LISTERIA RECOVERY IN PLANT ENVIRONMENTS
Plant Conditions Listeria recovery
Above average sanitization + excellent or moderate environmental control program
6.8%
Below average sanitization and slight or no environmental control program
27.5%
Walker et al. J. Food Protect. 1991
MAGIC
MIRACLEin a DRUM
or
LISTERIA CONTROL IS NOT . . .
RocketScience
CONTROL REQUIRES DOING THE RIGHT
THING EVERY TIME
LISTERIA CONTROL & PREVENTION Prevent Entry
Control incoming contamination
– Employees, Equipment, Ingredients, Packaging
Prevent Growth Remove growth nutrients; water & soil
– Keep it dry, Keep it cold, Use sanitizers
Eliminate Harborage SitesEliminate niches/harborages
– Sanitary equipment design & maintenance– Regular, effective & thorough C&S
Prevent Spread Control vectors (stop transmission)
– Employees, forklifts, cleaning tools, floor scrubbers, pests, water, air, etc.
PREVENT ENTRYCONTROL INCOMING CONTAMINATION
• Movement of people, equipment, materials, etc., needs to be monitored, controlled and restricted
• Zoning and traffic patterns
PREVENT ENTRYSOLUTIONS
• Environment Care Program
– Floor & Drain Management
– Doorway Sanitation
– Floor Sanitizers
– Hard Surfaces
– Cooler and Freezer Care
• Personal Hygiene Program
– One Step Disinfectant
– Cleaner-Sanitizers
– Boot Washers & Sanitizers
– Hand-care Solutions
PREVENT GROWTHIDENTIFY & EXECUTE APPROPRIATE CLEANING & SANITIZING PROGRAMS
CLEANING:
• Match the cleaner to the nature of the SOIL
• Match the cleaner to the WATER properties
• Optimize compatibility with the SURFACE
• Be appropriate for the METHOD of application
• Meet ENVIRONMENTAL guidelines
Clean surface,
ready to
sanitize
PREVENT GROWTHIDENTIFY & EXECUTE APPROPRIATE CLEANING & SANITIZING PROGRAMS
DRY CLEANING:
• Match the cleaner to the nature of the SOIL
• Optimize compatibility with the SURFACE
• Use appropriate METHODS for the application
• Meet ENVIRONMENTAL guidelines
Clean surface,
ready to
sanitize
PREVENT GROWTHIDENTIFY & EXECUTE APPROPRIATE CLEANING & SANITIZING PROGRAMS
SANITIZERS:
Sanitizer ConcentrationLog
Reduction
Chlorine 100 ppm >5
QAC 200 ppm >5
Iodophor 25 ppm >5
Fatty Acid 1oz/6gal >5
Acid Anionic 200 ppm >5
Peracid 1 oz/4 gal >5
Mixed
Peracid1 oz/6 gal >5
A.O.A.C. Germicidal Sanitizer Method - 25oC
For application claims and use instructions please refer to the product label
ELIMINATE HARBORAGE SITESPOOR SANITARY DESIGN AND MAINTENANCE WILL NEGATE THE BEST
CLEANING PROGRAM
TYPICAL HARBORAGE SITES INCLUDE:
Hollow rollers
Bad gaskets, bad welds
Sprockets & gears
Materials of different kinds
bolted together
Difficult to clean scrapper
blades
Conveyor wear strips & guides
KEEP IN MIND THE RIGHT “TOOL” FOR THE JOB
Typical causes of cross-contamination include:
Humans
High pressure rinsing during production
Leaks
Failure to follow GMP processes
Cleaning tools & equipment (floor
scrubbers, mop buckets, etc.)
PREVENT SPREAD &
CROSS-CONTAMINATIONYOU CAN NOT ELIMINATE LISTERIA; THEREFORE, IT IS EXTREMELY
IMPORTANT YOU PREVENT ANY KIND OF CROSS-CONTAMINATION TO
PREVENT AND CONTROL LISTERIA
FOUR FACTORS OF CLEANING
• Chemistry (type & concentration)- Proper detergent and concentration
for the job
• Temperature- Necessary for proper cleaning
performance (within a range)
• Time- To complete all necessary cleaning
procedures and pre-op
• Mechanical Force- Scrubbing, brushing, boosted water,
CIP, COP
RINSE WATER HOSE TEMPS
• Optimum rinse hose temperature is 130-140˚F, at the hose nozzle, for effective removal of animal fats
• >140˚F will start to bake soils on to surfaces causing build-ups and potential biofilms and can cause increased condensation
• 130-140˚F is also the optimum temperature for most detergents to perform - need hot water through foam cleaning
• Up to 10˚F temperature drop from point of heating to rinse hose nozzles
• Water temperatures at nozzle should be verified and monitored nightly and recorded on log sheet for historical reference
MECHANICAL – CENTRAL WATER SUPPLY
– Low Pressure: 40 – 100 psi (primarily scale cleaning)
– Boosted (Med Pressure): 100 – 250 psi (Optimum for short cleaning window)
– High Pressure: 250 – 1,000 psi (not recommended)*Some organizations may call >400 high pressure, but you MUST be careful
MECHANICAL – MANUAL CLEANING
FOAM SPRAY HAND WASH
pH range: 2-12
Rinse: 120-140°F
Foam and spray: Ambient temperature
Hand wash: Ambient – 120°F
CHOOSING THE RIGHT CLEANER
EFFECT
SOIL TYPE
CHEMISTRY
Fats & Oils Carbohydrates Proteins Minerals
Dissolve Liquefy Hydrolyze Disperse Emulsify
Rinse
Alkaline Acid Oxidizer Enzyme Solvent Surfactant
• Everything must be covered
• Belts should be running
• Work bottom to top when foaming
• Sanitary design is both friend and foe
CHEMISTRY – COVERAGE!
TIME
• Chemistry (type & concentration)- Proper detergent and concentration
for the job
• Temperature- Necessary for proper cleaning
performance (within a range)
• Time- To complete all necessary cleaning
procedures and pre-op
• Mechanical Force- Scrubbing, brushing, boosted water,
CIP, COP
FOUR FACTORS OF SANITIZING
• Chemistry (type & concentration)- Proper sanitizer and concentration for
the job
• Water quality, material compatibility, label claims
• Temperature- Necessary for proper performance
(within a range)
• Time- Allow enough time to perform “kill”
• Coverage- Complete coverage of surface areas to
reduce micro levels
Coverage
ChemistryTemp
Time
Sanitizing Program
Coverage! Coverage! Coverage! Coverage!
WHAT A SANITIZER IS/DOES• Reduce microbial contamination to a safe
level
• Two Types:- No rinse food contact surface sanitizer
• Approved for incidental food contact
• Must be adequately drained from the surface
- Non-food contact surface sanitizer
• Usage restrictions:- Only prepare in potable water
- Do not reuse for sanitizing (prepare fresh)
- Use the accurate concentration• Below = Questionable efficacy
• Above = Violate regulatory approvals
A Sanitizer
Does NotSterilize
&
Disinfect
DoesReduce
contamination to
safe level
&
Surface sanitizer
kills 5 logs in 30
seconds at 25 C
DIRECTIONS FOR USE:It is a violation of Federal law to use this product in a manner
inconsistent with its labeling.
A World of Food SolutionsOSI Group, LLC.
World Headquarters | Aurora, Illinois, USA630.851.6600 | www.osigroup.com1
Assessing and Controlling
Microbial Risk Through Periodic
Equipment Cleaning
Presented by:
James T DavisCorporate Sanitation Manager
OSI Group
May 9th, 2018
A World of Food Solutions
Overview
Key Definitions
Food Safety Hazards
Periodic Equipment Cleaning Program
Brief Note on Heat Treatment
A World of Food Solutions
Key Definitions
1.) What is RISK?
Chance of injury, damage or loss; dangerous chance or hazard
A World of Food Solutions
Key Definitions
2.) What is a NICHE?
An area or point on a piece of equipment or infrastructure that has the
potential to harbor food particulate and/or microorganisms
Example: Mounting plate on forming machine
A World of Food Solutions
Key Definitions
3.) What is HYGIENIC DESIGN of equipment?
The state in which equipment is engineered to optimize product quality, food
safety and operational efficiency through the elimination of niche or harborage
areas and ease of cleanability.
Listeria present in a hairline scratch of the surface of
stainless steel
Key Point: Microorganisms are very
small and have the potential to reside in
“niche” areas in equipment – hygienic
design is key to eliminate these areas!!
A World of Food Solutions
Key Definitions
4.) What is PERIODIC EQUIPMENT CLEANING (PEC)?
A preventative measure by which processing equipment is disassembled and
cleaned beyond normal daily sanitation requirements to address identified
risks in hygienic design to remove food particulate and microorganisms in
niche areas
A World of Food Solutions
Food Safety - Hazards
Three types of hazards associated with equipment, relevant to equipment design:
1) Biological
- L. monocytogenes, E. coli, Salmonella, etc
- Pathogenic vs. Non-Pathogenic
2) Chemical
- Allergens, processing chemicals, etc
3) Physical
- Metal, wood, plastic, etc
A World of Food Solutions
Periodic Equipment Cleaning (PEC) Program
Steps of PEC Program Development
1.) Perform an equipment hygienic design risk assessment
2.) Identify gaps and add to master sanitation schedule (MSS)
3.) Implement PEC to address noted deficiencies/gaps
4.) Validate PEC tasks and frequency
A World of Food Solutions
Step 1: Assessing Risk
What are factors pertinent in determining risk?
1.) Product factors
2.) Process/Operational factors
3.) Equipment design factors
A World of Food Solutions
Step 1: Assessing Risk
Examples To Use When Assessing Risk
2017 3-A Workshop (PRODUCT RISK) – Hygienic Design Risks (Source: 3-A.org)
Source: http://www.3-a.org/Portals/57/Documents/Annual%20Meeting%20Presentations/2017/May%201%20Basics/May1_Basics_03_Workshop%201%20Risks.pdf?ver=2017-05-08-
103056-857
Key Point: Understand what
risk level is your product!
RTE > Raw
Exposed RTE > Cook-In-Bag
A World of Food Solutions
Step 1: Assessing Risk
1. Cleanable to a microbiological level
2. Made of compatible materials
3. Access for inspection, maintenance, cleaning and sanitation
4. No product or liquid collection
5. Hollow areas should be hermetically sealed
6. No Niches
7. Sanitary operational performance
8. Hygienic design of maintenance enclosures
9. Hygienic compatibility with other plant systems
10.Validate cleaning and sanitizing protocols
North American Meat Institute – 10 Principles of
Sanitary Design (EQUIPMENT RISK)
A World of Food Solutions
Step 1: Assessing Risk
Example: Quantifying Risk Using the NAMI Sanitary Design
Checklist and Guidance
Determine equipment design and acceptability from industry guidance
Source: https://www.meatinstitute.org/ht/a/GetDocumentAction/i/97261
A World of Food Solutions
Step 1: Assessing Risk
Example: Quantifying Risk Using the NAMI Sanitary Design
Checklist and Guidance
Assign a score to a specific equipment design using document guidance
A World of Food Solutions
Step 1: Assessing RiskExample: Quantifying Risk Using the NAMI Sanitary Design Checklist and Guidance
Set design acceptability rating by risk level type or when action is needed
Example Requirement
a.) High Risk Level (A) ≥ 90%
b.) Moderate Risk Level (B) ≥ 80%
c.) Low Risk Level (C) ≥ 70%
OR
Example Requirement
a.) High Risk Level requires redesign or action for all “Unacceptable” or “Marginal” items
b.) Moderate Risk may require redesign or action (validate and monitor)
c.) Low Risk Level may require action (validate)
OR
????
A World of Food Solutions
Step 1: Assessing Risk
Number Zone (s) Risk
Microbial
Risk
Chemical
Risk
Foreign
Material Risk
1 2 High Y Y
2 2 High Y YInsert Plugs
Pressed connection producing
uncleanable seam;
incompatible synthetic
material cracking under
normal use
Item Sanitary Design Issue
Covers
Bolted/gasketed connections
producing uncleanable seam;
evidence of frayed gasket
Microbial Intervention?
(Yes/No)
Yes
Yes Disassembled & Cook Weekly Replace *See Photos Below
*See Photos Below
Current Intervention Recommendations/WOs Comments
Disassembled & Cook Weekly
Replace during inspection if
compromised
Example:
A World of Food Solutions
Periodic Equipment Cleaning (PEC) Program
Steps of PEC Program Development
1.) Perform an equipment hygienic design risk assessment
2.) Identify gaps and add to master sanitation schedule (MSS)
3.) Implement PEC to address noted deficiencies/gaps
4.) Validate PEC tasks and frequency
A World of Food Solutions
Step 2: Identify Gaps and List in MSS
Gaps are identified sanitary design constraints from step 1
Example Gaps List:
A World of Food Solutions
Periodic Equipment Cleaning (PEC) Program
Steps of PEC Program Development
1.) Perform an equipment hygienic design risk assessment
2.) Identify gaps and add to master sanitation schedule (MSS)
3.) Implement PEC to address noted deficiencies/gaps
4.) Validate PEC tasks and frequency
A World of Food Solutions
Step 3: Implement PEC – Example PEC
Remove all belt supports and guides
Remove modular plastic belt
Remove all stand-off mounted items
Remove all bearings, pillow blocks, fasteners
Remove all adjustment arms
Remove spray devices (or caps when not in
use)
Remove all sprockets and rollers from shaft(s)
**All disassembled pieces placed in COP
tank - 160°F for 30 minutes with chemical
WEEKLY REQUIREMENT
A World of Food Solutions
Step 3: Implement PEC – Example PEC
Key Points• All removed parts and pieces MUST be disassembled as far as possible
• Inspect for damage while disassembled
• Take “BEFORE” cleaning and “AFTER” cleaning swabs (TPC/APC, Environmental)
A World of Food Solutions
Periodic Equipment Cleaning (PEC) Program
Steps of PEC Program Development
1.) Perform an equipment hygienic design risk assessment
2.) Identify gaps and add to master sanitation schedule (MSS)
3.) Implement PEC to address noted deficiencies/gaps
4.) Validate PEC tasks and frequency
A World of Food Solutions
Step 4: Validate PEC Tasks and Frequency
Goal: Determine efficacy of PEC cleaning process AND the longest period of time that the
selected equipment can go between deep cleaning cycles while maintaining hygienic conditions
Determine Efficacy of Cleaning Process (“AFTER” PEC)
1.) Utilize organoleptic methods (sight, touch, feel) to determine cleaning effectiveness upon completion –
similar to existing pre-op standards
2.) Utilize swabbing (TPC/APC, Environmental, ATP) post-sanitation
Determine Frequency of Cleaning Process (“BEFORE” PEC)
1.) Utilize swabbing (TPC/APC, Environmental, ATP) after disassembly but PRIOR to any cleaning
2.) Visual inspection for soil load
A World of Food Solutions
Step 4: Validate PEC Tasks and Frequency
Key to Remember!!
“Before” swabs are used to validate & verify frequency of PEC
“BEFORE” SWAB FAILURES MEANS YOUR FREQUENCY IS INADEQUATE
“After” swabs are used to validate & verify cleaning effectiveness
“AFTER” SWAB FAILURES MEANS YOUR CLEANING IS INADEQUATE
You NEED to take both!
**Visual inspection SHOULD also be used during this time
A World of Food Solutions
Step 4: Validate PEC Tasks and Frequency
Key Points
• Set limits for acceptability
• Examples:
• APC: ≤ 100 CFU
• Listeria: Negative
• Determine what frequency should
be based on data
• Example
• Week of failure point (APC)
minus 1 week
• All PEC tasks should have a
validated frequency
A World of Food Solutions
Brief Note on Heat Treatment & PEC
1.) Heat treatment can be utilized in combination with deep teardown events to
enhance the hygienic conditions of the equipment or component in question.
2.) Several options available for heat treatment
A. Batch Smokehouse/Oven
B. COP Tank
C. Tent Steaming
3.) Important Factors
A. Time (Target minimum 30 minutes – Need to VALIDATE!)
B. Temperature (165-185°F – Need to VALIDATE!)
C. Humidity (Saturated steam/heat!)
D. Disassembly (More disassembly = less heat penetration needed)
A World of Food Solutions
Brief Note on Heat Treatment & PEC
Use of steaming may reduce frequency of extensive teardowns (PEC
events) for complex equipment
Time efficiency
Limitations of heat intervention
Does NOT replace extensive teardown (PEC events) but compliments
Soils still present in niche areas!
A World of Food Solutions
Questions or Comments?
Thank You!
James T DavisCorporate Sanitation Manager
OSI Group