FRUITS AND VEGETABLE PROCESSING PLANT SANITATION
INTRODUCTION
Sanitation is a applied science that incorporates the principles of design development implementation ,maintenance ,restoration o improvement of hygienic practices and conditions . It is creation and maintenance of hygienic and healthful condition.Effective preservation of fruits and vegetables depends on the prevention of contamination by spoilage causing and pathogenic microorganisms during production, processing, storage and distribution. The ultimate goal is to provide a finished product that is sanitary and wholesome.
CONTAMINATION SOURCES
RAW MATERIAL
These are exposed to many uncleaned sources and can be provide additional contamination in the receiving, raw material storage,and processing areas .They may pose biological hazard such as certain fruits and vegetables contaminated with microbes.These may contain chemical residue,metals,plastic,glass fragments or the water could be contain heavy metals or packaging materials may contain harmful chemical residues that could leach into the product. Generally chlorinated water is most frequently used sanitizer.
soil contamination
Soil may contain lots of microbial load that may affect the resultant produce such as Escherichia coli, Salmonella spp etc. Most pathogens are introduced to fruits and vegetables through irrigation shortly before harvesting and before the sun dehydrates and destroys the pathogen.
EXAMPLE : Heat resistant bacteria are present in the ground and can cause “FLAT SOUR” and other spoilage of the canned vegetables if washing is not thorough.
Air contamination
Contaminated air contributes to less sanitary raw products. Besides normal microbes and pollutants found in the air ,this medium serves as transport of pathogens. Uncleaned air into the processing plant can be purified by the use of air filters.
Pest contamination
Pest contamination can be expressed through the spread of virus, spoilage bacteria and pathogens as well as by physical damage. Infesting microbes frequently remains inactive because of protective skin layer of fruits and vegetables and even low availability of moisture on the surface . but as soon as they mature they become soft and moisture increases causing easy infestation of microbes. Pest which attack fruits and vegetables includes wasp, fruit fly etc.
SANITARY ASPECTS WHILE CONSTRUCTION
Construction of new and expanded fruits and vegetable processing plants must reflect hygienic design. If the processing plant is newly constructed ,expanded ,a renovated ,functional layouts, mechanical and plumbing layouts ,equipment and construction specifications should be reviewed by all professional personnel associated with the processing organisation .
principles of hygienic design
Equipment should be designed so that all surfaces in contact with the product can be readily disassembled for manual cleaning or CIP. Exterior surface should be constructed to prevent harboring of soil ,pest, microbes on the equipment as well as other parts of the production areas ,including walls floors , ceilings and hanging supports .equipment should be designed to protect food from external contamination .All surfaces in contact with food should be inert to reaction with food under conditions of use and must not migrate to or absorbed by the food ,And they should be smooth and nonporous to prevent accumulation of tiny particles of food ,insect eggs or microbes in microscopic surface crevices .Interior and exterior of plant should have following features
ledges and dirt traps should be avoided .Projecting bolts,screws and rivets should be
avoided to reduce the accumulation area for debris. Sharp and unfilled edges should be
avoided to reduce debris accumulation and microbial contamination.Proofing against
pest entry through double door constructions,heay duty strips and self closing mechanism
is essential .
CLEANING CONSIDERATIONS
HOUSE KEEPING: It relates to orderliness and tidiness. It is the responsibility of all the personnel’s of plant. Careful arrangement of supplies ,materials ,and clothing contributes to tidier operation ,reduces contamination and makes cleaning easier .
WASTE DISPOSAL: Separation of solid and liquid waste is essential for the effective management of byproducts
WATER SUPPLY: high quality water is essential as it is necessary to produce wholesome product and as well it is used as a cleaning media. And water must be analysed daily for bacterial content ,organic and inorganic impurities
CLEANING OF PROCESSING PLANT
Efficient cleaning method is required to reduce the microbial load on the fruits and vegetable ,and to improve the quality of the resultant recalls.
CLEANING METHODS:
hot water wash,high pressure ,low volume cleaning, foam cleaning, gel cleaning, slurry
cleaning
combination centralized high pressure ,low volume and foam cleaning
CIP ( Cleaning in place)
HOT WATER WASH (60-80º)
water provides the transport of cleaning compounds and suspended soil.sugars ,other carbohydrates and other compounds that are relatively soluble in water can be cleaned rather effectively with water .
ADVANTAGE : cost efficient
LIMITATION : laborious, energy cost ,and water condensation on equipment and surrounding, and this technique is not effective in removal of heavy soil deposits .
HIGH PRESSURE, LOW VOLUME CLEANING(<60º)
this technique is effective because heavy soils can be removed. Difficulty to reach areas can be cleaned more effectively with less labour ,and there increased effectiveness of cleaning compounds below 60º. Temperature should not exceed 60ºc because high temperature spray tend to bake the soil to the surface being cleaned and to increase the microbial growth.
FOAM CLEANING
portable foam cleaning is widely used because of ease and speed of foam application in cleaning ceilings ,walls ,piping,belt and storage containers in fruit and vegetable processing plant. Here cleaning compound is automatically mixed with water and air to form foam ,which s applied various stations installed throughout the plant.The equipment size and cost is similar to that of portable high pressure units .
GEL CLEANING
cleaning compound is applied as gel rather than as a high pressure spray or foam .Gel is an especially effective medium for cleaning canning and packaging equipment because it clings for subsequent soil removal .
SLURRY CLEANING
This method is identical to foam cleaning ,except that less air is mixed with cleaning compound .Slurry is more fluid than foam and penetrates uneven surface i a canning plant more effectively , but it lacks the clinging ability of foam .
COMBINATION CENTRALIZED HIGH PRESSURE ,LOW VOLUME AND FOAM
CLEANING
This system is same as centralized high pressure,low volume system, except that foam
can also be applied through the equipment.This method is more flexible because foam
can be used on large surface areas,and high pressure can be applied to belts ,stainless
steel conveyors,and difficult to reach areas in canning plant.
CIP(Cleaning in place )
In this method recirculating cleaning solution is applied by nozzles that automatically
clean ,rinse and sanitize the equipment .This technique is expensive and ineffective on
heavily soiled areas .It has application in vacuum chambers, pumpimg and circulation
lines ,and large storage tanks.
CLEANERS AND SANITIZERS
Halogen Compounds Chlorine and its compounds are the most effective sanitizers of the
halogens for sanitizng food processing equipment and containers, and for disinfecting
water supplies.
Calcium hypochlorite and sodium hypochlorite are two of the most frequently used
sanitizers in fruit and vegetable processing plants. Although elemental chlorine is less
expensive on an available chlorine basis, calcium hypochlorite and sodium hypochlorite
are easier to apply in low concentrations.
Hypochlorite solutions are sensitive to changes in temperature, residual organic matter,
and ph. These compounds are quick acting and less expensive than other halogens but
tend to be more corrosive and irritating to the skin.
2 .Chlorine Dioxide
Chlorine dioxide is approved as a flume water treatment for fruits and vegetables (that
are not raw agricultural commodities) at a concentration of up to 3 ppm and to control
microorganisms in process waters.Also, it is incorporated in wastewater treatment and
for slime control in cooling towers.The typical use concentration of the sanitizer is 1-
10ppm.
Quaternary Ammonium Compounds.
ACID SANITIZER
Peroxyacetic acid-based sanitizers provide microbial control for use in fresh-cut, further processed, and post-harvest fruit and vegetable flume and wash-water systems. They reduce the population of spoilage microorganisms including yeasts, molds, and bacteria on processed fruit and vegetables, and pathogenic bacteria on processed fruit and vegetable surfaces.This sanitizer is EPA registered for use in fresh-cut, further processed, and post-harvest processing facilities. Also, it is cleared for all other process applications after a processing step has occurred. An acidified sodium chlorite rinse can provide pathogen reduction and offers a possible alternative sanitizer for fresh-cut producer .
Ozone Sanitizing
Ozone effectively sanitizes raw materials packaging materials, and the processing environment. It has gained acceptance by many industries, such as fresh-cut produce processing, produce storage facilities, and fruit and vegetable processing. It sanitizes by interacting with microbial membranes and denaturing metabolic enzymes. It does not leave a chemical residue, and under ambient conditions, it has a half-life of 10 to 20 minutes. Ozone must be electrically generated on-demand and cannot be stored for lateruse. it has ability to readily oxidize microbes in solution. Once a surface is spray washed, the microorganisms physically lifted from the surface will be killed as they are conveyed to drying .
Phenolic Compounds
These compounds are used most frequently in the formulation of antifungal paints and antifungal protective coatings, instead of as sanitizers applied after cleaning. Phenolic compounds have limited utility in fruit and vegetable plants because of their low solubility in water.
Ultraviolet (UV) Light
This sanitizing technique has limited utility for equipment and processing and storage areas, but has been incorporated to reduce microbial growth on fresh fruits and vegetables. Accumulation of ethylene gas during storage is a potential detriment to fruit and vegetable quality after harvest. Potential solutions to this problem are development of a titanium dioxide photocatalytic reaction technology to decompose ethylene gas in the storage environment and UV irradiation has an energy source for the titanium oxide photocatalytic reaction. UV doses improve appearance and does not adversely affect fruits stored in dark environment.
CLEANING PROCEDURES
Facilitating Effective Cleaning
The following practices are recommended to aid in cleaning:
a.Reduce burn-on through careful, con_x0002_trolled heating of vessels
b.Promptly rinse and wash equipment after use to reduce drying of soil.
c.Replace facility gaskets and seals to reduce leakage and splatter.
d.Handle food products and ingredients carefully to reduce spillage.
e.Work in an orderly manner to keep areas tidy throughout the operating period.
f. During a breakdown, rinse equipment and cool to 35°C or lower to arrest microbial growth.During brief shutdowns, keep washers,dewatering screens, blanchers, and similar equipment running and cool to 35ºC or below.
To facilitate effective cleaning, it is necessary to prepare equipment and the area for
cleaning:
a.Remove all large debris in the area to be cleaned.
b.Dismantle equipment to be cleaned as much as possible.
c.Cover all electrical connections with a plastic film.
d.Disconnect lines or open cutouts to avoid washing debris onto other equipment that has been cleaned.
e.Remove large waste particles from equipment by use of an air hose,broom,shovel or other appropriate tool.
Processing Areas
PROCEDURE
a.Prerinse all soiled surfaces with 55°C water to remove extraneous matter from the ceilings and walls to the floor drains. Avoid direct hosing of motors, outlets, and electrical cables.
b.Apply a strongly acidic cleaner through portable or centralized foam cleaning equipment.( A centralized system is more appropriate for large plants. Portable equipment is more practical for smaller plant, Soak time for the cleaning compound should be 10 to 20
minutes.)
3.Rinse surfaces within 20 minutes after application of the cleaner to remove residues. The same rinse pattern as with prerinse and cleaning compound application should be followed by the application of 50 to 55°C wate.
4.Thoroughly inspect all surfaces and conduct any necessary touch-ups.
5.Apply a chlorine compound sanitizer (100ppm) to clean equipment with centralized orportable sanitizing equipment.
6. Thoroughly backwash and sanitize water filters and water softeners.
7. Eliminate scale (as needed) from the surfaces of pipeline blanchers, water pipes, and equipment to reduce the chance of thermophiles and other microorganisms being harbored.
8. Remove, clean, and replace drain covers.
9. Apply white edible oil only to surfaces subject to rust or corrosion. Furause the protective film harbors microorganisms.
10. Avoid contamination during mainte_x0002_nance by requiring maintenance workers to carry a sanitizer and to use it where they have worked._x0002_
Packaged Storage Areas
FREQUENCY At least once per week where processed products are stored and more frequently in a high-volume operation. Daily in areas where raw products are stored.
PROCEDURE
a.Pick up large debris and place in receptacles.
b.Sweep and/or scrub with a mechanical sweeper or scrubber, if one is available. Use cleaning compounds provided for mechanical scrubbers, according to directions provided by the vendor.
c.Use a portable or centralized foam or slurry cleaning system with 50°C water to clean areas heavily soiled unpackaged products, or other debris. Rinse as described for the processing areas
EVALUATION OF SANITATION
EFFECTIVENESS
A sanitation program must be evaluated to determine the effectiveness of cleaning and sanitation.Performance data not only measure sanitation effectiveness, but also provide documentation of the program being conducted. Sanitation goals and checks are vital in
the determination of sanitation effectiveness.
CONCLUSION
Effective sanitation prevents microbes that cause spoilage and food poisoning from getting into the fruits and vegetables during production processing, storage and distribution. It can enhance the product wholesomeness.
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