Environmental Hygiene Control in a Dry Environment Scott L. Burnett, Ph.D. Manager, Corporate Quality and Food Safety

Transcription

1 Environmental Hygiene Control in a Dry Environment Scott L. Burnett, Ph.D. Manager, Corporate Quality and Food Safety S37 What is Dry Sanitation? What is Dry Cleaning? 2013 IAFP Annual Meeting, Charlotte, NC

2 Who is MOM Brands?

3 Who is MOM Brands? Ames Mill Northfield, MN Campbell Mill Northfield, MN St. Ansgar, IA Tremonton, UT Asheboro, NC 3

4 Our War On Water: Transitioning from Wet to Dry Sanitation Practices

5 Plant water footprint Leak management program Sanitation Challenge: Our War on Water Sanitation objectives Dry sanitation definitions Dry method transition process Sustainability

6 Determine total water footprint Unnecessary Water Condensation Leaks Drain backups Imprudent water use Fix Root Cause Leak Management Program Necessary Water Process water Sanitation Minimize / Manage Eliminate / Reduce

7 Leak Management Program Elements Area monitoring Leak risk assessment -Leak source -Leak amount -Proximity to product stream -Foot / equipment traffic -Pre- vs. post-kill -Air flow Response action categorization -Level of aggression based on risk -Could include: Shut down process -Sanitation Isolate leak -Swabbing Repair& Prevention -Documentation

8 Focus on Water used in Sanitation Stop risky imprudent water activities Washing a dry clean only piece of equipment Washing equipment in close proximity to a dry finished product line Challenge sanitation procedures Post-kill vs. Pre-kill Challenge frequency of wet cleaning events Change to dry methods Assess water activities Product to product changeovers Thereby beginning our War On Water

9 Planning and Communicating the WOW Strategy Upper management commitment Paradigm shift / Behavioral change Grass root teams Committed resources Make WOW a priority Educate manufacturing facilities on WOW philosophy Develop scientific process for wet to dry sanitation transition

10 Develop maps of current state and future states Equipment flow diagram Product stream water activity at infeed & discharge of each piece of equipment Guidance for suitability of dry sanitation methods Visually display the WOW vision

11 Microbiological Lot Definition Allergen Removal Equipment Functionality Flavor Carry Over Particulate Carry Over Pest Prevention Fire Prevention Non-organic Removal Determine the Sanitation Objectives Why do we clean? Each process has different cleaning needs Equipment 1 X X X Equipment 2 X Equipment 3 X X X Equipment 4 X X X X

12 Microbiological Lot Definition Allergen Removal Equipment Functionality Flavor Carry Over Particulate Carry Over Pest Prevention Fire Prevention Non-organic Removal Determine the Sanitation Objectives Validation Success Criteria Visual no gross particulate Visual no visible residue ATP Luminescence APC Measurement Allergen Detection X X X X X X X X X X X X

13 dry clean ing noun Use of an effective cleaning procedure without notable use of water (including aqueous solutions, aqueous suspensions or steam). Dry cleaning methods may include wiping, scraping, brushing, sweeping, blowing, vacuuming, purging or flushing. Flushing agents may be non-aqueous liquids or solids. Dry cleaning methods will not add moisture to food processing equipment or facility.

14 dry san i tiz ing noun Use of an effective sanitizing procedure without notable use of water (including aqueous solutions, aqueous suspensions or steam). Dry sanitizing methods may include the wiping or spraying of alcohol-based sanitizers, application of heat, or gaseous antimicrobial agents. Dry sanitizing methods will not add moisture.

15 Isopropyl alcohol / QAC Sanitizer Ready-to-use sanitizer 58.6% IPA, 150 ppm QAC Fast drying, reduced moisture presence EPA-registered 5 log-reduction, 1 min Flammability dispensing & storage 15

16 Dry Method Feasibility Testing 1. Coordination with production scheduling 2. Draft SSOP (based on 7 principles) 3. Coordinate resource needs 4. Communicate time needs for test execution 5. Considerations for restart of operations Hold production Pre-op inspection Wet wash Sensory evaluation

17 Limited tools -Vacuums -Brushes -Dry wipes -Non-aqueous sanitizer application -Lifts & ladders Sanitary design of equipment -Personal safety -Accessibility -Quantify the cleaning time Identify Barriers

18 Develop a plan to eliminate obstacles Tools-WOW & Sanitation CO 2 sanitizer delivery HEPA blowers Ergonomic tools fabricated Swiffers Ladders & lifts

19 Develop a plan to eliminate obstacles Sanitary Design Engineering Department commitment Budget capital for enhancements Sanitary design standards Old vs. New

20 Finalize and approve written non-aqueous SSOP Develop documentation records or enhance existing records Gather all needed tools for success Provide proper storage for tools Provide properly labeled tools Make cleaning tools readily available Train Team Members & Front Line Managers Education with Q & A 1:1 training during cleaning events Document Provide adequate support Fly solo Implement New Non-aqueous SSOP

21 Our Progress Water drop down hoses in dry areas removed or locked out >80% reduction in internal leaks due to wet sanitation events >71% reduction in number of wet sanitation events Engineering Standards founded on dry sanitation principles

22 Track Metrics Make it Sustainable Total cleaning water consumption per line or area Microbiological, allergen, etc. monitoring Track internal adverse water events with direct correlation to wet washing No. of Wet Washes WOW/Sanitation Audit Correct Cleaning Record Used Cleaning Record completely Filled Out Water Used According to WI. Cleaning tools visually clean stored correctly Drains Covered

23 Make it Sustainable Audits Pinpoint behavior changes needed for success Audit each change over Feedback / training Reinforce positive behaviors Openly displayed corporate metric Reward success with a meal Vending bucks Friendly competition: who can remove their water hoses first

24 Strive for continuous improvement <4 hour wet cleans were water is necessary Controlled or contained cleaning water to drains Investigate dry sanitation tools Dry ice blasting Steam cleaning applications Soda blasting Clean product purging Make it Sustainable

25 Thank You! Scott L. Burnett, Ph.D. Manager, Corporate Quality and Food Safety

26 Questions 26