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A major challenge of management in the food industry is to recruit and train employees for an effective sanitation operation. The success or failure of a sanitation program depends on the extent to which management supports the program. An effective sanitation program includes provisions for constant training and education of employees. Educational information can be disseminated through sanitation training manuals and short courses given by trade associations, professional organizations, or regulatory agencies. The major functions of sanitation management are to delegate responsibilities and to train and supervise employees. Self-supervision and self-inspection are two tools that contribute to a more effective sanitation program. [ABSTRACT FROM AUTHOR]

Food is a source for microorganisms that cause food spoilage and illness. Increased handling of food is responsible for a more complicated and critical challenge of protecting food from contamination. To improve sanitation in foodservice establishments, the facility and equipment should be designed for cleanability. Choosing equipment with sanitary features has been simplified by a number of equipment standards provided by organizations and manufacturers. Food should be safeguarded through sanitary practices in the receiving, storage, preparation, and serving areas. It should be handled with equipment and utensils and in a physical facility that has been thoroughly cleaned and sanitized. If properly operated and maintained, mechanized cleaning by means such as a dishwasher can effectively remove contamination from utensils and equipment. To manage the sanitation operation of a foodservice facility properly, a cleaning and sanitizing program should be written, supervised, and evaluated, with subsequent documentation of results. [ABSTRACT FROM AUTHOR]

An effective sanitation program for fruit and vegetable processing facilities requires hygienic design of facilities and equipment, training of sanitation personnel, use of appropriate cleaning compounds and sanitizers, adoption of effective cleaning procedures, and effective administration of the sanitation program-including evaluation of the program through visual inspection and laboratory tests. Effective sanitation starts with reduced contamination of raw materials, water, air, and supplies. If the facility and equipment are hygienically designed, cleaning is easier and contamination is reduced. Cleaning labor can be reduced through use of portable or centralized high-pressure or foam cleaning systems, and CIP systems can be used in large operations. Many facilities, if designed of durable material, can be cleaned effectively with acid-cleaning compounds and sanitized most adequately and economically by paints and other protective coatings as additional sanitary precautions. The effectiveness of a sanitation program can be evaluated through the establishment of standards as guidelines, visual inspection, and laboratory tests. [ABSTRACT FROM AUTHOR]

Plant layout and construction affect microbial contamination and overall wholesomeness of the product. It is especially important to ensure that clean air and water are available and that surfaces in contact with dairy foods do not react with the products. Soils that are found in dairy plants include minerals, proteins, lipids, carbohydrates, water, dust, lubricants, cleaning compounds, sanitizers, and microorganisms. Effective sanitation practices can reduce soil deposition and effectively remove soil and microorganisms through the optimal combination of chemical and mechanical energy and sanitizers. This condition is accomplished through the appropriate selection of clean water, cleaning compounds, cleaning and sanitizing equipment, and sanitizers for each cleaning application. A current trend has been toward modification of CIP systems to permit final rinses to be utilized as makeup water for the cleaning solution of the following cleaning cycle and to segregate and recover initial product-water rinses to minimize waste discharges. Every processing facility should verify the effectiveness of its cleaning and sanitation program through daily microbial analyses of both product and various equipment and areas. [ABSTRACT FROM AUTHOR]

A hygienically designed plant can improve the wholesomeness of seafood and the sanitation program. The location of the seafood plant can contribute to the sanitation of the facility. The design and construction materials used in the plant and equipment are also critical to an effective sanitation program. Personnel allocation and an organized cleaning schedule with required cleaning steps are essential in maintaining a hygienic operation. This portion of the sanitation program should be matched with the most effective cleaning compounds, cleaning equipment, and sanitizers. The sanitation operation can be enhanced by the recovery of by-products, adoption of recommendations provided by regulatory agencies, and participation in voluntary inspection programs. [ABSTRACT FROM AUTHOR]

Sanitary design and construction of food facilities is essential to maintain a hygienic operation. A sanitary design begins with a site free of environmental contamination such as polluted air, pests, and pathogenic microorganisms. Site preparation is necessary to attain proper drainage and the reduction of contamination from the environment. All portions of a food facility must contain smooth, impervious surfaces that discourage pest entry. An appropriate process design incorporates a flow that prevents finished items from making contact with raw materials and unprocessed products. [ABSTRACT FROM AUTHOR]

An efficient cleaning system can reduce labor costs in meat and poultry plants by up to 50%. The optimal cleaning system depends on the type of soil and type of equipment present. High-pressure, low-volume cleaning equipment is normally the most effective for removing heavy organic soil, especially when deposits are located in areas that are difficult to reach and penetrate. However, foam, slurry, and gel cleaning have become more prominent because cleaning is quicker and cleaners are easier to apply using these media. Because of high equipment costs and cleaning limitation, CIP systems are typically limited primarily to applications that involve large storage containers. In meat and poultry plants, acid cleaning compounds are used most frequently to remove mineral deposits. Organic soils are more effectively removed through the use of alkaline cleaning compounds. Chlorine compounds provide the most effective and least expensive sanitizer for destruction of residual microorganisms. However, iodine compounds give less corrosion and irritation, and quaternary ammonium sanitizers have more of a residual effect. Appropriate cleaning procedures depend on the area, equipment, and type of soil. [ABSTRACT FROM AUTHOR]

Rigid sanitation practices are essential in low-moisture food manufacturing and storage facilities to maintain product acceptability and to comply with regulator requirements. A sanitary operation should be complemented with appropriate facility site selection and hygienic design of the building and equipment. Unprocessed materials should be sampled during the receiving operation to verify that they are not infested with insects, molds, rodents, or other unacceptable contaminants. During storage, unprocessed and manufactured products should be protected from contamination through effective housekeeping practices. Storage areas require routine inspection to observe for microbial and pest infestation. Inspection and cleaning frequency of storage areas depends on temperature and humidity. Cleaning in the manufacturing area should be done daily. Cleaning equipment consists of basic cleaning tools for lowmoisture product areas, including vacuum equipment, powered floor sweepers and scrubbers, and compressed air for certain applications. [ABSTRACT FROM AUTHOR]

Pests of major significance to the food industry include the German cockroach, American cockroach, Oriental cockroach, housefly, fruit fly, Norway rat, house mouse, pigeon, sparrow, and starling. Control of pests can be most effective through prevention of entry into food establishments and the elimination of shelter areas and food sources for subsistence and reproduction. If pests become established, pesticides, traps, and other control techniques are essential. These eradication devices should be considered a supplement to, rather than a replacement for, effective sanitation practices. Because pesticides are toxic, these compounds should be selected and handled carefully. Precautions during use, storage, and disposal are essential. Although a trained employee can handle pesticides, a professional exterminator should be employed for complex and hazardous applications. [ABSTRACT FROM AUTHOR]

High-pressure, low-volume cleaning equipment generally is among the most effective cleaning equipment in the removal of soil deposits with penetration ability in difficultto- reach areas. Foam, which has gained wider acceptance because it is easily applied and has the ability to cling to surface areas, tends to be more effective for large surface areas. A medium similar to foam, except that less air is present and it has reduced clinging ability, is called a slurry. A gel medium is most effective for cleaning equipment with small moving parts. A portion of the equipment used in food processing plants for fluid processing, such as for beverages and dairy products, is cleaned effectively with CIP units, which reduce cleaning labor. However, this equipment is expensive and is less effective where heavy soil and a variety of processing systems exist. Sophisticated CIP equipment includes a microprocessor control unit to monitor operating parameters. Parts and small utensils can be cleaned effectively with COP equipment. More sanitary lubrication of high-speed conveyors and other equipment is possible through the use of mechanized lubrication equipment. [ABSTRACT FROM AUTHOR]

To determine the optimal waste treatment systems, it is necessary to conduct a survey to ascertain waste volume and characteristics and water consumption records. Waste pollution is measured through BOD, COD, DO, TOC, SS, TSS, TDS, and FOG. Wastewater can be salvaged through recycling and reuse and recovery of solids. The basic phases of wastewater treatment are pretreatment by flow equalization, screening, and skimming; primary treatment by sedimentation and flotation; secondary treatment by anaerobic lagoons, aerobic lagoons, trickling filters, activated sludge, oxidation ditch processes, land application, RBCs, and tertiary treatment by physical separation, tertiary lagoons, and chemical oxidations. Disinfection of treated wastewater should follow other treatment phases to reduce the reaction of organic matter with the disinfectant. [ABSTRACT FROM AUTHOR]

Sanitizers are applied to reduce the pathogenic and spoilage microorganisms of food facilities and equipment. Soils must be completely removed for sanitizers to function properly. The major types of sanitizers are thermal, radiation, and chemical. Thermal and radiation techniques are less practical for food production facilities than is chemical sanitizing. Of the chemical sanitizers, the chlorine compounds tend to be the most effective and the least expensive, although they tend to be more irritating and corrosive than are the iodine compounds or the quaternary ammonium compounds. Bromine compounds are more beneficial for wastewater treatment than for sanitizing cleaned surfaces, although bromine and chlorine are synergistic when combined. The quats are more restrictive in their activities but are effective against mold growth and have residual properties. They do not kill bacterial spores but can limit their growth. Acid-quat and chlorine dioxide sanitizers offer potential for the control of L. monocytogenes, and ozone is being evaluated as a chlorine substitute. Glutaraldehyde can be incorporated as a sanitizer for conveyor lubricants used for food operations. Various tests are available to determine the concentration of sanitizing solutions. [ABSTRACT FROM AUTHOR]

An effective sanitation program includes knowledge of soil deposits and use of the appropriate, versatile cleaning compound for the specific cleaning application. Soil characteristics determine the most appropriate cleaning compound. Generally, an acidic cleaning compound is most effective for removal of inorganic deposits, an alkaline cleaner for removing non-petroleum organic soils, and a solvent-type cleaner for removal of petroleum soils. The major function of cleaning compounds is to lower the surface tension of water so that soils may be loosened and flushed away. Detergent auxiliaries are included in cleaning compounds to protect sensitive surfaces or to improve the cleaning properties. Knowledge of how to handle cleaning compounds is essential to reduce the potential for injury of employees. If a worker is accidentally splashed with a cleaning compound, the affected area must be flushed with a large amount of water immediately. [ABSTRACT FROM AUTHOR]

Product wholesomeness and uniformity can be more effectively maintained through a QA program that incorporates available scientific and mechanical tools. Quality is considered to be the degree of acceptability by the user. These characteristics are both measurable and controllable. The major ingredients needed for a successful QA program are education and cooperation. The HACCP approach can be incorporated in a QA program because it applies to a zerodefects concept in food production. Effective surveillance of a QA program can detect unsanitary products and variations in production. Statistical QC techniques make inspection more reliable and eliminate the cost of 100% inspection. The principal tool of a statistical QC system is the control chart. Trends of control charts provide more information than do individual values. Values outside the control limits indicate that the production process should be closely observed and possibly modified. [ABSTRACT FROM AUTHOR]

Hazard Analysis Critical Control Points is a state-of-the-art preventive approach to safe food production. This concept is based on the application of prevention and documentation. HACCP is a proactive prevention program based on sound science. The essential steps for HACCP plan development are: assembly of an HACCP team; description of the food and its intended use; identification of the consumers of the food; development and verification of a process flow diagram; conduction of a hazard analysis; identification of critical control points; and establishment of critical limits, monitoring requirements, corrective actions for deviations, procedures for verification, and record-keeping procedures. Good manufacturing practices are considered the building blocks of HACCP, and sanitation operating procedures are the cornerstones for an HACCP plan. Documentation needed for an effective plan includes descriptions of HACCP team-assigned responsibilities, product description and intended use, flow diagram with identified CCPs, details of significant hazards with information concerning preventive measures, critical limits, monitoring to be conducted, corrective action plans in place for deviations from critical limits, procedures for verification of the plan, and record-keeping procedures. Periodic auditing is necessary for validation and to provide a report card for the program. [ABSTRACT FROM AUTHOR]

Food handlers are potential sources of microorganisms that cause illness and food spoilage. Hygiene is a word used to describe sanitary principles for the preservation of health. Personal hygiene refers to the cleanliness of a person’s body. Parts of the body that contribute to the contamination of food include the skin, hands, hair, eyes, mouth, nose, nasopharynx, respiratory tract, and excretory organs. These parts are contamination sources as carriers, through direct or indirect transmission, of detrimental microorganisms. Management must select clean and healthy employees and ensure that they conduct hygienic practices. Employees must be held responsible for personal hygiene so that the food that they handle remains wholesome. [ABSTRACT FROM AUTHOR]

Food products are rich in nutrients required by microorganisms and may become contaminated. Major contamination sources are water, air, dust, equipment, sewage, insects, rodents, and employees. Contamination of raw materials can also occur from the soil, sewage, live animals, external surface, and the internal organs of meat animals. Additional contamination of animal foods originates from diseased animals, although advances in health care have nearly eliminated this source. Contamination from chemical sources can occur through accidental mixing of chemical supplies with foods. Ingredients can contribute to additional microbial or chemical contamination. Contamination can be reduced through effective housekeeping and sanitation, protection of food during storage, proper disposal of garbage and litter, and protection against contact with toxic substances. [ABSTRACT FROM AUTHOR]

Allergens are substances that cause the immune system to trigger an act against itself. Normally, this condition occurs when foreign bodies enter the human body. Those involved with sanitation should be aware of how to protect foods against allergens. Allergen infestation frequently occurs because of product cross-contamination through an allergen-containing product during manufacture. A definite trend toward product recalls associated with undeclared allergens in manufactured products has developed. An effective method for the control of allergens is the organization and implementation of an ACP. Such a plan can avoid inadvertent allergen cross-contamination, with resultant recalls and potentially adverse and potentially fatal reactions. Allergen contamination can be most effectively reduced through effective education, sanitation, and monitoring. [ABSTRACT FROM AUTHOR]

During the past decade, biosecurity has become a major concern of the food industry. Knowledge of the threat of bioterrorism in food processing and preparation is essential for the maintenance of a safe food supply. The food industry has focused on three areas that are referred to as the “3 Ps” of protection, which are personnel, product, and property. The U.S. Department of Agriculture has provided some beneficial guidelines for the processing, storage, and protection against bioterrorism and the FDA has implemented guidelines for enforcement of the Bioterrorism Act. Since pest management is an integral part of food security, the training of pest management personnel is a viable method to improve food safety through monitoring the premises for indications of bioterrorism. Biosecurity and pest management personnel should collaborate to create a set of common goals and training opportunities. The FDA and the U.S. Department of Agriculture (USDA) have a website for the food industry that includes an extensive amount of information about biosecurity. [ABSTRACT FROM AUTHOR]