16 replies to this topic

[nbobrowicz]

We are a printer of flexible  packaging used for direct food contact and I'm trying to find out what others are doing related to sanitizing procedure for presses, slitters, etc. How are other printers determining frequency of sanitizing and what methods are being used to determine this? Our printed food contact structures include paper/foil/poly as well as in-line laminated heat sealable poly structures, but we also print non-food contact laminations. There's not much information on this process for printers.

I already have a luminometer, but does anyone have suggestions or examples of current methods that they can share?

 

[SQFconsultant]

Are you using your Luminometer with a rapid ATP system?  Like the 3M Clean Trace system. What's neat about 3M is that they can assist you based on your facility, your volume, etc to set up a schedule that would best suit.  

 

[nbobrowicz]

I have the Hygiena Sure PLus with Super Snap ATP testers. I'm not familiar with 3M Clean Trace system; is it a service, or equipment?...

[zac2944]

I make flexible packaging too.  I've got my first SQF audit this April/May so I don't speak from much experience.  We were AIB for the last 10 years.

 

I have chosen verify/validate cleaning with visual inspection and not by swabbing on the basis that the material is low risk.  It's not like you're dealing with raw meat, or milk, or some other food or material that micro like to grow on. 

 

We use what we call Master Cleaning Schedules for each machine/work-cell. This document is a form that lists all the cleaning tasks in an area, who does it, frequency, and how to do it (cleaning equipment, chemicals, etc.).  Then there is a spot for initials and date for each cleaning task, and final a supervisor does a monthly verification and signs off when complete.  We verify/validate with monthly self-inspection.  It's all just visual though.

 

We also have cleaning procedures for product contact surfaces like rollers, idlers, anallox rollers, lift tables, etc.  We typically clean with a cleaner/detergent, then water rinse, then a solvent.  This type of cleaning only happens between campaigns (~every 2 weeks) where we do a major machine tear down and set up.  We have a sign off sheet to record that the work was done and then a supervisor verifies (visual inspection) and signs off, then we set up for the next campaign. 

 

We also do cleaning of equipment and utensils (ink pumps, primer sumps, splash guards, etc.).  We have procedures for these but currently don't keep records of the cleaning and don't have verification.  I'm evaluating the need to record this cleaning.

 

Per 13.2.11 Cleaning and Sanitation
1 - "The methods and responsibility for the cleaning of manufacturing and storage areas, staff amenities and toilet facilities shall be documented and implemented."
2 - "Provision shall be made for the effective cleaning of processing equipment, utensils and protective clothing."

 

Not sure if I only need to document "cleaning of manufacturing and storage areas", or by "Provision shall be made" SQF means cleaning of processing equipment needs to be documented too.  Are you documenting this type of cleaning nbobrowicz?

Edited by zac2944, 21 February 2014 - 04:40 PM.

[nbobrowicz]

zac,  how did your SQF audit go? Were your sanitation methods and documents found to be acceptable? We are still in the process of trying to determine what is needed and how to document, so you success report will help give me direction.

 

Thanks.

[ksteele]

I am also wondering how the audit went, Zak. I am implementing SQF for a food contact packaging manufacturing facility and not sure how in depth to go with verification of sanitation.

[ctzinck]

Good luck to everyone who has an upcoming audit, we are also food packaging (flexible packaging) and just had our 3rd audit which happened to be our first unannounced, we scored a 97 with 3 minor non conformance.

[nbobrowicz]

Do you print & convert food contact packaging? How are you verifying your press and finishing equipment cleaning? Our visual cleaning verification process is very subjective (eg. some rollers are stained or discolored) and we do not use sanitizers on any equipment since there is little to no real chance of micro growth - we clean product contact surfaces at press with our pH adjuster, which is IPA and ammonium hydroxide. Also,  how do you validate your equipment cleaning? Any swabbing?

Thanks for any input on this topic.

[ctzinck]

yes we are a printer/converter (snack foods). I'd be happy to share an example of one of our forms for equipment sanitation but I dont know how to post here.

 

we do not swab, risk analysis was low we deemed it unnecessary.

[nbobrowicz]

It would be great if you could share a form! I also have no idea how to attach a document here, or I'd share a copy of the form we are using as well...

How do you validate equipment cleaning?

[ksteele]

I am also interested in how the cleaning is done/verified for food contact packaging lines. We produce closures and I'm trying to decide the best way to clean the equipment and verify/validate cleaning. Thanks!

[zac2944]

I am also wondering how the audit went, Zak. I am implementing SQF for a food contact packaging manufacturing facility and not sure how in depth to go with verification of sanitation.

 

Sorry for the delayed response, but we passed SQF audit (98/100) using the methods described above.  No swabbing, just visual inspection.  I've got my unannounced coming up some time in the next 60-days.

[Charles.C]

In response to earlier posts, to attach a form to a post while writing, just click the "more reply options" on lower right hand side. This generates a new display where you follow the suggestions at lower left hand side (under the post). it's quite straightforward.

The attachment can be inserted anywhere in the body of text as desired.

[Simon]

Thanks for the reply Zac and congratulations.

 

Regards,

Simon

[nbobrowicz]

yes we are a printer/converter (snack foods). I'd be happy to share an example of one of our forms for equipment sanitation but I dont know how to post here.

 

we do not swab, risk analysis was low we deemed it unnecessary.

 

Attached is an example of the cleaning form we use at press.

 

We print both food contact (dry) & non-food materials (bottle labels, etc), so we mark the job tickets FOOD CONTACT PRODUCT so that operators know they must clean contact surfaces before starting the job. Unfortunately, there is no method for verifying this (we run 3-4 presses on 3 shifts, and can frequently have multiple job changes on each press per shift. 

 

We have never had a food safety recall or withdrawal. We passed our first SQF Level2 audit last September (9 minors) & are preparing for our 2nd. (We had no previous audits of any kind in the past, so were starting from zero). We currently verify cleaning by 'visual' method, but many of the equipment surfaces and rollers are older and 'stained' so they don't look clean, even when they are.  I know the auditor will start honing-in on equipment sanitation, so any thoughts or suggestion on how other printers are managing this would be appreciated.

Attached Files

•  Cleaning Schedule Plan - PRESS SAMPLE FORM.xlsx   32.45KB   85 downloads

[DN_QAMGR]

Congrats all on your passing of your SQF and other 3rd Party Audits.

 

This was a very useful thread for me. 

 

I do not do any swabbing, but send out random product samples quarterly for lab analysis, which they swab.

 

My food contact area is never touch when its extruded. Risk Analysis was accepted by BRC and got a "A" score. I'll let you know if my auditor is content with my steps this year. 

[Charles.C]

Hi All,

 

A few more vaguely overlapping (packaging) threads -

 

http://www.ifsqn.com...equipment-swab/

 

http://www.ifsqn.com...setup-machines/

 

http://www.ifsqn.com...food-packaging/

 

http://www.ifsqn.com...pt-qa-coverage/