CLEANING AND SANITATION

WHAT IS CLEANING?

Cleaning refers to removing visible dirt, food residues, grease, and other impurities from surfaces, equipment, and utensils used in chicken essence production. Cleaning involves pre-rinsing to remove debris, applying detergents, scrubbing surfaces, rinsing thoroughly, and inspecting for residues, focusing on equipment, storage tanks, production areas, and tools.

WHAT IS SANITATION ?

Sanitation goes a step further to eliminate microorganisms that can cause foodborne illnesses or spoilage, ensuring food safety. Sanitizer application involves using chemical agents like chlorine or QUATs, or thermal methods like hot water or steam, followed by proper drying to prevent microbial growth and validated by surface testing.

Cleaning method▶️ Closed cleaning ▶️ Single CIP (Cleaning In Place)

Clean-In-Place (CIP)

CIP is a cleaning process where the cleaning solution is circulated through the equipment without disassembling it. This method is ideal for difficult or impractical systems to disassemble for cleaning, like large-scale processing or thawing machines.

Advantage of CIP

Convenience: Cleaning while the equipment is still in place reduces downtime.
Efficiency: It uses automated processes to clean complex equipment, such as pipes, pumps, and tanks.
Consistency: Ensures consistent cleaning results every time, improving sanitation standards..
Cost-Effective: Although initial setup costs for CIP systems can be high, the reduction in manual labor and the efficiency of cleaning processes result in long-term savings in both time and labor costs.
Compliance with Food Safety Standards: ensure equipment meets required food safety standards - HACCP (Hazard Analysis Critical Control Points), GMP (Good Manufacturing Practices), and FDA regulations for food-grade equipment.

Key Considerations

Avoid Abrasive Cleaning Tools: Use soft cloths, sponges, or brushes to avoid scratching the stainless steel, as scratches can harbor bacteria.
Use pH-Neutral Detergents: Acidic or alkaline cleaners that are too strong can damage the stainless steel surface, so choose pH-neutral or food-safe cleaners.
Temperature Control: High temperatures help in breaking down fat and residues, but extreme heat can also damage gaskets and seals. Be cautious with water temperature and sanitizing solutions.

Cleaning Frequency

- Daily: Clean the separator after each batch or production run to prevent contamination.
- Weekly/Monthly: Perform deep cleaning and inspect the machine for wear and tear, particularly the bowl and rotor.
- Visual Inspection: After drying, visually inspect the machine to ensure it is free from any residues, adhesive buildup, or microbial contamination.
- Swab Testing: Conduct swab tests on critical areas (e.g., label rollers, conveyors) to ensure that no contaminants are present.
- Microbial Testing: If required, microbiological testing can be done to verify that the machine meets sanitation standards

Maintenance of CIP Systems

Check Pumps and Valves: Ensure that the pumps are operating correctly and that the valves are not clogged or damaged.
Monitor Detergent and Sanitizer Concentration: Regularly check the concentrations of cleaning agents to ensure that they are effective but not excessive, which can be wasteful.
Inspect Spray Nozzles: Ensure that spray nozzles are not clogged and are distributing cleaning solutions evenly.
Regularly Test Effectiveness: Periodically inspect the system for cleanliness by swabbing surfaces and testing for bacterial presence to verify the effectiveness of the CIP process.

TYPE OF EQUIPMENTS

Thawing Machine

🛑Frozen Chicken Meat Thawing Machine

Cooking Machine

🛑Stainless Steel Large Pressure Cooker

Filtration Machine

🛑Centrifugal Tubular Centrifuge Separator

Concentration Machine

🛑Vacuum Evaporator Concentrator

Mixing Machine

🛑High Pressure Homogenizer

Cooling machine

🛑Plate Heat Exchanger

Filling and Capping Machine

Automatic Jar Filling and Capping Machine

METHODS FOR CLEANING AND SANITATION FROM THAWING MACHINE TO FILLING AND CAPPING MACHINES

Pre-Cleaning Preparation

- Turn Off the machines: Always ensure that the pressure cooker is turned off and allowed to cool down before cleaning.
- Disconnect Power: If the cooker is electrically operated, disconnect it from the power source.
- Depressurize: Ensure that the machine is fully depressurized before opening.

CIP Steps:

Pre-Rinse: Spray or circulate cold water to remove large food particles, oils, and residues. (Product reclaim)
Detergent Wash: Circulate an alkaline detergent solution at high temperatures (60-80°C) to break down grease, oils, and food residues. Ensure the detergent is safe for food contact surfaces.
Rinse: Thoroughly rinse the cooker with clean water to remove the detergent and any loosened residues.
Sanitize: Use a sanitizing solution such as chlorine-based, quaternary ammonium, or peracetic acid. Sanitize all surfaces, ensuring the solution reaches all areas of the cooker.
Final Rinse: Perform a final rinse with clean water to remove any sanitizer residue.
Drying: Use air drying.
Post-Cleaning Inspection: Once the CIP process is complete, the system is checked for cleanliness.

Sanitizing Techniques:

Chlorine-Based Sanitizers: Effective for sanitizing but need to be used with care ( lower concentrations than detergents but should be effective enough to meet the required hygiene standards) , as they can cause discoloration or damage if not rinsed properly.

Labeling Machine

🛑Fully Automatic In-Line Round Bottle Labelling Machine

METHODS FOR CLEANING AND SANITATION:

1. Pre-Cleaning Preparation:

Turn Off the Machine
Remove Labels and Product: Clear out any unused labels and ensure the bottle conveyor system is empty of products.
Disassemble Removable Parts: If needed, remove parts such as label dispensers, rollers, and guides that are easy to clean separately.

2. Pre-Rinse (Initial Cleaning Step):

Cold or Warm Water Rinse: Begin with a rinse using cold or warm water to remove any loose labels, adhesive residues, or dust from the machine.
Drain Water: Allow the water to drain from the system to prepare it for the next cleaning phase.

3. Detergent Cleaning:

Alkaline Detergent: Use an alkaline detergent (heated to 60-80°C (140-176°F)) that is suitable for removing adhesive residues, oils, and other organic residues from the machine surfaces. Circulate the cleaning solution through the machine's internal components (about 10-15 minutes).
Rinse: Rinse the machine thoroughly with clean, warm water to remove detergent residues.

4. Sanitizing:

Sanitizing Solution: After detergent cleaning, apply a sanitizing solution to kill any remaining bacteria, yeast, or mold.
Circulation: The sanitizing solution should be circulated through the machine using CIP to all machine surfaces that come in contact with the product.
Contact Time: Allow the sanitizer to remain in contact with surfaces for at least 1-10 minutes.
Rinse: After the sanitizer has been applied, rinse the system thoroughly with clean, potable water to ensure all sanitizer residues are removed.

5. Drying:

Air Drying: Use compressed air or a drying system to remove any remaining moisture from the machine, particularly in hard-to-reach areas.

6. Post-Cleaning Inspection:

Visual Inspection, swab test, microbial test.

7. Restart

Test Run: Before restarting full-scale production, perform a test run to ensure the machine is functioning properly and that no cleaning residues remain.
Documentation: Record the sanitation procedure, including cleaning agents, time, temperature, and results of any inspections or tests.

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