Case Study: Adequate Cleaning & Sanitation in Food & Beverage Facilities

Facility Background

A beverage production plant producing fruit-based juices experienced multiple quality issues, including sporadic spoilage and elevated microbial counts. This facility produces approximately 10,000 gallons of juice daily, distributed regionally.

Problem Identification

Routine quality assurance testing revealed elevated microbial counts, specifically:

·         Pathogenic bacteria: Salmonella, Escherichia coli (E. coli)

·         Spoilage bacteria: Lactobacillus spp., Pseudomonas spp.

Investigation & Root Cause Analysis

A comprehensive sanitation audit was conducted. Findings included:

·         Residual biofilms in stainless steel piping and filler valves

·         Inefficient chemical concentrations used during CIP (Clean-in-Place)

·         Insufficient dwell times for sanitizers and acids during cleaning cycles

·         Gaps in employee sanitation training leading to inconsistent cleaning practices

Implemented Solutions

1.       Enhanced CIP Process

·         Increased caustic cleaning concentration from 2% to 4% to effectively dissolve organic matter.

·         Incorporated acid sanitizers with a minimum dwell time of 15 minutes to remove biofilms and mineral deposits.

2.       ATP Swabbing & Validation

·         Conducted regular ATP swabs at critical control points post-sanitation, ensuring ATP levels were below 50 RLU (Relative Light Units).

3.       Employee Training Program

·         Implemented standardized SOPs for sanitation with hands-on training.

·         Regular audits to ensure adherence and corrective training as needed.

4.       Upgraded Equipment

·         Installed borescope and UV inspection equipment to verify thorough cleaning of difficult-to-reach areas.

Results & Impact

Within three months of implementing these interventions:

·         Salmonella and E. coli were eliminated from product testing.

·         Lactobacillus and Pseudomonas counts significantly reduced, extending product shelf-life by 50%.

·         Customer complaints due to spoilage dropped by 80%.

Conclusion

The case study highlights the direct link between thorough equipment sanitation practices and control of pathogenic and spoilage bacteria. Regular monitoring, validation testing (such as ATP swabbing), and continuous employee training are critical for maintaining product safety and quality in food and beverage facilities.