Maintaining a link with cleaning

Performing an effective clean requires cleaning operatives to inspect machinery in minute detail, searching for and removing even the smallest particles of food, metal shavings or chemicals to prevent contamination, bacteria growth and pests. While production staff are understandably focused on the products, cleaning operatives are concerned only with equipment and surfaces, and so are ideally placed to flag potential problems before they reach danger point. 

The sequential approach to cleaning, which is suited to factories which shut down processes consecutively as the product moves through the system, allows lines to be cleaned in stages from start to end. This system benefits from following the same pattern each day, allowing cleaners to monitor areas of concern and note progressive deterioration over time. A worn conveyor belt might not initially pose a risk, for example, but rapid fraying could lead to damaged products. A cleaning operative looking after this equipment everyday could easily prevent such an occurrence by flagging with the maintenance team, allowing the belt to be repaired or replaced before it poses a risk. 

Sequential cleaning is not, however, suitable for all facilities. A production plant operating progressive processes will benefit more from a cluster cleaning approach, where each area is cleaned as soon as it falls idle. In maintenance terms, cleaning immediately means potential contamination from component corrosion or lubricant leakage affects only one batch, with the problem rectified before the next run. The cluster approach also allows cleaning to be planned around scheduled maintenance, reducing the cost impact.

Event cleaning addresses the concern that unnecessarily frequent cleans can pose a hindrance to maintenance engineers. In some facilities, not all areas will be in constant use and therefore will not need the regular cleaning made necessary by high volumes of activity. The event cleaning approach is based on detailed risk assessments and the judgement of skilled operatives, cutting down on unnecessary cleaning. This is of particular benefit to lubrication engineers, who may be called to re-grease a particular piece of equipment which has been washed down despite it not having been active since the last top-up. 

While cleaning operatives are on the front line and can flag up maintenance issues early, effective cleaning is also essential in maintaining the mechanical integrity of machinery. Properly removing all traces of previous production, particularly food baked hard onto surfaces or dusty particles which can work their way into moving parts, eliminates the risk of products themselves damaging equipment. 

In turn, properly maintaining equipment will also help reduce cleaning times. Corrosion of components can cause cracks or splits where dust or particles can collect, adding considerably to the cleaning time. Damaged valves or gearboxes can cause used lubrication fluid to leak into production processes, which can pose an additional challenge to cleaning operatives as the most appropriate detergent for the production line may not be the best solution for dealing with lubricant spillages, adding extra processes to the scheduled cleaning procedure and leading to increased downtime. 

When looking to establish a new cleaning schedule, the expertise of a specialist cleaning company is invaluable in developing the most suitable programme for the manufacturing facility and complementing the work of maintenance teams by identifying issues earlier – delivering increased efficiencies and uncovering cost saving opportunities, without compromising on eliminating contaminants and adhering to food safety standards.