Sanitation Standard Operating Procedures (SSOP)¶

Document Control¶

Field	Value
Document ID	FS-SSOP-001
Version	3.2
Effective Date	2026-01-15
Owner	Sanitation Manager
Approver	Food Safety Team Leader
Review Frequency	Annual

1. Pre-Operational Sanitation¶

1.1 Scope¶

Pre-operational sanitation covers all cleaning activities performed before the start of production each day, following any shutdown period exceeding 4 hours.

1.2 General Pre-Op Procedure¶

Step	Activity	Detail
1	Dry Clean	Remove loose debris, dust, and product residues using brushes, scrapers, or vacuum systems. No compressed air for dry cleaning unless HEPA-filtered.
2	Pre-Rinse	Rinse all product contact surfaces with potable water at 38–49 °C (100–120 °F) to remove residual soils.
3	Detergent Application	Apply approved detergent per Master Sanitation Schedule. Ensure foam contact time ≥ 10 minutes. Do not allow foam to dry on surfaces.
4	Manual Scrubbing	Scrub all product contact surfaces with dedicated colour-coded brushes (white = food contact, blue = equipment, red = drains/floor).
5	Post-Rinse	Rinse thoroughly with potable water until all chemical residues are removed. Verify with pH test strips if required (target pH 6.5–7.5).
6	Visual Inspection	Conduct line-of-sight inspection under adequate lighting (≥ 500 lux). Any visible soil triggers re-cleaning.
7	Sanitisation	Apply approved sanitiser per manufacturer instructions. Allow required contact time before rinse (if applicable).
8	Final Verification	Swab for ATP (Section 6) or allergen ELISAs (Section 8) as scheduled. Document release on pre-op checklist.

1.3 Line Release Criteria¶

No visible soil on any product contact surface.
ATP readings < 30 RLU for equipment, < 10 RLU for product contact surfaces.
Allergen ELISA (if required): negative result (< limit of detection).
Pre-op checklist fully signed by sanitation lead and QA.

2. Operational Sanitation¶

2.1 Spill Management¶

Spill Type	Response	Documentation
Dry product spill	Stop production in area, sweep/vacuum immediately, inspect for cross-contact	Spill Log FS-SSOP-F02
Wet product/liquid spill	Stop production, contain with absorbent pads, clean & sanitise the zone	Spill Log FS-SSOP-F02
Allergen spill	Stop production, zone affected area, perform allergen cleaning per Section 8, ELISA swab before restart	Allergen Incident Log FS-ALC-F03
Chemical spill	Evacuate area, follow SDS emergency procedures, notify EHS	Chemical Spill Report FS-EHS-F01

2.2 Scheduled Break Cleaning¶

Break	Duration	Activities
Mid-morning (15 min)	Line speed reduction, scrape surfaces, remove debris, spot clean	Dry sweep, empty waste bins, sanitise handwash stations
Lunch (30 min)	Partial shutdown: dry clean, wet clean if allergen changeover, floor scrub	As per zone schedule
End-of-shift	Complete wet clean per Master Sanitation Schedule	Full pre-op equivalent

2.3 Allergen Changeover Cleaning¶

Refer to Section 8 (Allergen Clean Validation) and Allergen Control Program (FS-ALC-001). Between production of products containing different allergens, complete a full wet clean with intermediate rinse verification.

3. Master Sanitation Schedule (MSS)¶

3.1 Schedule Overview¶

The MSS covers all areas, equipment, and utilities. Tasks are assigned by frequency: daily, weekly, monthly, quarterly, semi-annual, annual.

3.2 Master Sanitation Schedule Matrix¶

Area / Equipment	Task	Frequency	Chemical	Concentration	Method	Verification	Responsible
Receiving Bay	Floor scrub & drain clean	Daily	Alkaline Foam Cleaner	2–3% v/v	Apply foam, dwell 10 min, pressure rinse	Visual + ATP weekly	Sanitation Tech
Whole Seed Silo (S-101)	Dry clean interior	Weekly	N/A (dry clean only)	—	Vacuum + manual wipe with food-grade cloth	Visual + ATP monthly	Production Lead
Flax Mill (M-201)	Full wet clean	Weekly (or allergen change)	Chlorinated Alkaline	3% v/v, 45 °C	CIP cycle per SOP-CIP-01	ATP + ELISA post-clean	Sanitation Lead
Oil Press Line (P-301)	CIP (alkali-acid-sanitise)	Weekly	See Section 5 — CIP Procedure	Per CIP cycle	Automated CIP	ATP + pH final rinse QA	QA Specialist
Screw Conveyor (C-401)	Disassemble & wet clean	Monthly	Neutral Detergent	1.5% v/v, warm water	Manual scrub with brush, rinse, sanitise	Visual + ATP	Sanitation Tech
Packaging Hopper (H-501)	Full wet clean	Weekly	Acid Cleaner	2% v/v, 40 °C	Circulation 15 min, rinse, visual check	ATP < 10 RLU	QA
Magnetic Separator	Clean magnet surfaces	Daily	Dry brush	—	Remove debris from magnet rods	Visual	Production
Sifting Screens	Inspect & clean	Every batch change	Dry brush or compressed air (HEPA)	—	Brush screen mesh, check for tears	Visual + mesh gauge	QA
Floor Drains (all)	Scrub & sanitise	Daily	Quaternary Ammonium	200 ppm	Foam, brush, rinse, sanitise	ATP monthly	Sanitation Tech
HVAC Vents	Wipe & filter check	Monthly	Neutral Detergent	1% v/v	Wipe louvres, replace HEPA if needed	Visual	Maintenance
Cold Storage Room	Floor & wall wash	Monthly	Alkaline Foam	3% v/v	Foam, dwell, pressure rinse	Visual + ATP	Sanitation Tech
Overhead Structures (pipes/trusses)	Dust & debris removal	Quarterly	Dry vacuum + damp wipe	—	Vacuum, then damp cloth	Visual	Sanitation Lead
Lighting Fixtures	Clean & inspect	Quarterly	Glass/plastic-safe cleaner	Per label	Wipe, inspect for cracks/missing sleeves	Visual	Maintenance
Waste Compactor Area	Pressure wash	Weekly	Degreaser	5% v/v	Pressure wash, sanitise perimeter	Visual	Sanitation Tech

3.3 Seasonal / Deep Clean Tasks¶

Task	Frequency	Month(s)
Full mill disassembly & deep clean	Annual	Plant shutdown (August)
CIP chemical tank descaling	Semi-annual	March, September
Drain line jetting & camera inspection	Annual	January
Exterior wall & roof vent cleaning	Annual	May

4. Cleaning Chemical Specifications¶

4.1 Approved Chemical Inventory¶

Chemical Name	Active Ingredient(s)	Recommended Concentration	Min Contact Time	Temperature Range	Approved Surfaces	Rinse Required?
Alka-Clean Supreme	Sodium hydroxide (10–15%), potassium hydroxide (5–10%)	2–5% v/v	10 min	40–60 °C	Stainless steel, plastic, rubber (EPDM)	Yes — potable water
Chlor-Alkali Foam	Sodium hypochlorite (3–5%), sodium hydroxide (5–10%)	2–4% v/v	10 min	20–50 °C	Stainless steel, tiled walls, floors	Yes — potable water
Acid-Brite 50	Phosphoric acid (20–30%), nitric acid (5–10%)	1–3% v/v	5 min	40–65 °C	Stainless steel (passivates), glass	Yes — potable water
Neutral Kleen	Alkyl polyglycosides, non-ionic surfactants	0.5–2% v/v	5 min	20–50 °C	All food contact surfaces, soft metals	Yes — potable water
Quat-San Plus	Didecyl dimethyl ammonium chloride (10%)	150–200 ppm	30 sec to 1 min	Cold–50 °C	Stainless steel, plastic, floors, walls	No (no-rinse sanitizer)
Peroxy-San 15	Peracetic acid (15%), hydrogen peroxide (10–15%)	150–250 ppm	30 sec to 2 min	10–40 °C	Stainless steel, glass, plastic (verify compatibility)	No (no-rinse sanitizer)
Iodophor San	Iodine complex (2%), phosphoric acid (10%)	25–50 ppm iodine	2 min	20–40 °C	Stainless steel, plastic	No (no-rinse)

4.2 Chemical Handling Requirements¶

All chemicals stored in original containers or clearly labelled secondary containers.
MSDS/SDS available in the chemical storage room and sanitation office.
Personal protective equipment (PPE): chemical-resistant gloves, safety goggles, rubber boots, apron.
Chemical dispensing stations calibrated quarterly.
Follow all manufacturer concentration test strip verifications.

5. CIP Procedure — Oil Press Line¶

5.1 Equipment Covered¶

Oil press line including: press screw (P-301), filter housing (F-101), oil holding tank (T-201), centrifuge (C-101), transfer piping (DN50–DN100).

5.2 Standard CIP Cycle¶

Phase	Step	Solution	Concentration	Temperature	Time	Return Criteria
1	Pre-Rinse	Potable water	—	50 °C	5 min	Effluent clear
2	Alkali Wash	Alka-Clean Supreme	3% v/v	60 °C	15 min	Circulation flow ≥ 1.5 m/s
3	Intermediate Rinse	Potable water	—	50 °C	5 min	pH 6.5–8.0; effluent clear
4	Acid Wash	Acid-Brite 50	2% v/v	55 °C	10 min	—
5	Final Rinse	Potable water	—	Ambient	5 min	pH 6.5–7.5; conductivity < 50 µS/cm
6	Sanitise	Peroxy-San 15	200 ppm	Ambient	2 min	Peracetic acid test strip ≥ 150 ppm
7	Final Drain	—	—	—	2 min	—

5.3 Post-CIP Verification¶

ATP swab of final rinse water in holding tank (target ≤ 10 RLU).
Visual inspection of interior surfaces via access ports.
Record all CIP parameters in CIP Log (FS-CIP-F01).

6. ATP Swabbing Verification¶

6.1 Protocol¶

ATP bioluminescence testing is conducted using a SystemSure Plus™ luminometer with Ultrasnap swabs.

6.2 ATP Limits¶

Surface Category	Target	Warning	Action / Corrective Action
Product Contact (e.g., mill chamber, conveyor belt, hopper interior, packaging funnel)	< 10 RLU	10–30 RLU	> 30 RLU: re-clean, re-test. > 300 RLU: quarantine area, notify QA Supervisor, root cause investigation.
Non-Product Contact (Equipment) (e.g., equipment exteriors, control panels, framework)	< 30 RLU	30–100 RLU	> 100 RLU: re-clean. > 300 RLU: investigation.
Environment (e.g., floors, walls, drains, overheads)	< 100 RLU	100–300 RLU	> 300 RLU: re-clean, root cause if recurrent.

6.3 Corrective Action for ATP Exceedance (> 300 RLU)¶

Stop line release.
Isolate affected equipment.
QA notifies Sanitation Lead and Production Supervisor.
Re-clean per applicable MSS procedure.
Re-swab within 30 minutes.
If second failure: escalate to Food Safety Team for root cause investigation.
Document on ATP Corrective Action Log (FS-SSOP-F03).

6.4 Sampling Frequency¶

Product contact: Every pre-op release (daily) + post-allergen changeover.
Non-product contact: Weekly rotating schedule.
Environment: Monthly rotating schedule.
Annual trend analysis reported to Food Safety Team.

7. Microbiological Environmental Monitoring¶

7.1 Zone Classification (Based on ISO 14644 / FDA Aseptic Guidance)¶

Zone	Definition	Examples	Target Organisms	Sampling Method
Zone 1	Direct product contact surfaces	Mill interior, oil press screw, hopper interior, conveyor belt	Aerobic Plate Count (APC), Enterobacteriaceae, E. coli	Contact plates, swabs
Zone 2	Non-product contact adjacent to Zone 1	Equipment frame, machine guards, control panel	APC, Enterobacteriaceae, yeast & mould	Contact plates, swabs
Zone 3	Indirect contact — floor, walls, drains near product	Production floor, drains within 3 m of equipment	APC, Listeria spp., yeast & mould	Sponge swabs (drains), contact plates (walls)
Zone 4	Remote environment (outside production)	Warehouse, hallways, break rooms	APC, yeast & mould	Settle plates, air samplers

7.2 Sampling Plan¶

Parameter	Zone 1	Zone 2	Zone 3	Zone 4
Number of sites	10	8	6	4
Frequency	Weekly	Weekly	Monthly	Monthly
APC target	< 10 CFU/contact plate	< 50 CFU/contact plate	< 200 CFU/swab	< 500 CFU/settle plate
APC action	≥ 10 CFU: investigation	≥ 100 CFU: investigation	≥ 500 CFU: cleaning	≥ 1000 CFU: cleaning
Enterobacteriaceae target	< 1 CFU/plate	< 5 CFU/plate	—	—
Listeria spp.	—	—	Absent (in 25 g or swab)	—
Yeast & mould target	< 5 CFU/plate	< 10 CFU/plate	< 50 CFU/swab	< 100 CFU/plate

7.3 Corrective Actions for Pathogen Positives¶

Any Zone 1 or Zone 2 Listeria or Salmonella positive: Immediate line stop, quarantine affected product, deep clean, root cause investigation, enhanced sampling (3× frequency for 4 weeks post-clearance).
Zone 3 Listeria positive: Increase cleaning frequency, conduct vector analysis, swab adjacent Zone 2 sites.

8. Allergen Clean Validation — ELISA Swabbing¶

8.1 Purpose¶

Verify removal of allergen residues after changeover cleaning between products containing different allergens.

8.2 Target Allergens & ELISA Kits¶

Allergen	ELISA Kit (Supplier)	Limit of Detection (LOD)	Swab Area	Acceptance Criteria
Gluten	R-Biopharm Ridascreen® Gliadin	5 ppm gliadin	10 cm × 10 cm	< LOD (negative)
Milk (β-lactoglobulin)	R-Biopharm Ridascreen® β-Lactoglobulin	2.5 ppm	10 cm × 10 cm	< LOD (negative)
Soy	Neogen® Veratox® Soy	2.5 ppm	10 cm × 10 cm	< LOD (negative)
Flaxseed	In-house developed lateral flow (or 3^rd party if available)	LOD per kit insert	10 cm × 10 cm	< LOD (negative)
Mustard	R-Biopharm Ridascreen® Mustard	2 ppm	10 cm × 10 cm	< LOD (negative)

8.3 Swabbing Protocol¶

Select target allergen(s) based on previous product run.
Identify worst-case swab sites (hard-to-clean areas: crevices, gaskets, dead ends, undersides of belts).
Swab a 10 cm × 10 cm (100 cm²) area using the swab provided in the kit.
Process swab per ELISA kit manufacturer instructions.
Read result on plate reader at specified wavelength.
Record in Allergen ELISA Log (FS-ALC-F02).

8.4 Corrective Action on Positive Result¶

Do not release line for production.
Re-clean entire line per wet clean procedure.
Identify likely cause (incomplete disassembly, dead-leg, gasket residue).
Re-swab.
Only release after negative result.

9. Glass & Hard Plastic Register¶

9.1 Scope¶

Inventory of all brittle materials (glass, rigid plastic, ceramic, hard acrylic) in production, packaging, and storage areas.

9.2 Glass & Hard Plastic Register (Example)¶

Item ID	Type	Location	Qty	Condition	Inspection Frequency	Last Inspected	Inspected By
GL-001	Light fixture tube (LED shatter-proof)	Receiving bay	4	Intact	Monthly	2026-06-01	M. Chen
GL-002	Observation window (tempered)	Mill S-101, 450 mm	1	Intact	Weekly	2026-06-05	J. Smith
GL-003	Pressure gauge lens	Oil press P-301	3	Intact	Daily	2026-06-07	L. Wang
GL-004	Clock face	Production floor	1	Intact	Monthly	2026-06-01	M. Chen
PL-001	Sanitation bucket (polycarbonate)	Wet clean station	6	1 cracked (removed)	Weekly	2026-06-05	J. Smith
PL-002	Scraper blade (UHMWPE)	Conveyor C-401	2	Intact	Weekly	2026-06-05	J. Smith
PL-003	Cutting board (HDPE)	Sample prep bench	2	Intact	Weekly	2026-06-05	J. Smith
CR-001	Ceramic floor tile (round access)	Drain D-103	1	Intact	Monthly	2026-06-01	M. Chen

9.3 Glass Breakage Procedure¶

Stop all production in affected area immediately.
Evacuate personnel from zone (+ 5 m radius).
Block entry with barriers and signage.
DO NOT sweep — use adhesive tape or damp cloth to pick up fragments.
Inspect all product, ingredients, and packaging within zone — quarantine any potentially contaminated materials.
Document in Glass Breakage Incident Log (FS-SSOP-F04).
Conduct root cause analysis within 24 hours.
Replace with shatter-proof alternative (polycarbonate, acrylic, or shatter-film) wherever feasible.

9.4 Register Review¶

Full inventory count: Monthly.
Update on any addition/removal of brittle materials within 24 hours.
Annual verification by Food Safety Team.
All lighting in production must be LED shatter-proof type with protective sleeves.

10. Sanitation Records & Review¶

10.1 Records Maintained¶

Record	Retention	Location
Pre-Operational Sanitation Checklist (FS-SSOP-F01)	2 years	QA Office
Operational Sanitation Log (FS-SSOP-F02)	2 years	Production Office
ATP Swabbing Log (FS-SSOP-F03)	2 years	QA Office
Glass Breakage Incident Log (FS-SSOP-F04)	5 years	Food Safety Office
Master Sanitation Schedule (MSS)	Current + 2 years	QA Office
CIP Cycle Log (FS-CIP-F01)	2 years	Maintenance Office
Allergen ELISA Log (FS-ALC-F02)	2 years	QA Office
Chemical Usage & Concentration Verification Log	2 years	Sanitation Office
Microbiological Environmental Monitoring Report	3 years	QA Office
Training Records — Sanitation Personnel	Duration of employment + 1 year	HR / QA

10.2 Review Process¶

Daily: Sanitation Lead reviews pre-op checklists and ATP results before line release.
Weekly: QA Manager reviews operational logs and trend data.
Monthly: Food Safety Team reviews all sanitation KPIs (ATP pass rate, microbiological trends, chemical usage).
Annual: Full SSOP review and update by Food Safety Team Leader, incorporating regulatory changes, audit findings, and incident learnings.

10.3 Continuous Improvement¶

Audit non-conformances related to sanitation trigger formal CAPA.
Annual SSOP training for all sanitation, production, and QA personnel.
Mock sanitation inspection performed once per quarter by internal audit team.

Appendices¶

Appendix A: Sanitation Zone Map (floor plan with colour-coded zones)
Appendix B: Chemical Dilution Chart (concentration × flow rate × time)
Appendix C: ATP Swab Site Map (numbered locations)
Appendix D: Environmental Monitoring Swab Site Map

End of Document — FS-SSOP-001