plant sanitation

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ORGANIZATIONAL CHART


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SSOP: Color Coded Brushes and Buckets

To prevent cross contamination, brushes and

buckets used for cleaning are color coded

according to use, and segregated by location.

MATERIALS

1. White, yellow, red, and black brushes

2. White and red buckets

3. Brush racks

4. Sanitizer

PROTOCOL:

1. Specific color brushes are used for

specific

purposes.


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White brushes are used with white

buckets to clean pasteurized food contact

surfaces.

Yellow brushes are used with white

buckets to clean non-food contact

surfaces.

Surfaces that contact raw milk.

Black brushes are used to clean floordrains.

ion of use. Particular care is needed to ensure that brushes

and buckets used in the cultured products area are

not used to clean equipment elsewhere in the

production plant.

hould be rinsed with water and then with sanitizer.

ther hung on racks, or inverted and stored off the floor on

racks or mats.

eparately. They should be kept in racks which hold them off

the floor.

es

proper sanitation. In addition to clean food processing

ed with food production areas must be clean and properly

n locked rooms away from food handling areas.

g rooms:

ooms should be separate from and not lead

:

number of properly maintained hand-washing

nitary drains.

ot and cold potable running water, soap, sanitary hand drying

supplies or devices, and clean waste receptacles.

dequate number of conveniently located and properly

installed hand washing facilities.notices be posted in strategic points throughout the

processing plant to remind employees and

visitors to wash hands after using the bathroom

SANITATION STANDARD OPERATING

PROCEDURE Milk Can Cleaning

INTRODUCTION

Milk cans are used for the short term storage of products.

They must be thoroughly cleaned after each

use and sanitized immediately prior to their next use.

MATERIALS1. Supplies

a. Gloves

b. Goggles

c. Detergent

d. Brush


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e. Sanitizer

2. Hazards

a. Burns from hot water

b. Chemical burns to skin and eyes. Wear goggles and

gloves and avoid breathing the

detergent dust and concentrated sanitizer.

PROCEDURE FOR WASHING LIGHTLY SOILED

CANS

1. Rinse cans with hot water.2. Add some chlorinated alkaline detergent and hot water.

3. Use a long handled brush to scrub the inside of each can

and lid.

4. Empty cans and rinse thoroughly.

5. Place cans and lids upside down on the can rack to dry.

6. Immediately prior to use:

a. rewash cans with a chlorinated alkaline detergent

b. empty cans and rinse thoroughly

c. fill cans with a sanitizing solution

d. empty cans and allow them to drain

PROCEDURE FOR WASHING HEAVILY SOILED

CANS

1. Rinse cans with hot water.2. Add approximately scoop of a chlorinated detergent to

each can.

3. Fill cans to the top with hot water and allow them to soak

for at least 10 to 15 minutes.

4. Use a long handled brush to scrub the inside of each can

and lid.

5. Empty cans and rinse thoroughly.

6. Place cans and lids upside down on the can rack to dry.

7. Immediately prior to use:

a. rewash cans with a chlorinated alkaline detergent

b. empty cans and rinse thoroughly

c. fill cans with a sanitizing solution

d. empty cans and allow them to drain

Ice Cream

Manufacture

The basic steps in the manufacturing of ice cream

are generally as follows:

blending of the mix ingredients

pasteurization

homogenization

aging the mix

freezing

packaging

hardening


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Process flow diagram for ice cream

manufacture: the red section represents the

operations involving raw, unpasteurized mix, the

pale blue section represents the operations

involving pasteurized mix, and the dark blue

section represents the operations involving frozen

ice cream.

Blending

First the ingredients are selected based on the

desired formulationand the calculation of the

recipefrom the formulation and the ingredientschosen, then the ingredients are weighed and

blended together to produce what is known as the

"ice cream mix". Blending requires rapid

agitation to incorporate powders, and often high

speed blenders are used.
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Pasteurization

The mix is then pasteurized. Pasteurization is the

biological control point in the system, designed

for the destruction of pathogenic bacteria. In

addition to this very important function,

pasteurization also reduces the number of

spoilage organisms such as psychrotrophs, and

helps to hydrate some of the components(proteins, stabilizers).

Pasteurization (Ontario regulations): 69 C/30

min. 80 C/25s
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Bothbatch pasteurizers and continuous (HTST)

methods are used.

Batch pasteurizers lead to more whey protein

denaturation, which some people feel gives a

better body to the ice cream. In a batch

pasteurization system, blending of the proper

ingredient amounts is done in large jacketed vatsequipped with some means of heating, usually

steam or hot water. The product is then heated in

the vat to at least 69 C (155 F) and held for 30

minutes to satisfy legal requirements for

pasteurization, necessary for the destruction of

pathogenic bacteria. Various time temperature

combinations can be used. The heat treatment

must be severe enough to ensure destruction of

pathogens and to reduce the bacterial count to a

maximum of 100,000 per gram. Following

pasteurization, the mix is homogenized by meansof high pressures and then is passed across some

type of heat exchanger (plate or double or triple

tube) for the purpose of cooling the mix to

refrigerated temperatures (4 C). Batch tanks are

usually operated in tandem so that one is holding

while the other is being prepared. Automatic

timers and valves ensure the proper holding time

has been met.

Continuous pasteurization (see schematicdiagram for mix here) is usually performed in a

high temperature short time (HTST) heat

exchanger following blending of ingredients in a

large, insulated feed tank. Some preheating, to 30

to 40 C, is necessary for solubilization of the

components. The HTST system is equipped with

a heating section, a cooling section, and a

regeneration section. Cooling sections of ice

cream mix HTST presses are usually larger than

milk HTST presses. Due to the preheating of the

mix, regeneration is lost and mix entering thecooling section is still quite warm.

Homogenization

The mix is also homogenized which forms the

fat emulsion by breaking down or reducing the

size of the fat globules found in milk or cream to

less than 1 m. Two stage homogenization is

usually preferred for ice cream mix. Clumping or

clustering of the fat is reduced thereby producing

a thinner, more rapidly whipped mix. Melt-downis also improved. Homogenization provides the

following functions in ice cream manufacture:

Reduces size of fat globules
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Increases surface area

Forms membrane

makes possible the use of butter, frozen

cream, etc.

By helping to form the fat structure, it also has

the following indirect effects:

makes a smoother ice cream

gives a greater apparent richness and

palatability

better air stability

increases resistance to melting

Homogenization of the mix should take place at

the pasteurizing temperature. The high

temperature produces more efficient breaking up

of the fat globules at any given pressure and also

reduces fat clumping and the tendency to thick,

heavy bodied mixes. No one pressure can be

recommended that will give satisfactory results

under all conditions. The higher the fat and total

solids in the mix, the lower the pressure should

be. If a two stage homogenizer is used, a pressure

of 2000 - 2500 psi on the first stage and 500 -

1000 psi on the second stage should be

satisfactory under most conditions. Two stage

homogenization is usually preferred for ice creammix. Clumping or clustering of the fat is reduced

thereby producing a thinner, more rapidly

whipped mix. Melt-down is also improved.

Ageing

The mix is then aged for at least four hours and

usually overnight. This allows time for the fat to

cool down and crystallize, and for the proteins

and polysaccharides to fully hydrate. Aging

provides the following functions:

Improves whipping qualities of mix and

body and texture of ice cream

.

It does so by:

providing time for fat crystallization, so

the fat can partially coalesce;

allowing time for full protein and

stabilizer hydration and a resulting slightviscosity increase;

allowing time for membrane

rearrangement and protein/emulsifier
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interaction, as emulsifiers displace

proteins from the fat globule surface,

which allows for a reduction in

stabilization of the fat globules and

enhanced partial coalescence.

Aging is performed in insulated or refrigerated

storage tanks, silos, etc. Mix temperature shouldbe maintained as low as possible without

freezing, at or below 5 C. An aging time of

overnight is likely to give best results under

average plant conditions. A "green" or unaged

mix is usually quickly detected at the freezer.

Freezing and Hardening

Following mix processing, the mix is drawn into

a flavour tank where any liquid flavours, fruit

purees, or colours are added. The mix then enters

the dynamic freezing process which both

freezes a portion of the water and whips air into

the frozen mix. The "barrel" freezer is a scraped-

surface, tubular heat exchanger, which is jacketed

with a boiling refrigerant such as ammonia or

freon. Mix is pumped through this freezer and is

drawn off the other end in a matter of 30 seconds,

(or 10 to 15 minutes in the case of batch freezers)

with about 50% of its water frozen. There are

rotating blades inside the barrel that keep the ice

scraped off the surface of the freezer and alsodashers inside the machine which help to whip

the mix and incorporate air.
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Ice cream contains a considerable quantity of air,up to half of its volume. This gives the product its

characteristic lightness. Without air, ice cream

would be similar to a frozen ice cube. The air

content is termed its overrun, which can be

calculated mathematically.

As the ice cream is drawn with about half of its

water frozen, particulate matter such as fruits,

nuts, candy, cookies, or whatever you like, is

added to the semi-frozen slurry which has a

consistency similar to soft-serve ice cream. In

fact, almost the only thing which differentiates

hard frozen ice cream from soft-serve, is the fact

that soft serve is drawn into cones at this point in

the process rather than into packages for

subsequent hardening.

Hardening

After the particulates have been added, the ice

cream is packaged and is placed into a blastfreezer at -30 to -40 C where most of the

remainder of the water is frozen. Below about

-25 C, ice cream is stable for indefinite periods

without danger of ice crystal growth; however,
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above this temperature, ice crystal growth is

possible and the rate of crystal growth is

dependant upon the temperature of storage. This

limits the shelf life of the ice cream.

A primer on the theoretical aspects of freezing

will help you to fully understand the freezing and

recrystallization process.

Hardening invloves static (still, quiescent)

freezing of the packaged products in blast

freezers. Freezing rate must still be rapid, so

freezing techniques involve low temperature (-

40oC) with either enhanced convection (freezing

tunnels with forced air fans) or enhanced

conduction (plate freezers).

The rate of heat transfer in a frezing porcess is

affected by the temperature difference, the

surface area exposed and the heat transfer

coefficient (Q=U A dT). Thus, the factors

affecting hardening are those affecting this rate of

heat transfer:

Temperature of blast freezer - the colder

the temperature, the faster the hardening,

the smoother the product.

Rapid circulation of air - increases

convective heat transfer.

Temperature of ice cream when placed in

the hardening freezer - the colder the ice

cream at draw, the faster the hardening; -must get through packaging operations

fast.

Size of container - exposure of maximum

surface area to cold air, especially
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important to consider shrink wrapped

bundles - they become a much larger mass

to freeze. Bundling should be done after

hardening.

Composition of ice cream - related to

freezing point depression and the

temperature required to ensure a

significantly high ice phase volume. Method of stacking containers or bundles

to allow air circulation. Circulation should

not be impeded - there should be no 'dead

air' spaces (e.g., round vs. square

packages).

Care of evaporator - freedom from frost -

acts as insulator.

Package type, should not impede heat

transfer - e.g., styrofoam liner or

corrugated cardboard may protect against

heat shock after hardening, but reducesheat transfer during freezing so not

feasible.

Ice cream from the dynamic freezing process

(continuous freezer) can also be transformed into

an array ofnovely/impulse productsthrough a

variety of filling and forming machines, which

have ben identified on a separate page.

Back to the Ice Cream Section

Back to the Home Page of

ryedu/icmanu.html

HyurR7kk
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MASTER CLEANING SCHEDULE(TASKS OTHER THAN DAILY)DATES / INSERT DATES, WEEKS BY NUMBER, ORPERIODS

IGNED TO:

What Is a Master CleaningSchedule?

Kate Craig began her writing career inTennessee writing novels. She has alsowritten for The East Tennessean, EastTennessee State University's paper and TheEagle, American University's paper. In
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addition, Kate is a freelance writer forExaminer.com.By Kate Craig, eHow Contributor

Creating amaster cleaning schedule will mop up anypotential disagreements over division ofchores.A master cleaning schedule is an agreementbetween two or more parties regarding a set ofchores that will be completed during a specific timeperiod. These are ideal for roommates, families orany parties that share a common space.

Chores

o Typical chores included in a master

cleaning schedule are vacuuming,mopping, washing the dishes and taking outthe trash.

Time Frame

o Time frames for a master cleaning

schedule vary between either weekly ormonthly increments. Usually, a weeklyschedule is used for household chores.

Assigning Tasks

o Sometimes the chores are divided

equally. Other arrangements arise from

other necessities. It's best to jointly decidewho is responsible for what.

Task Description

o It's best to decide how tasks should

be completed to avoid misunderstandingsregarding cleaning approaches andcleaning standards.

Creating the Schedule

o A spreadsheet program such asExcel or Numbers will be useful whencreating a spreadsheet. However,templates can be found online. Though it's
http://www.ehow.com/weddings-and-parties/http://www.ehow.com/relationships-and-family/http://i.ehow.com/images/a05/ha/fl/master-cleaning-schedule_-800X800.jpghttp://www.ehow.com/weddings-and-parties/http://www.ehow.com/relationships-and-family/


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not necessary, templates can also bepurchased.

Placement

o It's best to keep the agreed upon

schedule in a common area for everyone toreference what chores they've been

assigned and when they're due.

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References

Single Mom: Cleaning List AIB International: Master Cleaning

Schedule

Photo Credit

Image by Flickr.com, courtesy ofHousewares for Creatives

Resources

Painted Gold: Free Printable WeeklyCleaning Schedule

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Setting a HouseCleaning Schedule

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Yes

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s

e

o

ff

w

ith

to

w

el

s

o

a

k

e

d

in

h

otw

at

er

.

14. R

et

u

r

n

ra

c

k

sto

o

v

e

n

15. W

ip

e

o

ff

o

ut

sid

e

o

f

o

v

e

n

w

it

h

h

ots

o

a

p


29/179

y

w

at

er

.

16. D

is

p

os

e

o

f

n

e

w

s

p

a

p

er

an

d

cl

e

a

n

u

p

fl

o

o

r.

WalkIn

Freez

er

PrepArea

Daily -

Broom

-Dustpa

n

1. Sw

e

e

p

o

ut

fr

e

e

z

er

2. B

es

u

re

to

s

w

e

e

p

u

n

d

erra

c

k

s


30/179

3. W

ip

e

o

ff

d

o

o

r,in

si

d

e

a

n

d

o

ut

,

h

a

ndl

e

a

n

d

d

o

o

r

g

a

s

ket

a

s

n

e

e

d

e

d

Mon

thly -B

room

-Dustpa

n

-Mop

and

bucket

-

Winds

hield

washing

solutio

n

1. C

hi

p

ice

c

h

u

n

k

s

o

ff

o

f

fl

oo

r

(s

u


31/179


32/179

l

p

ar

t

at

a

ti

m

ea

s

y

o

u

w

o

r

k

y

o

u

rw

a

y

o

ut

o

f

th

e

d

o

o

r3. M

o

p

u

p

s

ol

ut

io

n

w

it

hm

o

p

4. W

ip

e

o

ff

d

o

o

r,

insi

d

e

a


33/179

n

d

o

ut

,

h

a

n

dle

a

n

d

d

o

o

r

g

a

s

k

et

What Whe

re

Wh

enCleani

ngSuppl

ies

How W

ho

Walk

In

Freez

er

Prep

Area Yea -Pressurewasher

-

Cleani

ng

solutio

n as

recom

mende

d by

pressur

e

washermanufa

cturer

1. R

e

m

o

v

e

p

r

o

d

u

ct

fr

o

m

s

h

el

v

e

s

2. Re

m

o

v


34/179

e

s

h

el

v

e

s

fr

o

m

f

r

e

e

z

e

r

3. T

a

ke

o

u

t

b

a

c

k

i

n

t

he

p

a

r

k

i

n

g

l

o

t

4. Wa

s

h

w

it

h

p

r

e

s

s

u

r

e

w

a


35/179

s

h

e

r

5. A

ir

d

r

y

6. C

le

a

n

fl

o

o

r

a

s

de

s

c

ri

b

e

d

a

b

o

v

e7. R

e

p

la

c

e

r

a

c

k

s

in

fr

e

e

z

e

r

8. R

et

u

r

n

p

r

o

d


36/179

u

ct

t

o

a

p

p

r

o

p

ri

at

e

s

h

el

v

e

s

9. Wi

p

e

d

o

o

rs

i

n

si

d

ea

n

d

o

u

t,

p

a

y

i

n

gs

p

e

ci

al

at

te

n

ti

o

n

t

o

h

a

n


37/179

d

le

a

n

d

g

a

s

k

et

Walk

In

Coole

r

Prep

Area Dail -Broom

-

Dustpa

n

-Mop

andbucket

-

Ecolab

floor

cleaner

-Glass

cleaner

-Paper

towel

1. S

w

e

e

p

fl

o

o

r

to

rem

o

v

e

di

rt

2. Ma

k

e

s

u

rey

o

u

g

et

u

n

d

e

r

r

a

ck

s

3. U

si

n

g

h

ot

w

at

er

w

it

h

fl

o

o


38/179

r

cl

e

a

n

er

,

d

ry

m

o

p

fl

o

o

r

4. A

ll

o

w

toai

r

d

r

y

5. W

ip

e

d

o

o

rs

insi

d

e

a

n

d

o

ut

,

p

a

yi

ng

s

p

e

ci

al

at

te

nt

io

n

to

ha

n

dl

e


39/179


40/179

gl

a

ss

re

a

c

h

in

do

o

r

w

it

h

h

ot

s

o

a

p

yw

at

er

Yea -Pressurew

asher

-Cleani

ng

solutio

n

as

recom

mende

d by

pressur

e

washer

manufa

cturer

1. R

e

m

o

v

e

p

r

o

du

ct

fr

o

m

s

h

el

v

e

s

2. R

em

o

v

e

s

h

el

v

e

s

fr

o

mc

o

ol

er


41/179

3. T

a

k

e

o

ut

b

a

ck

in

th

e

p

ar

ki

n

g

lo

t

4. W

as

h

w

it

h

p

re

ss

u

re

w

a

sh

er

5. A

ir

d

r

y

6. C

le

a

n

fl

oo

r

a

s

d

e

s

cr

ib

e

d

a

bo

v

e

in


42/179

d

ai

ly

cl

e

a

ni

n

g7. R

e

pl

a

c

e

ra

c

k

s

8. R

et

ur

n

p

r

o

d

u

ct

to

a

p

p

ro

p

ri

at

e

s

h

el

v

e

s

9. W

ipe

d

o

o

rs

in

si

d

e

a

n

d

out

,

p

a


43/179

yi

n

g

s

p

e

ci

al

atte

nt

io

n

to

h

a

n

dl

e

a

n

dg

a

s

k

et

Steam

Jacke

ted

Kettle

Prep

Area Afte -Hotsoapy

water

-Clean

towels

-

Scrubb

ing

pads or

brush

-

Bleach

solutio

n in

spray

bottle

-

Degrea

ser

1. D

ra

in

k

et

tl

e

2. So

a

k

w

it

h

h

ot

,

s

o

a

py

w

at

er

if

n

e

e

d

e

d

to

rem

o

v

e


44/179

b

u

r

nt

o

n

f

o

od

3. S

cr

u

b

in

si

d

e

o

f

k

ettl

e.

4. D

ra

in

s

cr

u

b

w

at

er

an

d

ri

n

s

e

w

it

h

cl

e

a

nw

at

er

5. S

cr

u

b

o

ut

si

d

e

of

k

et

tl


45/179

e,

d

ra

in

ar

e

a

a

nd

pl

at

f

o

r

m

it

si

ts

o

n

an

d

b

a

c

k

s

pl

a

s

h.

U

se

d

e

g

re

a

s

er

if

n

e

c

ess

ar

y.

6. S

p

ra

y

in

si

d

e

o

fk

et

tl

e


46/179

w

it

h

bl

e

a

c

h

sol

ut

io

n

to

s

a

ni

ti

z

e.

A

ird

r

y

What Whe

re Wh Cleanin

gSupplie

s

Ho

w

W

ho

Alto

Sham

(Holdi

ng

Oven)

Prep

Area Afte -Hotsoapywater

-

Bleachsolutio

n in

spray

bottle

1. P

u

ll

u

n

it

o

u

t

fro

m

u


47/179

-Clean

towels

-

Degrea

ser

-

Silver

ware

soakproduct

n

d

e

r

t

h

e

ta

b

l

e

.

2. R

e

m

o

v

e

d

ri

p

tr

a

y

a

n

d

sc

r

a

p

e

o

ff

a

n

y

de

b

ri

s

3. S

o

a

k

d

ri

ptr

a

y

w


48/179

it

h

si

l

v

e

r

wa

r

e

s

o

a

k

p

r

o

d

u

c

t

if

n

e

c

e

s

sa

r

y

.

4. R

i

n

s

e

d

rip

tr

a

y

a

n

d

s

e

n

dt

h

r

o


49/179

u

g

h

d

is

h

m

ac

h

i

n

e

5. R

e

m

o

v

e

si

d

e

r

a

c

k

s

a

nd

s

h

e

l

v

i

n

g

r

ac

k

s

a

n

d

s

e

n

d

th

r

o

u


50/179

g

h

d

is

h

m

a

ch

i

n

e

6. S

c

r

u

b

d

o

w

n

i

n

si

d

e

w

it

hh

o

t

s

o

a

p

y

Documents

plant sanitation