Engineering Properties of Biological Materials and Food Quality 3(2+1)

Lesson 32.Cleaning And Sanitizing

32.1 Cleaning

Cleaning is the process of removing food and other types of soil from a surface, such as a dish, glass, or cutting board. Cleaning is done with a cleaning agent that removes food, soil, or other substances. The right cleaning agent must be selected because not all cleaning agents can be used on food-contact surfaces. (A food-contact surface is the surface of equipment or utensil that food normally comes into contact.) For example, glass cleaners, some metal cleaners, and most bathroom cleaners cannot be used because they might leave an unsafe residue on the food contact surface. The label should indicate if the product can be used on a food-contact surface.The right cleaning agent must also be selected to make cleaning easy. Cleaning agents are divided into four categories:

•  Detergents – Use detergents to routinely wash tableware, surfaces, and equipment. Detergents can penetrate soil quickly and soften it. Examples include dishwashing detergent and automatic dishwasher detergents.
• Solvent cleaners – Use periodically on surfaces where grease has burned on. Solvent cleaners are often called degreasers.
• Acid cleaners -- Use periodically on mineral deposits and other soils that detergents cannot remove. These cleaners are often used to remove scale in warewashing machines and steam tables.
• Abrasive cleaners -- Use these cleaners to remove heavy accumulations of soil that are difficult to remove with detergents. Some abrasive cleaners also disinfect.

 Clean food-contact surfaces that are used to prepare potentially hazardous foods as needed throughout the day but no less than every four hours. If they are not properly cleaned, food that comes into contact with these surfaces could become contaminated.

32.2 Sanitizing

Sanitizing is done using heat, radiation, or chemicals. Heat and chemicals are commonly used as a method for sanitizing in a restaurant; radiation rarely is. The item to be sanitized must first be washed properly before it can be properly sanitized. Some chemical sanitizers, such as chlorine and iodine, react with food and soil and so will be less effective on a surface that has not been properly cleaned.

32.2.1 Sanitizing Methods

• Heat. There are three methods of using heat to sanitize surfaces – steam, hot water, and hot air. Hot water is the most common method used in restaurants. If hot water is used in the third compartment of a three-compartment sink, it must be at least 171oF (77oC). If a high-temperature warewashing machine is used to sanitize cleaned dishes, the final sanitizing rinse must be at least 180oF (82oC). For stationary rack, single temperature machines, it must be at least 165oF (74oC). Cleaned items must be exposed to these  temperatures for at least 30 seconds.

• Chemicals. Chemicals that are approved sanitizers are chlorine, iodine, and quaternary ammonium.

Chemical Sanitizers

Different factors influence the effectiveness of chemical sanitizers. The three factors that must be considered are:

• Concentration -- The presence of too little sanitizer will result in an inadequate reduction of harmful microorganisms. Too much can be toxic.

• Temperature -- Generally chemical sanitizers work best in water that is between 55oF (13oC) and 120oF (49oC).

• Contact time -- In order for the sanitizer to kill harmful microorganisms, the cleaned item must be in contact with the sanitizer (either heat or approved chemical) for the recommended length of time.

32.2.2 Sanitizer Testing

Every restaurant must have the appropriate testing kit to measure chemical sanitizer concentrations. To accurately test the strength of a sanitizing solution, one must first determine which chemical is being used -- chlorine, iodine, or quaternary ammonium. Test kits are not interchangeable so check with your chemical supplier to be certain that you are using the correct kit. The appropriate test kit must then be used throughout the day to measure chemical sanitizer concentrations.

32.2.3Machine Warewashing

Most tableware, utensils, and other equipment can be cleaned and sanitized in a warewashing machine. Warewashing machines sanitize by using either hot water or a chemical sanitizing solution.

•  Check the machine for cleanliness at least once a day.

•  Make sure all detergent and sanitizer dispensers are properly filled.

•  Scrape, rinse, or soak items before loading them into the machine.

•  Load racks correctly and use racks designed for the items being washed.

•  Check temperatures and pressure at least once a day.

•  Check each rack as it comes out of the machine for soiled items.

•  Air-dry all items.

•  Keep your warewashing machine in good repair.

32.2.4 Cleaning and Sanitizing in a Three-Compartment Sink

1. Rinse, scrape, or soak all items before washing them in a three-compartment sink.

2. Wash items in the first sink in a detergent solution that is at least 110oF (43oC).

3. Immerse or spray rinse items in the second sink using water that is at least 110oF (43oC).

4. Immerse items in the third sink in hot water or a properly prepared chemical sanitizing solution.

5. Air-dry all cleaned and sanitized items before storing them.

32.2.5 Cleaning In Place Equipment

1. Turn off and unplug equipment before cleaning.

2. Remove food and soil from under and around equipment.

3. Remove detachable parts and manually wash, rinse, and sanitize them or run through awarewashing machine.

4. Wash and rinse all other food-contact surfaces that you cannot remove, then wipe or spray them with a properly prepared chemical sanitizing solution.

5. Keep cloths used for food-contact and non-food-contact surfaces in separate properly marked containers of sanitizing solution.

6. Air-dry all parts, then reassemble.

7. Resanitize food-contact surfaces handled during reassembly.

32.3. Storing Utensils, Tableware, and Equipment

Improperly storing cleaned and sanitized equipment, utensils, and linens could allow them to become contaminated before they are used again. Contamination can be caused by moisture from flooding, drips, or splash. Food debris, toxic materials, litter, dust, and other substances might also cause it.

32.3.1. Using Chemicals

Separate chemicals from food, equipment, utensils, linens, and single-use items. If chemicals are stored directly above or next to any of these items, they could spill onto the item and contaminate it. Only buy chemicals approved for use in a restaurant or food establishment. Store chemicals in their original container away from food storage and food preparation areas. If a chemical is transferred to a new container, label the container with the chemical name, manufacturer's name and address, and potential hazards of the chemical.Material Safety Data Sheets (MSDS) are one way that chemical manufacturers provide hazard information to users, such as foodservice workers.

32.4. Sanitary Facility Design

A general understanding of process and facility sanitation is important for the successful manufacturing of food products. When a new facility or process is designed, sanitation standards can be built-in. Good sanitation practices will improve product quality, minimize maintenance efforts, please inspectors and delight clients.

32.4.1 Building Exterior

Design and construct the establishment so that the internal environment is protected from external contaminants. Ensure the establishment (e.g. walls, roof) is of a sound construction and is maintained in good repair (e.g. no evidence of damage). Take steps to prevent or minimize the entrance and harbourage of pests, insects and contaminants (e.g. no holes or unprotected openings, weather stripping on exterior doors). Cover air intakes and openings or equip them with appropriate screens.

32.4.2.Cross-contamination Control

Separate operations that have the potential to cause cross contamination by physical partition, by work area designation, by designated equipment or by other effective means.

32.4.3. Personnel Facilities

Washrooms, change rooms and lunch and break areas(s) are provided and maintained to ensure that personal hygiene can be maintained to protect the safety and suitability of food. Washrooms are equipped with adequate lighting and an adequate number of flush toilets and hand-washing stations; are free of condensation, excess moisture or odours; and are designed to prevent or minimize contamination.

32.4.4. Internal Structures and Fittings

Internal rooms, structures and fittings are suitable and are maintained for the operations taking place within. Floors, walls, ceilings, overheads, doors, windows, stairs and other structures are cleanable, properly maintained, exhibit no evidence of degradation that would cause  contamination and are suitable for the activities in each area. The condition of internal rooms, structures and fittings protects the safety and suitability of food.

32.4.5. Lighting:

Ensure lighting levels are adequate to properly complete the tasks performed in each area (e.g. product inspection, sanitation, maintenance, visual examination of rooms).  Ensure light sources do not alter the natural colour or appearance of food where food assessments are performed.

32.4.6. Lighting Fixtures:

Light bulbs and lighting fixtures in areas of exposed food, ingredients, packaging materials or food contact surfaces are equipped with shatterproof bulbs or breakage shields to prevent or minimize contamination of food if breakage occurs.

32.4.7.Air Quality and Ventilation

The establishment has and uses ventilation to keep rooms free of excessive heat, humidity, steam, vapours, smoke, particulates and condensation. Ventilation openings have screens or filters that can be easily cleaned or changed. Ventilation systems do not permit air to flow from contaminated areas to clean areas.

32.4.8. Drainage and Sewage Systems

The establishment has and uses drainage and liquid waste disposal systems that are maintained to protect the safety and suitability of food and the potable water supply. Drainage and liquid disposal systems are equipped with back-flow preventers and no cross-connections exist with drainage or waste systems and potable water lines. Pooling of water and liquids is prevented or addressed.

32.4.9. Equipment Design, Construction and Installation

Equipment and utensils that may impact on food safety are constructed of nontoxic materials, exhibit no signs of degradation that could contaminate food, and are easy to clean, sanitize and maintain. Equipment design, location, construction and installation promote effective assessment, maintenance, and cleaning and sanitizing activities. Adequate equipment or facilities are available for the activities conducted to protect the safety and suitability of food. Equipment functions in accordance with its intended use.

32.4.10. Waste Containers and Utensils

Containers and utensils used for collection and holding of waste and inedible or hazardous substances are clearly identified, function properly, exhibit no signs of degradation that could lead to the contamination of food and can be cleaned and maintained. Containers and utensils are cleaned prior to entering food processing, handling or storage areas.

32.5. Pest Control and Sanitation

Control of pests and use of pesticides are particularly critical in places where food is prepared, served or packaged. Most industries and institutions (such as schools and hospitals) are inspected for sanitation by one or more state, federal or local agencies. 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; ...”

32.5.1. Importance of Pest Control

Pests are attracted to food premises since they are an ideal habitat in which to live and reproduce. Since pests pose a significant health risk, pest control is extremely important. Inadequate control can lead to pest infestation and serious consequences to consumer health.Besides potential health risks, pest infestation will inevitably lead to significant waste and, therefore, commercial loss. The loss caused by pest infestation of raw materials or the finished product can be large.

32.5.2.Hazards Posed by Pests

Food products are at a high risk of contamination if control measures are not in place. Pests are carriers of food poisoning microorganisms and viruses that pose major hazards to consumer health. In addition to the contamination by microorganisms and viruses, pests can also contaminate food with

• hair

• fur

• droppings/urine

• eggs

• dead bodies.

Certain pests, rodents in particular, can also cause significant damage to a factory by, for example, chewing through electrical wires and causing fires.

32.5.3Types of Pests

There are many different types of pests that can pose a risk to human health or the commercial viability of your company. These include

• rats

• mice

• insects – cockroaches, flies, ants

• stored product pests – larder beetles, weevils, flour moths

• reptiles – lizards

• birds

32.5.4. Habitats of Pests

Pests require certain conditions to survive and reproduce:

• security

• shelter

• food

• water

As a food safety manager, you must understand what conditions allow pests to survive and reproduce. If you aren’t fully aware of what these circumstances are, you business will suffer contamination and loss that may make the business no longer sustainable.

32.5.5.Prevention

Once pests have entered your factory, it is difficult to control and totally eliminate them, particularly if there is an infestation. You must prevent their invading your factory or facility!

Preventing any and all ingression of pests will be commercially more cost-effective than continually eliminating pest infestation.

The control of prevention of ingression of pests requires

• proofing the premises

• monitoring for signs of infestation

• practicing good hygiene.

32.6. Conditions to Minimise the Risk of Pest Ingression

Effective proofing of your factory premises is the preferred method for control of pests. Doors and windows pose the highest risk of ingression; thus a door and window closure policy should be introduced. Other methods may need to be considered: fine mesh screens for windows and doors, self-closing mechanisms on doors, and plastic curtains on internal and external door openings. Rodents can enter a factory through the smallest of openings, so any gap under doors should be covered with a metal plate. To prevent flying insects, reptiles, or birds, any  holes or openings in the fabrication of the factory must be filled with mortar or covered with metal/plastic sheets or mesh.

32.6.1. Awareness of Infestation

As the food safety manager, you must make sure all staff members are aware of signs of pest infestation and possible entry points. They should also be aware of the importance of reporting the presence of any possible infestation right away. Signs to look for are

• live animals

• dead animals

• droppings

• damaged packaging

• smell

• smears/discolouration of walls

• larvae/pupae

• eggs

• webbing

• piles of debris

• holes in fabrication.

32.6.2. Good Hygiene Practices

Denying pests food and shelter in your facility is another way of preventing infestation. This can be achieved by practicing good hygiene practices, effective cleaning, and proper waste disposal.

By using good hygiene practices, your staff is removing the food and shelter pests need to survive. All staff should be aware of these good hygiene practices:

• Keep the factory clean.

• Have proper waste control.

• Be sure food in preparation areas is kept covered.

• Clean spillages quickly and effectively.

• Be sure no food is left outside the facility.

• Keep food stored off the floor and away from walls.

• Be sure raw materials are checked upon intake and during storage.

• Be sure food is stored in pest-proof containers.

• Keep drains clean and screened.

• Allow no external shelter.

32.6.3. Control of Pests

Prevention methods should protect you from the ingression of pests; however it is a good practice to ensure there are control measures in place to minimise the risk of pest infestation in your factory.

As a food safety manager, you have a responsibility to ensure control measures are in place.

There are two types of pest control:

• Physical

• Chemical

Both types are designed to control specific types of pests, but by their very nature they should be correctly used since they themselves could pose a risk to your product or staff.

Physical Control

Physical means of control is usually the preferred option. By their very nature, however, physical means of control are not always 100% effective, a point that should be very seriously considered. In the event of a significant infestation, physical controls cannot cope with the numbers of pests, so alternative methods of elimination must be considered.

Typical physical control methods include

• electric fly killers

• rodent traps

• sticky fly strips

• curtains

• bird screens

• pheromone traps.

Since several of these methods will actually kill pests, you should consider the location and placement of control mechanisms such as electric fly killers and sticky fly traps in order to avoid possible product contamination.

Chemical Control

Chemical control measures are much more effective than physical control methods: however, chemical substances do pose possible risks to staff, so their use should be frequently and carefully controlled and monitored. Chemical substances also pose a risk to food contamination, so they should also be used only under controlled and monitored conditions.

Because of the risks involved, it is good practice to employ a professional to carry out chemical pest control.

Chemical controls include

• rodenticides

• insecticides

• fumigates.

Conclusion

Proper sanitation practices will contribute to improved product quality and wholesomeness and the “bottom line” of the companyAll sanitation practices must be individually developed to suit the particular facility and process of concern. Maintenance and development of sanitary conditions are an ongoing process, to be continually evaluated an improved.