Laboratory control of food production hygiene

26 september 2024

In the food industry, hygiene plays a crucial role in ensuring product safety and quality. The slightest violation of sanitary standards can have serious consequences: from deterioration of the taste of the product to a threat to the health of consumers.

Microbiological contamination, detergent residues on equipment or foreign particles on production lines can all lead to defective products. And this, in turn, can result in reputational and financial losses for the company.

Laboratory hygiene control plays a key role in preventing potential risks. It allows you to quickly identify possible deviations and take corrective measures, ensuring safety at all stages of production.

Thanks to laboratory control, it is possible to monitor the cleanliness of equipment, raw materials and finished products. This is critically important for maintaining high quality standards and compliance with legal requirements.

Basic hygiene requirements in food production

Compliance with hygiene standards in food production is regulated by several key international standards, among which the most important are HACCP and ISO 22000.

HACCP is a system aimed at preventing hazards that can negatively affect food safety. The system is based on the identification of critical control points at all stages of production — from raw materials to packaging of finished products. These points are strictly monitored to avoid risks. The use of HACCP helps businesses predict and prevent potential threats such as microbiological contamination or chemical residues.

ISO 22000 (Food Safety Management System). This standard sets out the requirements for a management system that aims to ensure the safety of products. Unlike HACCP, ISO 22000 covers broader aspects — from management

The basic hygiene requirements in food production include:

1. Cleanliness of equipment and production surfaces
All equipment in contact with food must be cleaned and disinfected regularly. Special foam sinks used in enterprises provide deeper cleaning and destruction of microbes.

2. Personnel control
Staff must strictly adhere to hygiene standards, including the use of special clothing, regular hand washing and work in conditions that exclude the possibility of contamination of products. This helps to prevent the introduction of microorganisms from the external environment onto production lines.

3. Water and air quality control
The water used in the production process and the air in the production premises must comply with established sanitary standards in order to eliminate the risk of contamination.

4. Prevention of cross-contamination
It is necessary to exclude contact of clean products with contaminated objects or raw materials. For this, it is important to clearly distinguish between cleaning and production areas, as well as the use of foam cleaning systems that minimize the risks of cross-contamination.

Compliance with these requirements minimizes the likelihood of dangerous situations at work and ensures the protection of the end user

Laboratory control methods

Effective laboratory control in food production is a key element to ensure compliance with hygiene standards. There are various control methods aimed at identifying and eliminating potential contaminants at each stage of production. These methods are divided into three main categories: microbiological, chemical and physical control.

Microbiological control

Microbiological control at food enterprises is aimed at identifying pathogenic microorganisms that may pose a threat to the health of consumers. The procedure includes regular sampling from surfaces, equipment, as well as from the products themselves.

The main stages of microbiological control:

Collecting samples from production lines, equipment, inventory, hands and clothing of personnel.
Seeding and cultivation of samples in the laboratory to detect bacteria, mold, yeast and other microorganisms.
Evaluation of the results to determine the level of microbiological contamination.

This type of control helps prevent the spread of bacteria such as Salmonella or E. coli, which can cause serious diseases. Regular microbiological monitoring allows you to quickly identify the sources of contamination and take measures to eliminate it.

Chemical control

Chemical control is aimed at detecting chemicals that may remain on the surfaces of equipment or in finished products. This type of control is especially important to prevent the ingress of substances dangerous to health, such as residues of detergents, pesticides or toxic substances.

The main stages of chemical control:

Collecting samples of water, air and products for subsequent analysis for the presence of chemicals.
Conducting laboratory tests to detect traces of chemical contamination.
Data analysis to determine the need for additional cleaning procedures or adjustments to production technology.

The use of high-quality detergents and effective cleaning systems, such as foam washers, minimizes the risk of chemical contamination residues. Chemical control ensures that products are safe for consumption and comply with established standards.

Physical control

Physical control consists in regularly checking the condition of production equipment in order to exclude mechanical contamination of products or deterioration of their quality due to wear and tear of equipment. This type of control covers the assessment of mechanical parts of equipment, tools and surfaces that products come into contact with.

The main stages of physical control:

Visual inspection of the equipment for contamination, corrosion or damage.
Assessment of the condition of filters, seals and other elements that may affect the purity of the production process.
Conducting tests for the presence of metal, plastic or other particles in products that could be caused by damage to the equipment.

This control helps to prevent foreign particles from entering food products and ensures the safety of the equipment for future use. Systematic assessment of the physical condition of the equipment also avoids unexpected failures in the production process.

Each of these laboratory control methods plays an important role in maintaining a high level of hygiene and safety in food production, ensuring consumer protection and compliance with strict legal requirements.

Collecting samples from equipment and surfaces

The first stage of laboratory control is the collection of samples for subsequent analysis. The procedure includes sampling from various parts of production equipment, surfaces, as well as from finished products and raw materials. Samples are taken from the most critical points where the risk of contamination is highest, such as production lines, packaging areas and work surfaces.

The main points of sample collection:

The use of sterile sampling instruments to avoid cross-contamination.
Collecting samples from the surface of the equipment after cleaning to assess the effectiveness of the cleaning methods used.
Sampling of water, air or detergents used in the production process to assess their quality.

This stage is the basis for further analysis and identification of possible deviations in the hygienic state of production.

Laboratory analyses: sampling and examination of samples

After collecting the samples, they are sent to the laboratory for microbiological, chemical or physical tests. In laboratory conditions, a thorough analysis of samples is performed using specialized methods and equipment.

Basic laboratory analysis procedures:

Microbiological tests: cultivation of microorganisms on nutrient media to determine the level of microbiological contamination.
Chemical tests: Analysis for the presence of residual chemicals such as detergents or traces of heavy metals.
Physical tests: checking for the presence of foreign particles (metals, plastics) in products, which may be the result of equipment wear.

The results of the analyses make it possible to identify possible deviations from established standards and determine how effective hygiene procedures are.

Evaluation of results and corrective actions

The last stage is the analysis of laboratory research results and decision—making based on them. If deviations from the norms are detected, the company must promptly take corrective measures to eliminate the problem.

The main actions at the assessment stage:

Comparison of the obtained results with acceptable standards for each type of analysis.
Identification of pollution sources and analysis of the causes of violations.
Re-cleaning the equipment or changing disinfection procedures.
Develop a corrective action plan to prevent similar problems in the future.

Regular laboratory monitoring and subsequent evaluation of its results make it possible to promptly eliminate any hygienic problems and maintain a high level of safety at work. The introduction of corrective measures helps to minimize risks to consumer health and avoid financial losses of the company.

Advantages of foam washing in cleaning equipment

Foam washers are a modern and efficient way to clean production lines and equipment. Their main advantage is that they allow deep cleaning of even complex and hard-to-reach areas of equipment due to thick, stable foam.

The main advantages of foam washing:

Deep penetration: Foam penetrates into the smallest cracks and joints of equipment where traditional cleaning methods may be less effective. This is especially important for cleaning complex technical structures where food residues accumulate.
Long-lasting effect: Due to its stability, the foam stays on the surface longer than conventional detergents, which allows the active substances to disinfect the equipment for a longer time.
Resource saving: Foam systems use less water and detergents compared to traditional methods, which reduces resource consumption and reduces environmental impact.

Automation of the process: Foam washers can be fully automated, which reduces the likelihood of errors related to the human factor and ensures stable cleaning quality.

Thanks to these advantages, enterprises can effectively maintain hygiene at all stages of production and ensure compliance with international standards.

The effectiveness of foam washing in reducing microbial load

Foam sinks have proven to be highly effective in reducing the microbial burden in food production. Microbiological contamination such as bacteria, mold and yeast is one of the main threats to food safety. The use of foam systems can significantly reduce the risk of their presence on the equipment.

Even the most modern equipment for washing and disinfection will not bring the expected result without regular cleaning procedures and a clear schedule of sanitary measures. Strict control and timely implementation of sanitary procedures are the key to product safety and quality.

Advantages

Work with us

Own production

We ourselves produce most of the items for the system: Pumping stations, foam stations, mobile carts, holders, mounting stands, etc.

Own Trademark

We have registered our own trademark and always make sure that the client is satisfied and recommends us to specialists from other enterprises

Our work experience

The OdysseySystems company provides a full range of services in matters of cleanliness in food enterprises: from application processing to facility commissioning and personnel training. Our specialists will install the system in any region of the Russian Federation.

Providing a test sample

For enterprises that have water treatment systems installed that provide a working pressure of 20 bar, we can provide a test sample of a foam satellite for 30 days for operation at the enterprise.

Staged financing

The advance payment is 50% of the total contract amount. 30% is paid before shipping the goods to the customer. 20% is paid within 10 days after signing the equipment acceptance certificate

Turnkey works

The OdysseySystems company provides a full range of services in matters of cleanliness in food enterprises: from application processing to facility commissioning and personnel training. Our specialists will install the system in any region of the Russian Federation.

+7 (3852) 22-32-14

+7-913-250-76-88

mail@odysseysystems.ru
Russian Federation, 656037, Altai Territory. Barnaul, Kalinin ave. 116/10
OGRN: 1142208000164
INN: 2208023628

ООО "OdysseySystems" 2014 - 2023

Development of the "Alliance"