Cleaning food processing equipment is essential for ensuring food safety, quality, and compliance. However, it can also be challenging, time-consuming, and costly. In this article, you will learn some best practices for keeping your food processing equipment clean, such as:
Depending on the type of equipment, product, and contamination, you may need to use different cleaning methods, such as manual, mechanical, chemical, or thermal. Each method has its advantages and disadvantages, so you should consider factors such as effectiveness, efficiency, safety, and environmental impact. For example, manual cleaning is suitable for small or irregular surfaces, but it can be labor-intensive and inconsistent. Mechanical cleaning, such as using water jets or brushes, can remove solid residues, but it may not eliminate microorganisms. Chemical cleaning, such as using detergents or sanitizers, can kill bacteria and fungi, but it may also damage the equipment or leave residues. Thermal cleaning, such as using steam or hot air, can sterilize the equipment, but it may also require high energy consumption and special precautions.
Cleaning starts with the design and workmanship. Better designed and built equipment are easy to clean either wet or dry cleaning depending on the product.
It is important to note that manual, chemical, mechanical, and thermal cleaning aren’t necessarily separate approaches to be used in isolation. Much of these methods need to be combined in the right ways and the right sequence to obtain the level of cleanliness required to obtain the necessary results.
A combination of cleaning methods are always utilized to ensure you remove soil matter and eradicate microorganisms. Common methods can include CIP which is basically a combination of detergents, temperature, contact time, frequency. CIP can be applied to removable parts of equipment where by scrubbing and soaking methods of cleaning can be applied.
Top 3 from me: 1. Effective cleaning starts with the choice and installation of the equipment. If you buy the right equipment that is suitable for food processing and then install it up against the wall or directly on the floor you are making it hard or impossible for the hygiene staff to effectively clean. 2. Ask the machinery manufacturers for instructions - they know their machinery best (and the chemical suppliers will certainly have seen your machinery before and know their chemical range best) 3. If you are going to use foaming make sure the foam stays where you put it. If it slides down the sides and pools on the floor you no longer have the concentration/contact time on the machinery but your floor will be super clean !
1)Following Daily Cleaning Routine i.e., SOP 2)Disassemble all required parts for cleaning 3)Different cleaning methods to implement like Jet wash, steam clean, soap oil cleaning etc 4)Train staff about importance of sanitation & Cleaning
To ensure thorough and consistent cleaning, you should follow a standard cleaning procedure that specifies the steps, materials, and parameters for each cleaning method. A common cleaning procedure consists of four stages: pre-rinse, main wash, post-rinse, and drying. The pre-rinse removes loose dirt and prepares the surface for the main wash. The main wash removes the remaining dirt and reduces the microbial load. The post-rinse removes any residues from the main wash and restores the pH balance. The drying removes any moisture and prevents microbial growth. You should also monitor and document the cleaning process, such as the temperature, pressure, concentration, and duration of each stage.
Not all equipment or facilities are suitable for cleaning that requires washing with water. Some foods can be ruined by the introduction of a water-based cleaning method and dry cleaning is the most suitable approach. When a dry clean is needed it should to be properly planned and executed using the right tools, approaches, and chemicals.
We must always remember that detergent removes debris and should be thoroughly rinsed off before introducing a disinfectant as this will affect the effectiveness of the disinfectant for killing microorganisms.
Another important aspect of keeping your food processing equipment clean is to maintain the cleaning equipment itself. This includes checking, cleaning, and replacing the parts and components of the cleaning system, such as pumps, hoses, nozzles, filters, tanks, and valves. You should also calibrate and verify the instruments and sensors that measure and control the cleaning parameters, such as thermometers, pressure gauges, flow meters, and pH meters. By maintaining the cleaning equipment, you can prevent malfunctions, leaks, blockages, or cross-contamination that could compromise the cleaning effectiveness and efficiency.
Preventively maintaining equipment can save a lot of time and money. Operators should be trained to do all these activities well and to troubleshoot issues that may occur.
Autonomous maintenance is a great way of identifying issues with equipment. During the cleaning one can identify issues before they become big.
One of the challenges of cleaning food processing equipment is to balance the cleaning frequency with the production schedule. Cleaning too often can waste time, resources, and energy, while cleaning too rarely can increase the risk of food spoilage, contamination, or non-compliance. To optimize the cleaning frequency, you should consider factors such as the type and volume of product, the level and type of contamination, the shelf life and storage conditions of the product, the regulatory and customer requirements, and the performance and availability of the cleaning system. You should also review and adjust the cleaning frequency based on the results of the quality and safety tests, such as microbiological, chemical, or sensory tests.
Achieving the optimal cleaning frequency in food processing is a delicate balance. Cleaning too often wastes time and resources, while cleaning too rarely increases the risk of contamination. Factors such as product type, contamination level, shelf life, regulations, and cleaning system performance must be considered. Regular quality and safety tests help adjust and fine-tune the cleaning schedule. Striking the right balance ensures efficiency, safety, and customer satisfaction, showcasing the expertise of production managers in maintaining high hygiene standards.
Validation of cleaning is very important. This can help the business identify the most time and cost effective way of cleaning without taking the risk of contamination.
Finally, keeping your food processing equipment clean requires the involvement and commitment of the staff who operate, clean, and maintain the equipment. You should train and educate your staff on the importance, methods, and procedures of cleaning, as well as the potential hazards and risks of improper cleaning. You should also provide them with the necessary tools, materials, and protective equipment to perform the cleaning tasks safely and effectively. Moreover, you should encourage and motivate your staff to follow the cleaning standards and guidelines, as well as to report and resolve any issues or problems related to cleaning.
Keeping your food processing equipment clean is not only a matter of hygiene, but also of productivity, profitability, and reputation. By following these best practices, you can ensure that your food processing equipment is clean, safe, and efficient.
Cleaning of Food processing equipment. Two methods applied generally (excluding physical and other methods) 1. Cleaning Out of Place- Dismantle machine, manually or mechanically clean it. Generic Steps: Pre-Rinse -->Chemical -->Rinse -->Sanitize -->Final Rinse -->Dry (Optional) 2. Cleaning in Place- This is internal cleaning program with equipment can be added externally. Bulky machines or food processing inclusive of tubes which can't be dismantled on daily basis fall under this category. Steps are mostly similar to COP. Control points: Chemical Strength/Concentration Time distribution in each steps. PS: All suppliers provide recommendation for cleaning method, chemicals & frequency for safer foods & longevity of machines.
We often forget that cleaning is a science. Most of the time assume that people know. Training is critical as cleaning incorrectly and using incorrect equipment can lead to more contamination.
In my experience no food manufacturing facility is like another and risk-based approaches must be employed holistically to plan for and execute all the cleaning activities, maintenance, and production. It is helpful to consult someone to guide you through this and to ensure there are no gaps that could lead to costly mistakes.
Costly-mistakes, Always finish the task-here's one for example at an assisted living facility kitchen you have medical staff along with kitchen crew in and out regularly. Kitchen staff is thoroughly trained in both the operation and maintenance of all the appliances, but sometimes the nursing staff would help out or use things in the kitchen. One day a crew member was cleaning the oven with a chemical that has to soak in. So after spraying oven they went and took care of other duties. 10 min later a nurse comes in and wants to heat her lunch so she turns in the oven. Within a few minutes the kitchen was filled with acrid smoke and the ventilation system made it worse and had to evacuate half the facility, call fire dept etc.