Cleaning plan in a 24 hour production plant

Hi All,

We are a granola cookie manufacturer. We are still a small manufacturer. Our main ingredients are: oats, corn flour, sugar, honey, molasses, canola oil

We currently run one long shift and conduct cleaning that day on equipment that comes into contact with raw dough such as the depositor and mixer etc.

We are looking to have 3 shifts a day and clean at the end of the week. 

What do you recommend to validate that production can run for 6 days and clean on the 7th without concerns? ATP Testing? 

We currently do no conduct ATP swabs- we conduct allergen swabs. I would be interested to know what your opinion is on doing ATP swabs daily as well. Is this needed? 

Thank you! 

ATP swabs can assist with proving that you can keep the plant relatively clean for 6 straight days, but only in that you can see what the differences are over time

TPC would be more helpful

My concerns would be:

A) e coli levels growing over the production week to levels capable of contaminating your finished goods (assuming you have a kill step)

B) salmonella levels multiplying (assuming you have egg in your product/ may not apply)

C) machinery failures due to buildup

D) allergen changeovers disappear as an option without a full clean

Hi All,

 

We are a granola cookie manufacturer. We are still a small manufacturer. Our main ingredients are: oats, corn flour, sugar, honey, molasses, canola oil

 

We currently run one long shift and conduct cleaning that day on equipment that comes into contact with raw dough such as the depositor and mixer etc.

 

We are looking to have 3 shifts a day and clean at the end of the week. 

 

What do you recommend to validate that production can run for 6 days and clean on the 7th without concerns? ATP Testing? 

 

We currently do no conduct ATP swabs- we conduct allergen swabs. I would be interested to know what your opinion is on doing ATP swabs daily as well. Is this needed? 

 

Thank you! 

Hi rai,

IMO, yr allergenic procedure to infer microbiological adequacy is illogical. Implementation of a zone-based EMPG to establish a micro. baseline is preferable.

Yr proposal to clean weekly seems likely to have a magnetic attraction for auditors. An attempt to validate would also require an EMPG  IMO.

Maybe this attached file will help you.

Maybe this attached file will help you.

It was great that I was able to see this file. Greetings everyone. And thank you also. Stay with love. -_-

Maybe this attached file will help you.

Hi jalex,

Many thanks yr attachment.

I found the first 3 items referred in yr attachment rather tricky to locate so I have separately attached them here for convenience -

Less_than_Daily_Sanitation_Procedures.pdf   84.34KB   32 downloads

FSIS directive 5000.5 rev3.pdf   330.59KB   15 downloads

FSIS Sanitation Performance Standards Compliance Guide,1999.pdf   196.57KB   18 downloads

Thks again.

PS - this explanative introduction can be read in association with 2nd pdf above - 

FSIS directive on Verif.of Less Than Daily Saniitat.Procs.2009.pdf   111.09KB   18 downloads