CLEANING AND SANITIZING NATIONAL ICE CREAM MIX ASSOCIATION MEETING 1/17/2017 David Blomquist DFB Consulting LLC 651-324-6158
THE BIG THREE OF CLEANING Soil Cleaner Equipment
THE BIG THREE OF CLEANING Soil Carbohydrates Fats & Oils Proteins Minerals Other compounds colors, flavors, additives e.g. titanium dioxide
THE BIG THREE OF CLEANING Cleaners Alkaline based cleaners Acid Based Cleaners Additives
REMOVING THE SOILS - CARBOHYDRATES Simple sugars Most are soluble in water Starches and complex carbohydrates Caustic and high temperatures
REMOVING THE SOILS FATS & OILS Alkaline cleaners and surfactants Temperatures above the fat s melting point
REMOVING THE SOILS PROTEINS Alkaline and chlorine Enzymes are used in some cases
REMOVING THE SOILS MINERALS Acids are typically used Acids typically used are phosphoric, nitric, sulfuric and organic Must be strong enough and must have low enough ph- typically below ph 1.8-2 Chelants can also be used e.g. EDTA, gluconic acid
REMOVING THE SOILS THE PROBLEM Most soils are not single compounds Soils that are not cleaned regularly may become harder to remove Heated surfaces also are more difficult to as the soils must be cleaned using both acids and alkaline cleaners e.g. HTST
EQUIPMENT CONSIDERATIONS Metal? Is equipment stainless steel? most resilient material and most able to be cleaned without damaging the equipment If it is mild steel it is susceptible to rust from water or acid If it is aluminum caustic (NaOH and KOH) can damage it. Acids will also damage aluminum Galvanized metal is also susceptible to acid and will eventually break down even with exposure to water
EQUIPMENT CONSIDERATIONS Elastomers? Buna N Silicone Teflon Gaskets, and valves
FACTORS OF CLEANING: 4 STEPS AND 4 FACTORS 1. Pre-Rinse Remove as much soil as you can prior to cleaning with the cleaning agents
FACTORS OF CLEANING: 4 STEPS AND 4 FACTORS 1. Pre-Rinse Concentration 2. Wash Temperature Time Mechanical Action
1. Pre-Rinse 2. Wash FACTORS OF CLEANING: 4 STEPS AND 4 FACTORS Time, temperature, mechanical action, concentration 3. Post Rinse Rinse to remove cleaner to background ph of supply water
Pre-Rinse Wash FACTORS OF CLEANING: 4 STEPS AND 4 FACTORS Time, temperature, mechanical action, concentration Post Rinse Rinse to remove cleaner to background ph of supply water Sanitize
SANITIZERS EPA approved antimicrobial that provide a 5 log (99.999% reduction) of bacteria within 60 seconds Must contact the organism to kill it
SANITIZERS Chlorine Iodine Quaternary Ammonia PeroxyaceticAcid Mixed Peroxyacetic Acid Chlorine Dioxide Ozone Perquat (Hydrogen Peroxide and Quaternary Ammonia)
Chlorine SANITIZERS Quick kill - oxidizer Effective against yeast & mold Affected by organic matter
Chlorine SANITIZERS Iodine Oxidizing sanitizer- quick kill and effective against yeast & mold More tolerant of soil than chlorine Can cause staining and can be corrosive If temperatures are >100 degrees it will sublime and deposit iodine on equipment surfaces
Chlorine Iodine SANITIZERS Quaternary Ammonia Soft metal safe Provides residual effect so is useful for environmental sanitizing Works on cell wall
Chlorine Iodine Quaternary Ammonia SANITIZERS Acid Anionic Sanitizers Requires low ph <3.8-4.0 Effective against bacteriophage Low ph provides control of minerals ph must be below 3.0
Chlorine Iodine Quaternary Ammonia Acid Anionic Sanitizers SANITIZERS Fatty Acid Sanitizers Low foam for CIP application Efficacious up to ph 3.8 4.0
Chlorine Iodine Quaternary Ammonia Acid Anionic Sanitizers Fatty Acid Sanitizers Peracetic Acid Sanitizers SANITIZERS Oxidizing sanitizers Not as affected by organic materials Fast acting oxidizing sanitizer
Chlorine Iodine Quaternary Ammonia Acid Anionic Sanitizers Fatty Acid Sanitizers Peracetic Acid Sanitizers SANITIZERS Mixed Peracetic Acid Sanitizers More efficacious on yeast & mold
Chlorine Iodine Quaternary Ammonia Acid Anionic Sanitizers Fatty Acid Sanitizers Peracetic Acid Sanitizers Mixed Peracetic Acid Sanitizers Ozone SANITIZERS Strong oxidizer Quick kill but not very soluble in water
Chlorine Iodine Quaternary Ammonia Acid Anionic Sanitizers Fatty Acid Sanitizers Peracetic Acid Sanitizers Mixed Peracetic Acid Sanitizers Ozone SANITIZERS Chlorine Dioxide Strong oxidizer Quick kill but not very soluble in water (more soluble than ozone)
Chlorine Iodine Quaternary Ammonia Acid Anionic Sanitizers Fatty Acid Sanitizers Peracetic Acid Sanitizers Mixed Peracetic Acid Sanitizers Ozone Chlorine Dioxide SANITIZERS Perquat sanitizer Both powdered and liquid forms available 2 part liquid mixed together create bubbles that penetrate otherwise inaccessible areas Have been shown to be very effective in reducing environmental contaminants e.g. salmonella or Listeria
BIOFILMS A biofilm is any group of microorganisms in which cells stick to each other and often these cells adhere to a surface. These adherent cells are frequently embedded within a self-produced matrix of extracellular polymeric substance (EPS). Source: Wikipedia
BIOFILMS A biofilm starts to form in about 8 hours They will be found in MANY places that are not expected: Gasketed joints Separators HTST plates Bushings on agitators
BIOFILMS A biofilm starts to form in about 8 hours They will be found in MANY places that are not expected: Gasketed joints Separators HTST plates Bushings on agitators
SURFACE ENHANCED CLEANING Cleaning using a patented peroxide additive The additive is circulated prior to adding the alkaline cleaner The additive will react with the alkaline cleaner and break down to water and oxygen to create bubbles when it reaches a temperature of 170 o F
GENERAL PROCEDURE HEATED SURFACES Prerinse Add Exelerate HS -1% by volume (Add 3-4 oz of Exelerate Boost as a stain preventer) Circulate and after 1-2 circuits, add caustic cleaner Wash as normal Rinse as normal
GENERAL PROCEDURE COLD WALL SURFACES Prerinse Add Exelerate HS -1% by volume (Add 3-4 oz of Exelerate Boost as a stain preventer) Circulate and after 1-2 circuits, add alkaline cleaner Wash as normal Rinse as normal Sanitize with peracid sanitizer like Synergex
EQUIPMENT SANITARY DESIGN FDA inspectors now consider ANY area in a RTE plant of <20,000 square feet outside of zone 1 areas to be a zone 2 Any environmental positive will be considered a significant issue
EQUIPMENT SANITARY DESIGN As FDA continues with new FSMA regulations, elimination of pathogens in the plant production environment will become more important
EQUIPMENT SANITARY DESIGN Design of equipment to allow better cleanability will become paramount to success.
EQUIPMENT SANITARY DESIGN: AMI SANITARY DESIGN PRINCIPLES 1. Cleanable to a microbiological level 2. Made of compatible material 3. Accessible 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. Validated cleaning and sanitizing protocols SOURCE: https://www.meatinstitute.org/index.php?ht=a/getdocumentaction/i/11006
RECOMMENDATION: Start making design improvements in equipment NOW making changes every year to prevent HUGE expenditures that will be needed when FSMA is fully enforced by FDA
QUESTIONS? Dave Blomquist DFB Consulting LLC 651-324-6158