Choosing an Effective Sanitizer

Transcription

1 Choosing an Effective Sanitizer, CEO - Shepard Bros., Inc. NWFSS 2017 Outline Antimicrobial Definitions Cleaning Comes First Biofilms Overview of Sanitizers Common Products New Technologies Organic Processing Choosing an Effective Technology Summary 2 Choosing an Effective Sanitizer 1

2 "The Great Race" Let's ask the question: "why do we sanitize?" Ultimately we are trying to: Keep food from spoiling long enough so that it can be consumed Keep food from being contaminated with microorganisms so that it is safe to consume Humans vs. microbes Think Roadrunner vs. Coyote 3 Antimicrobial Definitions 4 Choosing an Effective Sanitizer 2

3 Antimicrobial Definitions There are different levels of microbial "kill": Sanitizers reduce bacteria to levels considered safe by public health organizations Most used in food processing environments Disinfectants kills all bacteria, yeast and molds, and most viruses but not bacterial endospores (i.e. Bacillus spores) Typically used in hospitals Sterilants kills all bacteria, yeasts, mold, viruses, and bacterial endospores Aseptic processing; hospital instrument devices 5 Antimicrobial Definitions (2) Preservatives inhibit microbiological growth in/on a product by creating an "inhospitable environment" Preservatives are intended to protect the product from microorganisms that may be introduced post production NOT a replacement for Good Manufacturing Practices Common "food grade" preservatives Potassium sorbate Sodium benzoate Ineffective for use as a sanitizer 6 Choosing an Effective Sanitizer 3

4 Hard Surface Sanitizers Hard surface sanitizers are regulated by the U.S. Environmental Protection Agency (EPA) Food Contact Sanitizers Reduce bacteria by % (or 5 Log 10 ) Non Food Contact Sanitizers Reduce bacteria by 99.9% (or 3 Log 10 ) Products must be used according to label directions Claims substantiated during EPA registration process 7 Hard Surface Sanitizers: Food Contact Surface Sanitizers For use on hard surfaces where food products make contact Minimum requirement: reduce the levels of Staph aureus and E. coli by % (or 5 Log 10 ) within 30 seconds EPA mandates label claim of one minute All ingredients in the antimicrobial solution must be cleared under 40CFR A potable water rinse is not allowed after sanitization of a food contact surface 8 Choosing an Effective Sanitizer 4

5 Hard Surface Sanitizers: Non Food Contact Surface Sanitizers For use on hard surfaces where food products do not make contact Often referred to as "Environmental surfaces" Minimum requirement: reduce the levels of Staph aureus and Klebsiella pneumonia (or Enterobacter aerogenes) by 99.9% (or 3 Log 10 ) within five minutes Sanitizing non food contact surfaces helps prevent cross contamination of food contact surfaces % vs % Think 99.9% vs % is basically the same? Example: A contaminated surface has 1 million (6 log 10 ) colony forming units (CFU)/in 2 of bacteria Reduce bacteria by 99.9% there are still 1,000 CFU (3 log 10 ) bacteria remaining Reduce bacterial by % there are only 10 CFU (1 log 10 ) bacteria remaining NOTE: For many pathogens, the infectious dose is generally 100 CFU/g (or 2 log 10 ) of food product 10 Choosing an Effective Sanitizer 5

6 Cleaning Comes First 11 Sanitizing Begins With Cleaning Proper cleaning is the most critical step in a sanitation program Effective cleaning requires: Adequate water supply of sufficient quality Understanding of cleaning variables Chemistry, detergent performance and function of sanitizing agent(s) Conducting proper cleaning steps 12 Choosing an Effective Sanitizer 6

7 Considerations for An Effective Cleaning Program Materials of construction May restrict the type of chemicals that can be used Composition of soils Organic, inorganic, biofilms Personnel exposure levels to applied chemicals Foam (or non foaming) requirements Discharge limitations of some chemicals 13 Know What Kind of Soil You Have The composition of the soil you are trying to clean will dictate what kind of cleaner you need Inorganic Residues Mineral scale, iron, silicates, soaps Removed by inorganic acid cleaners Phosphoric, Nitric, Sulfuric, Hydrofluoric Organic Soils Use Acid Cleaners Use Alkaline Cleaners Proteins, carbohydrates and FOG (fats, oils, greases) Harbor bacteria and can inhibit physical contact between a sanitizer and bacteria May inactivate the sanitizer active ingredient Removed by alkaline cleaners / caustic cleaners and enzymatic detergents 14 Choosing an Effective Sanitizer 7

8 Biofilm A Unique Soil Situation Biofilm is a "slime" layer that adheres to surfaces A complex matrix made up of bacteria that secrete EPS (ExoPolySaccharides) and organic residues Organic residues made up of proteins, glycoproteins, minerals, polysaccharides, etc. Develops on a variety of surfaces: processing equipment, pipes, membrane filters, cooling devices Often undetected until microbial issues arise Biofilm is a constant source of contamination due to the unpredictable release of microbes Biofilm will slough off a layer of cells periodically causing bacterial count "spikes" to occur 15 Biofilm Formation Biofilm development stages 1. Organic cells adsorb/fixate on the surface 2. Growth of bacteria and EPS matrix 3. Mature biofilm; cells begin to slough off causing product contamination Biofilms often harbor a variety of organisms incl. Pseudomonas, Listeria, and Salmonella species 16 Choosing an Effective Sanitizer 8

9 Do You Have a Biofilm? Historically, the inability to identify a biofilm has in a timely manner has been a significant issue Sterilex has recently developed a commercially available biofilm detection product: Indicon Gel Ready to use gel that allows for quick visual indication of the presence of biofilm on a surface Allows plant to proactively seek and treat a biofilm situation 17 Technologies for Biofilm Realzyme Enzymatic detergents Used at the beginning of a cleaning protocol Specially designed, concentrated enzymatic cleaners for optimal cleaning and preparation of surfaces for sanitizing Requires subsequent application of an EPA registered biocide Sterilex PerQuat Technologies Biocidal System Used at the end of a cleaning protocol Two part liquid system that carries an EPA registration and biofilm claims On food contact surfaces, a potable water rinse followed by an EPA approved no rinse sanitizer is required Product portfolio expanded to include formulas for CIP and Metal Safe Use 18 Choosing an Effective Sanitizer 9

10 Sanitizer Products Overview 19 Chemical Biocides Quaternary Ammonium Compounds (QACs or Quats) Iodophors Acid Anionics Oxidizing Technologies Peroxyacetic Acid (PAA) Chlorine Dioxide (ClO2) Chlorine / Sodium Hypochlorite Ozone Newer Technologies PerQuat Technologies for Floors & Drains Silver Dihydrogen Citrate (SDC) 20 Choosing an Effective Sanitizer 10

11 Biocidal Modes of Action The mechanism by which the biocide works is referred to as the mode of action OXIDIZERS: ALL 3 MODES 3. Reactions denature proteins and inhibit DNA synthesis Alcohols 2.Reactions affect cellular components coagulation, mitochondria, etc. Peracetic Acid Acid anionics Chlorine Ozone Iodophors Quats Chlorine dioxide 1. Reactions disrupt cell membrane allows cell contents to leak 21 Quats Applications and Advantages: Well suited for environmental uses due to foaming properties Cetylpyridinium chloride (CPC) used in poultry intervention Safe for soft metals Stable to heat and organic loads Leave bacteriostatic films Disadvantages: Efficacy may be reduced in hard water Reduced efficacy in biofilm environments Incompatible with anionic surfactants Foam problematic in CIP systems Residual effects may harm starter cultures Not permitted in organic processing SURFACTANT Mode of Action: Disruption of cell membrane due to positive charge 22 Choosing an Effective Sanitizer 11

12 Iodophors Phosphoric acid and iodine complexed with a nonionic surfactant Applications and Advantages: Well suited for hand dips and sanitizing utensils Broad spectrum efficacy except against bacteriophage and bacterial endospores Fairly tolerant to hard water and organic loads (more so than chlorine) Disadvantages: Mode of Action: Causes staining Ineffective over ph 5 Disruption of cell membrane Denatures proteins 23 Acid Anionics Acid and anionic surfactant Applications and Advantages: Sulfonated oleic acid types and fatty acid types good for CIP Good control of mineral films Acid rinse and sanitizer in one step Broad spectrum efficacy including bacteriophage DDBSA types can be foamed Mode of Action: Disadvantages: Activity reduced above ph 3 Ineffective in presence of quats and other cationic surfactants Disruption of cell membrane Denatures proteins 24 Choosing an Effective Sanitizer 12

13 Peroxyacetic Acid (PAA) Applications: Excellent for CIP applications and some COP applications Direct fruit & vegetable contact and process waters; direct meat and poultry intervention Advantages: Very broad spectrum efficacy including bacteriophage Excellent cold water kill, unlike most sanitizers Acid rinse and sanitizer in one step Organic approved Environmentally friendly Disadvantages: Not for use with soft metals Safety and handling considerations Mode of Action: Burns through cell membrane Hydroxyl radicals denature proteins Inhibits DNA replication Oxidizes sulfur bonds 25 Chlorine Dioxide (ClO 2 ) Applications and Advantages: Significantly more powerful than chlorine when properly activated Very broad spectrum efficacy including bacteriophage Non corrosive at use concentrations Disadvantages: Chlorine dioxide generators can be dangerous Activation of sodium chlorite by acid activators is safer, but requires proper activation and continuous monitoring Potential to generate chlorine gas Short shelf life of activated solution Mode of Action: Burns through cell membrane Hydroxyl radicals denature proteins Inhibits DNA replication Oxidizes sulfur bonds 26 Choosing an Effective Sanitizer 13

14 Chlorine/Sodium Hypochlorite Advantages: Broad spectrum efficacy including bacteriophage Effective at low temperatures Hard water tolerant Inexpensive Disadvantages: Corrosive Use solutions have very short shelf life Environmental issues / discharge limits Consumed by organic matter Mode of Action: Burns through cell membrane Hydroxyl radicals denature proteins Inhibits DNA replication Oxidizes sulfur bonds 27 Ozone Applications and Advantages: Powerful oxidizer More than 15 year history of U.S. firms using ozonated water for direct contact with fish to reduce spoilage organisms Some studies show improved shelf life and flavor with direct treatment of fruits and vegetables Eco friendly Disadvantages: Inherently unstable Very reactive and corrosive Highly consumed by organics Requires capital investment and higher ongoing operating costs Mode of Action: Burns through cell membrane Hydroxyl radicals denature proteins Inhibits DNA replication Oxidizes sulfur bonds 28 Choosing an Effective Sanitizer 14

15 PerQuat Technology Drain Program 2004: FSIS/USDA audit of food processing facilities found 27.8% of drains positive for Listeria PerQuat proprietary technology Custom drain attachments recommended Control bacteria such as Listeria, and other food pathogens in drains to prevent cross contamination Eliminates hand scrubbing Allows for disinfection past the trap Recommended by USDA as a best practice for Listeria control 29 PerQuat Technology Dry Floor Sanitizer EPA registered dry floor sanitizer product based on the PerQuat technology Features& Benefits: Blue powder for easy identification Product has improved safety profile Less dusty formulation than previous dry floor sanitizer product Also foot pan specific claims not on previous product Not regulated for transport 30 Choosing an Effective Sanitizer 15

16 Silver Dihydrogen Citrate (SDC) Patented technology based on silver dihydrogen citrate (SDC) developed by Pure Bioscience Ready to use product of electrolytically generated SDC containing: 4.846% Citric Acid and 30 ppm Silver Ions Commercially available as Pure Hard Surface EPA registered, Ready To Use product approved for: Food contact surface sanitization with no rinse requirement Environmental surface sanitization and disinfection No rinse disinfection with 24 hour residual protection on food contact surfaces 31 Silver Dihydrogen Citrate (SDC) NSF registered D2 Classification No bleach, phosphates, ammonia, phenols or VOC emitting compounds Surface compatible; non corrosive, non flammable Well suited for applications on soft metals: Freezing tunnels Spiral freezers Aluminum coils, fittings, etc. Trucks Sanitary Transport Rule Applied as a fine mist ideal for dry processing environments Non toxic; EPA Category IV; Generally Regarded as Safe (GRAS) 32 Choosing an Effective Sanitizer 16

17 Processing 33 Organic Processing The USDA National Organic Program (NOP) is the federal regulatory body governing organic food Certification is handled by state, non profit, and private agencies that have been approved the USDA The Organic Materials Review Institute (OMRI) is one of the largest Sanitizer products are certified "organic" for use in organic processing Cleaners are not certified and organic processing does not require organic cleaners 34 Choosing an Effective Sanitizer 17

18 Organic Processing (2) The NOP approves the following no rinse sanitizers for use in organic postharvest systems: Chlorine calcium hypochlorite, chlorine dioxide and sodium hypochlorite Ozone Peracetic Acid Ammonium sanitizers, such as quats May be used on non food contact surfaces May not be used for direct food contact surfaces associated with organic foods 35 Choosing an Effective Technology No biocide is perfect for every application Considerations when selecting a biocide: Materials of construction Water hardness, temperature and quality Efficacy claims Cost Method of application Organic status Sanitizing is not a substitute for poor cleaning practices Sanitizing is only effective on clean surfaces 36 Choosing an Effective Sanitizer 18

19 Factors Influencing Biocide Effectiveness Concentration Use as indicated on the product label Check concentrations of use solutions Time Check label for minimum exposure time Longer contact times generally provide greater efficacy Temperature Practical optimum temperature is 60 F 100 F Chlorine volatilizes and dissipates quickly over 120 F 37 Factors Influencing Biocide Effectiveness (2) ph of Sanitizer Solution Plants with alkaline water sources may result in usesolutions with lower than expected ph Higher ph water source generates less hypochlorous acid Equipment Cleanliness Equipment must be completely clean for proper contact of surface with sanitizer Chlorine sanitizers can be inactivated by organic soils Improper Rinsing Quat based sanitizers are inactivated by anionic surfactants 38 Choosing an Effective Sanitizer 19

20 Summary Sanitization is a process to eliminate microorganisms with the potential to cause spoilage and/or harm to human health No biocide is perfect for every application Consider materials of construction; water hardness, temperature and quality; efficacy claims; cost, and method of application when selecting a biocide Sanitizing is not a substitute for poor cleaning practices Sanitizing is only effective on clean surfaces 39 Thank You 40 Choosing an Effective Sanitizer 20