10 th CII National Food Safety and Quality Summit Science behind - - PowerPoint PPT Presentation

Science behind detergents and cleaning

• agents. Designing a Right Mix for your

Business 10th CII National Food Safety and Quality Summit

PC Anil Kumar Head Food Safety & Hygiene December 02, 2015, India Habitat Centre, New Delhi

Key Terms

Cleaning

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- greasy to the touch and have no visible oxidation (e.g. rust).

Disinfection

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

• 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.

Sanitation

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

• chemicals. A sanitizer may or may not necessarily destroy pathogenic
• rganisms

Sterilization

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 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

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

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 – “inners Circle

Mechanical action Chemical action Time Temperature

Factors For a Cleaning Process

Detergent concentration Detergent composition Washing temperature Contact time Mechanical action Surface to clean

Inter-changeable factors

Automated Washing Manual Cleaning Mechanical action Chemical action Time Temperature

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

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Acid Side | Alkaline Neutral

Organic Soil Inorganic Soil

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

Soils

• Body Fluids
• Food Soils
• Fats & Oils
• Petroleum Based
• Hardness Scales/Iron
• Concrete/Rubber

Solubility

• Water Soluble
• Alkaline Soluble
• Surfactant Soluble
• Solvent Soluble
• Acid Soluble
• Non-Soluble

Soil & Their Solubility

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 surface Non food contact surface Plant water

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 Sanitizing equipment by immersion in a tank of sanitizing solution 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