Advanced Cleaning and Sanitation for the Produce Industry
Transcription
Advanced Cleaning and Sanitation for the Produce Industry
Advanced Cleaning and Sanitation for the Produce Industry Ian S. Bessell – Director of Business Development Phillip Ellis – Southeast Technical Representative FAFP Educational Luncheon November 21, 2013 The Birko Story 60 Years of Success • Founded in 1953, Birko is a 3rd generation family-owned manufacturer of cleaning and process chemistry for food producers • Chad Equipment, LLC, a Birko company, is a leading supplier of equipment for pathogen intervention and chemical handling • PMA Gold Circle Member • ColoradoBIZ Magazine Top Manufacturing Company 2013 Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Who Do We Work With? Customer base includes leading food and beverage producers Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Birko Capabilities • Over 250 specialized products including cleaners, sanitizers, process chemistry and direct food contact antimicrobials • Products suitable for use with natural and organic labels • Committed to research, development and innovation with strong collaboration with leading universities • 20+ patents related to food safety, and process chemistry and equipment • Only chemical manufacturer involved in original HACCP legislation • All technical reps are HACCP certified Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights QUESTION What is the purpose of cleaning and sanitation? Cleaning and sanitation is not just about cleaning the food processing surfaces, it is also about creating a sanitary environment in which to process food and protecting that environment during processing operations. Effective sanitation is the cornerstone of quality Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights The Food Safety Equation REPEATABLE FOOD SAFETY RESULTS TRAINED EMPLOYEES GMPs/GAPs SANITARY EQUIPMENT DESIGN VALIDATED & VERIFIED PROCESSES SANITARY FACILITY DESIGN HACCP CONTINUOUS IMPROVEMENT PROCESS Property of Birko Corporation From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Consequences • E. coli O157:H7 at Jack in the Box 1993 • 4 Children die, >700 gravely ill Listeria outbreak 2011/12 • Est. 38 adult deaths • 146 sickened in 28 states Bankruptcy Incarceration Death Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Jensen Farms Environmental Assessment Findings • • • 1. Facility Design – Refrigeration unit drain line, allowed for water to pool on the packing facility floor in areas adjacent to packing facility equipment, may have extended and spread the pathogen to food contact surfaces. – Packing facility floor was constructed in a manner that was not easily cleanable. Specifically, the trench drain was not accessible for adequate cleaning and may have served as a harborage site for Lm or contributed to the growth, or spread of the pathogen. 2. Equipment Design – Packing equipment, including equipment used to wash and dry the cantaloupe, did not lend itself to be easily or routinely cleaned and sanitized. – Several areas on both the washing and drying equipment appeared to be uncleanable, and dirt and product buildup was visible on some areas of the equipment, even after it had been disassembled, cleaned, and sanitized. – Corrosion was also visible on parts of the equipment. From: FDA Environmental Assessment: Factors Potentially Contributing to the Contamination of Fresh Whole Cantaloupe Implicated in a Multi-State Outbreak of Listeriosis (October 19, 2011) http://www.fda.gov/Food/FoodSafety/FoodborneIllness/ucm276247.htm Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Cleaning and Sanitation in produce It isn’t Rocket Science, is it? Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Various Material Used Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Process often introduces water Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Harvest, Transport & Cooling Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Facility Design presents some unique challenges Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights PACKING SHEDS Many Challenges – Similar to Field • Relatively Uncontained Environment – open barn with roof but no side walls • Not built with sanitation in mind • Pest Control – insects, birds rodent vectors • Limited sanitary facilities – bathrooms and hand washing facilities • Materials not amenable to cleaning • Temporary transient labor pool not invested in sanitation program • TIME – Do I Harvest or Do I Clean? Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights How do you clean this? Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Complex Product Mixes Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Field/Harvest Operations Many Challenges • Uncontained environment – exposed to the elements • Wild flora and fauna • Limited sanitary facilities – bathrooms and hand washing facilities • Materials not amenable to cleaning • Temporary transient labor pool not invested in sanitation program • TIME – Do I Harvest or Do I Clean? Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Sanitary Design –Cleanable to a Microbiological Level Food facilities and equipment must be constructed and be maintainable to ensure that they can be effectively and efficiently cleaned and sanitized over their life. The removal of all food materials is critical. This means preventing bacterial ingress, survival, growth, and reproduction. This includes product and non-product contact surfaces. Property of Birko Corporation From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Not all repairs are “good” repairs Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Passive Control Active Control Magnetic Lock RTE Area Cross Traffic Aisle From This Design Property of Birko Corporation Access Control Card Reader To This More Sanitary Design From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Pooling water From This Poor repairs Property of Birko Corporation Design To This More Sanitary Design From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Gaps No threshold or seal Threshold fully embedded in caulk From This To This More Design Sanitary Design Property of Birko Corporation From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Adequate Equipment Spacing— 360° Access From This Design Property of Birko Corporation To This More Sanitary Design From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights From This Design Property of Birko Corporation To This More Sanitary Design From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Problem Areas Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Design Issues – Catch Points Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Problem Areas Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Policies to Defend the Perimeter Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Zones of Control Cleanroom Trash Raw Welfare Cleanroom First Aid Sanitation Property of Birko Corporation From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Zones of Control Your goal is a logical process flow with strict zones of control Cleanroom Raw Processing Cleanroom Secondary Cook/Chill Cleanroom Packaging Cleanroom Raw Welfare Property of Birko Corporation Office RTE Welfare From John Miller, HACCP Consulting Group, LLC For FSIS “How to” Workshops Spring 2009 November 21,reserved. 2013 Copyright 2011 Birko. All rights Preventing Cross Contamination Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Protecting the Sanitary Space • Isolate the work area and keep it sanitary • Entryway Foamers • Helps to clean boots, truck tires and fork lift wheels • Typically apply a quat foam • Combine with floor powder (not sanitizing but helps control soil and inhibit bacterial growth Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Protecting the Sanitary Space Boot Scrubbers and Hand Washing Stations Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Question WHAT ARE THE ACTUAL STEPS IN THE CLEANING CYCLE IN A PRODUCE FACILITY? THEY ARE THE SAME BASIC STEPS AS ANY OTHER TYPE OF FOOD FACILITY Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Pre-Sanitation • Pre-sanitation task completed consistently (floors swept, equipment covered, materials removed, etc.) • Equipment disassembled to proper level to provide accessibility • Dry clean completed Hollow member + cracked weld Property of Birko Corporation 36 November 21,reserved. 2013 Copyright 2011 Birko. All rights Dry Cleanup Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Dry Cleanup Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Pre-Rinse Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Pre-Rinse Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights • Rinse until visually free of soils • Use lowest effective pressure to minimize aerosols and condensation • Lower pressure reduces risk of cross-contamination and machine damage Multiple lap joints Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights • Order of applications (necessary to reduce cross-contamination potential) – Wall/floors then equipment – Avoid drying of chemicals • Mechanical action Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Detergent Application Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Detergent Application Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Hand Scrub All Equipment Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Hand Scrub All Equipment Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Post Rinse and Inspect Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Manual Cleaning Failure Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Post Rinse and Inspect Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Verification of Cleaning • Visual Inspection – is it clean • Pre-Operational Testing • Sanitation can be confirmed through the use of pH test strips, ATP (Adenosine Triphosphate) test swabs or rapid bacterial test equipment. • Other confirmation test protocols may be included in a good sanitation program Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights QUESTION What are we doing during sanitation • Remove Soil • Kill Bacteria • Remove Biofilm Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Sanitizers Effective Cleaning is 99% of the sanitation job. The remaining 1% is the job of sanitizers Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Sanitizers Produce Bacteria • Listeria spp. • Salmonella spp. • Escherichia coli Organic vs. Conventional Process and Product will impact choice of sanitizers Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights BIOFILM • Major area of concern for food processors especially for ready to eat items in wet processing areas • Typically resistant to conventional cleaning and sanitation processes • Frequent culprit where persistent bacterial contamination is a problem • Very common in drains & condensate pans • Specialty products required to inhibit or prevent the formation of biofilm in previously cleaned drain pans – Quat Blocks Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights BIOFILM BIOFILM http://www.hygiena.net/images/biofilm-diagram.gif Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Biofilms • Biofilms are a leading source of bacteria in the food plant environment because of the presence of moisture • Many of the problem bacteria such as Listeria and Salmonella readily produce biofilm protected colonies • Not removing the biofilm means that colonies continue to produce more bacteria, releasing them into the plant • “Most general cleaning and sanitation products will not penetrate or detach the sturdy polysaccharide biofilm matrix”. Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Biofilms – Sterilex Products • The only EPA-approved biofilm remover • Removes E. Coli, Salmonella, Listeria and other problem organic contaminants • Used as a weekly “shock treatment” in drains and troughs or plant surfaces Property of Birko Corporation Drain Foamer November 21,reserved. 2013 Copyright 2011 Birko. All rights Sterilex Drain Program Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights The Future - What's Changing Food Safety • FSMA, Emerging Pathogens, Traceability Regulatory Changes • Federal Rules: OSHA, EPA, National Organic Program • State Level: California Prop 65, clean air and water rules Environmental/Sustainability Concerns • Water quality and conservation • Reduction of sodium chloride and TDS in process effluent Customer Demands • Reduce sanitation costs • Increased emphasis on fresh cut ready to eat value added items Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Beyond Chemistry The Role of Equipment & Technology B.O.S.S. - Blend on Site System Custom Formulas and Controlled Use • Concentrated products = enhanced functionality, reduced costs • Computer controlled mixing, allocation and dispensing • PIN controlled allocation – prevents over or under usage • Real time usage, inventory and cost reporting • Upload, collate and report data from multiple plants Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Putting it All Together Birko’s Integrated Approach to Produce Safety The Birko Shield Food Safety Assessment • On site evaluation • Process Chemicals • Interventions & Application Equipment • Cleaning and Sanitation • Process Environment Protection Property of Birko Corporation November 21,reserved. 2013 Copyright 2011 Birko. All rights Discussion and Questions www.birkocorp.com