Foreign Inspection Program Reviews Revised April2007

Sanitation’s Major Role in
Food Safety
Romania
July 2007
HACCP Consulting Group, L.L.C. 1

Importance of Sanitation
 Single MOST important element in Food
Safety
 Sanitation failures – the most frequent basis
for regulatory action (including plant
closures)
 Sanitation standards – the most difficult
challenge for international trade (for
industry & regulators)

During this Session
 Take a more detailed look
 May skip some slides but keep as reference

in handouts
 Use some photos, most taken in meat or

poultry plants

HACCP
Sanitation Standard Operating

Procedures (SSOP’s)
Prerequisite Programs/GMPs
Sanitation Performance Standards
Management Commitment

Management Commitment
 Detailed planning
 Appropriate resources
 Employee empowerment
 Commitment communicated throughout
the company
 Commitment for continued maintenance
of plant programs (SPSs, SSOP, HACCP)

PREREQUISITE PROGRAMS
GMPs
SANITATION PERFORMANCE
STANDARDS
(SPSs)

Prerequisite
Programs/GMPs/SPSs
 Describe industry practices or activities
 May not be plant specific or job specific
 Programs need to be in writing,

monitored and records maintained

Prerequisite
Programs/GMPs/SPSs
“Universal Steps or Procedures That
Control The Operational Conditions
Within A Food Establishment
Allowing For Environmental
Conditions That Are Favorable To
The Production of Safe Food.”

FSIS DIRECTIVE 11,000.1
Sanitation Performance
Standards (SPSs)

Performance Standards
 Grounds and Pest Control
 Construction
 Lighting
 Ventilation
 Plumbing and Sewage

 Dressing Rooms/Lavatories
 Equipment/Utensils
 Sanitary Operations
 Employee Hygiene

– Grounds must be maintained to

prevent conditions that could lead to
unsanitary conditions, adulteration of
products or interfere with inspection
by FSIS

– Program to prevent harborage and breeding
of pests
– Pest control substances must be safe and
effective
– Substances must be applied and stored to
prevent unsanitary conditions
– Inspector may request written designation of
plant boundaries

Pest Control
 Goal – Maintain Pest Free Facility
 Written Program
 Keep Records
 Outside Contractor may be best approach

Pest Control
Facility Sanitation
 Avoid Situations that Attract/Support Pests
Removal of Sources of Food and Water
Removal of Trash
Cutting Weeds
Remove Unused Equipment & materials
Clean Lockers & Welfare Facilities
Cooperation from Adjacent Property Owners

Pest Control: Plant
Maintenance
 Create Barriers to Entry of Pests
 Equipment & Facilities Repair or Replace
 Floors, Walls, Ceilings – Suitable Tight Fitting
Materials
 Broken Areas, Cracks & Separations – Seal
 Possible Access – Correct Immediately
 Floor Drain Covers In Place
 Openings, Doors, Windows – Screened, Tight Fitting

Pest Control: Written
Program
 Program Should Include
Map/Chart with Location of Bait Boxes, Traps,
etc.
List of Materials Used and Areas Treated
(Include copies of approved labels)
Identify Commercial Exterminator – if used

Pest Control: Written
Program
 Program Should Include
Map/Chart with Location of Bait Boxes, Traps,
etc.
List of Materials Used and Areas Treated
(Include copies of approved labels)
Identify Commercial Exterminator – if used

Pest Control: Written II
 Description of Controls: Where, When
Bait Boxes
Traps
Sticky Boards
 Information on Bait Boxes
Sequentially Numbered
Name/Type of Poison – words “Rodent Bait”
Name/Phone# of Exterminator

Insect Control - Written
 Describe Controls – Where and When

Electronic Insect traps
Sticky Boards/Strips
 Describe Insecticides Used – Where, When,
How
Non-Residuals
Residuals

Pest Control: Verification
 Routine Audits
 Identifyand Document All Deficiencies
 Pest Control File to Contain
Written Program
Weekly & Daily Reports
Commercial Exterminator’s Reports
Maps and Charts

Pest Activity: Non-Product
Areas
 Document
 NotifyOfficials
 Survey of Premises
 Determine if Commercial Exterminator
Needed

Pest Activity: Product Areas
 Before Operations
Determine Source and Extent
Rid Area of Pests
Clean and Sanitize Area
Implement Corrective/Preventive Actions
Document

Pest Activity: Product Areas II
 During Operations
Stop Operations
Protect Product
Eliminate Pests
Determine Source
Take Corrective Action
Document

 Construction
Buildings, their structures, rooms &
compartments must be of sound
construction, good repair and
sufficient size
Walls, floors,& ceilings must be built

of durable materials and be cleaned
and sanitized as necessary

 Construction
– Walls, floors, ceilings, doors, windows & other
openings must be constructed and maintained to
prevent entry of vermin (e.g., flies, rats and mice)
– Rooms in which edible product is processed,

handled or stored must be separate and distinct
from inedible product areas to the extent
necessary to prevent product adulteration

 Lighting
– Lighting of good quality and sufficient intensity to

ensure sanitary conditions are maintained and
provided in areas where:
 Equipment and utensils are cleaned

 Food is processed, handled, stored or examined
 Hand-washing areas, dressing and locker rooms and

toilets

 Ventilation
– Ventilation must be adequate to
control odors, vapors, and
condensation to the extent necessary
to prevent adulteration of product
and the creation of unsanitary
conditions

 Ventilation
While ventilation will not be able to
completely eliminate all odors, vapors and
condensation, it must control them as far
as necessary to prevent adulteration of
product or the creation of unsanitary
conditions

Condensation – Definition
 Condensate is the free moisture formed on a
surface or in the air when there is too much water
vapor for the air to hold.
 Condensation is the process by which condensate
is created.
 Condensate is formed only when the temperature
of the air or surface is below the dew point of the
surrounding atmosphere.

Condensation (2)
 A very common problem
 Often a critical finding in audits
 Plants often have all the elements needed
– Warm moist air
– Operations with huge temperature variations
from cooking to freezing
– Poorly designed airflow patterns

Condensation, – Post Clean-up
(3)
 Generated by wet cleaning process

 Often directly over product contact surfaces
 MUST be removed prior to the start of
operations

Condensation (slide 4)
 When condensate forms in air, it becomes
fog or rain.
 When condensate forms on a surface, it
wets it.
 If the condition persists, the moisture
accumulates – beads into drops and falls

 Water is a solvent for some materials
 Becomes a vehicle for carrying soluble and
particulate matter.
 Condensate tends to take on the character of
its environment. (including its microbes)

 Beaded and falling moisture mostly from
water vapor condensed on rails, pipes,
ceilings, or structural members is a common
problem in meat and poultry plants.
 In red meat plants may be most severe in
the hot carcass cooler

 Hot, moist carcasses from the slaughter
department entering a cold environment.
 Cool air passes across the carcasses
 Picks up the available heat and/or moisture
 Returns to the cooling unit to give up that
heat and/or moisture and repeat the cycle.

 Significantly different air characteristics

from place-to-place within the cooler
 Condensate generally forms in only some

areas rather than the entire cooler

Condensation – controls in
cooler
 Warm up the Cooler – after desired chill but
before more hot carcasses
– Turn off refrigeration – keep fans on
 Tempering period for equilibration
– Temperature equalizes between rails, walls,
ceiling and carcasses
 Reduces opportunity for condensation

Condensation – controls (2)
 Use of Fans - Strategically located

– eliminate static pockets of moist air
– increase air circulation in the room.
 In wrong location can aggravate
condensation problem.

Wet Coil Refrigeration
 Only used when room temperature is above
freezing.
 Coils operated below freezing in humid
environment,- quickly build frost.
 Frost inhibits air flow -- heat transfer is
reduced -- efficiency is impaired

Wet Coil Refrigeration (2)
 Frozen condensate = refrigeration loss
 Water to ice requires 144 BTUs of
refrigeration/pound (320 BTU/kg)
 BTUs not available for product
1 BTU =1054.35 Joules (251.9958

Calories)
 Energy to heat 1 pound water 1°F

Wet Coil Refrigeration (3)
 Gives maximum continuous heat transfer

 Does not depreciate in effectiveness
 No defrost cycle
 Continuous air circulation

Defrosting
 Wet coil may not be used if insufficient
coil surface
 Defrost by air flow - return the BTUs
from frost to useful refrigeration
 By raising suction pressure for 15-20
minutes to 50 psi (3.64 kg/cm2) or 34°F
(1°C) with fans operating.

Keep Coils Clean
 Coils may not be cleaned often enough -- if

ever.
 Film of fat and/or lint
– decrease efficiency
– Significantly reduces air capacity of fans.
 Fat is a good insulator - even if not felt may
impair performance

Condensation - Summary
 Big problem
 No easy solution
 Best to prevent - as much as possible
 Remove prior to operation
 During operations – carefully remove
before it drips

– Must be installed and maintained to:
 Carry sufficient quantities of water to
required locations
 Properly convey sewage from the plant
 Prevent adulteration of product, water

supplies, equipment
 Provide adequate floor drainage

– Must be installed and maintained to:
Prevent back-flow conditions in and cross-
contamination between piping systems
that discharge waste water or sewage and
piping systems that carry water for
processing
Prevent the backup of sewer gases

 Water Supply and Water, Ice and
Solution Reuse
A supply of running water that

complies with the National Primary
Drinking Water Regulations (40 CFR
Part 141)

 Water Supply and Water, Ice and Solution
Reuse
– Water, ice and solutions used to chill or cook,

ready-to-eat product may be used for the same
purpose provided they are free of: pathogenic
organisms and fecal coliforms; and, physical,
chemical or microbiological contamination has
been reduced to prevent adulteration.

Solution Reuse
- Water, ice, and solutions to chill or wash raw
product may be used for the same purpose
provided measures have been taken to reduce
physical, chemical or microbiological
contamination.

Solution Reuse
– Water that does not meet the use conditions

may not be used in areas where edible
product is handled or prepared.

 Dressing Room/Lavatory
 Dressing rooms, toilet rooms and urinals must
be: sufficient in number; ample size and
convenient; maintained in sanitary condition and
good repair; separate from rooms in which
products are processed, stored or handled.

 Lavatories must have running hot and cold
water, soap and towels; be placed in or near toilet
and urinal rooms; and, placed in the plant to
ensure the cleanliness of all persons handling
product.

– Refuse receptacles must be constructed

and maintained in a manner that
protects against the creation of
unsanitary conditions and adulteration
of product.

 Equipment – Utensils
– Equipment and utensils must be of such
material and construction to facilitate
cleaning and be maintained in a sanitary
condition.
– Not be constructed, located or operated that
prevents their inspection.
– Receptacles used to store inedible products
must not create unsanitary conditions.

Equipment & Utensils
Sanitation Goals
 Maintained in sanitary condition
 Constructed, located, & operated in a manner
that enables sanitation inspections.
 Receptacles for trash or inedible or condemned
product must be conspicuously marked and
never be used for any edible product

Equipment: Prior
Evaluation
 Prevention of Problems
 Ease of Cleaning
 Withstand Production Conditions
 Minimize Hazards to Product
 Maximize Worker Safety

Acceptable Materials
 Nontoxic and chemically acceptable
 Will not deteriorate through normal use or
during cleaning & sanitizing
 Smooth, corrosion and abrasion resistant
 Shatterproof
 Nonabsorbent and will not stain or migrate
to the product

Unacceptable Materials
 GLASS – avoid if possible - light
bulbs/tubes must be protected with
shatterproof plastic
 ENAMALWARE, PORCELAIN or
POTTERY
 TOXIC METALS such as lead (including
Solder), cadmium, mercury, antimony

Unacceptable Materials II
 LEATHER or FABRICS – due to porous nature
(few exceptions – fabric in certain fat or air filters)
 WOOD – is porous – will absorb moisture –
allows microbial growth – very difficult to clean
and/or sanitize.
 PAINT – should be avoided – DO NOT USE on or
near product contact surfaces

Equipment -- Sanitary
Design & Construction
 Primary Objective: To facilitate cleaning and
Prevent Product Contamination
Smooth Surfaces -- free from: pits; cracks; crevices; etc.
Internal Corners & Angles – a continuous & smooth
radius of > 0.65cm
Welding – continuous, smooth, even, & relatively flush
with adjacent surfaces. NO ‘spot welding’ *

Sanitary Design &
Construction II
– Welded Joints – must be resistant to the stress
of normal use.
– Must Be Self-Draining or otherwise able to be
completely evacuated
– Motorized Parts & Bearings – should be located
outside the product zone – if this is not
possible, then a ‘catch pan’ or some other
devise must be installed to prevent possible
lubricant leakage into product areas.

Design & Construction III
– Use as Simple Construction as possible with the
fewest number of parts as practical
– Time & Ease of Disassembly important. Tools
required for dismantling should be available
– Conveyor Guides, Splash Guards etc. must be
easily removed to permit cleaning and
inspection

Design & Construction IV
– Horizontal Ledges or Frame Members – outside
of product zone – minimize and use rounded or
tubular construction whenever possible
– Design, construction, and installation should
allow Easy Access for sanitary & mechanical
maintenance

Design & Construction V
– Product Zone -- free of recesses,open seams,
gaps, protruding ledges, inside threads, inside
shoulders, bolts, rivets, and dead ends.
– Large Equipment – appropriate clean-out &

inspection openings, catwalks, ladders, or other
provisions to ensure that all parts can be
cleaned and inspected.

Design & Construction VI
– Chutes, Pumps & Pipelines – conveying

product
 must be easy to dismantle for cleaning & inspection.
 Must not have dead space where product may
stagnate
 Install sanitary quick-disconnects at all changes of
direction

Design & Construction VII
 SAFETY designed, constructed and installed to
guard against injury to personnel
– Consider:
 Sharp edges
 Moving parts
 Electrical shock
 Excessive noise
 Other hazards
 Protective Guards

Clean-in-Place (CIP)
Systems
 CIP Systems Advantages
– Controlled more easily and closely
– Less dependent on human involvement – thus
less susceptible to error.
 Design & Operating Plan – critical for

success

Clean-in-Place (CIP) Systems
II
 Cleaning & sanitizing solutions and rinse
water must contact all interior surfaces
 Must be self-draining with no low or
sagging areas
 Pipe interiors must be highly polished (120-
180 grit) stainless steel

Clean-in-Place (CIP)
Systems III
 Elbows – easily removable
At each change of direction
Short enough for interior inspection
 Any part outside of CIP system must be
dismantled and cleaned manually
 Ability to safely inspect all parts
 Effectiveness evaluated by periodic
dismantling & inspecting

Equipment Lubricants
 Use ‘food grade’ lubricants
 Avoid Excessive Use
 Take measures to prevent contamination of
product

Equipment Installation
 Spacing
 One foot rule (30cm)
 Sealed with a water tight seal
 Waste water
 Water Supply
Air gap between pipe & highest level of liquid
Anti-backflow devices

Equipment Installation II
 Vent Stacks from Hoods
 Magnetic Traps and Metal Detectors
 Water on Work Table (2-3cm lip)
 Air Lines
 Filter on air intake
 Clean and free of oil and moisture **

Equipment Installation III
 Wash Sinks
Hand Wash Sink
Product Wash Sink
Equipment/Utensil Wash Sinks
 Equipment Washrooms **

Equipment Maintenance
 Routinely inspected and maintained
 Repair or replace part BEFORE product is
contaminated
 Do nor overload equipment
 Develop a Preventive Maintenance Program
**

Wooden Pallets
Avoid use if possible
Must not become a physical,
microbiological, or chemical
hazard.
Must be maintained in good
condition

Wooden Pallets II
Must not have any contact with

exposed product
Must not be used or stored in areas
where exposed RTE or other
sensitive products are processed or
handled
Wooden Pallets
Potential Problems
Often exposed to many kinds of

contamination and abuse
Readily splinter or break – nails,
staples or wood splinters may
adulterate product

Wooden Pallets
Potential Problems II
May absorb contaminants such as:

oil, grease, meat juices, animal
feces, chemicals, etc.
Washing/sanitizing difficult --
pallets are slow to dry

Plastic Trays
 Commonly Used in Many Plants
Raw product (exposed and packaged)
Emulsions
Cooked Products (exposed and packaged)
RTE Products (exposed and packaged)
In-plant Use and as Shipping Containers
Inedible/Condemned Products
 Many PROBLEMS **

Plastic Trays II
 Automated washing system
 Remove damaged trays
 Color coding
 Specific color for floor/pallet contact
 Suggest in-plant use only
 Suggest poly liners
 Clearly identify trays used for inedible/condemned
(Specific color)

– Food contact surfaces of utensils &
equipment be cleaned and sanitized as
frequently as necessary
– Non-food contact surfaces of facilities,
equipment and utensils must be cleaned
and sanitized as frequently as necessary
to prevent unsanitary conditions.

– Cleaning compounds, sanitizing agents,
processing aids and other chemicals
must be safe and effective under the
conditions of use.
– Product must be protected during
processing, handling, storage, loading
and unloading.

– During operations, product should not come
into contact with non-food contact surfaces.
– FSIS no longer approves nonfood
compounds and proprietary substances
– Documentation substantiating the safety of a
chemical use must be available for review.

– Plants are responsible for ensuring that all
proprietary substances and nonfood
compounds are safe for their intended use
and used appropriately.
– Plants are free to choose whatever
scientifically supportable method they find
effective in limiting microbial growth in their
operations.

– Cleanliness: All persons working in contact with

product, food contact surfaces and product
packaging materials must adhere to hygienic
practices.
– Clothing: Aprons, frocks and other outer clothing
must be: material that is disposal or readily cleaned,
worn at start of each working day, and changed as
often as necessary.

– Disease Control: Any person who has

or appears to have: an infectious
disease; open lesions, including boils,
sores or infected wounds; must be
excluded from any operations which
could result in product contamination.
Inspector Verification
Procedures
 Types of verification procedures include:
– Observation of conditions.
– Review of records.
– Verification of one or more SPSs.
– Randomly determine compliance with the
SPSs.
– Perform an unscheduled task when
noncompliance is suspected.

Prerequisite
Programs/GMPs/SPSs
 Programs play an important role when
conducting the HACCP plan’s Hazard Analysis
 If used in the hazard analysis, ALL programs

must be in writing, monitored and records
maintained
 Records must support decisions reached in the

hazard analysis

Cleaners & Sanitizers -
Definitions
 Acid Cleaner - pH below 7. chemicals which

release hydrogen ions (H+) in solution. These
hydrogen ions are chemically very active.
 They are particularly effective for removing mineral

deposits such as calcium and magnesium
precipitates from equipment.

Cleaning Definitions (2)
 Alkaline Cleaners - pH above 7. These are
chemicals which release hydroxyl ions (OH-) in
solution. The hydroxyl ion is relatively active.
 Differentiated as weak or strong depending on their

degree of alkalinity. Alkali's are used to remove
fats and other organic materials from equipment
surfaces.

Cleaning Definitions (Biofilm)
 Biofilm - Composed of closely packed
colonies of bacteria that adhere to a surface
(including stainless steel).
 Attach themselves to the surface by

producing a complex carbohydrate or
polysaccharide substance

Cleaning Definitions (Biofilm-2)
 Firmly adheres to the surface and traps
nutrients, other microorganisms, viruses, fat,
proteins, and other debris.
 This film continues to build in layers.
 It is not easily removed by ordinary cleaning
measures and resists the penetration of
sanitizers. **

L. monocytogenes – In Biofilm

 Buffer - A substance capable of maintaining
the pH of a solution at some fairly constant
value.
 Chelation - Chemical formation of a "ring"

around a metallic ion creating a stable
soluble compound thus allowing its removal.

 Disinfect - Destroying 100% of the targeted
pathogenic vegetative cells of bacteria. Some
disinfectants will destroy or damage some
spores.
 Sanitize - For sanitation purposes, sanitize

means the process of reducing the total
microbial population. (Heat or chemical).

 Surfactant - Compound that lowers the
surface tension of the solution. Also known
as wetting agents
 Suspension - Action which keeps insoluble
particles of solids uniformly distributed in a
solution, preventing them from settling and
forming deposits. Makes it easier to flush
them away from surfaces being cleaned

 Water hardness - Refers to water containing
chemicals, such as various minerals or
dissolved salts.
 Common water softeners exchange the

calcium ions in the water with sodium ions
from salt.

Water in Cleaning – Many Roles
 Acts as a solvent for the cleaning
compound;
 Wets the surfaces to be cleaned;
 Floats away loose debris and other
matter;
 Rinses away the residues of cleaning
compounds.

Water Supply (Public or Well)
 Notchemically pure
 Usually contains a variety of dissolved
minerals and organic chemicals.
 If not removed, the effectiveness of cleaning

compounds will be reduced and/or result in
"water spotting" on clean surfaces.

Hard Water Used in Cleaning
Tends to interfere with the lathering

action of soaps and detergents.
Requires the use of more of the

cleaning compounds.

Hard Water Used in Cleaning –
(2)
Increases the load on the waste
water treatment system.
Best to use water that is as soft as

practical and near neutral in pH.

Area or Location to be Cleaned
The least amount of foreign
material will be the easiest to clean.
The type of operation in the area

has a major influence on the
selection of a cleaning process.

Special Cleaning
 Dry Sausage processing areas often have a
natural microbiological population necessary
to fermentation.
 Compatible natural flora enhances drying &
fermentation
 And often are able to hold undesirable
organisms in check.

Special Cleaning (2)
 To destroy this flora could cause failures in
fermentation, and create an environment favoring
hazardous organism (i.e. Staphylococcus aureus).
 Not an argument against cleaning and sanitizing
such rooms, but
 Emphasizes the importance of appropriate
techniques for each specific process or area. (i.e.
Bakery -- Milk Plant – Meat Plant – Brewery --- all
have special problems and require different
cleaning techniques.)

Mechanical Cleaning
 Firststep in the cleaning process
 May be accomplished without the use of
cleaning compounds
 Physically removing gross debris by brushing,
sweeping, vacuuming, rinsing, or other
means.

Cleaning Temperatures
 Temperature of water pre-rinses; cleaning
compounds; and sanitizers, important for
effectiveness.
 Pre-rinse should use warm or cold water
 Hot water will coagulating proteins and "set"
them on surfaces.

Cleaning Temperatures (2)
 Once proteins are set on surfaces they are
more difficult to remove
 Cleaning and sanitizing preparations have
optimal use temperatures
 Important to use at the recommended
temperatures.

Sanitizers
 The use of chemical sanitizers is no
substitute for effective cleaning.
 Basic categories of authorized chemicals
used to sanitize equipment include
 Chlorine; iodine and iodophors; quaternary
ammonium compounds; and acid-anionic
surfactants.

Chlorine
 Chlorine - usually sodium hypochlorite.
– 200 ppm of available chlorine
– Inexpensive
– Corrosive
– Irrigating to skin & eyes
– Inactivated by organic matter
– Rapid dissipation

Chlorine - WARNING
 WARNING! Chlorine gas is extremely

toxic;
 Should never be combined with acids or

ammonia compounds because hazardous
gases and/or violent and dangerous reactions
may result.

Chlorine – WARNING (2)
 If acid cleaners are used, make sure there is no
available chlorine present when the cleaners are
applied.
 Should only be applied following the complete
removal of acid cleaners by thorough rinsing.
 Because the bactericidal action is very rapid,
chlorine sanitizers often are preferred on
equipment about to be used.

Iodophors -- iodine complexes
 Similar to chlorine in their effectiveness
 Maximum limit of available iodine is 25 ppm
 Only slightly corrosive
 Highly unstable in hot solutions above
151EF (66EC)
 Should be used within a narrow pH range
(4.5 to 5.5).

Quaternary Ammonium
Compounds
Commonly known as ‘quats’
Frequently used as sanitizers
Selectively effective against gram-
positive and gram-negative bacteria
Not effective against bacterial
spores.

‘Quats’
Not corrosive to the equipment
Not irritating to the skin
Stable in hot solutions above
151EF (66EC)
Leave an active residue.

‘Quats’ (2)
Some are affected by hard water,
others are not.
Quats are incompatible with
anionic wetting agents, soaps, wood,
cloth, cellulose, and nylon.

Acid-anionic Sanitizers
 Used in the final rinse of automated cleaning
systems
 Phosphoric acid is common in the
formulation
 Well suited to sanitizing stainless steel
surfaces
 Can prevent mineral deposits from
accumulating.

Acid-anionic Sanitizers (2)
 Maximum antimicrobial effectiveness of
these products is at a pH of below 3.0.
 Alkaline waters decrease their effectiveness.
 Activity of acid-anionic sanitizers against

bacteria is rapid

Restrictions on Chemical Use
 Remove food products and packaging materials
prior to cleaning a processing area
 Those with odors/fragrances when diluted for use –
may interfere with sanitary inspection and must not
be used on food contact surfaces
 Those containing abrasive materials ( silica,
pumice, etc.), -- may be used IF all residues are
removed with potable water.

Restrictions on Chemical Use (2)
 All cleaning compounds used in edible

product processing areas must be followed
by a potable water rinse.
 This includes so called "spray and wipe"

cleaners or other similar compounds

Restrictions on Chemical Use (3)
 Some sanitizers are approved for use without a
potable water rinse:
-- Must be used according to label directions
– Surfaces are drained thoroughly
 Any pooling or collection of liquids must be
removed before contact with food products.
 READ THE LABEL

Costs of Cleaning
> 90% labor

 < 3-5% cleaning chemicals & supplies
 Competent supervisor vital
 Proper training & techniques essential
 Rewards: Food Safety; quality; & shelf life

Technical Assistance
Chemical manufacturers
Supply companies
Many universities

Summary

Sanitation Program
Good Sanitation does not

“happen” -- It must be
designed into the system

Plant Responsibility
 It is the responsibility of Plant Management
to achieve the proper level of sanitation:
- Design, Construction & Maintenance of the

plant
- Use proper cleaning procedures and
frequencies
- Monitor to assure that standards are consistently
met on a daily basis

Inspector Responsibility
 Make sure that the plant meets its

responsibility

Sanitation Priorities
 Direct Product Contamination – most
critical (SSOPs)
 Indirect or Possible Product Contamination
 Potential Product Contamination
 Remote Potential for Contamination

Sanitation Standard Operating
Procedures (SSOPs)
 System used by the US Plants to prevent
Product Contamination:
– - Written Program that Includes both Pre-
operational and Operational Components
– - Daily Records of Findings– describes
deviation and corrective action taken (Including
Preventive Measures)
– - Findings are used to improve program

Pre-Op Inspection
Plant
 Good Flashlight
 Record Findings at Time of Inspection
 Highest Priority – any situation that might
lead to product contamination
 Operations do not start until area is OK
 Situations not related to product
contamination can be deferred

Operational SSOPs
Plant
 Items that are checked during plant
operations (some examples):
– - Employee practices – hand washing etc.
– - Protective clothing – hair nets, gloves etc.
– - Products Handling
– - Reconditioning Product
- Condensation Control
- Sanitary Dressing Procedures

Good Sanitation
is
Essential
in order to produce
Safe Product!

Foreign Inspection Program Reviews Revised April2007

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Sanitation’s Major Role in

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 May skip some slides but keep as reference

 Use some photos, most taken in meat or

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Sanitation Standard Operating

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 May not be plant specific or job specific

 Programs need to be in writing,

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– Grounds must be maintained to

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 Describe Controls – Where and When

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Walls, floors,& ceilings must be built

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– Rooms in which edible product is processed,

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– Lighting of good quality and sufficient intensity to

 Equipment and utensils are cleaned

 Hand-washing areas, dressing and locker rooms and

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 Generated by wet cleaning process

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 Significantly different air characteristics

 Condensate generally forms in only some

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 Use of Fans - Strategically located

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1 BTU =1054.35 Joules (251.9958

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 Gives maximum continuous heat transfer

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 Coils may not be cleaned often enough -- if

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