Industrial Food Safety: Sanitation Operator Training

COURSE CONTENT:

Foundational Level

Module Scope Module Objective Learning Objectives
Title: Participants will: Participants will be able to: At the conclusion of this module, participants will be able to: 
Introduction to cleaning and sanitizing Learn about the job functions and requirements of cleaning and sanitizing food manufacturing plants to ensure safe food. Describe the role and importance of sanitation and the sanitation operator position within food manufacturing plants. 1. Describe the purpose of the Industrial Food Safety program. 2. Explain the importance of the sanitation operator’s role. 3. Describe the work environment for sanitation operators in a food manufacturing environment. 4. Define a Food Sanitation Program in a food manufacturing plant. 5. Describe the roadmap for the Industrial Food Safety: Cleaning and Sanitizing Equipment and Facilities program.
Communcation and documentation Learn about the importance of communication and documentation in a food manufacturing environment, appropriate means of communication, basic communication techniques, and good documentation practices. Describe the necessity for, and means of, communication and documentation between co-workers and with supervisors, other departments, and other shifts within a food manufacturing facility 1. Describe basic methods of communication commonly used in the sanitation department of a food manufacturing facility. 2. Describe critical communication situations. 3. Describe the importance of and standards for proper documentation.
Hygienic Zoning Learn about hygienic zoning in food manufacturing environments and the importance of strict adherence to policies and practices regarding hygienic zoning. Describe hygienic zoning, the importance of transition zones, and the importance of maintaining tools and equipment within hygienic zones. 1. Explain hygienic zones and why they are important. 2. Describe transition zones and the hygienic practices when moving between hygienic zones. 3. Explain the necessity of adherence to hygienic zoning regarding tools and equipment.
Workplace organization Learn about the importance and necessity of workplace organization and the role it plays in maintaining proper sanitation and food safety levels within our food manufacturing and distribution facilities. Describe the importance of 5S and the integration of equipment, tools, utensils, and containers into the 5S principles. 1. Describe the foundational principles of workplace organization. 2. Describe 5S as a process for workplace organization. 3. Identify workplace organization principles for equipment, tools, utensils, and containers.
Basic food safety hazards Learn about basic food safety hazards (as applicable to a food manufacturing facility) and the importance of preventing and eliminating these hazards. Recognize the chemical, physical, and biological hazards in the food industry and the importance of preventing and eliminating the potential contamination. 1. Explain how regulatory authorities define adulterated and misbranded food and your role in preventing these conditions. 2. Describe chemical, physical, and biological hazards in a food manufacturing plant and processes. 3. Describe microbiological hazards and the conditions that contribute to microbiological contamination. 4. Identify methods to prevent and eliminate food safety hazards in a food manufacturing plant.
Harborages and Niches Learn about equipment and facility areas that have a tendency to hold bacteria or other contaminants within a food manufacturing environment. Describe harborages within food manufacturing facilities and on food manufacturing equipment that require special attention during cleaning. 1. Define harborages with regard to food manufacturing facilities and equipment. 2. Identify harborages. 3. Describe the importance of ensuring harborages are properly cleaned.
Allergens Learn about the major food allergens and the importance of cleaning techniques to prevent crosscontamination. Describe the risks associated with allergens and the responsibilities of a sanitation operator in the food industry. 1. List the major food allergens. 2. Describe the importance of managing allergens within the production environment. 3. Describe the importance of identifying allergen risk areas, segregating equipment and plant areas, and maintaining appropriate airflow during an allergen clean. 4. Describe adjacent line cleaning procedures and requirements. 5. Describe the proper cleaning techniques and practices to reduce allergen contamination or cross-contamination.
Pest Control Learn about pests within a food manufacturing facility and measures used to control pests. Describe common pests and the role of the sanitation operator in a food plant’s pest control program. 1. Describe what an Integrated Pest Management (IPM) program is and how the sanitation operator can assist in its success. 2. Describe types of pests in food manufacturing processes. 3. Describe pest control measures and devices used in pest control. 4. Describe exclusion methods.
SOPs/SSOPs Learn about Standard Operating Procedures (SOPs) and Sanitation Standard Operating Procedures (SSOPs), the necessity for them, and how the procedures are used within the food manufacturing plants to ensure safe food. Describe an SOP, an SSOP, the importance of using SOPs/SSOPs within the food plant, and where they are typically located. 1. Describe an SOP. 2. Describe an SSOP. 3. Explain the importance of SOPs/SSOPs. 4. Describe the typical location of SOPs/SSOPs.
Cleaning Techniques Learn basic cleaning techniques relative to food manufacturing equipment, including the importance and means of protecting components during wet cleaning. Describe basic cleaning techniques relative to food manufacturing production line equipment. 1. Explain the definition of clean. 2. Describe the steps of dry cleaning. 3. Describe the steps of wet cleaning. 4. Explain the reasons for dry or wet cleaning. 5. Identify tools typically needed/used for cleaning and sanitizing food manufacturing equipment.
Chemicals - Cleaning and Sanitizing Learn about common chemicals used for cleaning and sanitizing food manufacturing equipment and environments, associated health risks, and proper handling of chemicals. Describe common chemicals used for cleaning and sanitizing within food manufacturing facilities; proper storage, handling, and application; and the personal protective equipment (PPE) necessary when using hazardous chemicals. 1. Identify common types of chemicals used for cleaning production line equipment in food manufacturing facilities. 2. Identify health risks associated with common chemicals used within a food manufacturing facility. 3. Describe proper chemical storage and security
Basic Food Manufacturing Mechanical Learn the process to clean food manufacturing equipment. Describe the general process to disassemble, assemble, and operate equipment during cleaning and the importance of these tasks. 1. Recognize basic components of food manufacturing line equipment. 2. Recognize the tools required to disassemble and assemble the equipment. 3. Describe the disassembly process to gain accessibility. 4. Recognize damage and wear. 5. Describe the assembly of equipment.
Inspection and Verification Techniques Learn basic inspection techniques to provide initial assessment of cleaning. Describe a basic food manufacturing equipment cleanliness inspection. 1. Explain the importance of inspecting the food manufacturing product line, equipment, and facilities after cleaning. 2. Describe how to conduct a self-inspection. 3. Identify the tools needed to conduct an inspection. 4. Explain how to perform a final inspection.
Sanitizing techniques Learn the proper sanitizing techniques and the use of specific chemicals to sanitize equipment. Describe sanitizing food manufacturing equipment, sanitation requirements, sanitation chemicals, proper application, and the necessity of re-sanitizing.

1. Describe the difference between cleaning and sanitizing. 2. Describe sanitation chemicals typically used within food manufacturing facilities. 3. Describe the proper use of sanitation chemicals used within food manufacturing facilities.

 

 

Specialized Level

Module Scope Module Objective Learning Objectives
Title Participants will: Participants will be able to: At the conclusion of this module, participants will be able to: 
CIP systems Learn about Clean-In-Place (CIP) systems’ applications as a method of cleaning in food manufacturing plants, as well as the CIP cleaning basic operation, main components, and cleaning parameters to ensure effective and efficient cleaning. Discuss why some types of production line equipment have “clean-in-place” systems, what the systems do, and how to operate those systems. 1. Describe the importance of Clean-In-Place (CIP) systems in the cleaning of food manufacturing equipment. 2. Define CIP systems. 3. Understand the purpose of CIP systems. 4. Identify the basic required components of a CIP system and their functionality. 5. Describe the key elements of sanitation related to CIP systems. Learning Objectives © 2016 Module #16: “Clean-In-Place (CIP) Systems” Participants will be able to: 6. Describe the sanitation steps of the CIP system. 7. Recognize the different types of CIP systems. 8. Understand the CIP best practices programs for an effective CIP system. 9. Define Assisted Cleaning System (ACS) and recognize the difference between a CIP and an ACS.
COP - immersion and manual techniques Learn about Clean-Out-of-Place (COP), a method in which equipment and parts must be transported to another location (typically within the same facility), to be cleaned, inspected, and sanitized. Describe the concept of COP, production equipment components that are cleaned-out-of-place (including special considerations), and components that would not be cleaned-out-of-place. 1. Understand the mechanisms to achieve cleanliness. 2. Define COP. 3. Describe COP techniques. 4. Describe COP immersion tanks. 5. Describe a typical process for cleaning-out-of-place.
Yards and Grounds and Practicum Learn about the importance of maintaining clean food manufacturing facility exteriors and areas (perimeters) around the facility, and the potential impact of the exterior/perimeter state of cleanliness on the health of the customers who consume the products produced within the facility. Explain the necessity of maintaining the exterior and grounds immediately surrounding a food manufacturing facility and identify the exterior parts and areas around a food manufacturing facility. 1. Explain the importance of cleanliness of exterior parts of a food manufacturing facility. 2. Identify exterior parts for which sanitation operators may be responsible. 3. Describe yards and grounds best practices. 4. Describe the sanitation operators’ responsibility in keeping exterior plant areas clean and free of debris.
Janitorial Learn about the importance and necessity of properly cleaning employee amenities of the food manufacturing facilities, and the impact of the cleanliness of these areas on the health of employees and consumers. Describe the amenities, the importance of cleaning related areas, and the tools, equipment, and chemicals used to clean these areas of a food manufacturing facility 1. Identify the amenities within the food manufacturing facility. 2. Explain the necessity of properly cleaning these areas. 3. Describe the proper cleaning techniques used. 4. Identify the tools and equipment typically used to clean these areas. 5. Identify the chemicals typically used to clean amenities. 6. Explain the importance of documenting janitorial activities.
Detailed infrastructure and routine cleaning Learn cleaning and sanitizing techniques for food manufacturing production infrastructure. Describe cleaning and sanitizing techniques for detailed infrastructure and routine cleaning in a food manufacturing facility and why they are important to effective sanitation. 1. Describe the fundamentals of the Master Sanitation Schedule (MSS). 2. Describe detailed infrastructure and routine cleaning. 3. Describe proper and safe cleaning techniques used to clean ingredient storage areas. 4. Explain the importance of maintaining clean floors, drains, walls, ceilings, and overheads within a food manufacturing facility. 5. Describe cleaning programs/techniques used to clean floors, drains, walls, ceilings, and overheads within a food manufacturing facility. 6. Describe special considerations for cleaning the production line environment to prevent contamination of the production line.
Detailed equipment cleaning Learn cleaning and sanitizing techniques for food manufacturing production line equipment. Describe cleaning and sanitizing techniques for detailed equipment cleaning in a food manufacturing facility and the importance of effective plant sanitation. 1. Describe detailed equipment cleaning and how it differs from other cleaning activities. 2. Explain the importance of detailed equipment cleaning in a food manufacturing facility. 3. Explain the procedures involved in detailed equipment cleaning.

 

COURSE SCHEDULE:

  • Tuesday, Oct 3, 2017: 9 AM to 5 PM
  • Wednesday, Oct 4, 2017: 8 AM to 5 PM
  • Thursday Oct 5, 2017: 8 AM to 5 PM
  • Friday Oct 6, 2017: 8 AM to Noon