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| Table of Contents | ||||||
| Preface | xiii | |||||
| Chapter 1 | Sanitation and the Food Industry | 1 | ||||
| The food industry | 1 | |||||
| What is sanitation? | 3 | |||||
| Why sanitation? | 3 | |||||
| Sanitation laws and regulations and guidelines | 9 | |||||
| Establishment of sanitary practices | 13 | |||||
| Summary | 14 | |||||
| Study questions | 15 | |||||
| Chapter 2 | The Relationship of Biosecurity to Sanitation | 16 | ||||
| Potential risks of foodborne bioterrorism | 17 | |||||
| Bioterrorism protection measures | 17 | |||||
| The role of pest management in biosecurity | 22 | |||||
| Additional bioterrorism information | 22 | |||||
| Summary | 23 | |||||
| Study questions | 24 | |||||
| Chapter 3 | The Relationship of Microorganisms to Sanitation | 25 | ||||
| How microorganisms relate to food sanitation | 25 | |||||
| What causes microorganisms to grow | 30 | |||||
| Effects of microorganisms on spoilage | 34 | |||||
| Effects of microorganisms on foodborne illness | 35 | |||||
| Foodborne illnesses | 36 | |||||
| Microbial destruction | 53 | |||||
| Microbial growth control | 55 | |||||
| Microbial load determination | 55 | |||||
| Diagnostic tests | 62 | |||||
| Summary | 67 | |||||
| Study questions | 67 | |||||
| Chapter 4 | The Relationship of Allergens to Sanitation | 70 | ||||
| What are allergens? | 71 | |||||
| Allergen control | 71 | |||||
| Summary | 75 | |||||
| Study questions | 75 | |||||
| Chapter 5 | Food Contamination Sources | 76 | ||||
| Transfer of contamination | 77 | |||||
| Contamination of foods | 77 | |||||
| Other contamination sources | 80 | |||||
| Protection against contamination | 81 | |||||
| Summary | 82 | |||||
| Study questions | 82 | |||||
| Chapter 6 | Personal Hygiene and Sanitary Food Handling | 83 | ||||
| Personal hygiene | 83 | |||||
| Sanitary food handling | 96 | |||||
| Summary | 97 | |||||
| Study questions | 98 | |||||
| Chapter 7 | The Role of HACCP in Sanitation | 99 | ||||
| What is HACCP? | 99 | |||||
| HACCP development | 101 | |||||
| Interface with GMPs and SSOPs | 106 | |||||
| HACCP principles | 106 | |||||
| Organization,implementation,and maintenance | 111 | |||||
| Summary | 114 | |||||
| Study questions | 114 | |||||
| Chapter 8 | Quality Assurance for Sanitation | 116 | ||||
| The role of total quality management | 117 | |||||
| Quality assurence for effective sanitation | 117 | |||||
| Organization for quality assurance | 119 | |||||
| Establishment of a quality assurance program | 125 | |||||
| Summary | 139 | |||||
| Study questions | 140 | |||||
| Chapter 9 | Cleaning Compounds | 141 | ||||
| Soil characteristics | 141 | |||||
| Effects of surface characteristics on soil deposition | 143 | |||||
| Soil attachment characteristics | 144 | |||||
| Cleaning compound characteristics | 146 | |||||
| Classification of cleaning compounds | 148 | |||||
| Cleaning auxiliaries | 154 | |||||
| Scouring compounds | 156 | |||||
| Cleaning compound selection | 156 | |||||
| Handling and storage precautions | 157 | |||||
| Summary | 163 | |||||
| Study questions | 163 | |||||
| Chapter 10 | Sanitizers | 165 | ||||
| Sanitizing methods | 165 | |||||
| Summary | 188 | |||||
| Study questions | 188 | |||||
| Chapter 11 | Sanitation Equipment | 190 | ||||
| Sanitation costs | 190 | |||||
| Equipment selection | 191 | |||||
| Cleaning equipment | 193 | |||||
| Sanitizing equipment | 210 | |||||
| Lubrication equipment | 211 | |||||
| Summary | 211 | |||||
| Study questions | 212 | |||||
| Chapter 12 | Waste Product Handling | 213 | ||||
| Strategy for waste disposal | 214 | |||||
| Planning the survey | 214 | |||||
| Solid waste disposal | 218 | |||||
| Liquid waste disposal | 218 | |||||
| Summary | 233 | |||||
| Study questions | 233 | |||||
| Chapter 13 | Pest Control | 235 | ||||
| Insect infestation | 235 | |||||
| Cockroaches | 235 | |||||
| Insect destruction | 240 | |||||
| Rodents | 245 | |||||
| Birds | 249 | |||||
| Use of pesticides | 250 | |||||
| Integrated pest management | 252 | |||||
| Summary | 255 | |||||
| Study questions | 255 | |||||
| Chapter 14 | Sanitary Design and Construction for Food Processing | 257 | ||||
| Site selection | 257 | |||||
| Site preparation | 258 | |||||
| Building construction considerations | 258 | |||||
| Processing and design considerations | 260 | |||||
| Pest control design | 265 | |||||
| Construction materials | 266 | |||||
| Summary | 266 | |||||
| Study questions | 266 | |||||
| Chapter 15 | Low-Moisture Food Manufacturing and Storage Sanitation | 268 | ||||
| Sanitary construction considerations | 268 | |||||
| Receipt and storage of raw materials | 272 | |||||
| Cleaning of low-moisture food manufacturing plants | 280 | |||||
| Summary | 281 | |||||
| Study questions | 281 | |||||
| Chapter 16 | Dairy Processing Plant Sanitation | 283 | ||||
| Role of pathogens | 284 | |||||
| Sanitary construction considerations | 286 | |||||
| Soil characteristics in dairy plants | 287 | |||||
| Sanitation principles | 288 | |||||
| Cleaning equipment | 291 | |||||
| Summary | 296 | |||||
| Study questions | 296 | |||||
| Chapter 17 | Meat and Poultry Plant Sanitation | 298 | ||||
| Role of sanitation | 298 | |||||
| Sanitation principles | 306 | |||||
| Cleaning compounds for meat and poultry plants | 308 | |||||
| Sanitizers for meat and poultry plants | 309 | |||||
| Sanitation practices | 312 | |||||
| Sanitation procedures | 314 | |||||
| Troubleshooting tips | 324 | |||||
| Summary | 325 | |||||
| Study questions | 325 | |||||
| Chapter 18 | Seafood Plant Sanitation | 327 | ||||
| Sanitary construction considerations | 327 | |||||
| Contamination sources | 329 | |||||
| Sanitation principles | 330 | |||||
| Recovery of by-products | 334 | |||||
| Summary | 334 | |||||
| Study questions | 334 | |||||
| Chapter 19 | Fruit and Vegetable Processing Plant Sanitation | 336 | ||||
| Contamination sources | 336 | |||||
| Sanitary construction considerations | 338 | |||||
| Cleaning considerations | 340 | |||||
| Cleaning of processing plants | 341 | |||||
| Cleaners and sanitizers | 343 | |||||
| Cleaning procedures | 344 | |||||
| Evaluation of sanitation effectiveness | 346 | |||||
| Summary | 348 | |||||
| Study questions | 348 | |||||
| Chapter 20 | Beverage Plant Sanitation | 350 | ||||
| Mycology of beverage manufacture | 350 | |||||
| Sanitation principles | 350 | |||||
| Nonalcoholic beverage plant sanitation | 352 | |||||
| Brewery sanitation | 355 | |||||
| Winery sanitation | 361 | |||||
| Distillery sanitation | 367 | |||||
| Summary | 369 | |||||
| Study questions | 369 | |||||
| Chapter 21 | Foodservice Sanitation | 371 | ||||
| Sanitary design | 371 | |||||
| Contamination reduction | 374 | |||||
| Sanitary procedures for food preparation | 376 | |||||
| Sanitation principles | 376 | |||||
| Foodservice sanitation requirements | 389 | |||||
| Summary | 391 | |||||
| Study questions | 391 | |||||
| Chapter 22 | Management and Sanitation | 392 | ||||
| Management requirements | 392 | |||||
| Employee selection | 394 | |||||
| Management of a sanitation operation | 396 | |||||
| Total quality management | 400 | |||||
| Summary | 401 | |||||
| Study questions | 401 | |||||
| Index | 406 | |||||
Index
AAccelerated death phase. See Microorganisms, growth pattern of
Acid cleaning compounds. See Cleaning compounds
Acquired immune deficiency syndrome (AIDS), 28, 45
Activated carbon absorption, 231
Activated sludge. See Wastewater TreatmentAeromonas hydrophila, 36-37, 40, 301
Alkaline cleaning compounds.See Cleaning CompoundsAllergens,
- contamination causes of, 71-72
- control of, 71-73
- definition of, 71
- labeling of, 73-74
- management of, 74-75
- tests for, 73
Arcobacter butzleri, 49
Aw , 26, 31-33, 109B
Bacillus cereus, 37, 39
Biochemical oxygen demand (BOD).See Wastewater Treatment
Bacteria. See Microorganisms Bactericides, 32-33
Bacteriostats, 32
Beer pasteurization, 360Biofilms, 33-34
Bioluminescence, 58-60
Biosecurity,- guidelines, 19-22
- information, 22-23
- pest management in, 22
Biosensors, 66
Bird infestation, 249-250
Bottle cleaning, 360
Botulism. See Clostridium botulinumBrewery sanitation, 355-361
- cleaning compounds for, 358
- cleaning of air conditioning units, 360-361
- construction considerations for, 356
- control of microorganisms, 356-357
- heat pasteurization for, 358
- hygiene practices for, 358-361
- sanitizers for, 358
CCampylobacter, 40, 42, 49, 301
Campylobacteriosis, 38, 40, 42
Cetylpyridinum chloride, 186
Chain of infection, 77
Chloramines, 172
Chlorine dioxide. See Sanitizing
Chelating agents. See Cleaning Compounds
Cigarette beetle, 239-240, 276
Cleaning compounds, 141-143, 146-162,
- builders for, 153-154
- characteristics, 146-148
- chemical burns from, 162-163
- classification of,- acid, 149-151, 308
- alkaline, 148-150, 152, 308-309
- cleaning auxiliaries, 154-156
- neutral, 156 - phosphate substitutes, 153
- protection auxiliaries, 153-154
- solvent, 153
- synthetic detergents, 152
- detergent auxiliaries, 153
- enzyme based, 152-153- factors affecting effectiveness of, 147-148
- function of, 146-147
- handling precautions for, 157, 159-163
- scouring compounds, 156
- selection of, 156-157
- sequestrants, 154-155
- surfactants, 155-156
- terminology, 147-148
Cleaning equipment. See Sanitation, cleaning equipmentCleaning media,
- air, 145
- water, 145-146
Clostridium botulinum, 36-37, 39
Clostridium perfringens, 39, 42-43, 311
Cockroaches, 235-238
- common species of, 236-237
- control of, 237-238
- detection of, 237
Contamination,- human, 80
- protection against, 81-82
- sources of, 77-81
Contract sanitation, 400
Control point(s), 108
Critical control point(s), 100-101, 103, 108-112
Critical limit(s), 109-111308
Cryptosporidiosis. See Cryptosporidium parvumCryptosporidium parvum, 49
Cumulative sum (CUSUM) control charts, 139
Current good manufacturing practices (CGMPs), 105-106, 112
DDairy processing plant sanitation,
- CIP equipment for, 291-293
- cleaning compounds for, 288
- cleaning steps for, 290-291
- construction considerations for, 286-287
- COP equipment for, 293
- pathogens in, 284-286
- sanitation for cheesemaking, 295-296
- sanitation principles for, 288-295
- sanitizers for, 289-290
- soil characteristics of, 287-288
- storage equipment cleaning in, 294-295
Decimal reduction time (D value), 53
Detergent(s). See Cleaning CompoundsDetergent auxiliaries.See Cleaning Compounds
Diagnostic techniques, 8, 62-67
Disease transmission, 94-96
Dissolved air flotation, 222-223
Distillery sanitation, 367-369
- contamination reduction, 367-368
- equipment cleaning, 368-369
DNA-based microarray assays, 64
EElectrodialysis, 231
Electronic pasteurization, 54
Environmental regulations, 12
Enzyme-linked Immunoassay Tests (ELISA), 62-63
Escherichia coli, 43, 89
Escherichia coli, O157:H7, 41, 43-44, 285, 311, 344
Ethylenediaminetetraacetic acid (EDTA), 155
FFlies.See Housefly
Food and Drug Administration (FDA), 9-11
Foodborfle bioterrorism, 17-18
Foodborne disease. See Foodborne illnessFoodborne illnesses, 36-50
Food handling,- required personal hygiene for, 96
- sanitary facilities for, 97
Food safety assurance, 5
Foodservice sanitation, 371-391
- chemical sanitizing washers for, 380
- CIP equipment for, 380, 382
- cleaning steps for, 378- coffee urns, 385
- deep fat fryer, 387-388
- floor drains, 379
- floors, 382
- griddles, 384
- hoods, 383-384
- iced tea dispensers, 386
- meat slicers, 388-389
- milk dispensers, 387
- range surface units, 384
- refrigerated salad bars, 386-387
- shelves, 383
- stack ovens, 383
- stationary equipment, 378-379
- steam tables, 386
- toasters (rotary), 384-385
- vegetable choppers, 388
- walls, 382-383
- cleaning tools for, 379
- contamination reduction, 374-376
- employee training for, 390
- glove utilization for, 376
- high-temperature washers for, 379
- mechanized cleaning and sanitizing for, 379-382
- requirements, 389-390
- sanitary design for, 371-374
- sanitary principles for, 377-378
- sanitary procedures for, 376
Fruit and vegetable plant sanitation, 336-348
- cleaning compounds for, 343
- cleaning considerations, 340-341
- cleaning equipment for, 342-343
- cleaning procedures for, 344-346
- construction considerations for, 338-340
- contamination sources, 336-338
- sanitation effectiveness evaluation for, 346-348
- sanitizers for, 343-344
Fruit fly, 239
GGlutaraldehyde. See Sanitizing
Good manufacturing practices, 10-11, 106
HHand washing, 89-93
Hazard, categories, 107-108
- definition of, 100
- risk categories, 108
Hazard Analysis Critical Control Points (HACCP), 99-114, 313, 334, 341
- approach, 125-126
- cleaning approach, 192-193
- decision tree, 109
- development of, 101-104
- implementation of, 104
- maintenance of, 113-114
- principles of, 106-111
- validation, 114
- verification, 111
Helicobacter pylori, 49-50
Hepatitis, 28, 41
Housefly, 238-239
- control of, 240-245, 255
- effects of, 238-239
Hygiene,
- definition of, 83
- employee, 83-89
- required practices for, 95-96
- requirements, 95-97
IInorganic chloramines. See Sanitizing
Insecticide(s).See Pesticides
Insect light traps, 242-243
Insect-resistant packaging, 255, 277
Integrated pest management (IPM), 252-255
International Standards Organization (ISO), 120-121
Iodophor(s). See SanitizingIon exchange. See Wastewater Treatment
JJob enrichment, 121, 399
LLag phase. See Microbial Growth Kinetics
Legionella pneumophila, 50
Legionellosis. See Legionella pneumophilaListeria monocytogenes, 6, 101, 284-285, 295, 301-305, 311, 312, 315, 330, 332
Listeriosis, 41, 44-47
Logarithmic growth phase. See Microbial Growth KineticsLow-moisture foods manufacturing and storage, 272-280
- facility cleaning, 280-281
- housekeeping for, 277-279
- pest control for, 274-280
- external feeders,- cigarette beetle, 276
- drugstore beetle, 276
- flour beetle, 275-276
- grain beetle, 276
- indianmeal moth, 275
- mealworms, 277
- Mediterranean flour moth, 275
- spider beetle, 276-277
- internal feeders, 274-275- angoumois grain moth, 275
- lesser grain borer, 275
- weevils, 274-275
MMeat contamination, 300-301
Meat discoloration, 299-300
Meat and poultry plant sanitation, 298-325
- carcass and product decontamination, 310-312
- cleaning compounds for, 308
- cleaning equipment for, 306-308
- effects on product discoloration, 299-300
- pathogen control for, 301-304
- plant design for, 304
- practices for, 304-305, 312-313
- principles for, 306-308
- procedures for,- brine curing and packaging areas, 319
- dry curing areas, 319-320
- fresh product processing area, 317, 318
- garments, 323
- livestock and poultry trucks, 314-315
- livestock pens, 315
- locker and rest rooms, 323
- low-temperature rendering area, 322-323
- offices, 323 - packaged meats storage area, 322
- poultry mechanical eviscerators, 316
- poultry pickers, 316 - processed products area, 318
- processed products, offal, and storage cooler, 317
- processed products packaging area, 31
- receiving and shipping area, 316-317
- slaughter area, 315-316
- smokehouses, 320-321
- spiral freezers, 321 -322
- trolley washing, 323
- wash area, 322
- wire and metal containers, 323
- sanitizers for, 309-312
- troubleshooting tips for, 324
Mesophiles, 31
Mice. See Rodent InfestationMicrobial growth kinetics, 28-30
Microbial resistance, 187
Microorganisms,- bacteria, 27
- common to food, 26
- definition of, 25
- destruction of, 53-54
- deteriorative effects of, 34-35
- diagnostic tests for, 62-67
- effects on foodborne illness, 35-36
- generation interval of, 34
- inhibition of, 32-33, 55
- molds, 26-27, 180, 295
- proliferation factors, 30-34
- quantitative determination of, 55-61
- viruses, 27-28
- yeasts, 27, 180
Molds. See MicroorganismsMonitoring program. See Quality Assurance Monitoring Program
Most probable number (MPN), 57
Mycotoxins, 51-52
NNonalcoholic beverage plant sanitation, 350-355
- cleaning practices for, 351-355
- sanitation principles for, 350-351
OOrganic chloramines. See Sanitizing
Oxidation-reduction potential, 32
Oxine. See Sanitizers
PPesticides, 240-242, 247-248, 250-252, 254-255
- nonresidual, 240-241
- residual, 240
- use of, 240-241, 247-249, 250-252, 254-255
pH, 32, 169, 174-176
Pheromone traps, 243-244
Polishing ponds, 231
Polymerase Chain Reaction, 66
Protection auxiliaries, 153-154
Psychcosomatic food illness, 36
Psychrotrophs, 31
Pulsed light, 54
QQuality,
- characteristics, 117
- definition of, 117
Quality assurance (QA),
- basic tools, 131
- components of, 118
- description of, 117-119
- functions of, 118-119
- management role in, 121-122
- organization for, 119-124
- product recall, 129-130
- sampling for, 131
- sanitation programs for,- assay procedures for, 126-127
- auditing of, 128-129
- data interpretation for, 127
- establishment of, 125-126
- evaluation of, 126
- major responsibilities of, 119-120
- monitoring for, 127-128
- structure of, 121-124
- total quality assurance, 125
- total quality management, 117, 119
RRadiation, 54, 166-167
Rapid methods for microbial load determination. See Microorganizisms, quantitative determination ofRats. See Rodent Infestation
Raw materials,- receipt of, 272-273
- storage of, 273-280
Reduced death phase. See Microorganisms, growth pattern ofRodent infestation, 245-246
- control of, 246-247
- determination of, 246
- eradication of, 247-249
Rotating biological contactor. See Wastewater Treatment
SSalmonella, 39, 47, 186, 285-286, 301, 344
Salmonellosis, 39
Sampling. See Quality Assurance, sampling forSanitary design for food facilities, 257-266, 268-271
- construction considerations for, 258-265
- equipment considerations for, 271
- materials for, 266
- ready-to-eat operations, 262-265
- pest control considerations, 265-266
- principles for, 263-265
- site preparation, 258
- site selection, 257
Sanitation,
- cleaning equipment, 193-210, 307-308- centralized foam, 199-201
- centralized high pressure, low-volume, 197-198, 201
- cleaning-in-place (CIP), 201-209, 307, 308, 343
- cleaning-out-of-place (COP), 209-210, 308
- lubrication equipment, 211
- microprocessor control unit, 208-209
- portable foam, 198-199, 307
- portable gel, 201, 307
- portable high pressure, low-volume, 195-197, 307
- slurry, 201
- costs, 190-191
- definition of, 3
- employee selection for, 394-395
- employee training, 395-396
- equipment selection, 191-192
- guidelines, 9-13
- laws, 9-13
- management requirements, 392-394
- management responsibilities, 396-398
- practices, 13-14
- regulations, 9-13
Sanitation Hazard Analysis Work Point (SHAWP), 193, 398-399
Sanitizing, acid, 178-181, 310, 343-344
- acid anionic, 180-181
- acidified sodium chlorite, 311
- acid-quat, 181
- activated lactoferrin, 186-187, 311-312
- bromine, 176
- cetylpyridinium chloride (CPC), 186
- chemical, 168-187, 290, 309-310
- chlorine, 170-174
- chlorine dioxide, 172-173, 309, 343
- electrolyzed oxidizing water, 312
- equipment, 210-211
- glutaraldehyde, 182-183
- high hydrostatic pressure (HHP) 167-168, 333
- high-pressure pasteurization, 186
- hydrogen peroxide, 181
- iodine, 174-176, 309
- methods, 165-187
- microbicides, 183
- oxine, 173-174
- ozone, 182, 310, 333, 344
- peroxy acid, 179-180
- phenols, 312, 344
- quaternary ammonium compounds (quats), 176-178, 309, 343
- radiation, 166-167, 344
- strength determination, 188
- thermal, 165-166, 309- hot water, 166, 185
- steam, 166, 185
- vacuum/steam/vacuum, 168, 185-186
Sanitation Standard Operating Procedures (SSOPs), 106
Scouring compounds. See Cleaning CompoundsSeafood plant sanitation, 327-334
- cleaning schedule, 331-333
- construction considerations for, 327-330
- contamination sources, 329-330
- HACCP models for, 334
- recovery of by-products for, 334
- sanitation principles, 330-333
- sanitizers for, 332-333
- site requirements for, 327-328
Shigella, 39, 47-48
Shigellosis, 39, 47-48
Soil,- attachment characteristics of, 144-145
- characteristics in dairy plants, 287-288
- chemical characteristics of, 141, 143
- chemical properties of, 143
- definition of, 141
- deposit classification, 141-142
- physical characteristics of, 141-143
- solubility characteristics of, 142-143
- surface characteristics of, 143-144
Staphylococci, 39
Staphyloccus aureus, 39, 48
Stationary growth phase. See Microorganisms, growth pattern ofStatistical quality control,
- charts, 133-139
- definition of, 138
- lower control limits, 134-136
- rating scales,- exact measurement, 138
- subjective evaluation, 138
- role of, 131-138
- upper control limits, 134-136
Streptococci, 37
Surfactants. See Cleaning compounds
TThermal death time (TDT), 53
Thermophiles, 31
Total quality management, 117, 400
Trichinella spiralis, 40, 48
Trichinosis, 40, 48
UUnited States Department of Agriculture (USDA) regulations, 11
VVibrio, 50
Vibrio parahaemolyticus. See Vibrio
Viruses. See Microorganisms
WWaste disposal, 213-233
- liquid, 218-233
- solid, 218
- strategy, 214-215
- survey, 214-215
Wastewater,- fats, oil, and grease (FOG), 217
- pollution determination, 215-218
- residue in, 217-218
- sampling of,- biochemical oxygen demand (BOD), 215-2-16
- chemical oxygen demand (COD), 216
- dissolved oxygen (DO), 216
- total organic carbon (TOC), 216-217
Wastewater treatment, 220-233
- disinfection, 231-233
- pretreatment, 220-222- flow equalization, 221
- screening, 221-222
- skimming, 222
- primary treatment, 222-224- flotation, 222-224
- sedimentation, 222
- secondary treatment, 224-230- activated sludge, 227-228
- aerobic lagoons, 226-227
- anaerobic lagoons, 225-226
- contact stabilization process, 228
- extended aeration process, 228
- land application, 229
- magnetic separation, 230
- oxidation ditch, 228-229
- rotating biological contactor, 229-230
- trickling filters, 227
- tertiary treatment, 230-233- chemical oxidations, 231
- deodorization, 233
- disinfection, 231-233
- filtration, 230
- ion exchange, 231
- microstrainer separation, 230
- physical-chemical separation, 230-231
- physical separation, 230
- tertiary lagoons, 231
Water activity (Aw).See AwWeb of causation, 77
Winery sanitation, 361-367
- bottling area cleaning, 363-364
- cleaning compounds for, 362
- cleaning floors and walls, 362-363
- cleaning used cooperage, 364
- equipment cleaning, 363
- pest control, 367
- sanitary principles, 362
- sanitation monitoring, 367
- sterile filtration, 366
- tartrate deposit removal, 364-365
YYeasts. See Microorganisms
Yersinia enterocolitica, 41, 48-49
Yersiniosis. See Yersinia entewcolitica
