Food Protection Trends - September/October 2022 - 391

Monitoring is carried out in real time and involves observations,
gathering data and measurements, and making appropriate
corrective actions to the barriers, sources, vectors, and cleaning
program prerequisite to ensure that all activities and parameters
are brought under control should there be any nonconformances
identified. In addition, all observations, measurements, data
analysis, and corrective actions should be recorded.
Monitoring frequencies and methods will vary according to
the prerequisite type. For example, the monitoring of a high
hygiene barrier entrance spray tunnel, through which ingredient
containers could be decontaminated by chemical disinfectants,
could include the following:
* Measuring the disinfectant concentration
* Ensuring all spray nozzles are in place and working
* Measuring the speed of the conveyor to ensure a
determined disinfectant contact time
* Observing the loading of the containers on the conveyor
to ensure that all aspects of the containers are accessible to
the chemical spray
* Observing the cleanliness of the containers exiting the
spray tunnel
The monitoring of the use of gloves, where gloved handling of
the food product is a vector, could include the following:
* Observation of the cleanliness of glove storage facilities
* Observation that the correct glove and glove color is being
used for a particular process time or product
* Assessment of the handwash facilities (e.g., dispensers and
hand dryers in good condition, correct water temperatures,
clean taps and wash basins, well stocked soap and towels)
* Observation of individual handwashing procedures prior
to glove application
* Review or observation of any closed-circuit television
monitoring
* Observation that any required glove decontamination
step is undertaken correctly (correct disinfectant product
type, stock rotation, recorded usage)
The monitoring of an end-of-production clean could include
the following:
* Ensuring that the correct resources are in place, that the
area has been prepared ready for cleaning, and that there
is a sufficient hygiene window in place
* Equipment dismantling standards
* Rinse water conditions (e.g., visual assessment, water
hardness, temperature, pressure, flow)
* Equipment (dosing, application, cleaning tools)-
suitability, hygienic design, condition, and color coding
* Detergent and disinfectant chemicals (correct type,
concentrations, temperature, method of application,
coverage, and contact times)
* Visual inspection of postclean cleanliness
* Rapid hygiene assessment of visually clean surfaces (e.g.,
ATP, protein, chemical residues)
* Equipment reassembly standards
* Draining and drying times
Verification of prerequisites determines that the control
measures are still working as designed (validated) and are
consistently generating successful results. Verification may
include the following:
* Microbiological testing
* Analysis of customer complaint trends
* Trend analysis of monitoring results
* Ensuring operative adherence to specific work instructions
* Ensuring operative training records and competency
* Analysis of results of internal and external audits
* Record reviews
With respect to Listeria control, the most direct verification
of prerequisite controls is via microbiological sampling and the
design of the environmental microbiological sampling plan.
The routine environmental sampling plan is directly related to
the first four points of the Listeria 5-point control plan and is
undertaken for these purposes:
* Verify the high hygiene area barrier prerequisite controls.
Sampling around barriers should be undertaken during
production and at all times when barriers might be
challenged, e.g., during cleaning or maintenance activities.
* Verify the prerequisite controls applied to known or
potential Listeria sources. Sampling of source controls
should be undertaken during production.
* Verify the prerequisite controls applied to known or
potential Listeria vectors. Sampling of vector controls
should be undertaken during production.
* Verify the efficacy of the cleaning and disinfection
program, applied to both equipment and environmental
surfaces. Sampling of cleaned and disinfected surfaces
should be undertaken after the cleaning program has
finished, allowing sufficient disinfectant contact time.
* Via " collector " samples, establish any presence of Listeria
in the high hygiene area.
Collector samples are those samples that maximize the
detection of a pathogen. Such samples could be of objects that
have high environmental sampling surface contact, e.g.:
* Cleaning equipment
* Operatives' footwear
* Wheels of racks, totes, bins, and other equipment
Or samples could be of objects that, by their nature,
" concentrate " hazards within the environment, e.g.:
* A floor drain that draws in fluids from a large surface area
* A condensate discharge from an evaporative condenser or
freezer
* Food debris on a slicer blade that builds up through the
processing period
* Dust and debris building up on motor fans
* Vacuum cleaner contents
Collector samples should be undertaken after the use of
the collector, e.g., cleaning equipment, or toward the end of
production periods, when the chance for Listeria movement
out of any sources may be greatest.
September/October Food Protection Trends 391
Food Protection Trends - September/October 2022

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