Very poor Quality Audit score in case of cleaning & sanitizingThroughout all Emami units.Major gaps observed -There is no prerequisite program formaster cleaning & sanitizationObjective:The methods of cleaning and sanitizing,the types of chemicals used,the frequency of cleaning activities,andthe control of microbes must all bedone expertlyto protect our finished products fromcontamination issue.Why special focus oncleaning & sanitizing !!!
3S is the part of5S(technique applied forGood House Keeping)3S
The First “S"1S ActivitiesIndicators ofsuccessSeiri (sorting/segregation)- Sort though- Identify what is needed anddiscard the unnecessaryitems.- Productive area saving
The Second “S"2S ActivitiesIndicators ofsuccessSeiton(arrangement)- Set item in order by creatingplace for everything and puteverything in its place- Keep accessibility- Labeling- Time saved in searchingand returning
The Third “S"3S Activities Indicators of successSeiso (shine/cleanliness)- Eliminate dirt andforeign matter- Reduction in m/c downtime- Increased life of m/c parts- Reduction of no. of accidents- Reduction of rejection/rework- Higher productivity- Healthy environmentDeep cleaning
Removing physical contaminants such as soil, unwantedmaterials, dirt particles & waste materials from surface by rinsingand washing through the use of physical and chemical action. Cleaning removes 90-99% of the bacteria, but thousands ofbacteria may still be present.Cleaning
Types of cleanersAlkaline: CAUSTIC SODAAnionic / Nonionic : TEEPOL
StandardSolution inmasterplanStandardQuantityin masterplanFrequency Used inpresenttimeArea QuantityuseColin Daily Max GlassTeepol NotmentionedDaily Teepol 1Cap /1ltr.Lyzol 1 capful/4ltr. waterDaily Lyzol Admin &QualityPhenyl 2 capful/5Ltr.waterDaily Max Total area
Area ProcessAdmin Firsty cleaninig with the washing powder (like(active wheel ),then sanitizing with Lyzol.Quality Firsty cleaninig with the like (active wheel ,thensanitizing with Lyzol.Mfg Firsty cleaninig with the Teepol & ditergentpowder like (active wheel ).Pkg Firsty cleaninig with the ditergent powder (activewheel),then sanitizing with phenyl.
How cleaning agent work?Cleaning agent having surfactant reduce the surface tension of waterThe surfactants water-hating end is attracted to the oil in the soil. Atthe same time, the water-loving end is attracted to the watermolecules.The droplets of oil, surrounded by the detergent molecules form anemulsion in the water and are able to be washed away.
Caustic SodaConditions to apply ?• 1% solution• Temp 50-60oC• Contact time: 20 minutesHow it works?It can dissolve grease, oils , fats and protein based deposits.Suitable use for?SS equipments cleaning,Plastic drum & crate,Drain cleaning,
Teepol Active ingredients:Sod. Benzene Sulphonate,Alcohol ether sulphate Concentration: 1% Used for: Equipment, floor, glassware cleaning
Sanitizing - “Treating a cleaned surface to destroy andreduce the microorganism to a safe level”Types of sanitizers: Heat Chlorine VU IPA Lysol PhenylFor any chemical disinfection:(1) Must first satisfy the disinfectantdemand(2) Must then establish a disinfectantresidual(3) Must maintain the concentration &contact time effectively
HeatDry heat kills the organisms by destructive oxidation of essential cellconstituents.Conditions: temp 160 °C for 60 mins.Dry heat is employed for glassware, metal instruments which are notspoiled by high temperatures.Moist heat kills the organisms by coagulating and denaturing theirenzymes and structural protein.Conditions: temp 121 °C for 15 mins.Moist heat is used for the sterilization of culture media where steam canpenetrate.Moist heat is more effective than dry heat
Chlorine Chlorine is available in several forms calcium hypochlorite (solid) sodium hypochlorite (solution)◦ In water, chlorine forms hypochlorous acid(HOCl) and hypochlorite anion (OCl-)◦ HOCl is 80 to 100 times more potent germicidethan the hypochlorite ion (OCl-)Best practice for water disinfection:6-8 mg/L Free Chlorine Residual for 2 Hours Min contact time.
UV TreatmentUV range = ~100 to 400 nmGermicidalWavelengthsUV dose of 30,000 microwatt-seconds/cm2 at the end of 8,000hours of useEfficiency highlydependent onwater quality (must be free ofsuspendedsolids to formscale on UVtube)
UV Treatment mechanismPrimary mechanism isabsorption of UV by the DNA,and disruption of thechemical bases.Renders the cell unable toreproduce their DNA, and,therefore, cannot grow.At least a three-log (99.9%) reduction inbacteria, yeast and viruses
70% IPA- Disinfectant Isopropyl alcohol ( Isopropanol ) can be considered as adisinfectant as well as an antiseptic, antimicrobial agents thatdestroy microorganisms on living tissue. IPA affects the outercell membrane of bacteria by making the lipids in themembrane soluble to water. This solubility causes the cellmembrane to lose its structure, allowing alcohol into the cellwhere it denatures proteins. The denatured proteins becomecoagulated. Disinfectant: Destroy pathogenic microorganism (E.Coli-diaria, Salmonellae-typhoid).
70% IPA- Disinfectant Why 70% IPA better than 100%? 100% IPA causes protein to coagulate instantly. Thecoagulated proteins create a hardened protein wall aroundthe cell, protecting the interior. With the inside of the cellprotected, the organism is not killed but remainsdormant. 70% IPA is combined with 30% water. This dilution allowsprotein coagulation to occur gradually as the organismabsorbs the alcohol at a slower rate. The microorganismis slowly overcome and dies.
Lysol - Disinfectant The active ingredient in of the Lysol isBenzalkonium Chloride ( cationic surface acting agent ) Suitable for floor cleaning and disinfecting ( 7% in water )
Phenyl - DisinfectantIt is a mixture of phenols and cresols, used as a disinfectant.Spectrum of action – gram positive, gram-negative bacteria. Noactivity against viruses, fungi and spores.Mode of ActionIt acts by rupture of cell membranes and denaturation ofcellular constituents.Indications· Disinfectant for floors, washbasins, drain etc.· Waste disinfection – infective wastes such as urine.
FumigationFormaldehyde is active against bacteria, fungi and many virusesand spores. It acts by protein denaturation and reacting with theamine group in the cells, thus acting as a cytotoxic agent.Formaline is a commercially available as a 40% solution offormaldehyde vapour in water. When it is heated, formaldehydevapour is generated. Fumigation is most effective above atemperature of 20 C and relative humidity of 65%.Mixing formaline and water with potassium permanganate crystals isnot recommended (This can result in a violent reaction if the correctrelative concentrations of the two components are not used )Use 100 ml formaline plus 900 ml water per 1000 ft3 of space.The door should be locked for 12hrs.Fumigation is a hazardous operation, and it should be performed with extra care
Air filters fundamentalsAir filters (Mechanical) are used to remove air born contaminationsPre-filtersEfficiency: 99 % down to 5 microns( 5 to 7 Layers of high density poly ethylene mesh)Fine filtersEfficiency: 99 % down to 3 microns(Non woven synthetic media sandwiched between 2 layers of HDPE Mesh)High – Efficiency Particulate Air filter ( HEPA )The filter has a minimum efficiency of 99.97 % when tested with anaerosol of essentially mono dispersed 0.3 µm challenge aerosol.
Dettol antiseptic are insoluble in water, it produces a white -coloured milky emulsion of oil droplets when diluted ( 2% ) withwater during use in cuts, wounds. The active ingredient in Dettol is chloroxylenol (C8H9ClO)Dettol - AntisepticThe main differences between antiseptics and disinfectants are thatdisinfectants are used primarily to sanitize objects, and antisepticsare used on human skin.They both act as antimicrobials that kills the microbes that causeinfection
Sanitization of equipments & vessels of NRO ( R&D ref )Manufacturing section-Splash hot LLP (80 C) through the walls and drainthrough the filter after two circulation.Transfer 1 ltr. IPA into the mixer and activesblender and closed for 1hrs.Drain out IPA, allow the odor to get off, by keepingthe vessels open for some time.
Sanitization of equipments & vessels of ZB and MPB ( R&D ref )Manufacturing section-Clean the batch mixing using a steam inject formelting and removing The product.Heat about 30kg LLP in the melting kettle to about 75to 80 C and circulate it in all other vessel by transferline.Splash 3 ltr IPA into the mixer and actives blenderand closed for 1hrs.Drain out IPA, allow the odor to get off, by keeping thevessels open for some time.
Sanitization of equipments & vessels of BPAC ( R&D ref ) Clean the batch mixer using a steam injects formelting and removing the product adhered to the wallsand blades of the mixer. Fill the melting kettle with DM water and heat to 75 to80 C circulate it in all other vessel by transfer line anddrain. Repeat the process using fresh hot DM water. Then using 3ltr IPA and Close the lid for 1 hr thendrain out, allow the odor to get off, by keeping thevessels open for some time.Manufacturing section-
CIPClean in Place means cleaning and sanitizing themanufacturing system without dismantling the connectedpipelines, vessels, valves, filters etc.Sequence of CIP operation:1. Heat caustic solution ( 1% in water) upto 80C in steamjacketed vessel.2. Circulate the hot caustic solution min 30mins then drain.3. Rinse by water.4. Circulate citric acid solution ( 1% in water) for 30minsthen drain.5. Check pH ( std 7 ).Frequency: once per 6 months
Pest controlTarget Pest RecommendedchemicalsService frequencyCrawling insects Deltamethrin,Allethrin,Kerosene,Imidacloprid,Polybutene glue,BromadioloneMonthlyWeeklyLizardWeeklyCockroachWeeklyRat* No Pest control activity is allowed inside process areaTo prevent flies, air curtains and insect light traps to be installed suitably
Key LearningSOP of cleaning and sanitization should be justified by basicchemistry and applied uniformly as a benchmark.Effectiveness of cleaning & sanitization depends ona) maturity level, b) eye level and c) interest levelof HK zone owner.GHK evaluation to be done based on1. Sub-zones and overall Plant2. Snap shot3. Chemical compliance as specified4. Frequency compliance as specified5. Micro testing result monitoring6. Score as per 1s/ 2s/ 3s/ 4s/ 5s std