Description
Sanitation
Cleaning and Disinfection in the Food Industry
Author: Stanga Mario
Language: EnglishSubject for Sanitation:
Keywords
major; safety; concerns; todays; food; equipment; industries; disinfection; essential factor; physical; disease; agents; contamination; consumer; implications; legal; harmful; consequences; manufacturer; extremely
611 p. · 17.8x24.5 cm · Hardback
Description
/li>Contents
/li>Biography
/li>
Essential reading for food industry personnel.
Preface xvii
Acknowledgments xxi
Acronyms xxiii
Part One Chemistry and Problems of Industrial Water 1
1 Chemistry of Aqueous Solutions 3
1.1 Variables 5
1.1.1 Water 5
1.1.1.1 Hardness 7
1.1.1.2 Salinity 8
1.1.1.3 Alkalinity 8
1.1.1.4 pH 10
1.1.1.5 Conductivity 11
1.1.1.6 Scaling Tendency or Corrosion Tendency 13
1.1.2 Salts 15
1.1.2.1 Precipitation 16
1.1.2.2 Sequestration 19
1.1.2.3 Flocculation 26
1.1.2.4 Dispersion 27
1.1.2.5 Suspension 28
1.1.2.6 Anti-redeposition 30
1.1.3 Stability Constant 31
1.1.3.1 Theoretical Meaning 31
1.1.3.2 Practical Meaning 32
1.1.4 Critical pH 36
1.1.4.1 Effect on Bicarbonates 39
1.1.4.2 Effect on Phosphates 40
1.1.4.3 Effect on Sequestrants 41
1.2 Inorganic Competitors 43
1.2.1 Bicarbonates 43
1.2.1.1 Chemical Mechanism 43
1.2.1.2 Physical Mechanism 44
1.2.2 Silicates 44
1.2.3 Sulfates 45
1.2.4 Aluminates 49
1.2.5 Phosphates 51
1.3 Organic Competitors 53
1.3.1 Proteins 53
1.3.2 Starches 58
1.3.3 Fatty Acids 60
1.3.4 Other Carboxylic Compounds 63
1.3.5 Humic Substances 65
1.4 Self-Protected Contamination 67
1.5 Modifiers Affecting Deposits 68
1.5.1 Heating 69
1.5.1.1 Caramelization 70
1.5.1.2 Carbonization 70
1.5.2 Dehydration 71
1.5.3 Polymerization 72
References 73
2 Chemical-Physical Treatment 77
2.1 Softening 77
2.2 Deionization 79
2.3 Dealkalinization 80
2.4 Reverse Osmosis 81
Reference 82
3 Sequestrants 83
3.1 Definition 83
3.2 Coordination Groups 90
3.3 Sequestration Data 91
3.4 Food Cleaning Sequestrants 93
3.4.1 (Poly)phosphates 93
3.4.1.1 Hexametaphosphate (HEMP) 97
3.4.1.2 Pyrophosphate 98
3.4.1.3 Monomeric Phosphates 99
3.4.1.4 Tripolyphosphate 99
3.4.2 Phosphonates 100
3.4.2.1 Phosphonates and pH 103
3.4.2.2 Stability of Phosphonates 105
3.4.2.3 Phosphonates and Corrosion Inhibition 106
3.4.3 Hydroxy Acids 109
3.4.4 Poly(co-poly)acrylates 118
3.4.5 Aminopolycarboxylic Acids 131
3.4.6 Polysaccharides and Bentonites 143
References 145
Part Two Characterization of Chemicals Used in the Sanitation Process 149
4 Laboratory Tests 151
4.1 Turbidimetric Tests 151
4.1.1 Sequestration Test (Oxalate) 152
4.1.2 Nephelometric Titration 153
4.1.3 Sequestration Test (Hampshire) 153
4.2 Suspension Test 154
4.3 Dispersion Test 155
4.4 Static Test of Scale Forming 155
4.5 Dynamic Test of Scale Formation 156
4.6 Static Test of Scale/Soil Dissolution 157
4.7 Dynamic Test of the Dissolution of Scale/Soil 157
4.8 Chemical Stability Test 157
4.9 Solution Stability 158
4.10 Sequestrant Stability 159
4.11 EDTA and Calcium Titration 159
4.11.1 Titration of EDTA 159
4.11.2 Titration of Calcium Salts 160
References 160
5 Surfactants, Caustics, and Acids 161
5.1 Surfactants 161
5.1.1 HLB 162
5.1.2 Grouping of Surfactants 164
5.1.2.1 Anionic Surfactants 165
5.1.2.2 Nonionic Surfactants 166
5.1.2.3 Cationic Surfactants 167
5.1.2.4 Amphoteric Surfactants 167
5.1.3 Defoamers 168
5.1.4 Wetting Agents 169
5.1.5 Cleaning Agents 172
5.1.6 Disinfectants 172
5.1.7 Structural Boosters 174
5.1.8 Biodegradability and Toxicity 174
5.1.9 BPD and REACh 175
5.2 Caustics 176
5.3 Acids 179
References 181
Part Three Application to the Food Industry 183
6 Bottlewashing 185
6.1 Pre-washing 189
6.2 Caustic Zone 189
6.2.1 Modifications Induced by Alkalinity 190
6.2.2 Label Removal 194
6.2.3 Self-Adhesive Labels 201
6.2.4 Ceramic Labels 202
6.2.5 Mold Removal 204
6.2.6 Plastic Bottles 207
6.2.6.1 Procedure for Testing for Stress Cracking due to Cleaning Solutions 211
6.2.6.2 Procedure for Testing for Haze Suppression 212
6.2.6.3 Procedure for Screening Defoamer Rinsability 212
6.2.7 Exhausted Solution 213
6.2.8 Sequestrants in Washing 214
6.2.8.1 Polyphosphates and Phosphates 215
6.2.8.2 Gluconate and Gluconic Acid 215
6.2.8.3 Phosphonates 216
6.2.8.4 Phosphono-Carboxylate Polymers 217
6.2.8.5 Acrylic Polymers 217
6.2.8.6 EDTA and NTA 217
6.2.8.7 Polysaccharides and Bentonites 219
6.3 Rinse Section 219
6.3.1 Rinse Design and Chemicals Application 221
6.3.1.1 Second Rinse 223
6.3.2 Sequestrants of Rinse 224
6.3.3 Inlet Position 227
6.4 Environmental Impact from Labels 228
6.5 Outcoming Bottles 228
6.5.1 Non-homogeneous Coating of Water on the Bottles 229
6.5.2 Bottles React with Phenolphthalein 229
6.5.3 Bottles Dry Leaving Whitish Streaks or Foggy Glass 230
6.5.4 Homogeneous White Scale Covers Bottles 230
6.5.5 External Non-homogeneous Deposit on the Bottle 230
6.5.6 Bottles Contain Residues 231
6.5.7 Bottles Drain Leaving More than 2 Drops of Water 231
6.5.8 Bottles Sparkling when Just Filled 232
6.5.9 Just-Filled Bottles Contain Micro-Bodies (or Some Time After Filling) 232
6.6 Microbiological Condition of a Bottlewasher 232
6.7 What Can or Cannot Be Cleaned 234
6.7.1 Removable Organic Soils 235
6.7.2 Inorganic Soil Removable with Acids 236
6.8 Concepts of Problem Solving in Cleaning Bottles 236
6.8.1 Glass Bottles 236
6.8.2 Plastic Bottles (PET, PEN) 237
6.8.3 Plastic Bottles (PC-HOD) 238
6.9 Cold Aseptic Filling (CAF) 238
6.9.1 CAF Technology 239
6.9.2 Microbiological Sensitiveness 241
6.9.3 Cleaning Programs 242
References 244
7 Lubrication 247
7.1 Theory of Lubrication 247
7.1.1 Friction 248
7.1.2 Lubricity 250
7.1.3 Variables of Lubrication 253
7.1.3.1 Quantity of Solution on the Track 254
7.1.3.2 Quantity of Lubricant on the Track 254
7.1.3.3 Speed of the Track 255
7.1.3.4 Temperature of the Track 256
7.1.3.5 Friction and Micro-friction 256
7.1.3.6 Dry Tracks 257
7.1.3.7 Bottles, Cans, and Composite Containers (Cartons) 257
7.1.3.8 Type of Beverage 259
7.2 Soap-based Lubrication 260
7.2.1 Buffering Power and Alkalinity Donors 261
7.2.2 Types of Fatty Acids and their Concentration 263
7.2.3 Sequestrants 265
7.2.4 Keeping Tracks Clean 266
7.2.5 Fluidifying and Antigelling 267
7.2.6 Foam Control 268
7.3 Amine-Based Lubricants 269
7.3.1 Types of Lubricating Molecules 270
7.3.2 Anionic Interference 272
7.3.3 Sequestrants 274
7.3.3.1 Glycine 276
7.3.3.2 Lauryldimethylamine [CH3 (lauryl) CH2–N(CH3)2] (LDMA) 277
7.3.3.3 Fatty Alcohol Ethoxy Carboxylate (FAEC) 278
7.3.4 Cleaning and Microbial Control 279
7.3.5 Biofouling in the Delivery Plant 281
7.3.6 Chlorine Dioxide in Preventing Biofouling 283
7.3.7 Foam Control 284
7.4 Imidazoline-Based Lubrication 285
7.5 Lubrication Based on Fatty Quaternary Ammonium Compounds (FQACs) 286
7.6 Silicone-Based Lubricant 288
7.7 Dry Lubrication 290
7.8 Stress Cracking 294
7.9 Concepts of Problem Solving in Lubrication 297
References 299
8 CIP (Cleaning in Place) 301
8.1 CIP Classification 302
8.1.1 Total Loss CIP 302
8.1.2 Partial Recovery CIP 303
8.1.3 Total Recovery CIP 304
8.2 CIP Parameters 304
8.2.1 Flow Velocity 306
8.2.2 Flow Rate 307
8.2.3 Temperature 309
8.3 Dairy 310
8.3.1 Treatment with Heat Exchange 311
8.3.1.1 Conversion of Stainless Steel Oxides 316
8.3.2 Raw Milk Line 316
8.3.3 Separator 318
8.3.4 Churning 319
8.3.5 Curdmaking Process 320
8.4 Processed Food 324
8.4.1 Evaporator 326
8.4.2 Dough-Kneading Machine and Extruder 328
8.4.3 Pasteurizer and Sterilizer 328
8.4.4 Cooking, Baking, and Frying 332
8.4.5 Smoke Chambers 335
8.4.6 Blanching 336
8.4.7 High-Temperature Scraped Sterilizer 338
8.4.8 Fresh Cut Produce (4th Gamme) 339
8.4.8.1 Cleaning and Disinfection Procedures 344
8.4.9 Mechanical Cleaning of Equipment 347
8.5 Winery 349
8.5.1 Cleaning in the Cellar 349
8.5.2 Stabilization of Wine 351
8.5.3 Cleaning and Disinfection of Wooden Barrels 352
8.5.3.1 Disinfection of Wood 353
8.6 Enzymatic Cleaning in Food Detergency 355
8.6.1 Protease 357
8.6.2 Lipase 358
8.6.3 Amylase 358
8.7 Chemicals for Cleaning Tenacious Contamination 358
References 360
9 Acidic Cleaning 363
9.1 Infinite Dilution 364
9.2 Sequestrants 364
9.3 Cleaning of Molds 366
9.4 Cleaning of Chocolate Molds 368
9.5 Acidic Cleaning in a Brewery 370
9.5.1 Acids 372
9.5.2 Sequestrants 372
9.5.3 Surfactants 373
References 373
10 Open Aqueous Systems Exchanging Heat 375
10.1 Tunnel Pasteurizers 375
10.1.1 Deposition and Scale 377
10.1.2 Microbiology 378
10.1.3 Corrosion 378
10.1.4 Dome Staining 381
10.1.5 Chemical Treatments 382
10.1.5.1 Scale and Biofouling 382
10.1.5.2 Corrosion 383
10.1.5.3 Packaging Damage 383
10.2 Cooling Tower 383
References 385
11 Foam and Gel Cleaning 387
11.1 Foam 388
11.2 Gel 390
11.3 Foam-Gel Synergism 390
11.4 Body Structure 393
11.5 Sequestrants 394
11.6 Foam/Gel Free OPC 396
11.7 Practical Problem Solving in OPC 396
11.7.1 Bluish Stains 396
11.7.2 Yellowish-White Stain 397
11.7.3 Fat Removal in Patches 397
11.8 Equipment for Pressure Washing 398
11.8.1 Centralized Equipment 399
11.8.2 Decentralized Equipment 399
11.8.3 Loss in Pressure 400
11.8.4 Loss in Temperature 400
11.8.5 Generation of Aerosol 402
References 402
12 Membrane Cleaning (Crossflow Filtration) 403
12.1 Membrane 406
12.2 Module 410
12.2.1 Plate and Frame 410
12.2.2 Hollow Fibers 411
12.2.3 Tubular 412
12.2.4 Spiral Wound (SW) 413
12.2.5 Pleated 414
12.2.6 Modules 414
12.3 Diafiltration and Chromatography 416
12.4 Electrodialysis 418
12.5 Ultrasound Applied to Membrane Processings 419
12.6 Fields of Application 419
12.7 Cleaning 420
12.7.1 Alkalinity 421
12.7.2 Sequestrants 422
12.7.3 Surfactants 423
12.7.4 Enzymatic Systems 423
12.7.5 Acids 424
12.8 Cleaning Procedures 425
References 427
13 Milk Production 429
13.1 Mastitis 429
13.2 Cow and Milk 431
13.3 Milking CIP 434
13.4 Bulk Milk Tanks 438
13.5 Raw Milk Quality Standards 439
Reference 440
14 Biofilm 441
14.1 Microbiological Background 441
14.2 Formation and Growth of Biofilm 445
14.2.1 Surface Condition 447
14.2.2 Environmental Conditions 448
14.3 Practical Significance 448
14.4 Cleaning and Disinfection 451
14.4.1 Alkaline Cleaning 452
14.4.2 Acidic Cleaning 452
14.4.3 Disinfection 452
References 457
15 Environmental Sanitation 459
15.1 Environmental Particles 459
15.2 Physical Control 462
15.2.1 Air Filtration and Clean Rooms 462
15.2.2 Ultraviolet Radiation 464
15.3 Control by Chemicals 467
15.3.1 Atomization and Aerosolization 467
15.3.2 Chemicals 468
15.3.2.1 Aldehydes 469
15.3.2.2 Nitrogen Derivatives 469
15.4 Mold Control and Prevention 469
References 471
16 Ultrasound Cleaning 473
References 476
17 Corrosion and Corrosion Inhibition 477
17.1 Calculation and Monitoring of Corrosion 477
17.1.1 Intensity and Rate 478
17.1.2 Electrochemistry 479
17.2 Stainless Steel and Chloride 484
17.3 Chromium and Chemicals 486
17.4 Aluminium and Caustics/Acids 488
17.5 Copper and its Alloys 489
17.6 Zinc (Galvanized Steel) 490
17.7 Biofilm 491
17.8 Reliability of Supply 491
17.9 Post-Installation Treatment of Stainless Steel 493
17.9.1 Procedures and Recommendations 495
17.9.2 Example of Complete Program 495
17.9.3 Example of Simplified Program 496
17.9.4 Gaskets 496
References 497
18 Disinfectants and Sanitation Technology 499
18.1 Water 500
18.2 Manufacturing Environment and Types of Microorganisms 502
18.3 Disinfectants 504
18.3.1 Main Disinfectants for the Food Industry 506
18.3.2 Biocides from the Haber-Willstätter Reaction 506
18.3.3 How to Choose a Disinfectant 512
18.3.3.1 Basic Behavior Typifying the Application of Disinfectants 514
18.4 Physical Disinfection 521
18.4.1 Disinfection by Heating 521
18.4.2 Disinfection by UV Radiation 524
18.4.3 Disinfection by Filtration 525
18.4.4 Disinfection by Electrolyzed Water 527
18.4.5 Disinfection by Cold Plasma 529
18.4.6 Disinfection by High Pressure 531
18.4.7 Disinfection by Pulsed Electric Field 532
18.5 Regularity and Perseverance in Sanitation 534
18.6 Sanitation Plan 536
18.6.1 Early Stage 536
18.6.2 Planning 537
18.6.3 Validation 537
18.6.4 Application 537
18.6.4.1 Assessment of the Sanitation Result 538
18.7 Rapid Controls of Sanitation 539
18.7.1 Bioluminometer 540
18.7.2 Proteins Test 540
18.8 European (EN) Microbiological Tests 541
18.8.1 Bactericidal Activity 542
18.8.1.1 EN 1040 542
18.8.1.2 EN 1276 543
18.8.1.3 EN 1656 543
18.8.1.4 EN 13727 543
18.8.2 Fungicidal Activity 543
18.8.2.1 EN 1275 543
18.8.2.2 EN 1650 543
18.8.2.3 EN 1657 544
18.8.2.4 EN 13624 544
18.8.3 Sporicidal Activity 544
18.8.3.1 EN 14347 544
18.8.3.2 EN 13704 544
18.8.4 Main Tests Methodology 544
18.8.4.1 NF EN 1276 Procedure 544
18.8.4.2 NF EN 1650 Procedure 545
18.8.4.3 NF EN 13697 Procedure 546
18.8.4.4 NF EN 13704 Procedure 547
18.9 Hand Washing and Disinfection 547
18.9.1 Handwashing Products Structure 549
18.9.2 Handwashing Disinfectants 550
18.9.2.1 Products Performing Cleaning and Disinfection 551
18.9.2.2 Products for Terminal Disinfection after Washing 552
References 552
19 Waste Water Treatment 555
19.1 Understanding Terms 555
19.2 Purification Process 557
19.2.1 Preliminary Treatments 557
19.2.2 Chemical Treatment 558
19.2.3 Settling, Concentration, and Dewatering 559
19.2.4 Biological Treatment 561
19.2.5 Final Treatments 563
References 564
20 Boiler Treatment 565
20.1 Deaeration and the Generation of Noncorrosive Steam 565
20.1.1 Generation of Noncorrosive Steam 567
20.2 Scale Prevention 568
20.3 Chemical Treatments 571
20.4 Chemical Cleaning 571
References 573
21 Due Diligence (HACCP) 575
Index 577
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