CLEANING AND SANITATION OF DIARY PROCESSING PLANT

Introduction

Milk is a highly perishable food item- contamination starts from its production, collection,
conveying, processing and storage from plant personnel, packaging material and
environmental factors

Safe milk and milk products Right of consumers can only be

produced through the applicability and maintenance of efficient cleaning,
sanitization and hygiene practices

1
 Cleaning
Cleaning is the process in which complete removal of food soil ( unwanted
matter on food-contact surfaces) is accomplished using appropriate detergent
chemicals under recommended conditions from the internal and external
surface of the equipment

Some of the precipitates remains intact to equipment after cleaning and forms a
film over equipment surface called water stonewhite or grayish film

Heat denaturation of protein present on the equipment surface or absorbed by

other components forms milkstone quickly over heated surfaces
TWO TYPES OF SOIL:

2
1. Water soluble (sugar, starches and salts easily
cleaned by water)

3
2. Water insoluble which is further divided in organic
and inorganic/ mineral salt

4
5
 Source : Entrap
 Food product handled organic/inorganic
 Minerals from water residues debris, nutrients &
 Residues from cleaning compounds other organisms
Vary widely in composition and solubility •
properties Single detergent not capable of
removing different type of soil

• Biofilm:Organism attached to surface

with nutrients deposit, grows and multiply

6
 Properties of various food soils
Heat-Induced
Surface Deposit Solubility Ease of Removal
Reactions

Sugar Water soluble Easy Carmelization

Fat Alkali soluble Difficult Polymerization

Protein Alkali soluble Very Difficult Denaturation

Water soluble, Alkali Easy to Moderately Interactions with other
Starch soluble Easy constituents 8

Water soluble; Acid Generally not

Monovalent Salts Easy to Difficult
soluble significant
Interaction with other
+Polyvalent Salts Acid soluble Difficult
constituents
 Cleaning: Why?
• Proper cleaning of dairy equipment
Reduces the chance of product contamination at each step by reducing the
high initial load of micro-organism through removal of their available
nutrients
Promotes clean and tidy environment that improves operator’s
moral/confidence and helps to maintain safe work place, creates cleaner
production area, prevent/avoid accidents

Increases the life of equipment by increasing plant efficiency, improves process

economy thus profit of the organization

E.g. Efficiency of milk pasteurizer reduces with increase in process time due
to scale deposition on its heat exchanger plates and the same can be
8
 regained after its adequate cleaning, also true with Separator
Cleaning agents
Cleaning agents are mixture of several chemical compounds employed for a
particular function to perform like washing of floors and walls, used in cleaning
modes Manual, COP , CIP

Mainly used to reduce surface tension of water that results in dislodging and loosening of
soil followed by flushing away of the suspend soil particles

Classified as strong, heavy duty and mild alkaline and acids,

employed for a particular use

• Usually, fats, oils, greases, and proteins can be removed with alkaline
cleaners at pH ≥11

9
• Sodium hydroxide (caustic soda) potassium hydroxide (caustic
potash) strong alkali corrosion and tissue damage

• Sodium carbonate (soda ash, mild), and sodium silicates,

Trisodium phosphate (TSP)

• Acid based cleaning agents are the blend of phosphoric,

nitric, sulfuric and sulfamic acid used to remove
encrusted (having a hardened crust as a covering)
surface materials and dissolve mineral scale deposits
• Strong (hydrochloric, hydrofluoric, sulfamic, sulfuric &
phosphoric acids)
• Mild (hydroxyl acetic, acetic, gluconic acid, levulinic )

10
 Basics of Cleaning
• Cleaning is reversal of soiling and requires supply of energy usually in
the form of mechanical and chemical energy.

•To overcome the forces binding the soil to the surface both
mechanical and chemical effect must be provided by cleaning
system
EXPRESSION OF CLEANING RESULTS
Degree of cleaning results are expressed in terms of :

 Physical cleanliness –removal of all visible dirt from cleaned

surface

 Chemical cleanliness – removal of both visible and

microscopic residues not detected by naked eye but by
taste or smell only.

 Bacteriological cleanliness – attained by disinfection

Sterile cleanliness – destruction of all micro organisms.

MECHANISM OF CLEANING
 Cleaning mechanism consists of :
• Wetting of soiled surface i.e. bringing the cleaning solution into intimate
contact with the soil to be removed. For this the solution should have
adequate wetting and penetrating properties.

• Displacement of the soil from the surface by emulsification, saponification

and / or mechanical action.

• Dispersion of soil removed from the surface in the cleaning solution by

dispersion, de-flocculation.

• Rinsing to prevent re-deposition of the dispersed soil on the cleaned surface.

ACTION OF BLENDED DETERDENTS
 Rinsing with water
The water just runs off without wetting the surface –the fat
present in the soil prevents contact. Hot water achieves somewhat
better result by melting fat.
 Water with wetting agent (surfactant) added.

To obtain contact between the detergent solution and the film of

dirt it is necessary to add a wetting agent (surfactant) to lower the
surface tension of liquid.
 protein

Alkaline detergent in water dissolves protein

The continuous protein phase swells somewhat when it absorbs

water. Alkalis reinforce the swelling and dissolves the protein
and release other constituents.
 Cont…

Chelating agent added

Deposits of calcium salts on the surface are loosened and collected by

chelating agents in the detergent.
 Cont…

The residual film is now easily flushed away

The dirt deposit now requires only mild mechanical force

to flush away remaining deposits of dirt.
 Cont…

Dust particles are prevented from resettling on the surface

The film of detergent clinging on the surface gets diluted with

rinse water. If the detergent lacks the ability to hold the
entrained dirt in solution even when diluted, the dirt tend to
flocculate and redeposit on clean surface. Detergent must,
therefore, be capable of dispersing the suspended particles to
prevent flocculation.
PROPERTIES OF DAIRY DETERGENT
An effective and fast-acting detergent should have:
 Ability to dislodge dirt from the equipment surface

 High wetting effect to enable the detergent to penetrate dirt

deposits.
 Ability to break up the deposits and keep them dispersed so that
they are not re-deposited.
 Ability to dissolve calcium salt deposit from the equipment surface.

 Ability to hold calcium salts in solution so that no scale deposits are

left after cleaning.
  Moderate to low foam generation capacity.

 Non- corrosive.
BIO-DETERGENTS
• Alternative to synthetic detergents
• Fast emerging • Low toxicity
• Non-corrosive
• Environmental friendly
• Enhanced cleaning properties
 Steps Purpose
1. Recovery of •Minimizes product loss
product residue •Reduces load on sewage system
(flushing, scraping, •Saving in sewage treatment cost
Cleaning cycle
blowing etc)
2. Pre-rinse •Removes visible soil, Melt fats
(warm water) •Prevent protein adherence
•Prevent thermal shock
3. Wash •Removes remaining soil
(detergent) •Chemicals lift biofilms that bind to equipment
surfaces
4. Post-rinse •Removes suspended soils and chemical residues
•Prepares surface for sanitization
5. Sanitization •Kills bacteria that remain on equipment
 Sanitation
Sanitation was originated from Sanitas (Latin
word) having meaning “health” but the same
word has another meaning “creation and
maintenance of
hygienic and healthful conditions” in food
industry

It is considered as a joint venture

of principles of design,
development, execution,
maintenance, restoration,
improvement of hygienic
practices and conditions

Applied for the creation of hygienic

practices intended to continue a
clean and healthy environment from
food production to storage

25
Usually applied after cleaning
operation for the complete elimination
of all types of bacteria
Importance of sanitation

• Product can get contaminated

with in new and well-designed
plants if proper sanitary
practices are not adopted

• Its main focus is to prevent the

major food based safety
incidents to happen in future

( C) Copyright of Dr. P.N. Raju (2020)

26
 Major Food Safety Incide
Agent Food

S. enteritidis Ice cream

E. coli 0157:H7 Hamburgers 73

Benzene Mineral water Worldwide re

L. monocytogenes Hot dogs 101

Allergens Many foods 35–40% of U.S. po

150–200

Glass Bottled beer 15.4 million bottl

a

(Ma
and
200

Dairy Sanitizers
( C) Copyright of Dr. P.N. Raju (2020)

27
 Most frequently used dairy
sanitizers includes steam, hot
water and chemical sanitizers
In steam sanitizing,
steam is subjected and maintained on
the equipment surfaces for desired
time duration
•The International Dairy
Federation (IDF) recommends
circulation of hot water 85°C for
15 minutes for milk pasteurizer
sanitization
•For enclosed system,
minimum circulation of hot
water (77°C) for 15
minutes or >5 minutes
circulation at 94°C
recommended by Food
and Drug Administration
( FDA )
In chemical (chlorine, iodine etc.)
sanitization, sanitizing solution of
( C) Copyright of Dr. P.N. Raju (2020)

28
 desired concentration is kept in the
contact (circulation) of equipment
surface for 2-5 minutes with slight
back pressure in the pipe lines
Also be applied as fogging, spraying and with
help of brushes

Water attributes important to

cleaning and disinfection

( C) Copyright of Dr. P.N. Raju (2020)

29
• Sanitary quality. Water used in food
plant sanitation must be potable – that
is, fit for human consumption
• Microbiological standards. The following
are the main microbial specifi cations
for water, measured in colony forming
units (cfu) mL−1: total bacterial count <
100, coliforms absent in 100 mL, and
Escherichia coli absent in 100 mL.
• Taste, odour and colour. Objectionable
tastes, odours and colours are usually
acquired from rotting vegetation and
algae, and are best removed by
activated carbon filtration
Suspended matter comprises clay, silt
and other organic materials;
suspension of more than 1 ppm causes
visible turbidity, and is best removed
by sedimentation/filtration
( C) Copyright of Dr. P.N. Raju (2020)

30
• Total dissolved solids (TDS). This is a
measure of all the chemicals dissolved in
the water, and is generally not problematic
for cleaning and disinfection.
• Dissolved gases. Some, such as carbon
dioxide, can form weak acids, resulting in
the need for additional alkali, or in some
cases may cause corrosion.
• pH. This should ideally be between 6.5 and
7.5. Below pH 6.5 corrosion problems will
occur. The maximum alkaline pH value
allowed is 10.

• Alkalinity. High bicarbonate alkalinity may

contribute to scale formation.
• Silica. This is generally not significant in
cleaning and disinfection, but on stainless
steel surfaces it can form dull layers that
are diffi cult to remove.

( C) Copyright of Dr. P.N. Raju (2020)

31
Sulphides/sulphates. allowable level is 250 μg
SO4 L−1
• Chlorides. These should not be more than
250 μg mL −1 (maximum), but preferably
should be below 50 μg mL−1 because of
the possibility of corrosion, especially in
acidic conditions.
−1
• Iron. The maximum is 200 μg Fe L ;
staining will be the main issue here.
−1
• Manganese. The maximum is 50 μg Mn L

• Total hardness. This is the total of all

dissolved calcium and magnesium salts,
usually expressed as equivalent CaCO3.
Hygiene control

• Main objective of dairy equipment

hygiene to ensure that the quality of
dairy products is consistent and
keeping quality of such products

( C) Copyright of Dr. P.N. Raju (2020)

32
 being preserved to enhance consumer’s
faith in these products
• Affected by- D & L of dairy building, material
and construction of the equipment,
personnel, water quality, cleaning practices
and laboratory control
• Based on hardness water divided in four
groups crucial role in scale formation
Very hard (>180 ppm or mg/L)
Moderately hard (60-120
ppm) Hard (120-180 ppm)
Soft (0-60 ppm)

• For proper cleaning and

sanitizationsanitary piping and
fitting 3-A sanitary standards to
overcome the specific cleaning problem
• Personnel hygiene is mandatory which can be
maintained by proper training, education and
written instructions
( C) Copyright of Dr. P.N. Raju (2020)

33
 Conclusion
Plant design and layout,
construction material and
equipment surface, quality of air
and water and hygiene of dairy
workers affect microbial
contamination and end product
quality of the product

To provide microbiologically safe,

nutritionally rich, sensorially
acceptable dairy products with
naturally fresh like attributes to the
end users, proper cleaning,
sanitization and hygiene practices
must be strictly applied at each step
of production, processing, storage
and distribution

( C) Copyright of Dr. P.N. Raju (2020)

34