Avoiding pathogenic risks is a high priority for all in the food industry. Proper cleaning practices remains one of the most effective ways to prevent contamination in your facility remains.
This article discusses some typically underestimated locations in food factories when it comes to microbial contamination dangers and cleanliness. While we concentrate on food factories, these zones can also be applied to cold stores, distribution facilities, retailers, and restaurants.
Unclean food processing facilities can harbour microorganisms that cause food spoilage and poisoning 2. This is due to nutrients and moisture in the food, which, when combined with a favourable environment (pH, temperature, and oxygen level, etc.), promotes microbial growth, either in the food directly or in the environment, where cross contamination is a concern. Unclean food processing surfaces provide a favourable setting for microbial proliferation. When food comes into contact with contaminated surfaces, microorganisms transfer to the food. This is referred to as cross-contamination.
What areas should you ensure you are checking?
1. Your People
Ensure that all personnel understand their role in the significance of cleaning and sanitizing2.
Pathogenic microorganisms surround us. For instance, Listeria Monocytogenes which can be found in the dust on the floor 5. In such situations, Listeria monocytogenes travels often via footwear, highlighting the need of boot washing as a prerequisite for entering the clean production area.
Training, reminding, routines and record keeping can help reinforce the necessity for personal hygiene3. When people are engaged in the production process, there is always the possibility of product contamination. Personal hygiene can help to lower these risks by keeping personnel clean and safe. Hand washing, for instance, is often underestimated, yet it might be the difference in a good vs contaminated batch 3. Good hand-washing patterns can also help to keep the flu and other germs from spreading through the workplace.
2. Filling and other Food-contact Equipment
Avoid sites and materials where microorganisms might lodge and proliferate in production equipment 5. Any areas that can be adequately cleaned and disinfected using the CIP system are generally safe since this operation requires that all surfaces be smooth and easy to clean. This includes details like having no crevasses or only smooth surfaces, as well as always having angles that are more than 90 degrees.
Microorganisms typically accumulate in sites on equipment that require manual cleaning, have crevasses, and commonly involve standing water (or show evidence thereof, like calcite deposits 5. Regardless of water use, the design of the equipment must be water-wise. Avoid using water wherever feasible, unless during cleaning procedures.
Even while cleaning, avoid using high-pressure water hand spraying devices, as these might generate aerosols or facilitate in further embedding contaminants in crevices. These aerosols are vectors for microbiological contaminants, which might lead to their dissemination throughout the plant.
Filling nozzles, O-rings, or dead ends can be a problem in any food business, such as the restaurant industry or those that employ aseptic filling technology, sprayers, or pipelines 7. When was the last time these were all identified, dismantled, and cleaned?
Most common filling nozzles and O-rings are simple to unscrew and clean, however they are frequently neglected, allowing a multitude of microbes to accumulate, form biofilms, and eventually affect the product's quality or safety 7.
3. Behind and Under Equipment
Personnel may perform great work with cleaning on and around equipment, tables and booths, service stations, etc., but often disregard the regions in between, allowing for filth accumulation 7. Ensure that equipment and furniture are displaced from their typical locations and away from walls (especially in restaurant settings) so that any hard-to-reach areas may be cleaned thoroughly. Additionally, have employees double-check each other on these duties.
4. The Floor
Like other localities of a food facility, flooring can harbour a variety of contaminants 6. As personnel enter or roam the facility, these contaminants (including microbes and allergens) can become airborne and can thus migrate to and settle in other regions of the establishment, resulting in widespread contamination concerns 6.
Unless cleaning, strive to keep the manufacturing floors dry at all times as most food pathogens need water for survival 5.
Cleaning the facility's flooring is a multi-step operation 6 :
- First, is sweeping 6. Dust and other particles may contaminate surfaces and attract pests if left unattended. Sweeping creates a cleaner surface for applying cleaning chemicals, thereby enhancing their effectiveness.
- Next, apply cleaning agents per the instructions 6. Using elbow grease helps the agents penetrate all cracks and dislodge any stubborn residues.
- After rinsing away the cleaning agents, sterilize the floor to conclude the cleaning procedure.
Consider investing in your facility's water management 5. This might include the following:
- Transport water from the production lines to the drain via closed pipes 5. This helps to prevent splashes, spills, pest infestations etc. However, do not enter the pipe directly into the drain, as this might cause microorganisms from the drain to migrate into the pipe. Furthermore, ensure that the pipes are cleaned frequently.
- The flooring should slope toward a drain, with the drain being the lowest point 5. This prevents stagnant water pools, which pose a danger for microbiological and other contamination issues (e.g., flies, slippery chemicals etc).
If a product is spilled on the floor, do not flush it with excessive water 5. Rather, use a brush and scoop or paper towel to wipe up the spill. Only then consider using water (and, if required, cleaning agents) to remove any remaining product from the floor, ensuring that no slippery residue remains.
5. Drains
Facility floor drainage systems must also be kept clean and hygienic 6. Despite being a prominent reservoir for microbial growth and contamination, facility drainage systems are often overlooked. In a dirty drain, pathogens could survive and proliferate, ultimately contaminating other areas of the facility.
Installing proper, hygienically designed drainage in the correct localities is crucial 5. Drains in food processing plants typically act as a magnifying glass for the factory's biodiversity 5. This is due to all the unclean (and cleaning) water expelled through the drains. Moreover, many facilities' drains are not of proper sanitary design, resulting in an accumulation and environment that permits microbial entry and proliferation.
Lastly even with a hygienic design, the drainage system must still be maintained in a sanitary and clean condition 5. Inserting a chlorine tablet into the drains after each cleaning session or large water outflow is one way to do this. This will keep any potential standing water in the drains clean and sanitary.
6. Time-Temperature… and the Fridge?
It is a well-known fact that temperature affects food production 3. Where temperatures that are too warm (but not hot enough) for insufficient periods foster undesired microbial development, posing a possible safety concern. Good practices with this include keeping food outside the danger zone of 5 to 60 °C. Being cautious of food and surrounding (storage and production) temperatures and whenever feasible, recording temperatures routinely.
That being said. Keeping the fridge or freezer clean should not be neglected. Freezers and cooling systems are recognized hiding places for pathogens such as Listeria monocytogenes 5; Inside every freezer and refrigerator are evaporation plates 5. These plates are regularly defrosted automatically to minimize excess ice accumulation. Typically, there is a fan located behind the evaporation plates that forces air over the plates, thereby cooling it as it enters the holding container (the fridge or freezer).
Cleaning of these evaporation plates should be part of routine maintenance 8. Nevertheless, it has been suggested that more frequent cleaning, possibly employing automated cleaning technologies, be investigated to better maintain evaporator cleanliness 8.
Another component of the cooling system is the fan 5, which generates airflow and serves as a vector for aerosol contamination. Maintaining the cleanliness of these plates and fans at all times is crucial for preventing the spread of pathogens that can survive at low temperatures, such as Listeria Monocytogenes, which can remain viable at -5 °C. This is an often-overlooked area, yet there are companies that have developed specific cleaning solutions and foams for such applications.
7. The Air and Air Handling
Like cooling systems, the facility’s air handling system may employ evaporation plates to regulate air temperature 5. Consequently, the same measures must be taken when maintaining the air handling system as was addressed in the cooling systems.
For air handling systems, air ducts are an additional factor to consider 5. This includes the possibility of water accumulation due to condensation within the air ducts or air vents accessing the facility. After a manual cleaning of the facility and when there is excess water in the air, it is advisable to do a borescope inspection to determine whether there is water build-up in the air handling system.
Additionally cover open tanks 3. When it comes to cleaning and preventing contamination, processing food in open tanks or containers presents recognizable concerns. As a result, having and using coverings on these tanks may be of significant assistance in preventing contamination, while also demonstrating your proactive dedication to food safety.
8. Blades
The previous two points can be extended to almost all machinery or equipment with blades 8. Ideally, most bladed devices, such as bowl cutters8, should be dismantled for cleaning. However, this is frequently not the case for several reasons that we will not discuss here.
To make the operation easier and more frequent 8, a brush with a hand guard that protects employees can facilitate in-place cleaning of dangerous bladed- apparatus (think supermarket ham slicers).
9. What Walls?
When was the last time your facility's walls were thoroughly cleaned and inspected? Filth does not emerge as rapidly on walls, and even if it does, it is not felt or perceived to be 'in the way' as it is on floors 7. Hence many production facilities, kitchens, and restaurants tend to overlook these when addressing cleanliness and tidiness.
Walls may collect a considerable quantity of filth, including significant microorganisms, despite their vertical orientation 7. In turn, this raises the possibility of cross-contamination concerns. This is especially relevant in facilities with equipment and appliances that can spatter oil or other food particles.
In food production facilities, high walls might provide particular challenges 8. Even with a ladder, standard handles or brushes will not reach all the way up a factory's walls (and hold other safety dangers that are best to avoid). If this is the situation at your facility, you may want to invest in a telescopic handle to clean walls.
Ensure that the handles you select are easily adjustable as needed 8. Ideal handles should be hollow or made of a lightweight material (that’s food grade) to reduce weight for worker comfort and making longer handles simpler to manage. When considering the many alternatives or styles, keep in mind that you do not want your cleaning tools to become a source of contamination, thus ensure they can also be easily cleaned without crevasses that will allow for microbes to become lodged and proliferate.
10. Light Fixtures and Ceilings
Like the walls, ceilings are frequently overlooked since the filth and dust that accumulates there is not readily apparent 7. A dusty, unclean, peeling paint or stained ceiling, on the other hand, can indicate the reduced the air quality in the facility, impacting the food and everyone's health.
Maintaining a clean ceiling and routinely dusting fans, light fixtures, and other fixtures should be part of the routine housekeeping and deep cleaning procedures.
11. Outdoor Waste Disposal Sites (and responsible waste removal)
As a food organization, every employee is obligated to do everything necessary to maintain product safety, this includes safeguarding trash and disposing of it appropriately 7, 8, 9. To maintain food safety, proper waste disposal, storage, and removal procedures must be in place 7, 8. This is significant since discarded food can still attract a multitude of microorganisms and pests. If not managed effectively, this could result in cross-contamination or pest infestations.
In South Africa, food security is a continuing concern, and many people go hungry daily 9. Many of these individuals rely on scavenging food from dustbins, landfills, and wastes sites to survive. This is a heart-breaking reality in that not all have the luxurious right to safe food.
Unsafe food, on the other hand, cannot be served or repurposed for consumption and must be discarded 9. However, after rubbish is removed from the kitchen or production floor, it is frequently forgotten 7. Consequently, the exterior waste area is frequently overlooked since it is out of sight and, consequently, out of mind during ordinary cleaning operations.
Infestations are difficult to eliminate and should be avoided 7. The same holds true for anyone who might fall into depending on the unsafe, discarded food (even without your knowledge). For this reason, it is essential that this area be maintained in a secure, clean, and orderly manner. Additionally bind should be frequently decontaminated and their lids securely fastened. Revaluating and reducing food waste would not only save money but would also minimize pest infestations and microbiological harbourage sites.
Instead of being sent to landfills, food waste should be incinerated when possible 10. While there are alternatives to incineration, it is still your responsibility to ensure that protocols are followed and that records are maintained to prevent additional contamination or damage by animals or humans who may have attempted to feed on the discarded materials.
12. Involve all Personnel, providing facilities
Maintaining quality, and therein sanitation, in a food processing facility is everybody’s job 1. Even those who do not partake in the sanitation operation should be aware of its significance and understand the influence of their actions. This originates with management ensuring that sanitation teams have enough time, training, personnel, gear, cleaning agents, and potable water to do their jobs.
Involving everyone (from the newest employee to the CEO) also contributes to the development of a cleaning culture in which maintaining a clean workplace is more than a task 3. Everyone who enters the facility is responsible for maintaining its cleanliness and orderliness, both on the production floor and in the offices.
Furthermore, all personnel, irrespective of their core responsibilities, should feel comfortable approaching management to report any possible contamination, sanitation issues among other concerns 3. Not only is cleanliness (and tidiness) important for food safety, but a cleaning culture that incorporates this also improves staff safety, productivity, and morale 3. - Consider the broken window effect 4.
13. Clean, Neat and Tidy
Maintaining a tidy place involves eliminating clutter, which can contribute to an unclean and unsafe workplace 3. Clutter invites dust to accumulate, which could result in contamination as well as uncontrol, particularly if it is not dealt with promptly. Set aside separate storage locations, preferably away from the primary production line. Additionally, as a safety precaution, keep primary traffic routes clear and ensure that items in overhead storage are secure.
A dirty manufacturing line can cost thousands to restore, with added expenses if the contaminated product is to be destroyed 3. To ensure the seamless running of your operation, spend some time developing and implementing a system where housekeeping is continuous.
References
- (n.d.). 10 Best Practices for Cleaning and Sanitation in the Food Industry. Retrieved September 12, 2022, from https://blog.decon7.com/blog/10-best-practices-for-cleaning-and-sanitation-in-the-food-industry
- 2, & Ontario. Ministry of Agriculture, F., and R. Affairs. (2006). Food of plant origin: cleaning & sanitation guidebook.
- (n.d.). Quick Guide to Keeping Your Food Processing Facility Clean - FoodSafetyTech. Retrieved September 19, 2022, from https://foodsafetytech.com/column/quick-guide-to-keeping-your-food-processing-facility-clean/
- 4, van der Weele, J. J., Flynn, M. P., & van der Wolk, R. J. (2017). Broken Window Effect. Encyclopedia of Law and Economics, 1–4. https://doi.org/10.1007/978-1-4614-7883-6_624-1
- (n.d.). The 5 Most Common Places Where to Look for Listeria Monocytogenes - Food Safety Experts. Retrieved September 15, 2022, from https://www.foodsafety-experts.com/food-safety/listeria-monocytogenes-2/
- (n.d.). The Importance Of Clean Drainage In Food Manufacturing Facilities | FoodSafe Drains. Retrieved September 15, 2022, from https://foodsafedrains.com/blog/the-importance-of-clean-drainage-in-food-manufacturing-facilities
- (n.d.). 7 Surprisingly Common Areas Restaurants Forget to Clean | The Specialists. Retrieved September 18, 2022, from https://thespecialists.co.za/2017/11/10/7-surprisingly-common-areas-restaurants-forget-clean/
- (n.d.). Common Food Industry Cleaning Problems Solved. Retrieved September 19, 2022, from https://www.vikan.com/us/services/vikan-blog/common-food-industry-cleaning-problems-solved
- (n.d.). Why your hospital should worry about proper food waste disposal. Retrieved September 19, 2022, from https://blog.initial.co.za/why-your-hospital-should-worry-about-proper-food-waste-disposal
- (n.d.). FOODStuff SA | Responsible disposal of waste products in the SA food industry. Retrieved September 19, 2022, from https://www.foodstuffsa.co.za/responsible-disposal-of-waste-products-in-the-sa-food-industry/
