Managing and Documentation of Sanitation Programs

1.  Managing and Documentation of Sanitation Programs Ron Hall Don Bredeman Ecolab Food & Beverage- Northwest District

3. GMP’s - Good Manufacturing Practices 21 CFR 110 - Federal Law Minimum Standards Food - Manufacturing, Packing, Distribution Adulteration Unfit of Human Consumption Unsanitary Conditions that MAY Contaminate or be Injurious to Health

4. Risk, Rules, Reactions will continue to change Sanitation program must continue to evolve with the changes in business In the past – Continuous Improvement was the focus Today – Food Manufacturers are expected know how to produce SAFE Food and predict future risks

5. People at Risk Under 1 year Old Over 60 years Old Aids Patients Immuno Compromised – Chemo therapy Pregnancy

8. Sanitation Program Divide Legal Responsibilities Business Requirements Meet Business Plan Requirements Define Market and customer requirements Define your plan to meet 1 & 2 Measure and track the plan

9. Compare your Policy & Programs to Government web sites and industry news Published law is the minimum standard Laws + Regulatory Guidelines + Industry norms = The Industry Standard Plant Standard = # 1 + # 2 + Customer Standards (AIB, Cook & Thurber, SQF, BRC, IFS)

13. Challenges: In our back yard 3 Plants Burned down 4 Plant worker Deaths E-Coli Juice, Lettuce, Spinach Salmonella Alfalfa Sprouts Tomatoes, Cantaloupe Mad Cow Disease Slaughter House Listeria RTE Meat & Lettuce

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16. Plant Manger is Responsible Plant Manger uses inputs from resources to define programs and establish plant policy Corporate Directives Senior Management QA/QC Production Engineering/Maintenance Sanitation Finance Area Specific Supervisors

17. Operational Plan Policies Written procedures Work instructions Food Quality Plans Internal & external audits Security Plan Crisis Plan Corrective actions Documentation Management Legal training requirements Raw Product control program Sanitation Program Food Safety & Security Plan HACCP Plan Allergen Program Pest Control Program Warehouse/recall Program

18. If you do it, write it down! If its not written down, it hasn’t been done. Be able to trace the plan Be able to correct the plan Be able to present the plan

19. What is Sanitation?Perspective – stock holder/consumer ____________________________________ ____________________________________ ____________________________________

20. What is Sanitation? Rob – Maintaining the Plant in a Clean Condition to minimize Risk. Don – Required to make a saleable, revenue producing product Chris – An ongoing program that ensures the entire plant and grounds are maintained to ensure product integrity. Margarito – The most important part of the Production Day

21. What is Sanitation?Perspective – stock holder/consumerSurvey answers Protects product integrity A requirement by Federal Law A cleaning of the plant processing areas Insurance for Product Safety/guard against a recall Critical part of our production cycle Requirement to ensure safe food Assurance of quality for our customers Reduction of Risk Sanitation is the integrity of my plant Most unrecognized function in the plant

22. The Weeds (details)

23. The Weeds (details)

24. What is the plan? Plan Name of ________ Purpose : Function and agreement Buy in statement / Explanation What’s in it for me? You? them? (WHY?) Because the auditor says so – is not a reason. Your have an obligation to break the information down into usable form and obtain “Buy in” or conformity among the crew Follow up - Measurement

25. Definition of Sanitation Sanitation is the first step in the production cycle. Sanitation does not add value to a product which has just been manufactured it only protects the value of the product that will be produced.

26. What’s the plan? Define the parameters Validate the plan Verify the plan

27. Validate & Verify (The Plan) Training Plan Master Sanitation Schedule Chemical usage plan

28. Validate & Verify Training Plan – Legal Training Plan – Business The Topic, Need, Benefit, Justification The measurement – Before, after, later Follow-up Department Training plan Personnel training plan Refresher Training Does Training = Expectations?

29. Validate & Verify Master Sanitation Schedule

30. Validate & Verify Training Plan The Topic, Need, Benefit, Justification The measurement – Before, after, retention Follow-up Master Sanitation Schedule Product Contact – 1st and 2nd level Environmental Procedural / SSOP Evaluation Chemical usage plan

33. What’s the Risk? Start Program use rate Overuse $$ Underuse = Increased Risk

34. How much chemical do I use? What’s the plan? Target use rates? Legal requirement – Sanitizers, Process aids What’s the limit? Plant target? Action if your above or below Legal limit? Action if your above or below Plant Target? Business requirement – Cleaners ___% above or below the plan, justify when you are outside of plan range.

35. Cost Example 1 Chemical XYZ use rate is 5 oz/gal, $5.00/gallon 1000 gallon circuit 1 gal = 128 oz 5 oz/128 oz = .039 gallons x $5.00/gal = $.19 unit 1000/5 = 200 units x $.19 = $38.00

36. Cost Example 2 (10% increase) Chemical XYZ use rate is 5 oz/gal, $5.50/gallon 1000 gallon circuit 1 gal = 128 oz 5 oz/128 oz = .039 gallons x $5.50/gallon = $.21 1000/5 = 200 units x $.21 = $42.00

37. Cost Example 3 (10% increase) (20% water reduction) Chemical XYZ use rate is 5 oz/gal, $5.50/gallon 800 gallon circuit 1 gal = 128 oz 5 oz/128 oz = .039 gallons x $5.50/gallon = $.21 800/5 = 160 units x $.21 = $33.60 Savings 1st level = ($4.40) = (11%) Savings 2nd level = Waste Treatment

39. Food Safety RegulationsEarly Beginnings 600 AD "He who deliberately gives or sells it (unfit food) to another will be banished for a year. If the person to whom it has been given or sold dies, the offender will be hanged" T'ang Dynasty, China ?? "If dried or fresh meat causes illness, leftovers must be burned immediately. The producer will be flogged 90 strokes”

40. Education and Training Competent Management to Produce Safe and Clean Food Training Programs for Food Handlers and Supervisors Responsible Persons Identified

41. Sanitary Operations Maintain Facilities and Equipment in a Clean Condition Clean and Sanitize as Needed to Prevent Contamination Keep Cleaners and Sanitizers Free from Microorganisms

42. Production and Process Controls Validation - QC Microbial/Chemical/Extraneous-materials Raw Materials - Inspection/Segregated/Storage/Washing Manufacturing Operations - Processing Time/Temp./pH/Flow/Pressure/etc. Separation of Raw and Processed Control of Foreign Substances

43. The SPIRIT of the LAW GMP’s General Guidelines All Food Processors Processors Responsibility Interpret Guidelines Develop Specific GMP Plan / Policy Implement Train Monitor

44. SSOP’sSanitation - Standard Operating Procedures Required by USDA - FISI Mega-Reg Considered a Prerequisite to HACCP Require Effective GMP’s

45. SSOP Format 1. Date 2. Identification 3. Plant & Product ID 4. Management Structure SSOP Responsibility 5. Equipment Type 6. Cleaning Frequency 7. Procedure Including: Preparation & Disassembly Cleaning & Sanitizing Reassembly 8. Monitoring Concentrations, Microbial, ATP 9. Corrective Action- Who & What & Verified? 10. Record Keeping

46. SSOP - Example

47. Good Manufacturing Practices - GMP’s “Deadly Results” Consumer: People DIE Business: Lost Sales / Costly Recalls You: Plant Closes Everyone’s Job - 100% Commitment Safe / Quality Foods Safe Environment for: Food Production / Worker / The Environment -“Earth”