University of Wisconsin-Madison Page 1 of 1

Babcock Hall Dairy Plant Standard Sanitation

1605 Linden Drive
Madison, WI 53706
Operating Procedure
Department Title SOP Number
Sanitation 03-19
Drain Sanitation and
Prepared By/Date Effective Date
M. Shuda 8/02/2011 Maintenance 8/02/2011
Approved By/Date Supersedes SOP
Dated
__________________________ ____________________________
Supervisor Operator

1.0 OBJECTIVE
Drains must be cleaned monthly to decrease the amount of scum and bacteria build-up. This will
decrease the risk of contamination in the plant.

2.0 MATERIALS
2.1 Apron
2.2 Gloves
2.3 Goggles/glasses
2.4 Long handled scrubbing brush
2.5 Short handled scrubbing brush
.1 Brushes are located behind door of milk bottling room.
2.6 Octave sanitizer
2.7 Water/water hose

3.0 HAZARDS
3.1 Use of chemicals-Always wear proper PPE while handling.

4.0 PROCEDURE

5.0 MAINTENANCE

6.0 RECORD KEEPING

University of Wisconsin-Madison Page 1 of 2
Babcock Hall Dairy Plant Standard Operating
1605 Linden Drive
Madison, WI 53706
Procedure
Department Title SOP Number
Sanitation 03-20
Prepared By/Date CIP System Effective Date
M. Shuda 8/02/2011 8/03/2011
Approved By/Date Supersedes SOP
Dated
__________________________ ____________________________
Supervisor Operator

1.0 OBJECTIVE
The goal is to wash and sanitize all equipment that is soiled throughout the day. By day’s end,
all equipment must be ready for the next production day.

2.0 MATERIALS
2.1 MSDS sheets
2.2 Exxelerate CIP solution
2.3 Proper PPE (i.e. gloves, goggles, etc.)

3.0 HAZARDS
3.1 Chemicals- Exxelerate CIP solution
.1 Note: Student employees are not allowed to handle undiluted chemicals.
3.2 Hot water

4.0 PROCEDURE
4.1 Determine first process (area) for cleaning. Start immediately.
4.2 Hook up pipe work for that area to receive CIP solution.
4.3 Hook up return lines.
.1 When connections are complete, there should be a complete loop for the CIP
solution to flow through, beginning and ending at the CIP tank.
4.4 Double-check to make sure all CIP connections are correct. (I.e. The loop is complete
and connected to the correct machines.)
4.5 Make sure all air valves are in correct position.
4.6 Chill water flow must be shut OFF to the process being cleaned.
4.7 If applicable, turn agitator ON.
4.8 Make sure all return lines that are not in use are capped off and tightened.
.1 This allows CIP solution to flow effectively through desired path.
4.9 Go to CIP room:
4.10 Check to make sure there is enough chemical solution in drum.
.1 Check sanitizer.
.2 Check Exxelerate CIP solution-needs replacement about once every two weeks.
 SOP Number Page 2 of 2
Standard Operating Procedure 03-20

4.11 Record on CIP Recording Chart the process number at the tip of the green pointer.
.1 Each area corresponds to a specific process number.
4.12 Turn the dial and toggle switch (on panel) to correct settings.
4.13 Be sure that display panel corresponds to system that is to be washed.
4.14 Push green button to start the CIP system.
4.15 Immediately go into the plant to check that CIP solution went to the correct area that the
return lines are sealed.
4.16 After wash is complete:
4.17 Verify that system is done washing by viewing the panel in the CIP room.
4.18 Visually inspect equipment.
.1 If results are satisfactory, continue on with procedure.
.2 If any soil is observed, repeat process. Manual cleaning may be necessary before
second CIP process.
4.19 Disconnect and cap-off return line.
4.20 Determine which wash cycle is next and plan new connections accordingly.

5.0 MAINTENANCE
5.1 Daily, inspect CIP Recording Chart and check for any abnormalities. Sign chart.
5.2 Every week, inspect chemical pumps for leaks or other damage. Record in Chart 048.
5.3 Test chemical concentrations every week. Record in Chart 043. Make use of SOP 01-08.
5.4 Once a month, drain and flush CIP tanks. Clean outside of tanks. Record in Chart 048.
5.5 Once every three months, take apart spray-balls and inspect. Take care of any necessary
maintenance. Record in Chart 048.
5.6 Every six months, disassemble and hand-wash CIP valves.

6.0 RECORD KEEPING

6.1 This SOP requires the use of Chart 048. Turn into supervisor and replace as needed.
6.2 Maintain the CIP Recording Chart in CIP room.
Babcock Hall Dairy
GMP Documentation
Edited October, 2012

By:

Casey Whyte
Babcock Hall Dairy Plant
2/28/11

Good Manufacturing Practices

Good manufacturing practices (GMP’s) specify many of the production and process
controls to prevent contamination of products. The objective of GMPs is to prevent
adulteration (or contamination). Adulterated products are defined as products that “are
manufactured under such conditions that are unfit” or products that “have been prepared,
packed, or held under unsanitary conditions whereby they have become contaminated
with filth, or whereby they may have been rendered injurious to health”.

Two main categories of GMPs:

• Employee practices and good personal hygiene

• Equipment and plant cleanliness.

Employee practices and good personal hygiene include:

1. Hair
2. Jewelry
3. Fingernail
4. Uniform and clothing
5. Hand washing , hand sanitation and glove use
6. Footwear
7. Health practices
8. Food, drink, gum, cough drops

A: Employee Practices

1.0 Hair:
Hairnets and beard snoods should be kept at all production entrances allowing easy
access by all employees and visitors. Everyone, employees and visitors, will wear-head
covering restraints to contain their hair in the manufacturing plant.

Hairnets must be worn over your ears. Hairnets are to cover the entire head (front,
back, and sides) and include all hair: Often bangs or hair in the back of the head is
excluded from coverage within the hairnet. This practice is to be avoided. Caps or
hats can be worn over hairnets if they are clean. All employees in production,
packaging or other plant areas should be trained on proper hairnet usage:

• Hair restraints are required by Wisconsin law (ATCP 80.10(2)(a) and should be
worn at all times in production areas or all areas where product may be exposed
within the plant. Hair itself and its microorganisms may contribute to product
contamination.

Beard snoods are to be worn by those employees or visitors with sideburns,

mustaches and beards at a length greater than ¼ inch.

2.0 Jewelry

• Employees are not allowed to wear jewelry or watches in the production areas
with the following exceptions: medical alerts and hand rings as long as gloves
are worn.

• Visitors are not allowed to wear jewelry or watches in the production areas with
the exception of hand rings (as long as gloves are worn), medical alerts and ear
rings that do not hang below the bottom of ear lobe.

Medical alert bracelets / necklaces:

• By no means should and employee stop wearing this type of life saving
jewelry.
• Necklaces are a better alternative than bracelets and should always be kept
underneath clothing. Shirts should be tucked in to prevent the necklace from
being lost if it falls from around the neck.

3.0. Fingernails

Recent scientific studies have proven that fingernails are a common source of
contamination. Dirt and bacteria build up underneath fingernails. The longer the
fingernails, the greater the concentration of dirt and bacteria. Men and women both
should keep their fingernails short (no longer than ¼ inch) to help prevent bacterial
contamination.

Employees:
• Short fingernails facilitate washing and reducing dirt accumulation.
• Fingernails should be kept clean and trimmed (no longer than 1/4”) at all times.
• Longer fingernails cause holes in gloves.
• Fingernails should remain free from fingernail polish, decals or false fingernails:
• Polish or decals may chip off and fall into the product and may lead to bacterial or
physical contamination.

Visitors entering the production area who are wearing fingernail polish or artificial
nails should wear gloves.

4.0 Uniforms and Clothing

Uniforms and clothing are a common way to introduce contamination into the plant
and the product. Contamination can be of both a biological and physical nature.
Outside clothing can introduce hair, bacteria, dirt, buttons, or other contaminants. To
reduce clothing from cross-contaminating products, management will provide
laundered uniforms and designated footwear for all employees, particularly those
involved in production areas. Additional measures of food safety protection are
provided when the uniforms are professionally laundered and otherwise not allowed
to leave the premises. A locker is provided for changing and uniform storage. Under
no circumstances are uniforms to be stored in bathrooms. The plant will provide an
area for uniform storage.

• White pants and shirts are for production personnel. When maintenance on
equipment is performed during production, there is a greater opportunity for other
employees to notice and follow up with sanitation procedures prior to restarting
production on that piece of equipment. Maintenance personnel must wear lab
coats when working in production areas.
• Lab coats are required for all visitors and contractors.

Uniforms should be cleaned daily:

• A clean uniform shall be worn at the start of each production day and placed
in a designated container at the end of production day.

Locker rooms are provided:

• Employees shall change into their clothes and footwear upon arriving at work.
• Clothing should remain at work.
5.0 Hand Washing, Hand Sanitation and Glove Use

People normally carry 150 different types of bacteria on their bodies and over 400
different types of bacteria within their bodies. Many of these bacteria cause food
borne diseases if transferred to food. When bacteria are not washed off the hands
after using restrooms, they have the potential to make not only that person sick, but
others sick as well.

Therefore, when a person touches food, any bacteria on the skin will be transferred to
the food. People who eat that food may become quite ill and in some cases die
depending on the type of bacteria that are transferred (cross contamination). To avoid
illness due to cross contamination, proper hand washing is essential. Gloves are
required when touching finished products that are not yet packaged.

It is important to remember that gloves are meant to protect the food from the
employee and not protect the employee from the product. Because hands can so
easily transfer pathogens, it is necessary to properly wash hands:

• Experiments have shown that hands need to be washed for at least 20 seconds
to see a significant decrease in microorganisms on the surface of the hand.
• When washing, hands need to be scrubbed vigorously in the crevices of the
hand, fingertips, under fingernails and the space between the fingers with
warm water and soap.

Wash and sanitize hands at the following times (this is not an all inclusive
list):

• Upon entering production area hands must be washed and sanitized.

• Before handling exposed products.
• After visiting the restroom.
• After touching nose, mouth, face, or hair.
• After eating, drinking, using tobacco.
• After sneezing or coughing, after blowing or wiping nose.
• After any absence from work area or any other reason for leaving the
workstation.
• After handling garbage, soiled equipment/parts.
• After performing any maintenance tasks on equipment.
 • After handling personal belongings (street clothing, purses, cosmetics,
etc.).

6.0 Footwear

Proper footwear and properly maintained footfoamers are important aspects of employee,
food, and environment safety. Appropriate footwear reduces worker injury due to
slipping on wet floors or damage to toes. Footbaths/footfoamers reduce potential cross
contamination by removing dirt and debris that would otherwise be tracked throughout
the plant. Footfoamers should be checked for proper operation daily. Footfoamers should
be turned on first thing daily.

No open toed footwear or sandals worn by visitors or employees are allowed:

• For employee and visitor safety, open toed footwear or sandals is prohibited.
They do not protect against hot liquids, acids, and caustics used in the
facility. Such footwear does not protect the facility from contamination due
to feet or against heavy or sharp objects that may accidentally drop on an
employee’s foot.

Shoes worn by employees are to have a slip resistant sole:

• Sole grooves should be kept at a maximum of a quarter of an inch. The

greater the groove depth, the more dirt and other debris that may become
trapped and end up in product or on equipment.

Dedicated Plant footwear:

• Plant supplied footwear should not leave the building.
• If plant does not provide footwear, employee should carry in
footwear and leave footwear at plant. These should not be worn
outside of building.

Shoe covers will need to be worn over outside footwear:

• Shoe covers are available at the plant entrances.
• Visitors entering the plant should wear “in house” footwear or shoe
covers.
7.0 Health Practices

Employee health and hygiene, directly or indirectly, play an important role in food safety
and sanitation. Sick employees and poor hygienic practices rank second in the causes of
food borne disease outbreaks.

To avoid the possibility of foods becoming contaminated with pathogenic

microorganisms associated with employees who are ill, the following personal
hygiene practices should be strictly enforced:

• Supervisor notification is required when employees report to work with any

type of illness including head colds and sinus infections.
• The following conditions will strictly prohibit persons from handling
products. Special attention should be paid to those employees who handle
products after they have been through a heat treatment. This includes those
who handle product contact surfaces such as maintenance or sanitation
employees.

◦ Persons experiencing diarrhea or vomiting.

◦ Persons with contagious diseases, severe colds or conditions that result
in runny noses.
◦ Persons with wounds, boils or sores on hands, arms or face.

• Minor cuts on hands or arms should be treated promptly by washing with

warm water and soap.
• Band aid use must be reported to management.
• After washing, cover hands with gloves. Minor cuts on arms should be
covered with band-aids. Band aids must be removed at night to allow for
the wound to heal.
• Injuries on the hands and the lower portions of the arms such as cuts,
abrasions, burns and even a hangnail must be cleaned and treated
immediately. Often these injuries become infected. As a result, they can
contribute to the contamination of food and equipment with disease causing
bacteria.
• Supervisor notification should be required for those handling finished
products with a rash or sore to determine alternate duties that can be
performed until the rash or sore is healed.

8.0 Food, Drink, Gum, Cough Drops

The presence of food brought into the plant by employees can be a source of bacterial
contamination. Food and crumbs attract rodents and insects that can spread disease
causing bacteria, rodent droppings and hair to all parts of the manufacturing facility.
Food and beverages are to be consumed in the lunchroom, offices, conference room or
other authorized break areas. After breaks, employees need to wash and sanitize their
hands when returning to process area.

• Food and beverages are absolutely prohibited in production areas.

• Food and beverages are not to be kept in toolboxes.
• Food is not to be kept in plant coolers or freezers.
• Candy, gum, toothpicks, all tobacco products, and cough drops should only
be consumed / used on break and disposed of properly before returning to
work. These types of items require hand to mouth action and increase the
potential for bacterial contamination.