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Validation and Verification of Master Sanitation


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#1 ksteele

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Posted 20 January 2016 - 02:46 PM

We are a food contact packaging facility producing lined and unlined closures in the process of implementing a new master sanitation schedule. We are working towards SQF level 2.  We are trying to clean every product contact surface using various chemicals- not sure where it's going to land quite yet though. A few questions- what are other packaging companies doing for cleaning of injection molding machines and auxiliary equipment? Once we have our cleaning program locked down, how do I validate and verify the cleaning program? I have found grease test strips, and I'm thinking a cotton swab run over product contact surfaces for any visible dirt. Do we need to test for allergens if we do not process any allergens? Can anyone suggest a frequency for verification?



#2 ncorliss

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Posted 20 January 2016 - 03:35 PM

We are a packaging company, SQF level 2 certified. We use sani-wipe sanitizers which are FDA approved for food contact surfaces. Any lubricant that isn't in an enclosed system and has a risk of contact product is FDA approved food grade lubricants. When we do sanitation, we have a sign off of maintenance and production supervisor the cleaning was sufficient. We send our product out for monthly testing of residual bacteria and contaminants as a validation step. We do not do swabs or grease strips. We do not test for allergens, but have a policy to address allergens within the facility and any employee lunches / food brought in to the facility. So far we haven't been dinged as an insufficient process.



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#3 ksteele

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Posted 20 January 2016 - 03:40 PM

Do you clean just product contact surfaces and machinery above food contact surfaces with the Saniwipes? Do you have a sample equipment procedure you'd be willing to share? We're new to the standard and not sure where to even start!



#4 ksteele

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Posted 20 January 2016 - 03:40 PM

Sorry- and where do you send your product for testing? Approximate yearly cost?



#5 ncorliss

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Posted 20 January 2016 - 03:50 PM

We may use a mild detergent and hot water on exterior, non-contact surfaces of equipment. Because we are an IMS listed business, we send the test samples to a certified IMS lab. You can find certified labs here. http://www.fda.gov/F...m2007965.htm#lb. The testing cost will vary based on the size of your containers and what type of testing you do. We spend, approximately between 75 - 100 dollars per month on external testing. Our official SQF procedure is rather simplistic, it follows the bullet points of the code and says, "our company shall......(whatever the bullet point is). The cleaning schedule was put together based on what we felt was the appropriate frequency. We made sure to have the cleaning, cleaning materials, schedule and frequency.

 

Are you under any cleanliness requirements from a regulatory or customer needs? If yes, include this information in the procedure and risk assessment. You can check out the module 13 guidance documents. Have you had any consultation with your SQF implementation?



#6 ncorliss

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Posted 20 January 2016 - 03:51 PM

Sorry, meant to say we have made sure to have the cleaning, cleaning materials, schedule and frequency addressed in our risk assessment.



#7 ksteele

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Posted 20 January 2016 - 03:57 PM

We are planning to have an outside consultant come in soon, but we have a very aggressive timeline, so I'm trying to get ahead of the program. Your answer regarding the exterior cleaning answered my question regarding the sample procedure. I was just wondering how you clean different areas of the machine. How often do you clean your equipment? Based on the low risk of our product (and to be honest- capacity) we are planning on cleaning machinery monthly. 



#8 ncorliss

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Posted 20 January 2016 - 04:13 PM

Cleaning is based on particular events. So any product contact surfaces (sorting / inspection benches, conveyors) is cleaned beginning of each shift, with an operator sign off. If any maintenance work (pm, repairs) are conducted, there is a post cleaning step that must be signed off my maintenance and production lead. Molds are cleaned when pulled from a press or as needed during production runs. The remaining non-contact areas of equipment is cleaned as needed. This is done during operator down time or when capacity allows. We perform daily 5S audits too as part of our verification.  



#9 ksteele

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Posted 25 January 2016 - 11:57 AM

Anyone have any additional feedback?



#10 paulpaine

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Posted 26 January 2016 - 08:38 PM

We are a paperboard folding carton manufacturer but but are non-contact so we are SQF certified at level one.  We set up our cleaning and periodic maintenance to meet or exceed machine manufacturer's recommendations.  This seems to be a reliable base to work from and has helped us with both SQF and our GMI cerifications in the printing process.  Seemed to be a good place for us to start and our audits for both have gone well.  Good Luck.






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