24 hour production & cleaning

Our plant is looking to start running production 24 hours a day for 4 days a week with one cleaning of production equipment at the end of the week. One question I have is that we have several drains and standing water areas that need to be sprayed with a higher concentration of sanitizer. Is this possible through FDA & USDA regulation? I haven't been able to find much on the websites. Anyone else doing something similar?

I think we need more information.  What type of food, or operation is this?  Raw, frozen, cooked?

Is this one line that will run continuously for 4 days?  I don't think that will work.  If you have more that one line and can take one line down while you clean another, that may work. 

Setanta

I agree. More information regarding your process and product makes a huge difference regarding the answer.

"Our plant is looking to start running production 24 hours a day for 4 days a week with one cleaning of production equipment at the end of the week."

Depending on the products and environment you are producing them in, when you validate your SSOP you might find that you've stretched it just a little too far (environmental swabbing, etc.). Your sanitation chemical rep should be able to assist you with validating the SSOP, and also recommending other (expensive) systems to put in place in order to make extended runs possible (i.e. sanitizer sprays for conveyor belts).

"One question I have is that we have several drains and standing water areas that need to be sprayed with a higher concentration of sanitizer."

Is it possible to repair poor drainage areas and eliminate the standing water instead of figuring out how much sanitizer you need to dose the problem areas with?

It's dangerous territory when you try to cancel out increased risk with improved production.

Wish you the best of luck with this project!

-Chris

Hi.  We operate our bread making/crumb plant like this, no issues. Clean as we go.  Validate hygiene with swabs, testing of work in progress product, environmental exposure plates. Drying has a kill step so no risk.

This is a low risk product - as above you need to provide more info.

Cheers - Steve

Frozen, raw pizza crust is the product being produced. It is to be proofed and cooked by the customer.

We have wet areas due to the freezer tunnel dripping condensation on the floor.

The idea is to run the room 4 days straight and have a thorough cleaning of the room once a week.

I'm just brainstorming here...

Do you do any kind of swabbing?  For ATP, Listeria, etc?  If you could show that there was no increased activity, perhaps you could warrant running so long between cleanings.  Could you break the days up, since it is only 4 days and do 2 days production, a cleaning shift and 2 more days production?

Do you have routine FDA inspection? Can you ask them?

Setanta

I'm just brainstorming here...

 

Do you do any kind of swabbing?  For ATP, Listeria, etc?  If you could show that there was no increased activity, perhaps you could warrant running so long between cleanings.  Could you break the days up, since it is only 4 days and do 2 days production, a cleaning shift and 2 more days production?

 

Do you have routine FDA inspection? Can you ask them?

 

Setanta

 We do environmental listeria swabs only in this production room. The only problem areas we have found are the drain for obvious reasons: cold, wet, dark. For our production, it would be better to run 4 days straight.

We do not have routine FDA Inspection, we have USDA inspection for our other two production rooms and they occasionally look at this room.

our production also run 24 hours, our cleaning only done on day time , it is acceptable??

We do the same, produce for 4 days, wash down on day 5. And we do a dairy product.

No problems at all.

We try and keep the area as dry as possible. I do environmental swabbing, air plates etc, and we don't pick anything up.

Cazx