Sprouting Sanitation SOP

Hi Everyone,

I'm working as a QA in a company that handles grains and flour. Recently, there is a problem that our two sprouting workers have different standards on cleaning tank, bins, etc. One is very meticulous in cleaning, while the other is a little bit rougher (all surface microbial test results are still negative). So there is a conflict between the two of workers. Although we do have a sprouting sanitation SOP that describes how to do the cleaning and how often, there is no clear standard for what level of cleaning is correct.

Especially for a product with a history of issues like sprouts, I would opt for total visible cleanliness in your equipment after each run. A routine swabbing program like you have mentioned is also a great tool to understand your plant's sanitation level. For instant swabbing results, you could look into ATP testing products, although these can be expensive. Letting the material sit for a while just makes the cleaning harder to do later on when it's stuck on. Allowing material to stay uncleaned after a production run can be dangerous; how much do you really know about the microbial risk of that sprouted grain that has been sitting for days on end if it's left uncleaned on the bottom of the tank? Has it ever been tested? Even if the area has "no direct contact", it's still very close to your product. And how close does it get during loading/unloading? These are some of the questions you can ask yourself to understand the risk posed by allowing portions of the equipment to remain unclean. The answers to said questions can also help justify changes in procedure when you're training your staff. 

 

Hi Everyone,

 

I'm working as a QA in a company that handles grains and flour. Recently, there is a problem that our two sprouting workers have different standards on cleaning tank, bins, etc. One is very meticulous in cleaning, while the other is a little bit rougher (all surface microbial test results are still negative). So there is a conflict between the two of workers. Although we do have a sprouting sanitation SOP that describes how to do the cleaning and how often, there is no clear standard for what level of cleaning is correct.

 

The solution we are currently considering is to include objective standards such as picture samples in the SOP, rather than forcing one worker to follow the other worker's own cleaning standards. However, since I'm new to the company and sprouting process, I am not quite so sure about the feasibility of setting standards by myself. For example, when processing the same type of grain for several days, is it necessary to ensure that the bottom of the tanks that are not in direct contact (loading tank, drying tank, germination tank, etc.) must be no grains left at all after cleaning every day? Or is it acceptable to clean everywhere thoroughly during the weekly/monthly sanitation?

 

Definitely, I don't want any threat to the safety of our products, such as the growth of Listeria, because of inadequate cleaning.

So I was wondering if anyone who is more experienced with sprouting and related cleaning work could share with your thoughts or the correct standard.

 

Any help would be greatly appreciated! Thanks, Val

 

Hi Val,

Not my area but this is a notorious product in a microbial context. "Cleanliness" is a highly subjective terminology but  I suggest the key word regarding yr queries is Validation. You need to be able to quantitate the effect (if any) of the differences in Procedures referred together with the relevant existing SOPs / target limits.

Visually-made decisions are not uncommon (eg cost) in food industry but should be based on logic, experience and hopefully data.

Assuming this business is not a new enterprise there must surely already be some accumulated knowledge within the Company regarding yr queries ?