Cleaning chemical residue testing
Since our facility produce food packaging, we don't have a robust sanitation program compare to food/meat. Our cleaning typically involve spraying some diluted degreaser (with a squirt bottle) on our machine then follow up with hard surface sanitizer (also squirt bottle).
Our degreaser in its concentrated form is approved for use in food processing but must be completely rinse off with potable water. We diluted that degreaser to 1:64. We currently do not have any additional rinsing except just wiping it off with sanitizer afterward. Our sister facility got an audit finding for not using direct food contact safe and not have any validation to back up that the sanitizer can remove potential residue. I honestly have no idea how to validate this due to such a small concentration to begin with (1:64!). In my previous role in a meat plant, we would just test the rinse water for pH and chlorine but i cannot replicate it now.
Anyone have similar experience?
No experience, but it is a valid finding. Sanitizer is not a rinser. Since the degreaser requires a rinse step in between I don't think it is a good solution for your facility. You may want to look into cleaner / sanitizer combos like Drysan Duo, or a quat based item. There are some options out there.
But the real question, is a degreaser necessary on the packaging contact surfaces of the equipment? I would think if you get any "grease" or buildup in these areas it will cause issues with the equipment. Perhaps you can revise your sanitation program to NOT use the degrease on any primary packaging contact surface and only use a sanitizer that dries leaving no residual.
Considering your manufacturing environment, I assume you are not dealing with excessive amounts of debris, grime, oil, spoiled material, etc. You may benefit from a chemical that can be used as a cleaner and sanitizer. Because of the sanitizing properties, a large number of these chemicals do not require a rinse and are approved for use on food contact surfaces. Additionally, with the right chemicals, you could save on costs.
It may be worth it to look into these chemicals. Personally, I have had a lot of success with the chemical sold by Ecolab.
I hope this helps!
Depending on the type of packaging you manufacture, you might want to think twice about de-greasing your machines. We were told very directly NOT to wash, rinse or use any type of de-greaser on our equipment as it removes essential lubricants from vital areas of the machines. In fact, before Food Packaging had it's own code we had to keep a letter from the manufacturer in the FSM to exclude us from having to "wash down" our machinery. Our machines are dusted before use (Paperboard packaging) as there are no pathogens or other contaminants and the lubricants are metered and food grade. The only cleaning is done with lacquer thinner (recommended by mfg) or denatured alcohol and that is just to improve traction.