PENN STATE FOOD SCIENCE TRAINING SUPPORT Sanitation Controls for Fd Processing Effective Employee Education Starting with a gd foundation of relevant facts and applications, this information can be effectively delivered in short courses, workshops, and training sessions, but the material often fades from mind once employees have returned to work. Regular reinforcement of these principles helps keep employees focused on producing high-quality, safe fd. The enclosed posters and flashcards are novel training tls that can easily be used on site as visual reminders of key concepts in fd processing. The tip sheets are a helpful reference to have on-hand when developing procedures as a reminder of the elements to include in the written document. If you have questions or comments about these materials, contact Kerry Kaylegian, dairy fds research and extension associate, at kek14@psu.edu or 814-867-1379. To order contact the Publications Distribution Center at 877-345-0691. Suggestions for Use Flashcards Post with the key concept side out as a reminder Post with the details out for more information Use as quiz aids for on-site training Posters for Display Drs and lockers CIP rms Chemical storage areas Locker rms Lunch rms Employee training and notice boards Department of Fd Science
Penn State Fd Science Training Resources Fd-safety-related Short Courses and Workshops fdscience.psu.edu/workshops Dairy Basics: Fundamentals of Fd Safety Workshop Dairy HACCP Workshop Fd Microbiology Short Course Fd Safety and Sanitation for Fd Manufacturers* Fundamentals of HACCP Hazard Analysis Critical Control Point Programs (HACCP) for Meat and Poultry Processors Mushrm Fd Safety Pasteurizer Operators Workshop * Also available as an online course Custom Training Workshops Penn State can tailor short courses and workshops to meet the specific needs of your group. We can hold workshops at Penn State, on site at your facility, or other common space. Please contact Kerry Kaylegian at kek14@psu.edu for more information. Online Resources fdscience.psu.edu/workshops extension.psu.edu/fd/dairy extension.psu.edu/fd/safety fdscience.psu.edu Department of Fd Science Penn State is an equal opportunity, affirmative action employer, and is committed to providing employment opportunities to minorities, women, veterans, individuals with disabilities, and other protected groups. Nondiscrimination: http://guru.psu.edu/policies/ad85.html U.Ed. AGR 15-45 Code AGRS-132 1C6/15npc
Cleaning and Sanitizing KEY CONCEPTS THE STEPS 1 Pre-rinse 2 Wash 3 Post-rinse (acid) 4 Sanitize WASHING FACTORS 1 Time 2 Action (mechanical force) 3 Concentration 4 Temperature THE DETAILS 1 Follow SSOPs 2 Use the right supplies 3 Fill out records 4 Take pride CHEMICAL SAFETY 1 Correct chemical use 2 Chemical properties 3 Protective equipment 4 Accident and spill response PENN STATE FOOD SCIENCE TRAINING SUPPORT Department of Fd Science Penn State is an equal opportunity, affirmative action employer, and is committed to providing employment opportunities to minorities, women, veterans, individuals with disabilities, and other protected groups. Nondiscrimination: http://guru.psu.edu/policies/ad85.html U.Ed. AGR 15-45 Code AGRS-132 1C6/15gotprint
THE STEPS THE STEPS 1 2 1 Pre-rinse 2 Wash 3 Post-rinse (acid) 4 Sanitize Cleaning and Sanitizing 1. Pre-rinse Removes most of the gross soil Use warm water, 100 120 F 2. Wash Removes carbohydrate, fat, protein, and mineral soils Follow SSOPs for cleaning processes and chemical selection Key factors: time, temperature, concentration, mechanical force 3. Post-rinse (acid) Removes detergent and chlorine Rinse water may be acidified Removes minerals and prevents mineral deposits 4. Sanitize Reduces the number micrrganisms on surfaces Sanitize surfaces before use, follow SSOPs Only clean surfaces can be sanitized! Department of Fd Science Penn State is an equal opportunity, affirmative action employer, and is committed to providing employment opportunities to minorities, women, veterans, individuals with disabilities, and other protected groups. Nondiscrimination: http://guru.psu.edu/policies/ad85.html U.Ed. AGR 15-45 Code AGRS-132 1C6/15gotprint
WASHING FACTORS WASHING FACTORS 1. Time T little: not enough surface interaction T much: detergent deposits, temp cls Just right: surface wets, soils removed and washed away 1 Time 2 Action (mechanical force) 3 Concentration 4 Temperature Cleaning and Sanitizing 2. Action (mechanical force) Lsens soil and disrupts biofilms Need to have contact with all surfaces Use turbulent flow, slugging 3. Concentration T little: not enough cleaning power T much: may reduce efficiency and leave residues, costs $$$ Just right: does the job; work with your chemical supplier 4. Temperature Use correct temperature, see SSOPs Water should be 120 F at the end of the wash cycle T hot: proteins denature and deposit, dangerous for personnel Department of Fd Science Penn State is an equal opportunity, affirmative action employer, and is committed to providing employment opportunities to minorities, women, veterans, individuals with disabilities, and other protected groups. Nondiscrimination: http://guru.psu.edu/policies/ad85.html U.Ed. AGR 15-45 Code AGRS-132 1C6/15gotprint
THE DETAILS 1 Follow SSOPs 2 Use the right supplies 3 Fill out records 4 Take pride Cleaning and Sanitizing THE DETAILS 1. Follow SSOPs Standard Sanitation Operating Procedures (SSOPs) How to clean, step-by-step Chemicals, times, temperatures, processes 2. Use the right supplies Correct chemicals and concentrations Personal protection for chemical handling Color-coded brushes, buckets, wash tanks, etc. 3. Fill out records Sanitation records Fd safety plan monitoring and verification of records If it wasn t documented, it wasn t done! 4. Take pride Smile and take pride in producing clean, safe fd Department of Fd Science Penn State is an equal opportunity, affirmative action employer, and is committed to providing employment opportunities to minorities, women, veterans, individuals with disabilities, and other protected groups. Nondiscrimination: http://guru.psu.edu/policies/ad85.html U.Ed. AGR 15-45 Code AGRS-132 1C6/15gotprint
CHEMICAL SAFETY 1 Correct chemical use 2 Chemical properties 3 Protective equipment 4 Accident and spill response CHEMICAL SAFETY Cleaning and Sanitizing 1. Correct chemical use The right chemical and concentration for the job Correct mixing and use procedures Label and store chemicals properly 2. Chemical properties Physical state (solid, liquid, gas), concentration, ph Physical hazards (flammable, explosive, reactive) Health hazards (burns, poisons, carcinogens) 3. Protective equipment Gloves, lab coats, coveralls, ftwear Eye, face, and head protection Correct materials for the task 4. Accident and spill response Use and location of emergency equipment Emergency first aid and contact numbers Spill kits and procedures Department of Fd Science Penn State is an equal opportunity, affirmative action employer, and is committed to providing employment opportunities to minorities, women, veterans, individuals with disabilities, and other protected groups. Nondiscrimination: http://guru.psu.edu/policies/ad85.html U.Ed. AGR 15-45 Code AGRS-132 1C6/15gotprint
Writing SSOPs Sanitation Standard Operating Procedures PROCEDURES A SANITATION STANDARD OPERATING PROCEDURE Is a written document Outlines procedures or programs used to maintain equipment and the environment in a sanitary condition for fd processing Specifies what is to be cleaned how it is to be cleaned how often it is to be cleaned Is a step-by-step description of cleaning and sanitizing procedures Defines the records used to monitor the procedures An SSOP Is part of a fd safety plan May be a prerequisite program May be written for a piece of equipment several pieces of equipment in a process an environental area as a master sanitation plan for the whole facility Is updated when there is a change in processes or chemicals used Should be reviewed annually with the fd safety plan TIPS FOR WRITING SSOPs Use easy-to-understand language Describe the steps completely treat this a training document Include the specific chemical type, name, brand, and concentration Include the temperature and time conditions used Add notes as needed for clarification Department of Fd Science
Writing SSOPs PENN STATE FOOD SCIENCE TRAINING SUPPORT ELEMENTS OF AN SSOP Company Name Date Most recent update or effective date Version ID SSOP Number (optional) Title Name of the procedure or program Scope or Introduction What is covered Frequency How often this should be done Procedures Step-by-step instructions Use a logical, sequential order Add notes as needed for clarification Specify chemicals (type, brand name) chemical concentration time temperature Break into sections for multiple tasks Recordkeeping Identify which forms or logs are used Example: chemical concentration logs Person Responsible For the SSOP content and updates Include signature and date lines Page Numbers EXAMPLE SSOP Kay s Kreamery SSOP: 3.05 State College, PA Date Updated: April 28, 2015 Cheese Process Equipment Cleaning and Sanitizing SCOPE Cheese process equipment includes the pasteurizer, cheese vat, cheese press, tables, and utensils used during the manufacture of cheese. CLEANING AND SANITIZING SCHEDULE Processing equipment is sanitized immediately prior to use and cleaned at the end of each processing day. MANUAL SANITIZING 1. Fill 5-gallon bucket with rm-temperature water. 2. Add 1 packet of ABC powdered sanitizer (HIJ Company) to the bucket. Stir to dissolve. 3. Sanitize equipment using a clean brush, making sure to sanitize all surfaces and parts. MANUAL CLEANING (in a sink) 1. Dismantle equipment to be cleaned and rinse parts with warm water. 2. Make cleaning and sanitizing solutions according to manufacturers instructions. Note: Wear appropriate personal protection equipment (gloves, eye protection). 3. Wash parts using a clean brush, making sure to wash all surfaces and parts. 4. Rinse thoroughly with warm water to remove cleaner residues. 5. Rinse parts with sanitizer solution. 6. Visually inspect parts for damage and residual cleaner. CIP CLEANING OF THE HTST PASTEURIZER 1. Continue the flush rinse after product processing until the clean water comes out of the product lines (at least 20 minutes). Maintain water level in balance tank. 2. Prepare the HTST and homogenizer for CIP. a. Turn the temperature set point down to allow the flow to divert. Shut off the bster pump, homogenizer, and hot water system. Turn off the chilled water. b. Turn the switch on the back panel (CIP box) from Product to CIP. c. Reconnect the product recirculation line. Remove end caps and reconnect the bypass line on the homogenizer. d. Turn the product flow to CIP on the control panel. 3. Turn HTST system back on and stabilize conditions. a. Check water level in balance tank; add water if needed. b. Release the backpressure using the back pressure regulating valve. c. Adjust the temperature set point to 180 F. d. Turn on the homogenizer and bster pump to high speed. Turn on the hot water system at the control panel. 4. Add caustic solution and circulate for 20 minutes. a. Add city water to the balance tank to a level just below the side port. b. Add 4.5 pounds of caustic solution (EFG caustic cleaner by HIJ Company) to balance tank. c. Take a sample of the caustic solution from the balance tank and check concentration using the test kit for caustic wash. Record concentration of caustic wash on the Sanitation Test Log. d. Caustic solution should be 1 1.5 percent; adjust concentration and retest as needed. e. Switch between forward and diverted flow a few times to clean the entire system. 5. Drain caustic solution. a. Turn flow valve to Drain. b. When balance tank is almost empty, add clean water to balance tank for rinse. 6. Rinse with clean water for 20 30 minutes. 7. Add acid solution and circulate for 20 minutes. a. Turn flow valve back to forward flow (F/F). b. Add city water to the balance tank to a level just below the side port. c. Add 1.5 pounds of acid solution (KLM acid cleaner by HIJ Company) to balance tank. d. Take a sample of the acid solution from the balance tank and check concentration using the test kit for acid wash. Record concentration of acid wash on the Sanitation Test Log. e. Acid solution should be 8,000 10,000 ppm; adjust concentration as needed. f. Switch between forward and diverted flow a few times to clean the entire system. 8. Rinse with clean water for 30 45 minutes. a. Turn flow valve to Drain. b. When balance tank is almost empty, add clean water to balance tank for rinse. Add water as needed to complete rinse cycle. c. After rinse is complete, drain tank until only a small amount remains in the bottom. 9. Cl system. a. Turn off steam valve at control panel and allow the temperature to drop below 140 F. b. Adjust the temperature set point to 120 F. c. Wait until the temperature of the system is below 120 F before turning off the system. RECORDKEEPING Record the results from testing the concentrations of cleaning solutions on the Sanitation Test Log immediately following the test. Record CIP cleaning of the pasteurizer on the Pasteurization Chart at the end of the production run each day. Record manual cleaning of the cheese vat, tables, and equipment on the Daily Cleaning Log. The following individual is responsible for implementation of this SSOP: Name: Jane Doe Title: Plant Manager Date: 4/28/15 2 Department of Fd Science Penn State is an equal opportunity, affirmative action employer, and is committed to providing employment opportunities to minorities, women, veterans, individuals with disabilities, and other protected groups. Nondiscrimination: http://guru.psu.edu/policies/ad85.html U.Ed. AGR 15-45 Code AGRS-132 1C6/15npc
Kay s Kreamery SSOP: 3.05 State College, PA Date Updated: April 28, 2015 Cheese Process Equipment Cleaning and Sanitizing SCOPE Cheese process equipment includes the pasteurizer, cheese vat, cheese press, tables, and utensils used during the manufacture of cheese. CLEANING AND SANITIZING SCHEDULE Processing equipment is sanitized immediately prior to use and cleaned at the end of each processing day. MANUAL SANITIZING 1. Fill 5-gallon bucket with rm-temperature water. 2. Add 1 packet of ABC powdered sanitizer (HIJ Company) to the bucket. Stir to dissolve. 3. Sanitize equipment using a clean brush, making sure to sanitize all surfaces and parts. MANUAL CLEANING (in a sink) 1. Dismantle equipment to be cleaned and rinse parts with warm water. 2. Make cleaning and sanitizing solutions according to manufacturers instructions. Note: Wear appropriate personal protection equipment (gloves, eye protection). 3. Wash parts using a clean brush, making sure to wash all surfaces and parts. 4. Rinse thoroughly with warm water to remove cleaner residues. 5. Rinse parts with sanitizer solution. 6. Visually inspect parts for damage and residual cleaner. CIP CLEANING OF THE HTST PASTEURIZER 1. Continue the flush rinse after product processing until the clean water comes out of the product lines (at least 20 minutes). Maintain water level in balance tank. 2. Prepare the HTST and homogenizer for CIP. a. Turn the temperature set point down to allow the flow to divert. Shut off the bster pump, homogenizer, and hot water system. Turn off the chilled water. b. Turn the switch on the back panel (CIP box) from Product to CIP. c. Reconnect the product recirculation line. Remove end caps and reconnect the bypass line on the homogenizer. d. Turn the product flow to CIP on the control panel. 3. Turn HTST system back on and stabilize conditions. a. Check water level in balance tank; add water if needed. b. Release the backpressure using the back pressure regulating valve. c. Adjust the temperature set point to 180 F. d. Turn on the homogenizer and bster pump to high speed. Turn on the hot water system at the control panel.
4. Add caustic solution and circulate for 20 minutes. a. Add city water to the balance tank to a level just below the side port. b. Add 4.5 pounds of caustic solution (EFG caustic cleaner by HIJ Company) to balance tank. c. Take a sample of the caustic solution from the balance tank and check concentration using the test kit for caustic wash. Record concentration of caustic wash on the Sanitation Test Log. d. Caustic solution should be 1 1.5 percent; adjust concentration and retest as needed. e. Switch between forward and diverted flow a few times to clean the entire system. 5. Drain caustic solution. a. Turn flow valve to Drain. b. When balance tank is almost empty, add clean water to balance tank for rinse. 6. Rinse with clean water for 20 30 minutes. 7. Add acid solution and circulate for 20 minutes. a. Turn flow valve back to forward flow (F/F). b. Add city water to the balance tank to a level just below the side port. c. Add 1.5 pounds of acid solution (KLM acid cleaner by HIJ Company) to balance tank. d. Take a sample of the acid solution from the balance tank and check concentration using the test kit for acid wash. Record concentration of acid wash on the Sanitation Test Log. e. Acid solution should be 8,000 10,000 ppm; adjust concentration as needed. f. Switch between forward and diverted flow a few times to clean the entire system. 8. Rinse with clean water for 30 45 minutes. a. Turn flow valve to Drain. b. When balance tank is almost empty, add clean water to balance tank for rinse. Add water as needed to complete rinse cycle. c. After rinse is complete, drain tank until only a small amount remains in the bottom. 9. Cl system. a. Turn off steam valve at control panel and allow the temperature to drop below 140 F. b. Adjust the temperature set point to 120 F. c. Wait until the temperature of the system is below 120 F before turning off the system. RECORDKEEPING Record the results from testing the concentrations of cleaning solutions on the Sanitation Test Log immediately following the test. Record CIP cleaning of the pasteurizer on the Pasteurization Chart at the end of the production run each day. Record manual cleaning of the cheese vat, tables, and equipment on the Daily Cleaning Log. The following individual is responsible for implementation of this SSOP: Name: Jane Doe Title: Plant Manager Date: 4/28/15 2