Reviewing Sanitation Procedures for Snack and Bakery Production

In the midst of the ongoing COVID-19 pandemic, snack and bakery companies—many of which have instituted higher levels of production in the wake of increased shopper demands—are reviewing sanitation standard operating procedures (SSOPs). “The key to any sanitation program in a bakery environment is the master sanitation schedule. The manager needs to be diligent and thorough and ensure all master sanitation items (non-daily sanitation) are performed as scheduled and verified as being completed and acceptable,” recommends Kent Bruns, senior director of food safety, PSSI, Kieler, WI. “This will include overhead structures and deep cleaning of equipment that requires extensive disassembly and cleaning. The Sanitation Manager needs to work hand in hand with the FSQA Manager to ensure the master sanitation schedule program is effective and make changes to the program as warranted.” Jesus Madera, food safety professional, AIB International, Manhattan, KS, says some of the biggest sanitation issues we see today are also some of the most basic and easily addressed. “In bakeries, we see the improper maintenance and cleaning of overhead pipes and structures, which leads to infestations of cereal insects. In snack plants, there is often a focus on product zone cleaning, while neglecting the rest of the facility. In general, we see a lack of proper training, including qualified and certified food safety managers.” Jeff Gatto, senior manufacturing project engineer, Hixson Architecture & Engineering, Cincinnati, says that dust is one of the major sanitation challenges snack and bakery facilities need to control and manage. “Facilities must be able to contain, capture, clean and dispose of dust. Engineering controls should be designed into the process equipment to contain and capture dust, while facility design promotes proper cleaning and disposal of dust. Current codes require Dust Hazard Analyses to be performed to ensure engineering controls are in place to mitigate hazards and safeguard personnel. Good housekeeping procedures should be followed to eliminate or mitigate fugitive dust. Other benefits of dust control include the reduction of allergen spread and compliance with food safety plans,” he adds. Another sanitation issue that Hixson sees is the management and cleaning of cooking oil. “Keeping these production lines clean requires facilities to put in place the means and methods to clean all components including fryers, roasters, and exhaust hoods and ductwork,” Gatto notes. Evan Reyes, director of sales, sanitation division, Goodway Technologies, Stamford, CT, says that there has definitely been an increased emphasis on cleaning environmental surfaces. “It’s an area that hasn’t been a big focus for snack and bakery facilities, but changes in legislation over recent years requires more environmental monitoring. Instead of conducting swabs in only food-contact areas, they need to do micro swabs all over the plant. This is leading to a strong need for improved sanitation on non-food contact surfaces and outside of just the production lines,” he says. Consumers have an increased interest in packaged foods since they are staying at home, creating greater demand on production facilities, Reyes notes. “As these facilities try to keep up with demand and extend production, it is a challenge to balance an increase in output with the necessary downtime to properly clean and sanitize the entire plant. They are trying to get the same sanitation results in a lot less time. These plants are also facing a lot of pressure to stay price competitive and reduce labor costs. Not only is there an increase in sanitation standards through legislation, but COVID-19 has heightened awareness of food safety and customers are expecting an increase in both food safety and product quality.” The culmination of all these factors is creating a challenge for sanitation professionals and, Reyes is working with them to make sure they have the best solutions to quickly and effectively clean and sanitize both food-contact and non-food contact surfaces, says Reyes. “And it’s more than getting them the right equipment, but partnering together to incorporate best practices into their sanitation process and drive improvement.”