Disinfection in the Food Industry

Cleaning and disinfection in the food industry represent a crucial part of the production cycle. These activities can have devastating consequences if they are not carried out properly. Both constitute the foundation for being able to deliver and guarantee a safe final product, and society, in general, is increasingly concerned about food. Carelessness during the handling and storage of food can lead to serious health problems.

In 2022, the World Health Organization highlighted that foodborne diseases cause nearly 125,000 deaths annually among children under the age of five. The food industry is one of the most important activities for the well-being and development of society. Unsafe food containing bacteria, viruses, parasites, or harmful chemicals causes over 200 diseases, ranging from diarrhea to cancer. It also creates a vicious cycle of disease and malnutrition, which particularly affects infants, young children, the elderly, and people suffering from other illnesses.

Hygiene and disinfection processes include both the removal of visible residues or dirt and the use of chemical substances (direct application, nebulization, etc.). Cleaning methods have changed significantly in the food and beverage processing sector, which is increasingly focusing on reducing cross-contamination, reducing bacteria, and increasing productivity.

The hygiene and disinfection process in a food facility consists of 4 steps:

• removal and collection of all waste;
• washing of surfaces;
• disinfection of surfaces;
• disinfection of equipment.

1. Disinfection vs. sanitization – what is the difference?

Disinfection means the destruction or irreversible inactivation of fungi and bacteria (but not necessarily spores) on hard surfaces.

Sanitization means reducing microorganisms that are critical to public health to levels considered safe, based on established parameters, without affecting either the quality of the product or its safety.

Risk factors for food hygiene

During the food manufacturing process, a series of unwanted materials accumulate, including food waste, foreign bodies, chemicals derived from the process, and microorganisms. This situation can result from the normal production process, such as food waste adhering to work surfaces, or from process anomalies, such as those resulting from contamination due to poorly maintained equipment or environmental contamination. Food contamination can be caused by biological, chemical, or physical hazards.

Biological contamination

When microorganisms such as bacteria, viruses, molds, fungi, and toxins come into contact with food, it becomes contaminated. Microorganisms found in/on food come from various sources, including the atmosphere, soil, water, handlers, tools used, equipment, and the raw materials from which they are produced.

Common pathogens include Pseudomonas, Listeria monocytogenes, Salmonella sp., Shigella flexneri, Vibrio cholerae, Bacillus sp., and Campylobacter jejuni. Microbial biofilms represent a major threat to the food industry because most microbes are capable of forming biofilms even in the presence of minimal moisture and nutrients.

Chemical contamination

Chemical contaminants are substances that are unintentionally present in food or animal feed. These substances can be present in food products as a result of the various stages of their production, processing, or transport. They can also result from environmental contamination. Chemical pollutants can be harmful to humans and animals.

Physical contamination

Physical contamination of food refers to the presence of foreign objects, particles, or materials in food products that can be harmful to consumer health. Physical contamination can cause serious complications for the consumer, including dental fractures or choking. In 2018, physical contamination caused by foreign materials in food was declared the main cause of food product recalls in the USA.

2. Hygiene standards in food facilities

When implementing hygiene, sanitation, and safety standards in the workplace, you must pay attention to feasibility studies from the moment you choose the site, build the factory, install the equipment, and select employees.

Employee personal hygiene is one of the most important aspects in the food industry. Personnel represent both reservoirs and vectors of microorganisms and can act as a source of microbial contamination of food products. The regulations in force regarding personnel in food units provide for the following aspects:

Art. 85. – In food units, the operations of handling, preparation, transport, serving, and sale of food will be performed only by persons who have undergone medical examinations upon hiring and periodically, at sanitary units and under the conditions established by the Ministry of Health (Order 976/1998).

Art. 86. – In all food units, their managers or specifically designated persons in the unit have the obligation to check the individual hygiene status of personnel daily and to identify persons who present with fever, diarrhea, or acute infections of the nose, throat, or skin. These persons will not be received in the unit without medical clearance (Order 976/1998).

Employees must wash their hands with warm water and soap before starting any activity related to food handling. This includes washing hands after using the toilet, touching contaminated objects, or handling money.

Another important aspect in ensuring food safety is the sanitization of kitchens. Kitchen cleaning rules require planning and organizational methods that must be followed daily. The goal is to avoid contamination and other problems that can arise due to inadequate cleaning habits. The manager or the person responsible for the kitchen should have a checklist that includes all cleaning processes, whether daily, weekly, or monthly. The area where food is handled and prepared must be cleaned constantly, depending on requirements. Dirty surfaces are breeding grounds for microbes which, in turn, can contaminate food.

Equipment that comes into regular contact with food should be made of materials that can be cleaned and disinfected, are corrosion-resistant, and are non-toxic. Equipment should be arranged in a way that allows for sufficient cleaning of it and the area around it.

3. Disinfection methods

Disinfection methods are essential in the food industry to prevent the growth and spread of harmful bacteria, viruses, and other pathogens that can cause foodborne illness. Some commonly used disinfection methods in the food industry include cryogenics, dry steam cleaning, and UV light.

It is important to remember that these disinfection methods must be used in conjunction with other cleaning and sanitization practices to ensure a comprehensive approach to food safety. Additionally, proper training, maintenance, and adherence to guidelines are essential to ensure the effectiveness of these methods in the food industry.

Cryogenics

Cryogenics involves the use of extremely low temperatures to destroy bacteria and other pathogens. Liquid nitrogen or carbon dioxide is sprayed onto surfaces or into equipment to freeze and destroy microorganisms. This method is effective in killing bacteria and can be used both for hard-to-reach areas and for equipment that cannot be easily cleaned manually.

Dry steam

Dry steam cleaning uses steam at high temperatures (above 110°C) to disinfect surfaces in the food industry. Dry steam is delivered through a nozzle, killing microorganisms on contact and removing contaminants. This method is effective in penetrating and disinfecting crevices, cracks, and other hard-to-reach areas.

UV light

Ultraviolet (UV) light disinfection is a non-chemical method that uses UV-C radiation to destroy or inactivate microorganisms. This method disrupts the DNA and RNA of bacteria, viruses, and other pathogens, preventing them from multiplying and causing infections. UV light can be used to disinfect surfaces, air, and water in the food industry. It is commonly used in food processing plants, storage facilities, and water treatment systems.

Ozone

Ozone can be applied directly to various types of food to improve safety and extend their shelf life. Food can be subjected to ozone treatment in the form of a gas, but also in the form of sprays or aqueous solutions. A favorable aspect of using ozone is that it acts relatively gently on food, and high levels of ozone can be used without affecting the taste or appearance of the products. Furthermore, ozone also has the advantage of reducing the number of microorganisms in the water used for washing.

4. Types of disinfectants and their use in the food industry

There are several types of disinfectants used in the food industry, including chlorine, peroxyacetic acid, and quaternary ammonium disinfectants.

Chlorine

Chlorine-based disinfectants are frequently used in the food industry for disinfecting surfaces and equipment. It is effective against a wide range of microorganisms, including bacteria, viruses, and fungi. Chlorine-based disinfectants are often used in food processing facilities to sanitize surfaces that come into contact with food, such as countertops and containers.

Peroxyacetic acid

Peroxyacetic acid-based disinfectants, also known as peracetic acid, are known for their broad-spectrum antimicrobial properties, meaning they are effective against a wide range of microorganisms, including bacteria, molds, and yeasts. These disinfectants work well in cold conditions (~4°C). Peroxyacetic acid is commonly used for disinfecting equipment, tanks, and food processing surfaces. It is also used in the sanitization of fruits, vegetables, and in poultry processing.

Quaternary ammonium disinfectants

Quaternary ammonium compounds are another type of disinfectant widely used in the food industry. These disinfectants are often used for sanitizing surfaces that come into contact with food, utensils, and equipment.

Conclusions

In conclusion, disinfection methods, such as cryogenics and steam cleaning, offer effective solutions for maintaining hygiene standards in the food industry. These methods have proven to be extremely effective in eliminating pathogens and reducing the risk of illness caused by foodborne diseases.

Furthermore, continuous innovations in disinfection technology are constantly improving the effectiveness of these methods. Advanced equipment and machinery are being developed to ensure rapid and complete disinfection, ensuring better food safety and hygiene.

Companies that comply with hygiene standards and implement these disinfection methods can reap several benefits. Firstly, they can significantly reduce the risk of illness and food poisoning outbreaks, protecting the health of their consumers. This can improve their reputation and strengthen customer confidence in their products.

Implementing effective disinfection measures can help companies comply with regulatory standards and avoid penalties or legal issues related to hygiene violations. By maintaining high hygiene standards, companies can also reduce the chances of product recalls, which can be costly and damaging to their brand reputation.