Académique Documents
Professionnel Documents
Culture Documents
Presented by
John Miller
HACCP Consulting Group, LLC
For FSIS How to Workshops
Spring 2009
1
Objectives
2
Discussion Question
3
Why Is It Important to Have a
Sanitary Facility?
5
Sanitary Definitions
6
Factors that Contribute to a Sanitary
Facility
Facility design
Equipment design
Good cleaning and sanitizing procedures
Good written sanitation programs and
monitoring procedures
7
Evaluating the Effectiveness of a
Sanitation Program
Microbiological testing
Adenosine triphosphate (ATP) testing
Use of sanitation records
Training
8
Review of Regulatory Requirements
9
Sanitation Requirements for
Official Meat and Poultry
Establishments
9 CFR 416Sanitation
10
Section 416.1General Rules
11
Sanitation Performance Standards
(SPS) 9 CFR 416.2416.6
12
SPS 9 CFR 416.2
13
SPS 9 CFR 416.3416.6
14
SPS for Grounds and Pest Control
(416.2a)
15
SPS for Grounds and Pest Control
(416.2a) (cont)
16
Grounds and Pest Control: Plant
Responsibilities
17
Grounds and Pest Control: FSIS
Verification Procedures
19
SPS for Construction (416.2b)
(cont)
20
Construction:
Plant Responsibilities
21
SPS for Lighting (416.2c)
22
Lighting:
Plant Responsibilities
23
SPS for Ventilation (416.2d)
24
Ventilation:
Plant Responsibilities
25
SPS for Plumbing and Sewage
Disposal (416.2e-f)
26
SPS for Plumbing and Sewage
Disposal (416.2e-f) (cont)
27
Plumbing and Sewage Disposal:
Plant Responsibilities
28
SPS for Water Supply and Water, Ice, and
Solution Reuse (416.2g)
29
SPS for Dressing Room/Lavatory
(416.2h)
30
SPS for Dressing Room/Lavatory
(416.2h) (cont)
31
SPS for Dressing Room/Lavatory
(416.2h) (cont)
Lavatories must
have running hot and cold water, soap, and
towels
be placed in or near toilet and urinal rooms
placed in the plant to ensure the
cleanliness of all persons handling product
32
Dressing Room/Lavatory:
Plant Responsibilities
33
SPS for Equipment and Utensils
(416.3)
34
Equipment and Utensils:
Plant Responsibilities
35
SPS for Sanitary Operations (416.4)
36
SPS for Sanitary Operations (416.4)
(cont)
37
Sanitary Operations:
Plant Responsibilities
38
SPS for Employee Hygiene (416.5)
Cleanliness
All persons must adhere to hygienic
practices while on duty to prevent
adulteration of product.
Clothing
Aprons, frocks, and other outer clothing
worn by persons who handle product must
be of material that is durable and readily
cleaned. Clean garments must be worn at
the start of each working day.
39
SPS for Employee Hygiene (416.5) (cont)
Disease control
Any person who has or appears to have an
infectious disease or an open lesion (e.g.,
boils, sores, or infected wounds) must be
excluded from any operations that could
result in product adulteration.
40
Employee Hygiene:
Plant Responsibilities
41
SPS for Tagging Insanitary Equipment,
Utensils, Rooms, or Compartments (416.6)
42
SANITATION STANDARD
OPERATING PROCEDURES
(SSOPs)
9 CFR 416.11416.17
43
Section 416.11General Rule
44
Section 416.12Development of SSOPs
45
Section 416.12Development of
SSOPs (cont)
46
Section 416.13Implementation of SSOPs
47
Section 416.14Maintenance of
SSOPs
48
Section 416.15Corrective Actions
49
Section 416.16Recordkeeping
Requirements
50
Section 416.16Recordkeeping
Requirements (cont)
51
Section 416.17Agency Verification
52
Discussion Question
53
Effective Sanitation
54
The Food Safety Equation
SANITARY SANITARY
GMPs EQUIPMENT FACILITY HACCP
DESIGN DESIGN
55
Controlling Microbial Hazards
L. monocytogenes understanding
the hazards, then
E. coli O157:H7 preventing entry
Salmonella points into the
Campylobacter facility and the
establishment of
Legionella niches and
harborages
56
Cleanable to a Microbiological Level
Food facilities and equipment must be constructed and be maintainable to ensure that they
can be effectively and efficiently cleaned and sanitized over their life. The removal of all food
materials is critical. This means preventing bacterial ingress, survival, growth, and
reproduction. This includes product and non-product contact surfaces.
57 57
Factors Affecting the Presence and
Concentration of Pathogens in Niches
Temperature
Moisture
Nutrients
pH
Competitive flora
58
Three Broad Sanitation Themes
59
Theme 1: Provide Zones of Control
60
Principle 1
61
Zones of Control
Cleanroom
First Aid
Sanitation
62
Zones of Control
Cleanroom
Cleanroom
Raw Secondary
Cook/Chill
Processing Cleanroom Packaging
Cleanroom
Raw RTE
Welfare Office Welfare
63
Principle 2
64
Passive Control
Active Control
Magnetic Lock
RTE Area
66
Principle 3
67
Pooling water
69
Principle 5
71
Poor Ventilation Design
72 72
Good Ventilation Design
73
Typical Unit Cooler
74
Theme 3: Design to Facilitate Sanitation
75
Principle 6
76
$
$$
$$$
$$$$
77
Principle 7
78
Gaps
80
Adequate Equipment Spacing360
Access
82
Column spaced off of IMP
Sloped girts
84
From This To This More
86
Sanitation hose station
87
88
Vat washer
Discussion Question
89
Benefits of Sanitary Equipment
Design
90
Items Needed for a Balanced
Sanitation Program
Facility
Process equipment
GMPs
Handling practices
Sanitation
91
Facility
92
Process Equipment
93
Cleanable and Catwalk over Product
94
No Metal to Metal
95
Good Manufacturing Practices
(GMPs)
96
GMPs (cont)
97
Color-Coded Frocks
98
Edible, Inedible Markings
99
Handling Practices
100
Sanitation
101
Discussion Question
How do you
document
deficiencies in your
plants monitoring
during performance
of pre-op sanitation
inspection? Why do
you use this
approach?
102
Seven Steps in a Sanitation
Program
103
104
Salt (120m, 4724 -inch)
Micro-Size
39.37 -inch
105
Secure and Disassemble
106
Pre-sanitation task completed consistently
(floors swept, equipment covered, materials
removed, etc.)
Equipment disassembled to proper level to
provide accessibility
Dry clean completed
108
Dry Cleanup
109
Step 2First Rinse
110
Pre-Rinse
111
Pre-Rinse
112
Pre-Rinse
113
Rinse until visually free of soils
Use lowest effective pressure to minimize aerosols and
condensation
Lower pressure reduces risk of cross-contamination and
machine damage
114
Step 3Soap and Scour
115
Order of applications (necessary to reduce cross-
contamination potential)
Wall/floors then equipment
Avoid drying of chemicals
Mechanical action
116
Contact time, concentration, and mechanical action!!!
Scrub product contact surfaces daily
Scour framework weekly minimum
Chemicals are not a substitute for mechanical action
Work from walls and floor to equipment
Traps Nutrients
Bacterial Mass with Protective
Attachment Film (Slime) and Bacteria
117
Cleaning Drains
118
Detergent Application
119
Detergent Application
120
Hand Scrub All Equipment
121
Hand Scrub All Equipment
122
Step 4Post Rinse and Inspect
124
Post Rinse and Inspect
125
Step 5Remove and Assemble
126
Step 5Remove and Assemble (cont)
127
Remove and Assemble
128
Step 6Pre-op
130
Facility Pre-op
131
Step 7Sanitize
133
Periodic Sanitation/Heat
134
Pop Quiz
135
Sanitation Effectiveness
Verification
Physical verification
Organoleptic (site, smell,
taste)
Step 6Pre-op
Microbiological verification
Bioluminescence/ATP (immediate results)
Aerobic plate count (results in 23 days)
Environmental monitoring (results in 35
days)
136
ATP Bioluminescense Testing
Advantages
Quick and immediate results
Measures level of sanitation by looking for
levels of ATP common in food (and
bacteria)
Can track and trend results
137
ATP Bioluminescense Testing (cont)
Disadvantages
Expensive
Does not give you the levels of bacteria on
surfaces, just food residues
138
Microbiological Testing
139
Microbiological Testing (cont)
140
Sanitation Records
141
Training
Critically important
Develop specific Standard Operating
Procedures (SOPs) for cleaning and sanitizing
equipment
Involve everyone in the plant
142
Sanitation and RTE Meat and
Poultry Products
143
L. monocytogenes
144
Why the Concern?
145
Listeria in Meat Plants (n = 41)
LOCATION % (+)
Floors 39%
Floor Drains 39%
Cleaning Aides 34%
Wash Areas 24%
Sausage 22%
Food Contact Surfaces 20%
Condensate 7%
Walls & Ceilings 5%
Compressed Air 4%
146
Focused Efforts
147
Focus on RTE Equipment
148
Facility
149
Process Equipment
150
Lead to Ineffective Sanitation
Aerosols
Spraying drains and drain components
Drains pooling/backing up
Hollow rollers, fixed sleeved assemblies, concave
surfaces
Cross traffic
Lack of accessibility
Biofilms
Idle equipment (not being used)
Standing moisture
151
Design Considerations
High-pressure water
Compressed air
Control buttons and screens
Bearings
Congestion in RTE area
Cabinets in RTE areas
Traffic patterns
GMP requirements
Sanitation process NOT documented/sequenced--
How do you sustain protocols?
152
No Niches
No lap joints
All welds are continuous, smooth, and
polished
Hermetically sealed spacers
Sleeved assemblies <1
Press fittings are not used
Fasteners not used in or above product zone
Belt supports constructed from single piece
153
Hollow Areas Hermetically Sealed
155
Sanitary Design of Food
Processing Equipment
Will Reduce Risks and Improve
Food Safety
156
Resources
http://www.fsis.usda.gov/Science/Resources_&_
Information/index.asp
http://www.fsis.usda.gov/Science/Small_Very_Small_
Plant_Outreach/index.asp
http://www.fsis.usda.gov/Small_Very_Small_Plants/
index.asp
http://www.fsis.usda.gov/Regulations_&_Policies/11000_
Series-Facilities_Equipment_&_Sanitation/index.asp
http://www.fsis.usda.gov/News_&_Events/Food_Safety_
Inspection_Podcasts/index.asp
157
Development of
Standard Operating Procedures
(SOPs)
158
Purpose of SOPs
159
Developing SOPs
160
Steps in Developing SOPs
161
Steps in Developing SOPs (cont)
162
Tools and Techniques for
Developing SOPs
163
Relevant Questions
164
Elements of a SOP
165
Development of
Sanitation Standard Operating
Procedures
(SSOPs)
166
SSOPs: Identify Reassembly
167
SSOPs: Recordkeeping Procedures
SSOP on file
Daily record of findings
Corrective/preventive action records
Supporting documentation
168
Operational Sanitation Monitoring
169
Modification of SSOPs
Regulatory changes
Equipment/process changes
Request for change form
Change pages included in SSOP
Changes signed and dated
170
Operational SanitationCleaning
Procedures
171
Pre-Operational Sanitation
Monitoring
172
Monitoring Frequency
173
SSOP Monitoring Methodology
174