Q. How do we handle/document seasonal equipment on our master cleaning schedule? Some of our equipment can go several months without being used.

A.This is a great question! It is vital to ensure unused equipment is maintained to prevent possible pest or microbiological development. The first thing to consider is whether the equipment is permanently mounted in the active production area or is portable and taken to an equipment storage/warehouse area when not in use.

A master cleaning schedule (MCS) should include an established cleaning frequency for equipment that is in use; let’s say this is weekly. If the equipment is moved to storage, add a row on the MCS below the weekly row that lists the inspection/cleaning frequency: as needed. Assuming the equipment is cleaned before it is put in storage, an inspection could be conducted monthly to monitor for general cleanliness, such as lack of dust, cobwebs, etc. Then cleaning could be done as necessary, based on the inspection. The purpose of listing two rows for one piece of equipment is to allow accountability for the equipment for the entire year, whether it is in use or in storage.

For equipment that is permanently mounted in the production area, MCS documentation can be handled like the first scenario—with one major difference: equipment in the production area still will be exposed to production dust, water, and elements. If the equipment is cleaned weekly when in use, it probably would be best to evaluate it each week when off-use for a period of time to determine how much dust, dirt, or moisture is accumulating on the unused equipment. The off-use frequency will vary for every facility. Some companies may need to continue with a weekly cleaning schedule, while others may be able to reduce the frequency to bi-weekly or even monthly. The MCS chart (below) provides an example.

It is vital to ensure that all equipment is included on the MCS, whether it is in use or in storage. Inspections have revealed significant issues, such as pest infestations, in equipment that is not in use and not maintained as part of the MCS.

Tracking unused equipment also allows for accountability and time management. Every line on the MCS should have an estimated time of completion for the task. By tracking unused equipment, assigning a frequency, and estimating time, you can better budget and allocate resources. This can be very beneficial in justifying a specific number of people hours for the MCS for an entire year.

Do you have a question for Lance Reeve? If so, e-mail him at lreeve@aibonline.org.

Protecting consumers from foodborne illness has become a global challenge. The increase in foodborne illness outbreaks raises food safety concerns. Many such outbreaks have been associated with the formation of biofilm by foodborne pathogens. In nature, most bacteria do not exist as suspended individual cells. Rather, they exist in a group (mass of bacterial cells) attached to a surface. A biofilm is a mass of microorganisms in which cells stick to each other on a surface. A biofilm can form over a period of time on food-contact surfaces that have not been properly cleaned and disinfected. Bacteria adhere to a solid surface and enclose themselves within a self-produced matrix of extracellular polysaccharide.

The biofilm is highly protective for the bacteria. In fact, it is an important survival strategy. Microorganisms within the biofilm are protected from external agents such as cleaning and sanitizing agents, antibiotics, etc. Both pathogenic and non-pathogenic bacteria are capable of forming a biofilm. The formation of biofilm in food processing environments is a special concern especially with pathogenic bacteria because their survival rate and chance to contaminate foods increase. Preventing and removing biofilms in food processing establishments is critical.
 

Biofilm Formation.

The formation of biofilms typically involves four steps (Figure 1, below):

1. Initial attachment: It begins with the attachment of free-floating bacteria to a surface.
2. Irreversible attachment: The biofilm grows through a process of cell division, and these cells stick to each other and to a surface with the aid of a self-produced matrix of extracellular polymeric substance (EPS). The EPS helps strengthen the bond between bacterial cells and the substratum. Over a period of time, these bonds are strengthened, making the attachment irreversible.
3. Maturation: The biofilm develops into an organized, resistant structure which displays a multifold resistance to toxic chemicals and biocides.
4. Dispersion: The biofilm is completely established and may change only in shape and size. Bacterial cells are released into the environment.
   
    

Factors Affecting Biofilm Formation.

Biofilm formation is a dynamic and complex process. The availability of moisture and nutrients, the pH level, the temperature of the contact surface, the presence of other bacteria, the type of surface, and other factors affect biofilm formation. Additionally, nutritional properties of the food matrix also affect biofilm formation and persistence.

Impact on THE Food Industry. Biofilm growth in food manufacturing establishments leads to opportunities for microbial contamination of the processed food affecting the safety of finished products. Biofilms exist on all types of surfaces in food plants, such as metal, concrete floors, walls, pipes, nylon materials, glass, rubber, steel, wood, plastic, etc. They also are found on some food products, including spinach, lettuce, sprouts, etc.

Biofilms can cause serious hygiene issues, and economic losses due to cross contamination. In general, the sporadic colony counts observed on swab samples taken from environmental and food-contact surfaces indicate the presence of a biofilm. Although any bacterial species are capable of forming biofilms in food manufacturing establishments, the most important species in relation to food safety are Listeria monocytogenes, Salmonella spp., pathogenic Escherichia coli, Campylobacter jejuni, Pseudomonas spp., etc. Some bacteria (e.g., Pseudomonas spp., Listeria spp., Salmonella spp.) have the ability to form multi-species biofilm, which are more stable and resistant to sanitizing agents.
 

Controlling Biofilm Formation.

The cleaning process. This is the first and most important control strategy to avoid biofilm formation in a food manufacturing establishment. Product residues (spills/debris) in the facility promote bacterial proliferation and subsequent biofilm formation. Hence, regular removal of food residues is a key to preventing biofilm formation. The main purpose of the cleaning agents (e.g., surfactants, alkali products) is to break up or dissolve the polysaccharide matrix associated with the biofilms so that the disinfectants (e.g., chlorine, hydrogen peroxide, iodine, etc.) can gain access to the bacterial cells hidden inside the biofilm.

Chemical methods. A wide range of chemical disinfectants is available and can be broadly divided into three groups:

1. Oxidizing agents (chlorine-based compounds, hydrogen peroxide, ozone, etc.).
2. Surface-active compounds (including quaternary ammonium compounds and acid anionic compounds).
3. Iodophores.

The efficacy of these is influenced by pH, temperature of the contact surface, concentrations of cleaning and sanitizing agents, contact time, etc. Disinfectants are less effective around food residues.

Physical methods. Physical methods, such as ionizing radiation, atmospheric plasma inactivation, ultrasound, electric fields, etc., have been developed and studied as alternatives for chemical disinfectants used in the food industries. These techniques appear to be effective against biofilms and on microorganisms. However, the applicability of these techniques should be examined with consideration of their cost and regulatory aspects.
 

Established Biofilm.

Once established, biofilms are very hardy communities that require considerable time and effort to eliminate. Facility and equipment should be hygienically designed so bacteria cannot find harborage sites that protect them from cleaning and disinfection. Additionally, the removal of biofilms is greatly affected by the application of mechanical force, such as brushing and scrubbing, to the surface during cleaning.

Past research has clearly demonstrated that the best result is achieved using hurdle technology. Hurdle technology usually works by combining two or more different treatment methods. For example, the combination of sodium hypochlorite (NaClO) with UV irradiation, NaClO with hydrogen peroxide (H₂O₂), and ultrasound with enzyme had better results than a single treatment. This is one of the promising new approaches in controlling biofilms in the food industry.

It is important for a food manufacturing facility to develop custom cleaning and disinfection procedures that take into consideration their target pathogens, economic costs, and regulatory aspects. Also, it is vital to identify the biofilm-prone sites on a facility map and monitor the microbial load in these sites.

The author is Director, Microbiology, AIB International.

In addition to plant managers, QA managers, and other food industry personnel who typically complete AIB’s Food Defense Coordinator courses, there also are always several attendees from pest control companies. Did you know that the pest control operators (PCOs) who service your food operation can be a great asset in protecting your facility, products, and people from intentional contamination or harm?

There are typically several contractors at your facility on any given day. These could include suppliers, vendor service providers, uniform service providers, truck drivers, contracted maintenance workers, and pest control service providers. Interestingly, the pest control provider is the one contractor who likely has access to all areas of a food processing plant, makes several observations, and walks the entire inner and outer perimeter of a facility. While performing their essential and contracted duties, pest control operators service pest control devices inside and around the facility and look for signs of pest infestation.
 

Pest Control as Defense.

So, how do pest control operators help keep a food facility safe from intentional contamination or harm? There are many ways:

• PCOs are typically very familiar with the normal operations of the facilities they service. They know the building structure and layout, the components of the operations, the products being produced and processed at the plant, and the number of people typically found at the particular location.
• They survey the building looking for unusual circumstances, damage, and openings to the building where a pest could enter. Being keenly aware and monitoring the facility is critical to the pest control operator’s success.
• PCOs often observe the surrounding landscape (i.e., trees and bushes) that could become pest harborages. They make note of these conditions, bring them to the attention of plant management, and recommend measures to eliminate or reduce the risk of pests entering the facility.
• They also are aware of neighboring buildings and property conditions that may attract pests. This includes waterways, streams, railroad tracks, dense forests, and other such areas.
   

Someone planning an attack against a food facility will likely do so by observing the facility operations. This may include watching the facility premises, taking pictures of the property, tugging on perimeter doors to determine if there is access, or simply asking suspicious questions about the plant and its operations.

Pest control operators who have been trained in food defense and facility protection can be a great asset to the overall security of a food plant. In addition to their regular duties of looking for and protecting against pests, they can look for red flags that could indicate suspicious activity while making their rounds of the facility. For example, while servicing bait stations along the exterior perimeter, PCOs can look for overgrown bushes and shrubs in which someone could hide, observe the lighting fixtures, make note of areas outside the plant where it appears a person or persons has been by propping a perimeter door open, and anything else that appears unusual. They can observe areas along exterior perimeter fencing that are damaged and increase the security vulnerability to harmful activity.

During a recent facility security vulnerability assessment, I noticed obvious tool indentations at a perimeter door that led into the processing plant, indicating that someone had attempted to break into the facility. It was obvious that someone had tried to pry open the lock to gain unauthorized entry. Interestingly, the pest control operator had recently placed a rodent bait station near this door, so my investigation included talking with him to try to determine a timeframe that this attempted break-in occurred. The pest control operator was extremely helpful and indicated that the tool marks on that door occurred after his last visit to the plant, which was within a week. Thanks to an alert and observant pest control operator, local police were able to rapidly move forward with their investigation in an attempt to solve the case.

Pest control operators can observe the perimeter camera systems to determine if the cameras are damaged or if vegetation or other materials have blocked the view of the camera. They can observe incoming gas lines for tampering and make sure product ingredient ports are locked and sealed. They can look around the lot to see if they notice any used seals that have been removed from trailers or tankers and improperly disposed of.

They also can monitor parking lots while servicing the exterior perimeter to observe any suspicious vehicles parked on the company lot. If your facility has an established parking program, your PCO can make note of vehicles that are not in compliance with company requirements (e.g., not displaying the required decal).

While making outside observations, operators can look at security signage to ensure the paint or ink is not wearing off and that the signs are visible, readable, and able to be seen at night. While looking at perimeter doors, they can ensure that all are numbered, and that the numbers are in chronological order, and can be readily identified in an emergency. Further, the PCO can note any unoccupied service or delivery vehicles on the company lot that are left with the engines running and keys in the ignition. Removing keys and turning off vehicles while unattended is critical in preventing the theft of entire loads of products.

Pest control operators also can help inside the facility. Walking through the entire facility gives the PCO the opportunity to identify people who may be violating or compromising security procedures (e.g., not wearing required identification badges, propping a perimeter door open, acting suspicious, etc.). They can observe other visitors and contractors to ensure they are following established company security guidelines. They also can look for objects and occurrences that appear to be out of place (e.g., boxes or chemicals that are out in the open and unattended) and make note of any cameras that do not appear to be operating properly.

PCOs who have been trained in food defense also can recommend countermeasures to plant management in an effort to enhance the overall security of the facility. For example, if a perimeter door is not used for entry but still has hardware on the outside, the hardware should be removed; if the facility’s visitor log is not being properly filled in, the PCO could bring this security concern to management’s attention. Basically, the pest control operator would be performing a mini security-vulnerability assessment at each visit to the facility.
 

The Enhanced Inspection.

To take full advantage of the PCO’s ability to provide this enhanced service, you should discuss the option with your pest control provider. You could plan to provide your PCO with a mini security-assessment list that identifies your specific areas of concern or have the operator perform a mini assessment in a different area of the operation at each visit. For example, one week the assessment could consist of looking at security measures within shipping and handling. The list might ask:

• Are seals being properly used and secured when not in use?
• Are dock doors being locked when unattended?
• Is the outside dumpster free from products or other materials that could potentially harm someone?
   

In order for a pest control operator to be an effective asset to plant management, he or she should have continuing and documentable training in food defense, with an emphasis on conducting security vulnerability assessments. The training should focus on the added responsibilities of the pest control operator, understanding crime and terrorism at a food facility, and working with management to recognize and report suspicious activity, understand security systems, spot outside foliage and shrubbery concerns, and address any other security-related matters. The PCOs should be well versed in Food Safety Modernization Act requirements regarding food defense.

Pest control operators can be a vital asset to a food facility’s food-defense operations. Whether there is a contractor who refuses to follow established protocols, a temporary worker who is unaware of the security requirements, or suspicious activity indicating a brewing act of workplace violence, pest control operators trained in food defense and facility protection that take note of and inform management of observed circumstances are very beneficial. Pest management companies who staff appropriately trained pest control operators offer a value-added service to their clients and put themselves one step ahead of their competitors.

The author is Subject Matter Expert, Food Defense, AIB International.

A place for everything and everything in its place. But how do these items get to their proper place? Traffic patterns in a food plant are often established out of convenience, rather than with food safety in mind. Let’s think about the movement of raw materials, people, and waste in a food facility and how these pathways could pose a threat to food safety.

Raw materials may contain hazards, such as microbes or allergens that can contaminate the areas through which they travel. Raw materials are typically stored in a warehouse or bulk silos near the perimeter of the building. These materials must then travel to the line for use. However, in getting to the line, they may pass other lines. Is there a reasonable probability that an allergenic ingredient (such as a partially used bag of a seasoning) may contaminate the line it passes by?

Another consideration is raw materials that do not get added at the beginning of the line. These would include items such as toppings added near the end of the process or packaging which is applied at the end of the line. When that packaging travels from the raw material warehouse to the packing area, might it be exposed to microbes in the pre-kill step portion of the process? If so, the result could be packaging that re-contaminates cooked or processed product.

Waste is something that travels from various locations within the plant to outside of the plant. This includes liquid waste in drains or solid wastes in containers. Think about drains that you have in your facility. Do you know what direction they flow? Drains should flow from the “cleanest” areas of the plant toward the dirtier areas. For example, if there is a raw side and a cooked side of an operation, there would be significant risk if drains flowed in the same direction as the process. The food is typically getting “cleaner” as it gets processed. Consideration also should be given to routes for removal of waste from break areas and restrooms. The route to move the materials from the garbage cans to the dumpster should not be through product processing or product storage areas.

People in the plant, including employees and contractors, often are viewed as vectors. Not only can they transmit hazards that they bring with them into the plant, such as an existing illness, they can transfer hazards from one area of the plant to another. In high-risk environments, such as in meat and dairy plants, there are typically controls like changing of protective clothing and footbaths. However, risks of microbial cross contamination also exist for other types of operations. There are also risks of allergen cross-contact as employees or contractors traverse across the plant. Some of the highest risk employees are those in quality and maintenance who work closely with the product, but who are not linked to a single line. They may transfer contaminants from one line to another.

There are several strategies to mitigate the risks posed by traffic routes. The first step is to identify routes and potential risks. This is often done with mapping, where each type of route (raw material, waste, forklift, and personnel) is identified with a different color. Risk factors, such as areas of exposed allergens or areas with microbial-prone materials (ingredients and waste) are identified. When a route has been identified as posing a risk, control measures must be implemented. These may include a combination of the following: identifying a different route; signage; addition of handwashing stations, footbaths, or smock-donning stations; or the addition of barriers, such as hallways.

Take a hard look at your traffic patterns. You just might find the source of an ongoing problem or head off a problem that is just around the corner.

The author is Vice President, Food Safety Services Innovation, AIB International.