Milk plant and Dairy Equipment Hygiene
DR. S. RAJAGUNALAN
A S S I S TA N T P R O F E S S O R
Introduction
After use of dairy equipment a thin layer of milk
remains and it dries out
It is difficult to clean and it can act as foci for
microbial growth
Introduction
Cleaning or washing refers to the removal of soil from
the surface of each machine
Sanitization (also referred as Sterilization) implies
destruction of all pathogenic and almost all non
pathogenic microorganisms for equipment surface
Both are complementary process – either of it alone
won’t achieve desired result – remove milk residues &
viable organisms
Introduction
Detergents or cleaning / washing compounds are
substances capable of assisting cleaning
To remove the residues
To kill microorganisms
Sanitizers are substances capable of destroying all
pathogenic and almost all non pathogenic
microorganisms
Milk stone
An important soil
It is an accumulation of dried milk solids and salts
from hard water and washing solutions
It consists largely of calcium phosphate, milk
proteins, precipitated, coagulated and baked-on by
heat and insoluble calcium salts from water and
washing solutions
Moisture: 2.7-8.7%
Fat: 3.6-17.7%
Protein: 4.4 – 17.7%
Ash: 42-67.3%
Importance
All equipments should be cleaned and sanitized
properly, else microbes can grow easily on it
The detergents / sanitizers used should not damage
the equipment
Detergents: Desirable characters
Wetting and penetrating power
Emulsifying power
Saponifying power
Deflocculating power
Sequestering and chelating power
Should be freely, easily, quickly and completely
soluble
Non corrosive on metal surfaces
Economical & stable during storage
Mild on hand
Germicidal action
Detergents
No single detergents possess all the properties
So two or more compounds are used to have
efficiency
Detergents
DETERGENT FUNCTIONS LIMITATION
S
Alkalies Digests, disrupts Some of the
Eg: Sodium Hydroxide or dissolves soil alkalis have
Sodium Carbonate material. poor solubility
Sodium Bicarbonate Bactericidal. and wetting
Sodium phosphate Strong alkalies properties.
Sodium silicate saponify the fat.
Trisodium phosphate Weak alkalies
dissolve protein.
Detergents
DETERGENT FUNCTIONS LIMITATION
S
Acids Acts as descaling Strong acids are
Eg: agent and removes corrosive and
Phosphoric acid milk scales. Mild dangerous.
Nitric acid acids used to Strong acids
Sulphuric acid remove milk stone should not be
Hydrochloric acid used at more
Citric, gluconic, tartaric than 1%.
Detergents
DETERGENT FUNCTIONS LIMITATION
S
Complex Phosphates Water softening, Excellent, but
Eg: Tetra sodium soil displacement unstable in hot
pyrophosphate by emulsification, solution and
prevention of re- also in the
Sodium triployphosphate deposition of soil. presence of
strong alkalies.
All are used along with
acids and alkalies.
Detergents
DETERGENT FUNCTIONS LIMITATIO
NS
Chelating agents/ Sequestering, water
Sequestering Agents softening properties.
Eg: EDTA Remove mineral
deposition and
All are used along with control re-
acids and alkalies. deposition of soil.
Detergents
DETERGENT FUNCTIONS LIMITATIO
NS
Wetting agents or Wetting and Quaternary
Surfactants penetrating action Ammonium
Eg:Anionic (Sodium on solid material. compounds
salt of various organic Stable dispersion (QAC) are
materials) and emulsion expensive.
formation. Used
Cationic (QAC) alone or in
conjunction with
Non-ionic (Teepol) acids and alkalies
Sanitizers
Desirable characters
Non toxic
Quick acting
Relatively non corrosive to hands and equipments
Easily and quickly applied
Relatively in expensive
Sanitizers
Common ones used dairy are
◦ Hot water, Steam
◦ Steam under pressure is used for complete sterility
◦ Hot water 75- 80o C is used for immersion of small utensils
◦ Chemical sanitizers (chlorine compounds, iodophors
and Quaternary ammonium compounds)
◦ Radiation – UV rays at 254 nm is used
Sanitizers
Sanitizer Mode of action
Chlorine compounds Highly bactericidal. Nascent
Eg:Hypochlorites, H ion destroys microbes by
Hexachlorophenol inhibiting enzymatic reactions,
glucose oxidation and also
affects permeability.
Sanitizers
Sanitizer Mode of action
Iodophors Acts through halogenations
Eg: Iodine and a carrier and oxidation of sulphydryl
groups. Dissociation of Iodine
from the surfactant is
responsible for bactericidal
action.
Sanitizers
Sanitizer Mode of action
Quaternary Ammonium Acts on cell membrane.
Compounds Responsible for disintegration
Eg: Acetyl trimethyl and denaturation of proteins
ammonium bromide essential for growth.
Inactivates enzymatic system
responsible for respiration of
cells.
Cleaning & sanitizing procedure
Principle : In the selection of any particular detergent
consideration should be given to
◦ type of soil
◦ quality of water supply
◦ material of surface and the equipment to be cleaned
◦ method of cleaning viz., soaking, brushing, spraying and
/ or recirculation.
Detergents are invariably used as aqueous solutions
Cleaning & sanitizing procedure
Principle : In the selection of dairy sanitizer following
consideration kept in mind
1. High temperature sanitizing: high penetrating ability &
quick drying of equipment
Eg Heat at specific time and temperature
◦ Steam 15 psi/15 min
◦ Scalding water 90-95 0C/10 min
Cleaning & sanitizing procedure
2. Low temperature sanitizing:
Can be done just before use
Avoids excessive strain on equipments
Permits flushing out of equipment immediately before use.
E.g. Chlorine at 15 – 20oC containing150 – 200 ppm
available chlorine for 1-2 min contact time is used.
Cleaning & sanitizing procedure
1. Draining: to remove any residual milk
2. Pre-rinsing: With cold or tepid water to remove as much
milk residue
3. Warm / hot detergent washing with detergent solution
of 0.15-0.60% alkalinity to remove remaining milk solids
Cleaning & sanitizing procedure
4. Hot water rinsing to remove traces of detergents
5. Sanitizing to destroy pathogens & non pathogens
6. Draining and drying: to prevent bacterial growth and
corrosion. Drying is done with heat and ventilation not with
cloth
Cleaning & sanitizing procedure
Methods
1. Hand washing
2. Mechanical washing
3. Cleaning in place
Cleaning & sanitizing procedure
Hand washing
0.8- 1.0% detergent mix in tap water to give 0.5% alkalinity is taken in
a wash up tank and maintain at 50 0C
Rinse utensils with cold/tepid water
Introduce detergent solution into equipment, thoroughly brush its
surface with a clean brush
Wash with enough cold water using a clean brush again to remove all
detergents
Drain the equipment and dry (1-2 h)
Sanitize with steam/hot water/ rinse with chlorine water just before use
Cleaning & sanitizing procedure
Mechanical washing
Done for can washing and bottle washing
Can washing can done in rotary type / straight through type washer
Cleaning & sanitizing procedure
Mechanical washing of cans
[Link] stage for liquid milk residue
[Link]-fed pre rinsing with cold or Luke warm water
[Link]
[Link] fed jetting with detergent at not less than 70ºC
[Link]
Cont---
Cleaning & sanitizing procedure
Mechanical washing of cans
6. Rinsing – Pump fed or by steam and water ejector at
not less than 88ºC
7. Final fresh water rinsing with steam and water ejector
at 88 – 93ºC
8. Live steam injection
9. Hot air drying at 95 – 115ºC
Cleaning & sanitizing procedure
Mechanical washing of Bottles
1. Pre rinse using water at 32 – 38ºC.
2. Detergents wash usually with 1 – 3 % caustic soda,
given in two stages at different temperatures with in 60 –
75ºC.
3. Warm water rinse: To remove all traces of detergents.
Water temperature varies from 25 – 45ºC and is usually re
circulated.
4. Cold water rinse: Normally re circulated chlorinated
water (35 to 50 ppm available chlorine) is used to prevent
re-contamination of bottles.
5. Draining after the bottles come out of the machine.
Cleaning in place / In-place cleaning
Refers to the system of cleaning and sanitization which
does not require the daily dismantling of dairy equipment.
Here the detergent goes to the equipment rather than
taking the equipment to the detergent
Here detergents and sanitizers are circulated for a specific
period of time at a specified speed and in a specific
sequence
Cleaning in place / In-place cleaning
Merits
Ensures all equipment receives uniform treatment by
eliminating human factor
Less damage to equipment
Saves total clean up cost and man hours (25%)
Reduces contamination through human errors
Improved plant utilization and appearance
Cleaning in place / In-place cleaning
Types
Manual control : setting up and CIP circuits are operated
manually
Automation : Three levels of automation possible viz.,
Low level, Medium level or High level
Cleaning in place / In-place cleaning
Two different techniques are used in CIP
Single use system / Total loss system
cleaning solution are used once at the lowest possible
strength, and discharged in to the sewer at the end of each
cycle.
Cleaning in place / In-place cleaning
Re-sue system / Saving solution system
◦ In this system, the same solutions are used for a large
number of cleaning operations. Separate tank for each type
of detergent used.
◦ The recovery of ‘spent’ cleaning solution and its strength
is maintained automatically
◦ Reduces water requirement by 25 - 30%, steam requirement
by 12 - 15% and chemical consumption by 10-12%.
Cleaning in place / In-place cleaning
Procedure
1. Pre rinse with cold water till discharge water runs clear.
2. Acid rinse with phosphoric acid solution of 0.15% to 0.60%
acidity, re circulated at 65 to 71oC for 20 to 30 minutes.
3. Drain out acid solution
4. Hot water rinse with water at 65 to 71 oC for 5 min. Rinse
water should drain out.
Cleaning in place / In-place cleaning
5. Alkali rinse with alkali detergent solution of 0.15% to 0.60%
alkalinity, re circulated at 65 to 71 oC for 20 to 30 minutes.
6. Drain out alkali solution.
7. Final hot water rinse with water at 71 to 82 oC till the whole
system has been heated. Rinse water should be drained out.
Slightly loosen plates to drain and dry
Cold water – 15 min
Acid detergent – 30 min
Hot water – 15 min
Caustic detergent – 30 min
Scalding – 15 min
ASSESSING EQUIPMENT HYGIENE
Efficiency of cleaning and sterilization are assessed by
enumerating the microbes on the surface/inner surface of
tanks/utensils, pipelines etc.
Done after cleaning and sanitizing
Two types of techniques are employed to assess the equipment
hygiene:
Surface sampling method
Agar contact method
ASSESSING EQUIPMENT HYGIENE
Surface sampling method
Swab contact method
Surface rinse method
Adhesive tape method
Vacuum method
ASSESSING EQUIPMENT HYGIENE
Agar contact method
RODAC (Replicate Organisms Direct Agar Contact)
method
Agar slice method
Direct surface agar plating method:
molten agar is poured over surface, good recovery but
not applicable to equipment like pipelines and cans
Thanks!
