Transcript Smoked Fish Consortium June 5th & 6th, 2001

Sanitation and
GMP Controls for
Listeria
Listeria Controls
Sanitation, Good Manufacturing
Practices, and Employee Training
Programs are the key elements of an
effective Listeria control program!!!!
There are no “magic bullets” for Listeria control
Sanitation & GMP controls provide a series of
hurdles that prevent or minimize contamination
Sanitation Goals
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Minimize contamination coming into plant
 Prevent cross contamination by people,
products and equipment in the plant
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Eliminate in-plant niches and contamination
sources where and when they are found
Prevent contamination of finished products
during processing and packaging
Start by Evaluating:
1. The potential for cross contamination
associated with your plant ‘s:
Process & Product Flow
Design & Layout of operations
Movement of people and equipment
2. Where there are potential niches for Lm to
establish itself in your plant
3. How effective are Routine and Intensive
Cleaning & Sanitizing procedures
4. Employee hygiene & food handling practices
Evaluate Design & Layout
of Processing Operations
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How Linear is Your
Product Flow ?
Is there adequate
separation of raw
products & processes
from finished
products & processes?
Process Flow
Receive Product
Cook
Cool
Pick tail meat
Weigh
Package
Chill
Pack
Finished Product Storage
How Is Your Plant “Zoned”?
Establish successively cleaner processing zones
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“Dirty Zone” – Where raw product is handled.
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“In-Process Zone” – Intermediate steps in the
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“Clean Zone”–Where finished product is handled,
E.g. receiving, storage, cooking
process. Crawfish picking
processed and packaged. E.g. weighing,
vacuum packing, chilling
Where do Process
Steps Occur
In the Plant ?
Evaluate the location of all processing steps
Raw or semi-processed products handled in the
“dirty” side of the plant must be separated from
locations where finished products are handled or
processed in the “clean” side of the plant.
Evaluate Traffic Flow:
Movement of People & Equipment
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Prohibit entry of people,
equipment, packaging etc.
into finished product areas
from outside the plant.
Control movement of
equipment and people
between raw and finished
product areas
Assign equipment, people
& cleaning tools to finished
product areas only
Control Strategy Options:
People
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Discourage traffic between finished product
(“clean”) areas & raw product (“dirty”) areas.
Require all employees (including supervisors, office
workers, management, delivery people & visitors)
to wash hands & change outer garments before
entering the plant.
Do
Not
Enter
Control Strategy Options:
People … continued
Restrict movement of employees and visitors from
raw product or “dirty” areas to finished product or
“clean” areas.
When this is not possible, minimize traffic to the
extent possible and use strict controls (wash
hands, change outer garment, use footbaths etc.)
before entering finished product handling areas.
Before You Go
Through this Door
Control Strategy Options:
People
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Require employees to use
dedicated & easy to clean
footwear in the plant.
Require the use of a foot
bath or chemical foam
barrier when moving from
“dirty” to “clean” areas.
Control Strategy Options:
Equipment
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Prohibit movement of equipment between finished
product (“clean”) areas & raw product (“dirty”) areas.
Wherever possible use designated
items like containers, utensils,
tools, trash barrels etc.
in finished product areas
and don’t move them
to other areas of the plant.
Control Strategy Options:
Equipment -continued

Separate operations
physically if possible or
separate by timing the
movement of product to
prevent cross
contamination
Processing
Cook
Room
Room
Chute
Training and Monitoring
1. Develop and finalize new procedures and
policies as necessary.
2. Assign supervisors, team leaders etc. to monitor
performance and ensure that new procedures or
policies are implemented properly.
3. Implement a system to reward or recognize
compliance and/or penalize for non compliance
4. Train employees to ensure that they understand
what is expected, why it’s important, and what
impact/consequences their performance will have.
Find and Eliminate Listeria
monocytogenes (Lm) Niches
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Niches are places in the plant where Lm
persists and grows over time.
Niches can occur anywhere there are cracks
and crevices that can accumulate bacteria,
water, & nutrients (food debris) and are hard
to reach with cleaning tools & sanitizer.
Lm can form biofilms in these niches that
protect it from the environment.
Find and Eliminate Listeria
monocytogenes (Lm) Niches

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Normal cleaning and sanitation
procedures may not be effective when
Lm has colonized a niche.
During operation, Lm can work its way
out of a niche and contaminate
equipment & products as they move
downstream in the process.
Bacteria like Listeria can form a biofilm to protect themselves
Potential Reservoirs
or Niches of Lm
Floors & Floor Mats
Drains
Cleaning Tools
Blowers & Chillers
Other Potential Sources of Lm
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Baskets
Chutes
Counters
Scales
Packaging Equipment
On/Off Switches
Rubber seals on doors
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Trash/waste receptacles
Floors with standing H2O
Condensate traps
Ice makers
Underneath Cleaning
table
Sanitation Procedures
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Routine Cleaning & Sanitation Procedures
are essential to eliminate new day-to-day Listeria
contamination that continually comes into the
plant with product, people, supplies,
and/or equipment.
Intensive Cleaning & Sanitizing Procedures
are used to eliminate Listeria monocytogenes
niches where and when they are found.
General Cleaning and
Sanitizing Procedures
Step 1 – Remove exposed
products
Step 2 – Dry clean & sweep area
Remove garbage, food debris & other waste
Step 3–Wet down area to be cleaned
Step 4(a) – Apply detergent
Applying Detergent with Foamers
Courtesy Hydro Systems Company
Step 4(b)- Scrub area vigorously
Be sure to use the right
amount of Sanitizer:
Use Test Strips
Areas to be Sanitized with
Quats or Peracid Sanitizers
Drains
Floors
Waste containers
Walls
Condensate drip pans
HVAC
Coolers*
Freezers*
Daily
Daily
Daily
Weekly/monthly
Weekly
Weekly/monthly
Weekly/monthly
Semi-annually
* Chlorine may be more effective than Quats if the temperature is low
Step 7– Air Dry/Store Properly
Cleaning Tips – Sanitation Don’ts
DO NOT use high pressure hoses to clean
drains, minimize use elsewhere
DO NOT use compressed air to clean equipment
DO NOT start cleaning & sanitizing if there is
any exposed product in the entire
area
DO NOT do a wet mid-shift cleaning
DO NOT stack or nest tubs, totes, pans etc.
after they are cleaned and sanitized
DO NOT let water spray on cleaned & sanitized
surfaces such as those close to the
floor while cleaning
Cleaning Tools
Designate cleaning tools for a specific purpose.
For example, never:
Use floor brooms/floor squeegees on tables
Use pads or brushes used for cleaning garbage barrels
on packing tables
Use the same brush to clean floor drains on any food
contact surface.
Use brushes, pads, brooms or squeegees in raw
product area and then in finished product areas
Clean & Sanitize all brooms, brushes and pads
every day, after plant is cleaned.
Store all cleaning aids properly
Plant Procedures
for Cleaning and
Sanitizing
Food Safety is Everyone’s Job!
Sanitation Procedures: Drains
Drains are likely to be the most highly
contaminated area of the plant
An inadequate drainage system with frequent
backups is a critical problem. If a backup
occurs production must stop. All exposed
product should be removed. The drain should
be cleared, cleaned with caustic, rinsed &
sanitized before starting production. Never
use high pressure to unclog a drain
Consider the location and type of each drain when
determining what procedure to use
Drains -Daily Clean-up
1. Move equipment or food contact surfaces that
could get contaminated or use a splash guard
2. Remove drain cover
3. Rinse with low pressure hose
4. Apply foam or detergent solution
5. Scrub with designated brush (1/4 inch smaller
than drain opening)
6. Rinse with low pressure hose
7. Flood with sanitizer
8. Insert bactericidal ring if used
9. Replace drain cover
10. Clean drain brush and store in sanitizer
Raw Product Areas
End of Day Clean-up
1) Remove & store all raw or in-process products
2) Remove garbage/food waste, clean tables &
other surfaces & sweep floors.
3) Wet all surfaces with water
4) Apply detergent to all surfaces
5) Scrub all surfaces with brushes or pads
6) Rinse and inspect for cleanliness
7) Apply sanitizer
8) Store equipment properly to air dry
9) Remove standing water from floors
10) Wash cleaning tools, sanitize & store
Finished Product Areas - End of Day Clean-up
1) Never use cleaning tools from raw product areas
2) Remove & store all exposed products
3) Remove garbage/food waste, clean tables &
other surfaces sweep floors.
3) Wet all surfaces with water.
4) Apply detergent to all surfaces
5) Scrub all surfaces with brushes or pads
6) Rinse and inspect for cleanliness
7) Apply sanitizer
8) Store equipment properly to air dry
9) Remove standing water from floors
10) Wash cleaning tools, sanitize & store
Trays, Pans & other Utensils
End of Day or After Use Clean-up
1)
2)
2)
3)
4)
5)
6)
7)
Fill sink compartment with warm water & detergent
Make sanitizer solution and check with test strips
Scrape/clean to remove food debris
Soak as necessary
Scrub all surfaces with brush or pad
Rinse and inspect for cleanliness
Immerse, spray or flood with sanitizer
Store properly on racks, shelves or hooks & air dry
Storage Coolers
Daily and End of Week Clean-up
Daily – Remove debris/trash & standing water
Visually inspect for proper product storage,
no condensate or drip, no cross contamination
Weekly –
1. Remove all products
2. Remove trash & standing water and sweep
3. Wet all surfaces
4. Apply detergent to all surfaces including ceiling
5. Scrub with brushes and floor broom
6. Rinse and inspect for cleanliness
7. Apply sanitizer to all surfaces
You May Need Special Cleaning
and Sanitizing Procedures for:
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Floor Mats
Totes and tubs
Colanders
Aprons and boots
Boot dips
Sanitation Implementation
Consistency & attention to details is critical
 Assign reliable dedicated employees to cleaning
and sanitation tasks and train them
 Seek expert assistance as necessary to ensure
that effective chemicals, procedures and delivery
systems are being used and monitored properly
 Assign reliable supervisory level personnel to
routinely monitor cleaning crew performance and
proper use of chemicals and cleaning tools
Good Personal Hygiene Practices
For ALL Employees Include
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Good Personal Habits
Proper Clothing
Good Health
Hand Washing
Handling Products Properly
Make sure Employees
Keep Themselves Clean
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Bathe or shower
daily
Keep fingernails
clean and
trimmed at all
times
Implement, Monitor and Enforce
Policies that Ensure that Employees:
Keep their hands away from their mouth,
nose, arms or other body parts when
working.
Do not eat, drink, or smoke in the food
handling areas.
Train and monitor
employees to
ensure that they
never touch dirty
objects and then
touch food
products while
working unless they
properly wash their
hands or at a
minimum change
their gloves.
Dress Properly for Work
Require all employees to
wear clean, washable
outer garments or
uniforms.
Require employees to wear
hairnets, caps, or other
suitable covering to
confine hair.
Supervisors & management
should set an example
Do not allow employees
to wear fingernail
polish or jewelry
when preparing or
handling food.
Implement procedures
to ensure employees
keep shoes or boots
clean.
ALL Employees Should Come
to Work in Good Health
Require any illness to be
reported to a supervisor
and have ill employees
avoid contact with food,
food contact surfaces
and utensils.
Gloves shall be worn to
touch food and food
contact surfaces when an
employee has any cuts,
sores, rashes, casts, or
wears nail polish,
artificial nails or jewelry.
How to Wash Your Hands
1. Wet hands with warm water;
2. Use ample liquid soap from a
dispenser;
3. Lather exposed arms and hands for
20 seconds by vigorously rubbing;
4. Thoroughly rinse hands in warm
water;
5. Use foot operated faucets to
prevent re-contamination of hands;
6. Dry hands thoroughly and properly
dispose of paper towels;
7. Dip hands in sanitizing solution; and
8. Do not touch unsanitary objects.
When to Wash Your Hands
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Before starting work
After using the
bathroom
After leaving the
work area
Before returning to
the work area
When To Wash Your Hands
continued
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After touching bare human body parts;
After coughing, sneezing, using a
handkerchief, or disposable tissue;
After handling soiled equipment;
Immediately before handling food
During food handling as often as
necessary; and
After other activities that may
require it.
Don’t Allow Poor Food Handling Practices
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Make sure all equipment is
clean before it is used
Don’t let employees bring
personal items to work
Never putting finished
product back onto a
packing line if it dropped
onto the floor or touched
something dirty
Credits
This training program was developed as part of a project entitled
“Control Strategies for Listeria monocytogenes in Food
Processing Environments” funded under the National Food Safety
Initiative in 2000 by the Cooperative State Research Education
and Extension Services of USDA Project No. 00-51110-9768.
Lots of hard work was contributed by:
Cornell University
Virginia Sea Grant
New York Sea Grant
LSU Cooperative Extension
Delaware Sea Grant
National Fisheries Institute
Maryland Sea Grant
National Food Processors Assoc.