonium compounds. Mechanical Sanitization: Employs pressure washing to physically remove contaminants.  2. Methods of Sanitizing Relatively inefficient because of the energy required. Microorganisms can only be destroyed if: correct temperature is used. Thermal heated long enough. heat is permitted to penetrate to all areas (application design, equipment and plant design, etc.). Expensive and frequently ineffective Steam Condensation is a complication. Thermal Pouring “hot” into a container is not reliable cause it is difficult to maintain high temp. Hot water: Effective and nonselective for food contact surfaces 80 °C or more Spores may survive more than an hour at 100 °C Shorter time requires a higher temperature However, hot water is readily available and nontoxic. If incorporated, sanitizing can be accomplished either by pumping the water through assembled equipment or by immersing equipment in the water.  2. Methods of Sanitizing Radiation in the form of ultraviolet (UV) light or high-energy cathode or gamma rays will destroy microorganisms. UV light has been used in the form of low-pressure mercury vapor lamps to destroy microorganisms in hospitals and homes. Radiation UV activity appears to be pH and temperature independent and produces no taste or odor in treated water. It produces few, if any, undesirable by-products and little or no mutagenic activity or halogenated by-products (carcinogens). The effective killing range for microorganisms through use of ultraviolet light is very short → limited utility in food operations (even though its activity is independent of pH and temperature). Light rays must actually strike the microorganisms. Radiation does not penetrate well, and its use as an antimicrobial agent should be restricted to microorganisms on sources in the air, or in clear liquids. Liquids that may be treated with UV light include beverage plant water, brine solutions, vegetable product transfer water, cleaning-in-place (CIP) rinse water, heating and cooling water, cheese curd rinse water, and wastewater effluents.  2. Methods of Sanitizing Radiation Sources of ionizing radiation available for the treatment of food products Electron beam (e- Gamma rays X-rays beam) Penetration range One or more One or more of approximately meters meters 7.5 cm  2. Methods of Sanitizing Safety is a major concern since UV radiation can cause Radiation severe eye damage and skin irritation of exposed individuals. Also, bacterial cells injured by UV light can repair themselves.  2. Methods of Sanitizing High Hydrostatic technique is applied to liquid or solid food, packaged or unpackaged, that are subjected to high pressure (which varies depending upon application) usually for 5 min or less. HHP It is used on raw and cooked meats, fish and shellfish, fruit and vegetable products, cheeses, salads, dips, grains and grain products, and liquids including juices, sauces, and soups. High pressure does not destroy the food (applied evenly from all sides). It inactivates microorganisms living on the surface and in the interior of the food via their molecular structure. HHP is equally effective on molds, bacteria, viruses, and parasites. It is also successful in treating some bacterial spores. HHP inactivates certain hydrolytic enzymes that result in the deterioration of food.  2. Methods of Sanitizing Vacuum and Steam Vacuum Exposes solid food products to vacuum, steam, and vacuum again. Have potential for the destruction of pathogenic microorganisms in fresh meat and poultry, processed meats, seafood, and fruits and vegetables.  2. Sanitizing Methods Chemical Sanitizers To be effective, chemical agents must find, bind to, and transverse microbial cell envelopes before they reach their target site prior to initiating the reactions that destroy microorganisms. The more concentrated a sanitizer, the more rapid and effective its action. They lack penetration ability → microorganisms present in cracks, crevices, pockets, and mineral soils may not be totally destroyed (that’s why it should be coupled with cleaning agents).  3. Efficacy of Sanitizers Exposure Temperature Time Concentration pH Water Equipment Hardness Microbial Bacterial Population Attachment  3. Efficacy of Sanitizers Logarithmic pattern Exposure Time Microbial load + the population of cells (varied susceptibility to the sanitizer due to age, spore formation, and other physiological factors) determine the time required for the sanitizer to be effective. A higher temperature generally lowers surface tension, increases pH, decreases viscosity, and creates other changes that may help Temperature bactericidal action. Except for iodophors that vaporize above 50 °C. Thus, chemical sanitizers should be applied at ambient temperatures, ideally 21-38 °C. Concentration Increased sanitizer concentration enhances the rate of destruction of the microorganisms. Minor pH changes in the medium can drastically affect microbial growth. pH Chlorine and Iodine compounds are less effective with an increase in pH.  3. Efficacy of Sanitizers Failure to clean surfaces properly can reduce the effectiveness of a sanitizer. Equipment Some chemicals react with organic materials (soil). Water The presence of bicarbonates, sulphates, and chlorides of calcium and magnesium Hardness Water composition can make the sanitizer chemically inactive or buffer the pH and diminish effectiveness. All sanitizers are not equally effective against all microorganisms. Microbial Population Cells in the spore state or in a biofilm are more resistant than those in the vegetative and freely suspended state. High numbers can overwhelm the sanitizer. Bacterial The attachment of certain bacteria to a solid surface provides an increased resistance to chlorine. Attachment  4. Desired Properties of Effective Sanitizers Key Characteristics: Uniform & broad-spectrum microbial destruction properties against vegetative bacteria, yeasts, & mold to produce rapid kill. Environmental resistance (effective in the presence of organic matter [soil load], detergent and soap residues, and water hardness and pH variability). Good cleaning properties. Non-toxic and non-irritating properties. Water solubility in all proportions. Acceptable (or no) odour. Stability in concentrated use & dilution. Ease of use. Ready availability. Inexpensive. Ease of measurement in use solution.  5. Overview of Chemical Sanitizers Chlorine compounds: Types: Sodium hypochlorite, calcium hypochlorite, and chlorine dioxide. Effective Concentrations: Recommended levels for effective sanitization in food settings (e.g., 50- 200 ppm for sodium hypochlorite). Safety Precautions: Risks of chlorine gas exposure; proper ventilation and handling are essential. ➔ Chlorine types and effective concentrations.  5. Overview of Chemical Sanitizers Iodine compounds: Use of Iodine: Effective sanitizer with broad-spectrum antimicrobial activity. Advantages: Rapid action and effectiveness in low concentrations. Limitations: Potential for staining surfaces and corrosive properties; needs careful application.  5. Overview of Chemical Sanitizers Bromine compounds: Bromine Sanitizers: Effective in warm water and non-corrosive properties. Key Benefits: Good for sanitizing food processing equipment and surfaces. Precautions: Proper dilution and handling to avoid skin irritation. ➔ Bromine: benefits and precautions.  5. Overview of Chemical Sanitizers Quaternary ammonium compounds: Characteristics: Cationic surfactants with antibacterial properties; stable and effective at low concentrations. Applications: Ideal for surfaces and utensils, especially in food service. Benefits: Low toxicity, non-corrosive, and pleasant odor.  5. Overview of Chemical Sanitizers Acid sanitizers: Types: Citric acid, lactic acid, and peracetic acid. Applications: Effective against specific pathogens, particularly in food processing. Safety Measures: Use of PPE and compatibility checks with equipment and surfaces. ➔ Acid sanitizers: effective against specific pathogens.  5. Overview of Chemical Sanitizers Acid-quat sanitizers: Combination of acid and quaternary ammonium compounds for enhanced effectiveness. Advantages: Broader spectrum of antimicrobial action; suitable for diverse applications. Applications: Use in food contact surfaces and equipment cleaning.  5. Overview of Chemical Sanitizers Ozone as a sanitizer: Mechanism of Action: Ozone is a powerful oxidizing agent that effectively kills microorganisms. Applications: Utilized in water treatment and direct application on food. Regulatory Considerations: Adherence to guidelines for safe use in food processing environments. Sanitization Potential of Ozone and Its Role in Postharvest Quality Management of Fruits and Vegetables (Aslam et al., 2020)  6. Sanitizer Resistance & Rotation Concept of Resistance: Microbial adaptation to repeated use of the same sanitizers can lead to reduced effectiveness. Importance of Rotation: Implementing a rotation schedule helps prevent resistance and maintains efficacy. Microbial resistance to sanitizers in the food industry: review (Alonso et al.,  7. Testing Sanitizer Strength Methods of Testing: Use of test strips, titration, and photometric analysis to assess sanitizer concentrations. Importance of Regular Testing: Ensures compliance with health regulations and maintains effective sanitization practices.  8. Best Practices for Sanitization Guidelines for effective use: Follow manufacturer instructions for dilution and application. Ensure staff are trained in proper sanitization protocols. Conduct regular audits of sanitation practices and compliance.  Conclusion ➔Importance of effective cleaning and sanitizing for food safety. ➔ Role of ongoing education, vigilance, and adherence to best practices in sanitation.  Case Studies in Sanitizer Use Examples of effective sanitizer applications → showcase successful case studies from food industry settings & lessons learned  1. Case Study: Meat Processing Plant (Pathogen Control) Setting: Large-scale beef processing facility Challenge: The facility needed to reduce the risk of pathogen contamination, particularly E. coli and Salmonella, which are common in meat processing. Solution: The plant implemented a two-step sanitizer process. First, an acidic pH sanitizer was used on all surfaces (conveyors, knives, and cutting boards) immediately after contact with raw meat. Following this, a high-level chlorine dioxide sanitizer was applied to sanitize the production floor and equipment. Results: Significant reduction in pathogen counts. Enhanced safety of meat products, ensuring compliance with USDA standards. No instances of pathogen-related recalls for over two years. Improved operational efficiency due to fewer contamination-related downtime incidents.  2. Case Study: Fruit and Vegetable Processing Facility (Chemical-Free Sanitization) Setting: Organic fruit and vegetable packing facility Challenge: The facility needed to maintain high hygiene standards while adhering to organic certification requirements, meaning they could not use traditional chemical sanitizers that might leave residues. Solution: The company adopted a ozone-based sanitation system. Ozone (O3) was used to disinfect raw produce and food-contact surfaces. The ozone was generated on- site and applied as a gas for surface sterilization or dissolved in water to sanitize produce in wash tanks. Results: Zero pesticide or chemical residues on products, maintaining the facility's organic certification. A significant reduction in bacterial counts (e.g., Listeria monocytogenes and E. coli) on produce. Improved shelf life of products due to effective microbial control. The system became a selling point for consumers concerned about pesticide use.  3. Case Study: Bakery (Contamination Control & Shelf Life Extension) Setting: Artisan bakery Challenge: The bakery struggled with mold growth on bread products, leading to high product waste and short shelf life. Solution: The bakery introduced a food-safe sanitizer containing peracetic acid in its cleaning protocols for all equipment, counters, and storage areas. Additionally, the bread was lightly sprayed with a diluted solution of peracetic acid just before packaging. Results: Mold growth was reduced by 90%, leading to a significant decrease in product waste. Products stayed fresh for up to 3 days longer compared to previous batches. Customer satisfaction improved, as the bakery could now offer fresher products for longer periods. The bakery was able to reduce overhead costs associated with frequent product disposal.  Case Studies in Sanitizer Use –Lessons Learned Different food sectors require tailored sanitizer solutions depending on the type of product, contamination risks, and regulatory requirements ➔ Customized Solutions Emerging technologies like ozone, UV light, and electrolyzed water are proving to be highly effective alternatives to traditional chemical sanitizers, particularly for organic and eco-conscious markets ➔ Innovative Technologies Sanitizer protocols must align with industry regulations (e.g., USDA, FDA, EPA), ensuring product safety and preventing costly recalls ➔ Regulatory Compliance Effective sanitization not only enhances food safety but can streamline cleaning processes, reduce downtime, and improve overall product quality and shelf life ➔ Operational Efficiency Questions