CLEANING AND DISINFECTION IN FOOD ESTABLISHMENTS The operations of cleaning and disinfection are essential parts of food production and the efficiency with which these operations are performed greatly affects final product quality. 1. Cleaning The surfaces of the equipment used in the manufacture of foods inevitably become soiled and require cleaning. If not continuous, cleaning must at least be performed at regular and frequent intervals so that a consistently good quality of product is maintained. How this cleaning is done depends principally on: the nature of the soil or contamination to be removed; the type of surface to be cleaned; the materials used for cleaning; the degree of water hardness; and the standard of cleanliness required. The basic steps in cleaning can be summarized as: the removal of gross soil or dirt; the removal of any residual soil with detergent; and rinsing to remove detergent and soil. The first step is omitted where continuous cleaning or CIP systems are installed. But cleaning often needs to be followed by disinfection (sanitizing) or sterilization which involves two further steps, viz. the disinfection or sterilization of surfaces with suitable agents to destroy microorganisms and the rinsing off of these agents. 1.1. Types and removal of soil The type of soil to be removed varies according to the composition of the food and the nature of the process to which the food has been subjected. However, the food constituents themselves vary markedly in terms of their cleanability 2 (Table 1) so that a wide choice of cleaning materials must be available for their removal. Table 1 Soil characteristics Component Solubility Ease of on surface Change on heating removal Sugar water soluble easy caramelization; more difficult to clean Fat water insoluble, alkali soluble difficult polymerization; more difficult to clean Protein water insoluble, alkali very difficult soluble, slightly acid soluble denaturation; much more difficult to clean Mineral salts water solubility varies; variable generally insignificant most are acid soluble Food residues may be dry particulate, dried-on, cooked-on, sticky, fatty or slimy. Such residues may be best removed by physical means or by the use of hot or cold water supplemented with detergents. The length of time of food residue is left undisturbed also affects the ease of cleaning. For example, fresh raw milk can be readily washed away but if it is allowed to dry greater difficulty will be experienced. This is due to the denaturation of the milk protein and the breakdown of the fat emulsion which results in the fat spreading over other milk particles making them more difficult to remove. Since the main function of a detergent is to facilitate soil removal, any preliminary conventional cleaning might be unnecessary. However, if the bulk of the debris can be removed in a preliminary cleaning process a much reduced and more accurately assessable amount of detergent can be used to remove the residual soil; therefore this latter approach is recommended where feasible and it should be initiated as soon as possible after processing has stopped. 3 The preliminary cleaning of smaller equipment may involve presoaking in warm or cold water to remove loosely adhering debris. The more tenacious food debris can then be brushed or scraped off by hand in warm water (c. 45oC). Brush bristles should be as hard as possible but should not cause damage to the surfaces to be cleaned. Any cleaning aid causing damage to stainless steel or other food contact surfaces must be avoided since crevices can be formed which are more likely to retain bacteria. The sole use of high pressure water jets for cleaning is usually inadequate; only gross dirt is removed and even that can be ineffective especially when machines are poorly designed. 1.2. Detergents 1.2.1. Required properties Detergents must be capable of removing many different types of soil under a variety of conditions; the list of properties required for a good detergent is therefore an extensive one. Thus, ideally, detergents should be: readily soluble in water at the desired temperature; non-corrosive to equipment surfaces; non-toxic, non-irritating; odourless; biodegradable; economical in use; readily rinsable; effective cleaners of all types of soil. In general, detergents are not expected to possess bactericidal properties although in practice some of them do. However, detergents do physically remove a large number of bacteria during cleaning and this makes subsequent disinfection that much easier. 1.2.2. Classification and main compounds Inorganic alkalis. Many detergents incorporate an alkali as one of the principal ingredients. Sodium hydroxide (caustic soda) is the strongest of the alkalis and cheap. It has excellent dissolving properties, is a very strong 4 saponifier and has added advantage of being strongly bactericidal. It is, however, highly corrosive to metals especially aluminium and extreme care must be taken when handling this detergent as it can cause severe burns to the skin; for this reason protective clothing must be worn together with goggles and rubber gloves when working with this detergent. As with all the alkali detergents sodium hydroxide precipitates insoluble calcium and magnesium salts from hard water so that sequestering agents need to be incorporated with alkali cleaners in any detergent formulation. Sodium metasilicate, although a strong alkali, is non-caustic and therefore much less corrosive than sodium hydroxide. It supresses the corrosive activity of sodium hydroxide and the two are often combined in detergents for this reason. Sodium carbonate (soda ash) is a relatively weak detergent, is somewhat corrosive and precipitates calcium and magnesium salts from hard water. However, it is cheap and has a good buffering capacity (i.e. stabilizes pH) and is frequently included in detergents for this reason. Trisodium phosphate (TSP) is a good emulsifier and saponifier has strong dispersive properties and has the ability to soften water by precipitating the salts. Although again somewhat corrosive, it is often incorporated in detergents. Inorganic and organic acids. Acids are not widely used in the food industry as they are usually corrosive, and many are dangerous and can cause severe skin burns so that protective clothing must be worn. Of the inorganics, hydrochloric, sulphuric and nitric acids have been used in the past by the dairy industry to remove hard water scale and other mineral deposits (e.g. “milkstone”, a deposit of protein, calcium carbonate and other salts which builds up in pasteurizers when milk films are not completely removed) but, due to the extremely corrosive nature of these acids, they have been largely replaced by milder acids. Amongst these are phosphoric and sulphamic acids which are less corrosive and, when coupled with a corrosion inhibitor, can be very effective. However, low levels of stronger acids may be used where deposit build up is excessive. 5 Organic acids, which are bacteriostatic in action, are much milder than the inorganic acids and are therefore safer to handle. Amongst the organic acids which have been incorporated in detergent formulations we can find gluconic, hydroxyacetic, citric and tartaric acid. Acid detergents usually incorporate corrosion inhibitors and wetting agents and as such can be employed in the removal of inorganic deposits and milkstone, and in bottle washing. Surface active agents. Surface active agents reduce the surface tension of water to facilitate wetting. The classical surface active agent is soap which is usually composed of sodium or potassium salts of fatty acids such as stearic, palmitic and oleic acids. Soaps are reasonably effective in soft water but their reduced solubility in cold water constituents a disadvantage; in addition, soaps form precipitates with calcium in hard water to give insoluble deposits. For these reasons they have been largely replaced by synthetic detergents which are either anionic, cationic, non-ionic or amphoteric depending on their active electrical charge when in solution. When negative charges predominate the surfactant is classed as anionic, when positive cationic, whilst surfactants that do not dissociate in solution are termed non-ionic. Where the predominant charge varies according to pH the surfactant is then termed amphoteric. Surface active agents have a molecular structure comprising a hydrophilic and a hydrophobic portion. One end of the molecule is thus attracted by water and the other end is repelled but is attracted by fat and oil and this is the basis of the cleaning action of surfactants. There are many hundreds of surface active agents now available which are incorporated into detergent formulations. Surfactants are usually excellent emulsifying agents, they have good wetting and penetrating powers, they are non-corrosive, non-irritating and readily rinsable. In addition, they are highly soluble in cold water, are largely unaffected by hard water and many are stable in both acid and alkaline conditions. Whilst the bactericidal activity of both the anionic and non-ionic detergents is poor, that of some cationics is excellent although the latter are less good as detergents. For this reason the cationic surfactants are used as disinfectants and sterilizers (and are discussed later in this chapter). Many 6 surfactants produce high amounts of foam especially where considerable turbulence is generated during cleaning. To control the extent of foaming, antifoaming agents are often incorporated in formulations. The principal anionic surfactants used today are alkyl sulphates or alkylbenzene sulphonates. The hydrophobic portions of the molecules are represented by the alkyl (i.e. lauryl) and benzene groups whilst the hydrophilic portions are represented by sulphate and sulphonate; the cations are commonly sodium or potassium. All anionic surfactants are high foam producers and none can be combined with a cationic detergent. The non-ionic surfactants are not dissociated in solution and can be used in conjunction with either anionic or cationic agents. They are powerful emulsifying agents, are unaffected by hard water and vary considerably in their foaming characteristics. As with the anionic agents, the list of non-ionic surfactants is an extensive one. Two of the major categories are based on products formed by condensation reactions between ethylene oxide and synthetic long chain alcohols (e.g. lauryl alcohol ethoxylate) or between ethylene oxide and alkyl phenols (e.g. nonyl phenol ethoxylate). The former represent the major group of low foaming surfactants in many countries. Amphoteric surfactants can exist in solution in either the cationic or anionic form depending on the pH. They are based on amino acids and have the general formula R-NH-CH2-COOH where R is usually an alkyl radical. An example is dodecyl diaminoethyl glycine. The amphoteric agents are relatively good emulsifiers, are stable in both acids and alkalis and show a good tolerance to hard water. Sequestering agents are added to detergents to prevent calcium and magnesium salts although in the long term it is often far cheaper to soften a hard water supply than to add high concentrations of sequestrants to detergents. Obviously the amount of sequestrants that is added depends on the extent of water hardness and the overall detergent formulation. Of the inorganic sequestering agents, sodium polyphosphates are widely used. They are also good emulsifiers, dissolving and dispersing agents and also generally 7 enhance rinsability. The principal organic sequestering agents, also called chelating agents, are ethylene diamine tetraacetic acid (EDTA) and its sodium and potassium salts, and the sodium salts of gluconic and heptonic acid. In spite of their relative expense they are fairly widely used, because of their high solubility in liquid detergent formulations. Modern detergent formulations are carefully blended mixtures of different chemicals each contributing to the desired properties of the detergent. A general-purpose cleaner may contain alkali builders to break up grease, surfactants to improve wetting, dispersion and rinsability, and sequestrants to stabilize magnesium and calcium; the level of the sequestrants should be carefully adjusted depending on the degree of water hardness and in-use concentration. Sodium metasilicate may also be added as a cleaning agent with the added benefit of being a corrosion inhibitor especially if susceptible metals such as aluminium are to be cleaned. When disinfecting food contact surfaces of equipment and pipework it is rarely necessary to achieve absolute sterility. The usual aim is to so reduce the numbers of microorganisms that those remaining (i.e. some bacterial spores and possibly a few highly resistant vegetative cells) could not affect the microbiological quality of the food coming into contact with these surfaces. Either heat or chemicals can be used for plant disinfections operations but it is important to stress that these operations must be preceded by thorough cleaning. The efficiency of chemical disinfectants is undermined by the presence of soil and the cleaner the surface the more effective will be the disinfectant. Disinfection should follow immediately after cleaning although it is often advisable, if not essential, to disinfect surfaces a second time immediately before a process run if the equipment has been left unused for a lengthy period. 8 2.1. Chemical disinfectants 2.1.1. Desirable properties Disinfectants for use on food contact surfaces should ideally have the following properties: Capable of rapidly killing microorganisms and, in particular, equally effective against both Gram-positive and Gram-negative bacteria. The majority of mould spores should be killed and the destruction of bacterial spores would be an added advantage. Reasonably stable in the presence of organic residues and, if necessary, effective in the presence of hard water salts. Non-toxic and non-irritating to the skin and eyes. Non-corrosive and non-staining to plant surfaces of whatever type. Odourless or have an inoffensive odour. Readily soluble in water and readily rinsable. Competitively priced and cost-effective in use. 2.1.2. Classification and main compounds used in food industry Chlorine-releasing compounds. The hypochlorites are the most widely used for all disinfectants in the food industry but there are a number of other chlorine-releasing compounds which are also used on a more limited scale. Amongst the latter are gaseous chlorine and chlorinated trisodium phosphate as well as the organic chloramines, derivatives of isocyanuric acid and dichlorodimethylhydantoin. In general, chlorine-releasing compounds are powerful disinfectants with a broad spectrum of activity, Gram-positive and Gram-negative bacteria being equally susceptible; furthermore, these compounds show some activity against bacterial spores. Many chlorine-releasing compounds are inexpensive; all are easy to use and unaffected by hard water. However, it is essential to maintain a high pH to prevent corrosion effects even though, as a consequence, some loss of bactericidal activity is experienced. Perhaps the main disadvantage of chlorine-releasing agents is that they are rapidly inactivated by the presence of 9 organic matter although an additional weakness is that they must be carefully rinsed off to prevent corrosion. Of the hypochlorites, hypochlorous acid (HOCl) itself is unstable but many of its salts can be prepared and these are invariably more stable. In solution these salts dissociate to form OCl- which is the ion that is responsible for the bactericidal properties of the hypochlorites. The most widely used salt is sodium hypochlorite (NaOCl) which is available in commercial form as a concentrated liquid containing c. 10-14%, available chlorine. Also used is calcium hypochlorite (Ca(OCl)2) which is available in powdered form and contains c. 30% available chlorine. Hypochlorite solutions should always be stored in dark containers; stability is also improved if chill storage is employed. Solutions are more stable above pH 9.5 whereas germicidal activity is maximal between pH 4 and pH 5; at the letter pH corrosion effects are also maximal. Because of these corrosion problems, solutions of pH 10-11 are used and operating temperatures are kept relatively low since at higher temperatures corrosivity and loss of stability of the disinfectant occur. In-use concentrations typically vary between 50 and 200 ppm available chlorine and contact times of between 3 and 30 min are normal; it should be remembered that in each situation the minimum concentration and time to effect the necessary kill-off should be employed in order to avoid possible corrosion of susceptible surfaces. Chlorine gas is commonly used for the disinfection of water supplies but is also has some application in the food industry. Where employed it must be fed into the water supply at a constant rate by means of a chlorinator. It is necessary to chlorinate above the “break point” of water, that is the level at which the chlorine demand of the water, a variable factor depending primarily on the amounts of suspended solids and organic matter, has been satisfied. In fact chloramines (see later) are formed if ammonia-releasing compounds are present in the water and at higher chlorine doses these are oxidized. Only after this is the “break point” reached so that thereafter any additional chlorine 10 creates a residuum of free chlorine. A residual chlorine level of between 1 and 5 ppm is suitable for most continuous plant chlorination systems. The chloramines, e.g. chloramine T, chloramine B and dichloramine T are much more stable than the hypochlorites in the presence of organic matter, they are less irritating and toxic but their expense has undoubtedly limited their use. Furthermore, in spite of an available chlorine content of 25-30%, they are weaker bactericides except at high pH values (>10) where they are more active than the hypochlorites. Chloramines release chlorine slowly and are often used where equipment and utensils can be soaked for long periods since they are only weakly corrosive; rinsing after their application is necessary, however. They are often combined with alkali detergents to from detergentsterilizers. Iodophors. These compounds consist of soluble mixtures of iodine with a surfactant (typically non-ionic, although anionic and cationic surfactants may be used) which acts as a carrier for the iodine; it is the iodine which imparts the bactericidal activity. Iodophors can thus also be regarded as detergentsterilizers although the detergency power depends on the amount of surfactant in the mixture. Since iodofors are most active in the pH range of 3-5, usually also an acidic component, mostly phosphoric acids is added to the mixture in order to lower the pH of the solution (phosphoric acid buffers in the required range). Iodophors effect the rapid killing of a broad spectrum of bacteria and resemble hypochlorites in this respects but they also maintain a reasonable activity in the presence of organic wastes provided in the pH is not above 4 and the quantity of waste is not excessive; iodophors are, however, much less active against spores than hypochlorites. Iodophors are rather expensive and, in consequence, are not used widely; they are essentially non-corrosive, non-irritating, non-toxic and have little smell but they must be thoroughly rinsed off after use. Some plastic materials may absorb the iodine and become discoloured when exposed to these compounds; rubber also tends to absorb the iodine so that long contact times with the iodophor are to be avoided to prevent possible tainting of foods. 11 Iodophors are unsuitable for cleaning equipment used for processing starchcontaining foods since iodine forms a purple complex with starch. One advantage of the iodophors is that they are unaffected by hard water salts; they are also stable in concentrated form although over long periods of storage at high ambient temperatures some loss of activity is possible. Iodophors are used mainly in dairies where, in addition to their bactericidal powers, the phosphoric acid is useful in the control of milkstone; iodophors are also used in the brewing industry. Operating temperatures of up to 45-50oC can be employed with iodine concentrations varying between 10 and 100 ppm. Quaternary ammonium compounds. Quaternary ammonium compounds, known as “quaternaries”, “quats” or “QACs”, are essentially ammonium salts with some or all of the hydrogen atoms in the (NH4)+ ion substituted by alkyl or aryl groups; the anion is usually a chloride or bromide. The general formula is thus: R2 R1 N + R3 X- R4 where R1, R2, R3 and R4 represent one or more alkyl or aryl groups substituting for hydrogen and X- represents a halide, either Cl- or Br-. The large cation is the active part of the molecule whilst the anion is important only in that it can affect the solubility of the QAC. The QACs are very active bactericides against Gram-positive bacteria but are less effective against Gram-negative forms unless sequestrants are present; bacterial spores are relatively resistant. After disinfection surfaces treated with QACs retain a bacteriostatic film due to the adsorption of the disinfectant on the surface; this film prevents the subsequent growth of residual bacteria. When required, rinsability can be improved by adding a small quantity of a non-ionic surfactant to the disinfectant. QACs retain their activity over a relatively wide pH range although they are most 12 active in slightly alkaline conditions and activity falls off rapidly below pH 5. In comparison with the hypochlorites the QACs are more expensive but they have many desirable properties. Thus Qacs are largely unaffected by the presence of organic debris, they are non-corrosive, although some types of rubber may be adversely affected, and they are non-irritating to the skin, except at high concentrations, so they can be handled with reasonable safety. Since QACs are cationic surfactants they also have some detergent activities but they cannot be used in conjuction with anionic surfactants or even with certain non-ionic surfactants. Hard water salts reduce the activity of QACs. However, care must be taken with the selection of the sequestrant employed since some are incompatibel with some QACs and cause their precipitation. Strong alkalis induce a similar effect and cannot be used with many Qacs; in general, detergents containing such materials must be carefully rinsed off before the QAC is added. QACs often foam vigorosuly in solution so they are generally unsuitable for CIP systems (see later). They are used at concentrations of between 50 and 500 ppm, at temperatures in excess of 40 oC and with contact times varying between 1 and 30 min. Amphoteric compounds. Whilst some of the amphoteric surfactants are primilary detergents with weak bactericidal powers there are others, the imidazoline derivatives, which are relatively stronger bactericides and weaker detergents; an example is ethyl -oxypropionic imidazole. Amphoterics can exist as cations or anions depending on the pH of the solution and it is in the cationic state that these compounds are bactericidally active. They are generally more expensive than other disinfectants and are not particularly effective bactericides although they can be blended with Qacs to improve their efficiency. Amphoteric disinfectants are not markedly affected by organic matter or by water hardness, they are non-corrosive, non-toxic and odourless, and they are stable, even in dilute form, for lengthy periods. However, they do tend to foam and, becasue of their expense and limited activity, amphoteric dsinfectants have not been widely used in the food industry. 13 Phenolic compounds. Many phenolic compounds have strong bactericidal powers and they are widely used as general-purpose disinfectants. Phenolics are, however, not used in disinfecting operations on food plant because of their strong odours and because of the possibility of transmitting off-flavours to foods. Detergent-disinfectants. Detergent-disinfectants or also known as detergentsanitizers, are essentially combinations of compatible and complementary ingredients; they contain a detergent and a separate disinfectant, so that cleaning and disinfection can be performed in a single operation. Many of the aforementioned ingredients have been used in combination; widely used groupings are given in Table 2. Table 2 Commonly used detergent-disinfectant combinations Detergent Inorganic alkalis Disinfectant + Hypochlorites Organic chlorine-releasing compounds QACs Inorganic acids + Non-ionic surfactants Iodophors Anion surfactants + Organic chlorine-releasing compounds Non-ionic surfactants + QACs Iodophors In practice, the detergent-disinfectant formulations are likely to contain other components such as sequestering agenst and buffers, and two surfactants are often included in a single formulation provided they are compatible. 2.2. Use of heat Heat alone can also be used to disinfect food plant and it can be supplied in the form of steam, hot water or hot air. Heat in the form of pressurized steam is the most effective method of sterilization; moist heat kills microorganisms at 14 relatively low temperatures by denaturation of the protein but proteins are far more stable in dry conditions so that far higher temperatures and/or longer times are necessary to effect a kill using hot air. Thus, whenever possible, moist forms of heat are used to sterilize equipment but obviously the efficiency is also dependent on the temperature and time employed. Moist heat is a favoured disinfecting or sterilizing agent because it is non-corrosive, economical, has excellent penetration powers, leaves no residue and is active against the large majority of microorganisms. Steam. Saturated steam is a good disinfecting agent and has the potential to destroy all but the most heat-resistant bacterial spores. However, it is essential that heat is applied to surfaces, both internal and external, long enough to heat them to a temperature of c. 85oC for 1 min; under these conditions all but bacterial spores should be killed. Unfortunately steam guns are frequently misused and the short-term blowing of steam against equipment may do more harm than good by supplying warmth and moisure to bacteria enabling them to thrive, especially in the presence of food debris. It is very important that steam per se is not a cleaning agent and it should thereore only be used to treat clean surfaces. Hot water. It can be used to disinfect food plant at 80-90oC. It is used at these temperatures in cleaning-in-place (CIP) systems where it usually acts as a detergent carrier rather than as the disinfecting agent; contact times of 5-15 min are desirable when it is used in the latetr capacity. Small items of equipment can be disinfected by immersing them in water which is heated to about 80oC for 10 min when all but bacterial spores should be killed. 3. Cleaning-in-place (CIP) CIP has largely replaced manual clenaing for equipment used for process liquid foods, i.e. in the dairy, brewing and soft drinks industries. The form CIP takes can vary considerably from the cleaning of individual items of equipment to sophisticated operations involving whole processing lines. The cleaning principle is similar in all cases and involves the sequential circulation of water, 15 detergents and disinfectants through pipelines and processing equipment which remain assembled. The basic sequence of operations is: a pre-rinse with cold water to remove gross soil; the circulation of detergent to remove residual soil; an intermediate cold water rinse to flush out detergent; the circulation of disinfectant to kill any residual microorganisms; a final cold water rinse to flush out disinfectant. This can be varied, for example, by the use of detergent-sterilizers to replace certain stages. Apart from the chemical effects of the detergents and disinfectants, the mechanical force generated by the flow of fluids through pipes or from spray heads assists in the removal of soil from food contact surfaces; in the case of pipes a velocity of c. 1.5 m/s is required to obtain the desired turbulence. CIP is commonly used for pipelines, tanks, vats, heat exchangers and homogenizers but other food processing equipment can be suitably designed to enable CIP systems to be introduced. 4. Assessment of cleaning and disinfection efficiency The efficiancy of process line sanitation can be checked by visual inspection or by using microbiological techniques. Visual inspection is a simple but rough method which cannot determine the microbiological cleanliness achieved. Much depends on the care taken by the inspector. With experience the inspector may know where to look for signs of inadequate cleaning but residual soils vary in their visual detectability (e.g. some soils are not visible if there is a film of water on the cleaned surface) and high intensity lighting must be directed on surfaces during inspection. These inspections can be carried out during or immediately after cleaning or even shortly before the start of the next production run. A check-list of various items of equipment should be prepared and items, once cleaned and inspected, can be given a cleanliness rating which can be compared with earlier data. All the findings should be recorded in an inspection report. Additionally, records of the cleaning materials, dilutions and application times used should be kept. If equipment has not been adequately cleaned there should be time available for corrective 16 action before processing is restarted; particular care should be taken with the subsequent inspection of equipment given low cleanliness ratings. The most commonly used tests are by ATP-bioluminescence and microbiological culturing. The ATP-bioluminescence test determines the hygienic status since it is not specific for microbial ATP but will detect ATP form residual food material as well. Microbiological culturing typically involves estimations from surface areas of the total numbers of viable bacteria, indicator organisms (i.e. coliforms, E. coli, etc.) and, where warranted, specific food spoilage, or food poisoning bacteria (i.e. Listeria). In general, however, estaminations are limited to “total numbers” as this is the most sensitive guide to microbial hygienic status. The bacteria are removed from surfaces by means of sterile swabs, by rinsing with a known volume of sterile diluent or by agar contact method. The inherent problem with standard microbiological methods is that test results are normally unavailable until after 48 h period due to the need for incubation of the test samples. Hence the ATPbioluminescence method has found considerable favour in the food industry mainly because the results are obtained rapidly.