10 th CII National Food Safety and Quality Summit Science behind detergents and cleaning agents. Designing a Right Mix for your Business PC Anil Kumar Head Food Safety & Hygiene December 02, 2015, India Habitat Centre, New Delhi
Key Terms Removal of Visible physical dirt and stains. A clean surface is defined as being free from soil (e.g. food residues), free from bad odours, be non- Cleaning greasy to the touch and have no visible oxidation (e.g. rust). The process of killing pathogenic bacteria , but not spores and all viruses by 99.999% during a time frame greater than 5 but less than 10 Disinfection mins. Commonly brought about by heat or application of chemicals. Disinfectants have a higher level of germ kill capability for pathogenic bacteria as compared to sanitizers. The process of reducing microbes to safe levels ie a 99.999% of a specific bacterial test population within 30 secs. Done by heat or Sanitation chemicals. A sanitizer may or may not necessarily destroy pathogenic organisms The process of destroying all microbes including spore forms. Its done by the use of drastic methods such as concentrated toxic/ non toxic chemicals (Chlorine, formaldehyde, glutar-aldehydes, etc.), very Sterilization high temperatures, or intense radiation. A sterilized item cannot support life in any from.
Basic Principles of Cleaning • What is Cleaning? – Cleaning is removal of soil from substrate to make to surface fit for its desired use. • What is �Clean “urface�? – A clean surface is one that is, • Free from Residual film or soil • Should not contaminate food products • Free from micro-organisms. • What is Soil? – Undesirable foreign matter on surfaces. – A heterogeneous mixture of many substances • Physical properties • Chemical properties
What Should be Cleaned and Sanitized? • All surfaces that may contact the food product, such as utensils, knives, tables, cutting boards, conveyor belts, ice makers, ice storage bins, hands, gloves, and aprons. Surfaces that do not directly contact the product such as walls, ceilings, floors and drains have a profound effect on environment. What Else Should be Cleaned and Sanitized? • Cleaning tools like brooms, mops, squeegees, buckets, sponges, scrapers, foaming equipment, water guns, etc., should be cleaned and sanitized. Cleaning tools can be a major source of microbial contamination if not cleaned. Cleaning tools should be washed and sanitized after every use. They should be stored clean, dried, and secured.
Cleaning Cleaning Process – Primary step • removal of soil from substrates – Secondary step • stabilisation of dispersed or dissolved soil in the wash liquor to prevent re-deposition (long term effect) • Detergents react with soils to change their chemistry so they will dissolve into the water and be carried away. • Detergents modify the nature of water so that it may efficiently penetrate, dislodge, disperse and carry away surface soils.
pH – Value and Scale • The logarithm of the reciprocal of the hydrogen-ion concentration. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Acid Side | Alkaline Side Neutral - Water based cleaning and maintenance products as well as other aqueous liquids are either alkaline, acidic or neutral. - The alkalinity or the acidity of a liquid can be measured. - The indicator is called pH-value. The pH-value shows the concentration of hydrogen ions and identifies acid or alkaline contents of an aqueous solution. - The scale ranges from 0 to 14; pH-value 7 is neutral. The pH-value can only be measured in liquids containing water.
pH Scale
Surface Tension • Surface tension – Force Per unit Length • Caused by the attraction between the liquid molecules by various intermolecular forces. • Resulting in surface area minimization
General Terms Water hardness • Expressed as ppm (parts per million) of calcium carbonate ( most common form) • Temporary Vs Permanent Total Dissolved Solids • Total Amount of Solids – Dissolved and Suspended in a solution ( Principally Calcium, Magnesium, Sodium, Chlorides, etc)
General Terms • Biodegradability: This is a general term referring to the decomposition of ingredients into their components. Biodegradability by micro-organisms is specially important in sewage treatment plants. The biodegradability of surfactants is proven by standardised test methods. • Specific Gravity Specific Gravity is the mass per volume unit. Examples: 1,00 g/ml or 1,00kg/l 1,04 g/ml or 1,04 kg/l
Factors – Affecting Cleaning • W - Water • A – Action • T - Time • C - Chemical • H - Heat
Cleaning Cycle – “inner�s Circle Mechanical Temperature action Time Chemical action
Factors For a Cleaning Process Detergent Contact concentration time Detergent Mechanical composition action Washing Surface to temperature clean
Inter-changeable factors Manual Cleaning Automated Washing Temperature Mechanical action Chemical action Time
Basic Chemistry of Soils • Organic Soils • Sugar • Protein • Starch • Fat / Oils / Grease • Inorganic Soils - Mineral Salts • Water Hardness Scales • Rust • Beer • Milk
Concept – pH – Soils Organic Soil Inorganic Soil 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Acid Side | Alkaline Neutral
Cleaning and Sanitation program The cleaning and sanitation program of food contact surfaces typically involves five steps STEP – 1 – Scrapping STEP – 2 - Pre-rinse (brief) STEP – 3 - Detergent application ( may include scrubbing) STEP – 4 - Post – rinse and STEP – 5 - Application of a sanitizer
Type of Cleaning Manual & Mechanical • Wet & Dry • Immersion cleaning • COP • CIP • High Pressure sprays
Soil & Their Solubility Solubility Soils • Water Soluble • Body Fluids • Alkaline Soluble • Food Soils • Surfactant Soluble • Fats & Oils • Solvent Soluble • Petroleum Based • Acid Soluble • Hardness Scales/Iron • Non-Soluble • Concrete/Rubber
An �Ideal� “anitizer – Acceptable toxicity – Wide, non-selective spectrum – Rapid action – Reasonably soil tolerant – Non corrosive – Compatible with cleaning materials – Useable in ambient conditions – Easily measured and monitored – Free rinsing – Non-toxic to the environment – Cost effective & safe to handle.
Sanitizers concentration commonly used in Food Plants Sanitizer Food contact Non food Plant water surface contact surface Chlorine 100-200* ppm 400 ppm 3-10 ppm Iodine 25* ppm 25 ppm Quats 200ppm* ppm 400-800* ppm Chlorine dioxide 100-200* # ppm 100-200# ppm 1-3#ppm Peroxyacetic acid 200-315* ppm 200-315 ppm * The higher end of the listed range indicates the maximum concentration permitted without a required rinse ( surface must drain) # Includes mix of oxychloro compounds Source 21 CFR 187.1010
Types of Sanitizers
Sanitizers - Sanitizing methods Spray Sanitizing Use of spray to sanitize equipment surfaces CIP Sanitizing Sanitizing by circulation of the chemical agent inside pipeline and equipment. Immersion / COP Sanitizing equipment by immersion in a tank of sanitizing solution Sanitizing Fogging Fogging the chemical agent to sanitize the air and surfaces in a room. Chlorine All food contact surfaces, sprays, CIP, fogging Mixed Halogens All food contact surfaces, CIP, spray sanitizing Iodine All food contact surfaces, spray, CIP, approved as hand dips. Peracetic Acid All food contact surfaces, CIP, especially cold temperatures and Carbon di oxides environments. Acid Anionics All food contact surfaces, CIP, spray, combined with sanitize and acid rinse step into one. QUATS All food contact surfaces, mostly used for environmental control: walls, drain and tiles
Cleaning Standards Cleaning standards can be determined through: General appearance Visual test – Reagent Test (Protein / Starch / Left over detergent) Microbiological test contact agar method swab/rinse method rapid hygiene test.
Results of Improper Cleaning • Poor Quality Food • Food-Unsafe for Human Consumption • Increased Utility Consumption viz. Steam, Water, Refrigeration etc. • Wastages & Reduced Safety • Increased level of chemical usage • Risk of Brand Damage • Continuous deposition of soil on surfaces, which may become difficult to remove even manually • Affects economy of production adversely
Conclusion Assure the Safety and Quality of food products Reduction in Total Operating Cost Customers / Regulatory requirements Lack of Trained �Hygiene Technicians� It is next to impossible to achieve quality and safe food without following Proper Cleaning & Hygiene Systems.
pc.anil@sealedair.com
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