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Visit our food industry focus site at www.foodprocessingvacuum.com
Industrial Cleaning Best Practices
Contamination Control in the Food Industry
Presenter:
Kim Kanis, Senior District Manager, Nilfisk CFM
2011
Overview
• Why Clean?
• A Common Enemy: Contamination
• Cleaning Methods: – Pros and Cons– Preferred Methods– Dry Cleaning Techniques
• HEPA-Filtered Industrial Vacuums
• Combustible Dust in the Food Industry
Visit our food industry focus site at www.foodprocessingvacuum.com
Contamination Control – Why Clean?
• GMPs
• HACCP
• Product Safety
• Product Quality
• Company Reputation
• Cost of Recalls
• Cost of Lawsuits
Visit our food industry focus site at www.foodprocessingvacuum.com
Contamination Control – Why Clean?
• The CDC estimates 76 million cases of foodborne disease occur each year in the United States, responsible for 325,000 hospitalizations and 5,000 deaths.
• Financial: the average food/beverage recall is $10 million.**Deloitte, GMA and FMI study, 2009.
Visit our food industry focus site at www.foodprocessingvacuum.com
Contamination Control - Threats
• Bacteria and viruses
• Parasites
• Allergens
• Rodents/pests
• Mold, toxins, and contaminants
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Contamination Control
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“We Live in a Microbial World”
The consequences of failure to attain adequate control of airborne microbial contamination can result in product spoilage and/or a foodborne disease hazard. Airborne bacteria counts will normally be greatest in dusty environments and can range as high as 10,000 organisms per cubic meter.
Source: Sanitation in Food Processing - Second Edition
Cleaning Methods
• Controlled Wet - minimal wet cleaning methods used as needed
• Wet - wet cleaning methods used for all standard cleaning procedures
• Dry - dry cleaning methods used for all standard cleaning procedures
Visit our food industry focus site at www.foodprocessingvacuum.com
Cleaning Methods
Visit our food industry focus site at www.foodprocessingvacuum.com
Dry Cleaning: The Preferred Method
Although microorganisms survive, they cannot grow in dry foods or in their equipment soils. To introduce water in any form into such a process is to court disaster. Therefore, for routine cleanup of dry food lines use only procedures such as vacuuming, wiping with clean cloths, brushing or scraping.
Source: Principles of Food Processing Sanitation
Dry Cleaning - Methods
• Brooms/Mops• Compressed Air• Shop-Style Vacuums• Central Vacuum System• HEPA Vacuums
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Cleaning Methods - Tips
• Work from top down• Vacuum, brush or shovel to remove fines and dust• Use a scraper to remove excessive product buildup• Vacuum, brush or wipe to remove fines created by
scraping• If possible, integrate industrial vacuum into process to
collect excess dust during production run, packaging, etc.
• Sanitize as needed• Compressed air should not be used to substitute a
vacuum cleaner, brush or broom
Visit our food industry focus site at www.foodprocessingvacuum.com
Cleaning Methods
Dust removal is accomplished by use of:
1. Vacuum Cleaners
2. Brooms and Brushes
3. Compressed Air
These are given in order of preference. The vacuum cleaner must be used whenever possible. Compressed air should be used only where a vacuum and brushes will not reach.Source: AIB - Basic Food Plant Sanitation Manual
Visit our food industry focus site at www.foodprocessingvacuum.com
Brooms and Mops
Pros• Ease-of-use• Readily available• Inexpensive
Cons• Not effective for fine powder collection• Can disturb and spread dust, bacteria, allergens & insects• Limited to floor cleaning• Must be regularly cleaned and zoned for some areas• Mops introduce water and can leave residue• Cleaning water can become a source of contamination if not
changed frequently• Mops must be cleaned, dried and stored properly
Visit our food industry focus site at www.foodprocessingvacuum.com
Compressed Air
Pros• Ease-of-use• Useful in tight areasCons• Distributes contaminants in
compressed air system• Spreads fine dust, bacteria
and allergens everywhere• Does not remove fine dust• Blows dust into hard-to-reach
areas
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Compressed air just moves dust from point a to point b; it does not eliminate the dust
Shop-Style Vacuums
Pros• Ease of use• Many are designed for wet and dry collection• Can be used to clean a variety of areas• InexpensiveCons• Not effective for fine powder collection,
bacteria, or allergen control• Motor burn-up (not cost-effective)• Many do not hold up well in industrial
environments• Loud• Static electricity build-up
Visit our food industry focus site at www.foodprocessingvacuum.com
Source: http://jc-coleman.com/shopvac-meltdown/
Central Vacuum Systems
Pros• Convenient to use• Powerful• Continuous-duty capabilities• Large collection capacity• Ideal for multiple operator use
Cons• System failure can leave many people without a way to clean• System cannot be used outside of immediate area• Piping can become blocked and/or contaminated• Cannot collect liquid; mold build-up in pipes• Can be expensive
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HEPA-filtered Vacuums
Pros• Ease-of-use• Multi-stage filtration / HEPA
filtration captures bacteria• Multiple filter options • Many are designed for wet and
dry collection• Can be used to clean a variety
of areas (general maintenance and specialized applications)
• Many have unique filter loading indicators and filter cleaning options
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Manual filter shaker removes caked on dust; maintaining performance
Nomex® filters and high-temp wands withstand hot ovens to remove crumbs, etc.
HEPA-filtered Vacuums
Pros• Continuous-duty
capabilities
• Multiple construction material choices
• Multiple vacuum performance choices including portable units and central systems
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•Portable
•Wet/Dry
•Stainless Steel
•Three-Phase
•Pneumatic
•Drum-top
•EXP
HEPA-filtered Vacuums
Cons• Initial Cost• Problems can arise if dry-only HEPA vacuums are used
for wet collection• Some require filter changes between wet and dry use• Not all vacuums are created equal
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HEPA-filtered Vacuums
Accessories• Food-grade• Color-coded• Wall/Overhead• Floor • High-temperature• Stainless• Bulk collection• Micro tools• Anti-static
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HEPA-filtered VacuumsNot just for general maintenance…
Visit our food industry focus site at www.foodprocessingvacuum.com
Industrial vacuum decreases product loss by collecting pistachios that fell during transport from silo to plant.
Industrial vacuum removes excess product and fine dust from production line; can be integrated into line for continuous processing
Quickly collect bulk materials
Combustible Dust
• Food Industry is particularly under the microscope• OSHA NEP raises the issue of using “properly-equipped”
industrial vacuums as defined by NFPA 654.• Classed materials may require an “explosion-proof”
vacuum, as determined by Authorities Having Jurisdiction (AHJ, eg. building inspector, fire marshall, insurance agent).
• Often, a standard, non-EXP industrial vacuum cleaner is suitable for collecting “combustible dusts.”
• Remember, it is up to the AHJ to determine if your work area or facility is classified hazardous, which then determines the type of equipment you should use.
• Shop-style vacuums can add to the risk!
Visit our food industry focus site at www.foodprocessingvacuum.com
Visit our food industry focus site at www.foodprocessingvacuum.com
Air-operated Explosion Proof
Air-operated, Pneumatic Vacuums
• Powered by compressed air (Venturi principle)• No electrical components• No moving parts• Use when electricity is prohibited or unavailable
• Intrinsically Safe• Meet the requirements for use in Class II areas• Made of non-sparking materials• Conductive accessories• Grounded
Explosion-Proof Vacuums
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• Certified as “Explosion Proof” by NRTL– CSA, UL, ETL– EXP rated TEFC motors– EXP rated sealed switches/connections– Internally/externally grounded (filters, body, tank, wheels,
etc.)– Conductive hose and accessories
• Beware of posers!– Some companies offer “dressed up” models with antistatic
accessories
• Remember, investing in the proper equipment is only one part of the equation. Inspect your facility to ensure you have proper safety measures in place, including Explosion Prevention (NFPA 69) and Deflagration Venting devices (NFPA 68).
Approved for use in Class I, Group D and Class II, Groups E, F & G
Resources
AIB ResourcesGeneral Websitewww.aibonline.org
Food Plant Sanitation Workshops https://secure.aibonline.org/php/ecomm-catalog.php?catalogNbr=392
FDA ResourcesAvoid a Recallhttp://www.fda.gov/Safety/Recalls/IndustryGuidance/default.htm
Federal Food Safetyhttp://www.foodsafety.gov/
Other Resources
Combustible Dust NEP:
www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=DIRECTIVES&p_id=3830
Nilfisk CFM Food Industry Focus Sitewww.foodprocessingvacuum.com
Visit our food industry focus site at www.foodprocessingvacuum.com