BCMA

Food Industry
“Ten Sanitary Design
Principles”
Hygienic Restoration
Gary Goessel R.S.
9-21-2009
 Sanitary Design Principles for Equipment

1. Cleanable
2. Made of Compatible Materials
3. Accessible for Inspection, Maintenance, Cleaning and
Sanitation
4. No Liquid Collection
5. Hollow Areas Eliminated or Sealed
6. No Niches
7. Sanitary Operational Performance
8. Validate Cleaning and Sanitizing Protocols
9. Separate Processes Wherever Possible
10. Meet Personnel Hygiene and Sanitation Requirements

Adapted from American Meat Institute (AMI, 2002)

Sanitary Design Principles for Equipment
During Hygienic Restoration

 Cleanable
 Accessible for Inspection, Maintenance,
Cleaning and Sanitation
 Validate Cleaning and Sanitizing Protocols
 Separate Processes Wherever Possible
 Meet Personnel Hygiene and Sanitation
Requirements
FDA Home Page | Search FDA Site | FDA A-Z Index | Contact FDA

Recall -- Firm Press Release

Peanut Product Recalls:
Salmonella Typhimurium
Hygienic Restoration
Sanitation
 Hygienic Restoration - Sanitation

Establishing A Clean Break

 Transportation
 Peanut Paste Storage and Distribution Systems
 Peanut Butter Processing and Packaging
Equipment.
 Hygienic Restoration - Sanitation
Scope of Plant Hygienic Restoration Sanitation
Activity
All Building Structures
Ceilings
Walls
Floors

All Equipment Surfaces

Multiple Production Lines
Peanut Paste Delivery and Peanut Butter Storage
Peanut Butter Mixing, Peanut Butter delivery
 Hygienic Restoration - Sanitation
Sanitation Strategy
1. Determine level of clean.
2. Assess facilities and infrastructure in place to perform
sanitation tasks.
3. Assess manpower requirements to get work done in
expedited fashion.
4. Review existing cleaning SSOP’s and enhance or
develop additional.
5. Determine necessary level of disassembly to attain
targeted level of clean.
6. Obtain vendor support for supplies and equipment and
contracted services.
7. Establish sanitation verification and validation.
 Hygienic Restoration - Sanitation
Determine level of clean Principle # 1
Criteria for specific target “Level of Clean”
Microbiologically Clean
“Clean to a level that completely removes residual
food from the product zone and renders
surfaces free from harmful and/or excessive
microorganisms. Generally considered in
situations where there are potential
microbiologically sensitive ingredients, products
and/or processes.”
 Hygienic Restoration - Sanitation

Considerations for a microbiological mitigation

 Maintenance and Engineering
 Vendors and Suppliers
 Verification procedures and documentation
 Validation protocol.
 Documentation of all activity
 GMP’s
Monitored 24/7
 RTU Alcohol Surface Sanitizer
Product Description:
 A ready-to-use sanitizing and disinfecting solution
for use on hard, non-porous food contact surfaces.
 Convenient and Easy to Use
 Ideal for sanitizing areas where water use is
limited.
 Dries quickly to help protect water-sensitive
equipment.

Application:
 Any person entering the plant (employee, contractor,
etc.) must spray boots with RTU Sanitizer then walk
through mat filled with Sani-Step prior to entry into
all isolated areas and upon exiting.
 Use as a final sanitize step on production equipment
Temporary Isolation
 Sani-Step
Product Description:
 A water activated, time-released, EPA-registered
solid floor sanitizer designed to help improve
environmental sanitation on processing floors
during production where wet conditions favor
microorganism growth.

Application:
 Any person entering the plant (employee,
contractor, etc.) must spray boots with RTU
Sanitizer then walk through mat filled with Sani-
Step prior to entry into all isolated areas and upon
exiting.
 Hygienic Restoration
How was this Accomplished?
 A Call For Resources
 Internal
 External
 Implementing Available Technologies
 Ancillary Cleaning / Sanitizing Solutions
Must Pre-Clean, Rinse and Post Sanitize after EVERY use!

 Ameri Vap Steam Cleaner  Alcohol Sanitizer / Bio-mist System

 Must follow with RTU

CO2 Propellant for RTU
Sanitizer
Sanitizer
 Hygienic Restoration - Sanitation
Tornado electric powered wet
vacuums

HAFCO Pneumatic powered drum

vacuums with high efficiency filters
COP Tanks
Hygienic Restoration - Sanitation
 Ancillary Cleaning / Sanitizing Solutions
Must Pre-Clean, Rinse and Post Sanitize after EVERY use!

 Ameri Vap Steam Cleaner  Alcohol Sanitizer / Bio-mist System

 Must follow with RTU

CO2 Propellant for RTU
Sanitizer
Sanitizer
Hygienic Restoration
Dry Steam Sanitation
Hygienic Restoration - Sanitation
 Eco-Wipe FCS
Product Description:
 Eco-Wipe FCS is an EPA registered, pre-
moistened, single use sanitizing wipe for use on
hard, non-porous food contact surfaces.
 175 ppm Quaternary Ammonium Compounds
 5.48% alcohol
 100 Pre-measured, Pre-moistened Wipes per
canister

Application:
 Remove any gross soils with mechanical action
using one wipe
 Once visually clean, follow with another wipe as a
sanitize step
 All tools wiped at least once/shift and at entry and
exit of isolated areas.
 Principle #3 Validate Cleaning and
Sanitizing Protocols

 Sanitation Verification Using ATP

 Provides rapid “real-time” results


Make Decisions

Take Proper Corrective Action
 Provides On-line or near-line
testing

 Testing should be done once

visibly clean
Shelf-Stable
(Up to 12 months at room temp)
 The Scope
 The Scope of Cleaning Verification
 Visibly Clean
 ATP Testing of food contact surfaces
 Random Microbiological Testing
 On All Equipment and Building Surfaces
 Peanut Paste System
Establishing A Sanitation Break
 Transportation
 Peanut Paste Storage and Distribution
 Thermal Sanitization
 Visual Inspection
The Scope
Transportation
Heat Trace
 Commissioning Procedures

 Dis-Assembly Complete
 Cleaning and Sanitization Complete
 Area Secured
 Inspection and Environmental Sampling
 Re-Assembly Complete.
 Sanitization during reassembly.
 Sign Off of Visibly Clean
 Final Cleaning and Sanitization
 Secure Area for:
 Environmental Samples
 Test Shots Finished Product
Questions ?