Sanitation and GMP Controls for Listeria Listeria Controls

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 n Minimize contamination coming into plant § Prevent cross contamination by people, products and equipment in the plant n n 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 n n 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 n “Dirty Zone” – Where raw product is handled. n “In-Process Zone” – Intermediate steps in the n “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 n n n 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 n n 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 n n 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 n n 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 n Separate operations physically if possible or separate by timing the movement of product to prevent cross contamination Processing Cook 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 n n n 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 n n 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 n n n n Baskets Chutes Counters Scales Packaging Equipment On/Off Switches Rubber seals on doors n n n Trash/waste receptacles Floors with standing H 2 O Condensate traps Ice makers Underneath Cleaning table

Sanitation Procedures n n 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 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 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, 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 no

You May Need Special Cleaning and Sanitizing Procedures for: n n n Floor Mats Totes and tubs Colanders Aprons and boots Boot dips

Sanitation Implementation Consistency & attention to details is critical ü Assign reliable dedicated employees to cleaning and sanitation tasks and train them ü Seek expert assistance as necessary to ensure that effective chemicals, procedures and delivery systems are being used and monitored properly ü 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 n n n Good Personal Habits Proper Clothing Good Health Hand Washing Handling Products Properly

Make sure Employees Keep Themselves Clean n n 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 ü ü Before starting work After using the bathroom After leaving the work area Before returning to the work area

When To Wash Your Hands continued n n n 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 ü ü ü 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.