Food Industry Cleaning and Sanitation: Procedures for Safe Production

For leaders in food manufacturing, sanitation goes beyond food safety; it is a true test of teamwork. Success depends on quality, sanitation, maintenance, and operations teams joining forces to run an effective program.

Good food safety and sanitation programs protect consumers, help meet certification standards, and make operations run more smoothly. When manufacturers treat sanitation as a clear and measurable process, they can provide safer food with more confidence.

​This article covers important terms, step-by-step procedures, and practical solutions for cleaning and sanitation in the food industry.

Food Industry Safety: Cleaning vs. Sanitizing

Both cleaning and sanitizing in the food industry play an important role in keeping food safe. They both work together to control risks in food manufacturing. Despite these terms being used interchangeably, they serve different purposes within the cleaning and sanitation procedures in the food industry. Equally, they are foundational to HACCP programs, GMP compliance, and third-party food safety and certification requirements.

What Is Cleaning?

Cleaning means getting rid of both visible and hidden dirt from surfaces. This includes leftover food, grease, dust, things that cause allergies, and other things that can help germs grow.

In the sanitation in the food industry context, cleaning usually involves the following steps:

• Dry removal of debris
• Application of detergents or cleaners
• Using tools or machines to clean, such as scrubbing, spraying, or using special cleaning systems
• Rinsing with clean, safe water

Cleaning alone does not remove most germs. Still, it is essential because sanitizers do not work well on dirty surfaces. Poor cleaning can lead to the following food safety problems:

• Ineffective sanitizing
• Increased risk of cross-contamination
• Allergen carryover
• Sticky layers of germs can build up on equipment and drains

As a basic rule within cleaning and sanitizing food safety programs, cleaning always comes before sanitizing.

What Is Sanitizing?

Sanitizing is the step that follows cleaning. Its purpose is to reduce the number of microorganisms on surfaces, using either chemical or physical methods.

In food safety and sanitation systems, sanitizing usually involves the following steps:

• Use approved food-grade chemical sanitizers like chlorine, quats, or peracetic acid.
• Make sure the sanitizer is at the right concentration and remains on the surface for the proper amount of time.
• Apply sanitizer only to surfaces that have already been cleaned.

Sanitizing is different from cleaning because it lowers the number of harmful bacteria. However, it does not get rid of all of them. Sanitizers do not work as well as sterilants, which remove more microorganisms.

Improper sanitizing is a common cause of sanitation failures found during audits.

Food Sanitation in Context

Food sanitation is an integrated system, which is a combination of cleaning, sanitizing, inspection, and record keeping to avoid contamination and maintain the product safety during production.

The food sanitation is not only an individual work, but also includes the following elements:

• Implementing a defined process, e.g., Sanitation Standard Operating Procedures (SSOPs).
• Making sure that employees are well-trained.
• Ensuring tight control over the usage of chemicals.
• Performing frequent monitoring and verification functions.
• Working toward constant improvement through data analysis and regular audits.

These practices are preventative in the wider context of sanitation in the food industry. The main idea is to prevent the risks prior to their appearance, and not to react once the contamination has already occurred.

Strong food sanitation schemes are needed because of a number of reasons:

• Meeting the regulatory requirements.
• Fostering customer trust.
• The certification of the Global Food Safety Initiative (GFSI) and other food safety and sanitation certifications.

Relationship to Food Safety, HACCP, and GMPs

Cleaning and sanitizing in the food industry are not separate tasks. They are important parts of organized food safety systems.

Food Safety Programs

In food safety management, cleaning and sanitizing help to lower the risks from biological, chemical, and physical hazards. It also helps manage and control allergens. Moreover, it keeps equipment in good condition and maintains a clean facility.

HACCP (Hazard Analysis and Critical Control Points)

In HACCP systems, cleaning and sanitation are considered prerequisite programs, or PRPs. They serve several important roles:

• They help create a clean environment so that critical control points (CCPs) can work as intended.
• They lower the chances that hazards will reach critical points in the process.
• They also help with checking and confirming that hazard controls are working.

Although sanitation is not usually a CCP, problems with cleaning and sanitation often cause HACCP systems to fail.

GMPs (Good Manufacturing Practices)

GMPs require:

• Clean and sanitary facilities
• Properly maintained equipment
• Documented sanitation practices
• Trained personnel following approved procedures

Cleaning and sanitizing are some of the most closely checked parts of GMPs.

Regulatory and Standards Framework

A good sanitation program must be based on recognized standards in the industry. Cleaning in the food processing industry is not optional. It is a formal requirement found in food safety regulations, prerequisite programs, and certification schemes.

HACCP and Prerequisite Programs

In HACCP-based food safety systems, cleaning and sanitation in the food industry are classified as Prerequisite Programs (PRPs). PRPs establish essential hygiene standards for safe food production, allowing HACCP plans to address critical hazards.

​Within HACCP, cleaning and sanitation reduce the risk of biological, chemical, and physical hazards. These include biological hazards like pathogens, chemical hazards such as residues or allergens, and physical hazards like equipment debris.

As mentioned above, sanitation activities themselves are not often designated as CCPs. However, poor cleaning is often the main reason for HACCP deviations, environmental positives, and audit non-conformities.  As such, sanitation PRPs must be:

• Clearly documented through SSOPs
• Consistently implemented
• Verified and validated through inspections and testing

GMPs and Sanitation Expectations

Good Manufacturing Practices, or GMPs, set the basic rules for food production. One of the main focuses is sanitation. GMPs make sure that facilities, equipment, and staff all work in clean conditions to prevent contamination.

In food processing, compliance with GMP requires that cleaning ensure the following:

• Equipment and surfaces that touch food are cleaned and disinfected as often as needed.
• Floors, drains, walls, and ceilings are kept clean to stop germs from spreading, even though they do not touch food.
• We store, label, and maintain cleaning tools, chemicals, and utensils properly.
• All employees are trained in proper sanitation procedures and personal hygiene.

Regulators and auditors assess sanitation compliance by reviewing the following areas:

• SSOP documentation
• Sanitation records and logs
• Chemical usage and concentration controls
• Evidence of verification, such as visual checks, ATP tests, or swabs

GMPs are legally required. Failure to maintain proper cleaning and sanitation in the food industry may result in regulatory violations or loss of certification.

Applicable Standards and Certification References

Besides following regulations, many food manufacturers also meet extra standards set by customers or chosen on their own. These standards clearly define sanitation expectations.

​The following are some of the most widely used frameworks:

• ​FDA rules and similar national laws require clean work areas and buildings.
• GFSI-recognized programs like BRCGS, SQF, and FSSC 22000 add more sanitation rules by looking at risks, separating areas, and checking that cleaning is done right.
• NSF and equipment cleaning rules affect how equipment is made and how simple it is to clean.

These standards usually require the following:

• Maintain documented cleaning and sanitation procedures.
• Set up cleaning times based on how risky each area and piece of equipment is.
• Make sure cleaning works by checking regularly and keeping records.
• Keep making things better by looking at patterns and inspection results.

You usually need to follow these rules to keep your food safety certification. Therefore, sanitation programs should be built to do more than just “pass audits.” They need to help keep contamination risks under control for the long term.

Sanitation Standard Operating Procedures (SSOPs)

Sanitation Standard Operating Procedures (SSOPs) are the foundation of effective food manufacturing sanitation programs. They interpret requirements, HACCP prerequisites, and GMP expectations into clear actions. In return, these ensure food production cleaning that is consistent across teams and facilities. 

SSOP Fundamentals

Essentially, SSOPs are written procedures that outline the steps for performing cleaning and sanitation activities. It also details how it is monitored and verified in a food manufacturing environment. In short, SSOPs define the what, how, when, and who in cleaning.

In food manufacturing cleaning, SSOPs serve to:

• Make sure sanitation practices are consistent for all equipment, work areas, and staff.
• Help maintain the necessary programs that support HACCP.
• Show that we follow GMP and meet certification standards.
• Work to stop contamination, allergen mixing, and the growth of microbes.

SSOPs need to be practical and easy to use, rather than just generic documents made for audits. Use clear language, organize steps logically, and ensure they align with real-world operations to be effective.

Responsibilities and Roles

Every SSOP should clearly define who is responsible for each task. This helps prevent confusion, missed steps, and problems with accountability during sanitation.

Sanitation operators are responsible for cleaning tasks. Supervisors or QA personnel oversee and verify cleaning processes. Maintenance teams handle equipment disassembly, reassembly, and repairs. Finally, management ensures that adequate resources, training, and compliance are in place.

Clearly defined role assignment is critical in food manufacturing sanitation because effective cleaning requires collaboration among multiple departments.

Safety and PPE Requirements

SSOPs should make employee safety a key part of their sanitation process. Food production cleaning often involves chemicals, hot water, pressurized systems, and confined spaces.

Safety requirements should include the following:

• Wearing the required personal protective equipment, including gloves, goggles, aprons, and boots.
• Follow lockout and tagout procedures when cleaning equipment.
• Make sure to use proper ventilation and follow safety precautions in confined spaces.
• Knowing the emergency response steps for chemical exposure or spills.

Including safety steps in SSOPs helps ensure that sanitation is done safely, protecting workers and avoiding issues in daily operations.

Chemical Handling and Use

Chemical control plays a key role in SSOPs and is regularly reviewed during audits. SSOPs need to cover these key points clearly:

• List which cleaning and sanitizing chemicals that are approved
• State the correct dilution and concentration ranges
• Explain how to apply the chemicals and how long they should stay on surfaces
• Describe when and how to rinse, if needed
• Include instructions on how to store, label, and dispose of chemicals properly

In food manufacturing cleaning, using chemicals incorrectly can cause poor sanitation or damage equipment. Clear, detailed instructions help everyone avoid mistakes and achieve consistent results.

Schedule and Frequency

SSOPs should clearly state when and how often to perform sanitation tasks. These tasks include doing the following:​

• Clean all areas every day as part of your regular routine.
• Clean surfaces whenever you change products or switch between allergens.
• Do a thorough deep clean once a week or at other scheduled times.
• Clean up right after any spills or when maintenance work is finished.

In food manufacturing, sanitation, and scheduled cleaning are based on risk. Clean higher-risk areas and food contact surfaces more often than low-risk zones.

Monitoring and Recordkeeping

Effective SSOPs use clear monitoring steps to ensure procedures are followed as written. Monitoring may include:

• Completion checklists to track finished tasks
• Supervisor sign-offs to confirm that the work is reviewed
• Chemical concentration logs for recording measurements
• Equipment inspection records to document safety checks

Accurate records demonstrate that you are following the rules and help you locate information quickly in the event of an investigation. In many facilities, inspectors and auditors review sanitation records more than any other documents.

SSOP Integration with Audits

SSOPs are important for both internal and external audits. Auditors look at more than just whether SSOPs are in place; they also check if they meet certain standards:

• Current and accurate
• Consistently followed
• Supported by training and records
• Verified for effectiveness

Good SSOPs make audit preparation easier because they clearly connect cleaning, monitoring, and corrective actions in food production. 

Sanitation Procedures

Good sanitation relies on using a clear and consistent process rather than cleaning at random. Clear sanitation procedures in food manufacturing keep processes consistent, reduce the risk of contamination, and help meet safety standards. 

Most cleaning and sanitizing procedures in the food industry are built around the 7 steps of sanitation. Together, they make up a full and checkable cleaning cycle.

Step 1: Preparation

Good preparation is the key to effective sanitation. Before you start cleaning, make sure the area and equipment are safe and ready to use.

This step usually involves:

• Stopping production and removing exposed product
• Performing lockout/tagout on equipment, where required
• Gathering approved tools, chemicals, and PPE
• Reviewing the applicable SSOPs and sanitation checklist

Preparing properly helps prevent cross-contamination and makes sure the rest of the sanitation process goes smoothly and safely.

Step 2: Removal of Debris

The second step is to remove gross soil, such as large food particles, packaging materials, and other visible debris, from surfaces.

Here are some important steps to follow:

• ​Start by dry scraping, sweeping, or vacuuming the area.
• Do not use water yet, as this can spread contamination.
• Pay special attention to cleaning equipment crevices and other hard-to-reach areas.

By removing debris thoroughly, you make later cleaning and sanitizing easier and lower the risk of biofilm forming.

Step 3: Pre-Rinse

Pre-rinsing with clean water removes loose dirt and prepares surfaces for detergent.

Follow these best practices:

• Use the correct water temperature to prevent proteins from sticking.
• Keep water pressure under control to avoid creating airborne droplets.
• Rinse from the top down to stop dirt from spreading again.

Pre-rinsing helps you spot what needs cleaning with detergent and makes each of the 7 steps of sanitation more effective.

Step 4: Detergent Application

The first step in cleaning is applying detergent. Approved detergents help break down fats, proteins, and carbohydrates where microorganisms can grow.

Keep these key points in mind:

• Choose the right type of detergent for the kind of soil and the surface you are cleaning.
• Mix chemicals to the correct concentration as recommended.
• Use enough mechanical action, such as manual scrubbing or using a CIP system, to help remove soil.
• Let the detergent sit for the amount of time specified in the SSOPs.

If detergent is not used properly, sanitizers applied afterward will not work as well.

Step 5: Rinse and Inspection

Once you have used detergent, rinse the surfaces well to get rid of any leftover chemicals and dirt.

​Here’s what you need to do next:

• ​Rinse with clean, drinkable water.
• Check the surfaces to make sure they are clean.
• If you notice any dirty spots, clean them again before you continue.

Visually checking the surfaces is important. This helps you avoid moving on before everything is clean and tidy.

Step 6: Sanitization

Sanitization reduces the number of microorganisms on clean surfaces to a safe level.

​Follow these steps to sanitize surfaces correctly:

• ​Always use sanitizers that are safe and approved for contact with food.
• Use the correct amount of sanitizer and follow the label instructions.
• Allow the sanitizer to stay on the surface for the time specified on the label to ensure it works effectively.
• Rinse the surfaces after sanitizing only if the instructions require it.

This step is a crucial part of the cleaning and sanitizing process. It also helps control biological hazards in food safety systems.

Step 7: Final Drying and Reassembly

This step usually involves the following tasks:

• Allow surfaces to air dry so microbes do not have a chance to grow.
• Reassemble the equipment using clean and safe techniques.
• Double-check everything before you start up again.
• Make a note that you have completed all the sanitation steps.

Ensuring all equipment is dry and properly reassembled helps prevent contamination. It also shows that you have followed all 7 steps of sanitation correctly.

Area-Specific Sanitation Procedures

Cleaning and sanitation in the food industry must address the specific risks present in each area of a facility. Some surfaces are more likely to get contaminated. Food safety programs, therefore, use specific methods, tools, and cleaning schedules for them. Knowing what food sanitation is means understanding that procedures vary depending on the area, equipment, and level of risk.

Equipment and Food Contact Surfaces

Food contact surfaces are at the highest risk of contamination, so sanitation programs in food manufacturing pay special attention to them. These surfaces come into contact with raw materials, products during processing, and finished goods. Cleaning and sanitizing them is necessary to keep food safe.

Selecting the right cleaning method is important in the food processing industry. The two main options are Clean-in-Place (CIP) and Clean-out-of-Place (COP).

​CIP systems clean the inside surfaces of equipment without taking them apart. They are commonly used for tanks, pipelines, and systems that handle liquids. CIP helps keep food production cleaning consistent and efficient, but it does require:

• Making sure that flow, temperature, and chemical levels are properly set and checked
• Regular checks to confirm the cleaning process works well

COP, on the other hand, means taking equipment apart and cleaning the parts in special wash areas. This method is often needed for equipment that is complex or has a lot of buildup. COP cleaning makes it possible to inspect parts closely. This is especially important in the food industry because there are higher risks from allergens or germs that can make people sick.

​Many facilities use both methods. The choice often depends on how the equipment is built and the level of risk involved.

Floors, Walls, and Ceilings

Floors, walls, and ceilings are important for keeping food facilities clean. If these areas are not maintained, they can gather moisture, debris, and germs that might spread into production areas.

Here are some simple tips to help keep these areas clean:

• Set up regular cleaning routines for these surfaces, and keep them separate from the routines you use for food contact areas.
• Use separate cleaning tools for these areas to help prevent cross-contamination.
• Be careful not to let cleaning sprays spread into the air while you clean.
• Check these surfaces often for any damage where dirt or germs could hide.

Careful management of non-food contact surfaces is key to keeping food safe and maintaining good sanitation.

Drains and Hard-to-Reach Zones

Drains, tight corners, and other hard-to-reach spots are some of the riskiest places in food facilities. These spots often have biofilms and tough microorganisms. This makes them especially important for maintaining long-term sanitation in food manufacturing.

Here are some effective cleaning practices:

• Clean these areas more often than places that people do not touch as frequently.
• Use foaming or gel cleaners, as they are effective on vertical or enclosed surfaces.
• Scrub the surfaces to break up any biofilms.
• Check your cleaning results by monitoring the environment more closely.

Issues with drainage and sanitation can harm the environment. They are closely watched during food safety and sanitation certification audits.

Zoning and Risk-Based Scheduling

Zoning is a key part of today’s cleaning and sanitation practices in the food industry. Facilities are split into different areas depending on how likely they are to get dirty, and cleaning plans are made to match these risks.

​A standard zoning plan usually covers these areas:

• Zone 1: covers food contact surfaces, which have the highest risk.
• Zone 2: includes nearby surfaces that do not touch food.
• Zone 3: made up of floors, drains, and other structural parts of the facility.
• Zone 4: refers to remote areas or spaces not used for production.

Zoning helps cleaning teams avoid using the same method everywhere and instead focus their work where it is most needed.

Verification and Validation

Verification and validation help show that sanitation programs are being followed and are working. ​Cleaning and sanitizing are done every day, but verification and validation make these tasks measurable and easy to check.

Visual Inspection

Visual inspection is the first step in checking sanitation and must be done before any advanced testing.

This step involves the following tasks:

• ​Check all food contact and non-contact surfaces for visible dirt, residue, or damage.
• Make sure equipment is reassembled correctly after cleaning.
• Check that there is no standing water, leftover chemicals, or foreign materials left behind.

Sanitation supervisors or QA staff usually perform these visual checks and record them in the sanitation logs. Although visual inspection cannot confirm that all microbes are removed, it ensures surfaces are ready for sanitizing and further testing.

ATP and Rapid Testing

ATP (adenosine triphosphate) testing quickly measures how clean a surface is by detecting leftover organic material.

People often use ATP testing to:

• Check if cleaning in the food industry worked right after sanitation
• Find spots that need to be cleaned again before production starts
• Compare how well different shifts or teams clean

ATP testing helps fill the gap between just looking at surfaces and doing lab tests for germs. Although it cannot find specific pathogens, it is a reliable way to regularly check if cleaning is consistent.

Microbial Swabbing

Microbial swabbing verifies that cleaning procedures reduce microorganisms to safe levels.

This method generally involves the following steps:

• Swab surfaces that contact food as well as high-risk areas that do not.
• Test for specific indicator organisms or harmful bacteria.
• Use accredited laboratories or validated in-house testing methods.

Microbial testing results confirm the effectiveness of cleaning during audits and food safety or sanitation certification checks.

Trending and KPIs

Trending transforms sanitation data into actionable insights. Facilities use Key Performance Indicators (KPIs) to monitor performance, rather than relying solely on verification results.

Common sanitation KPIs include:

• ATP pass/fail rates
• Environmental swab results by zone
• Re-cleaning frequency
• Sanitation-related deviations or non-conformities

Tracking trends enables teams to identify recurring issues, monitor improvements, and sustain progress in sanitation.

Documentation for HACCP and GMP Compliance

The main types of documentation include:

• SSOPs and sanitation schedules
• Visual inspection and ATP logs
• Microbial test results
• Corrective action reports
• Trend analyses and review records

If records are inconsistent during audits, it can be seen as a sanitation failure, even if cleaning was done properly.

What Are Common Mistakes in Cleaning and Sanitation?

Well-documented sanitation programs can still fail if common problems in execution are not addressed. Most problems found during audits, investigations, or environmental testing come from a few repeated mistakes. 

Here are common failures and some practical fixes that QA, sanitation, and operations leaders in food manufacturing can apply.

Inadequate Pre-Cleaning

If you skip or hurry through pre-cleaning, like brushing off dry bits and rinsing first, food bits stay on surfaces. This makes cleaners work less well and lets germs survive when you sanitize.

Practical fixes:

• Before using water, first clean the area by scraping, sweeping, or vacuuming.
• Include a visual ‘clean-before-wet’ checkpoint in the SSOPs.
• Use the right tools for each type of soil, like scrapers for fats and brushes for dry powders.
• Teach teams why pre-cleaning is important, not just how to do it.

Incorrect Chemical Concentrations

Using the wrong amount of detergent or sanitizer can happen if you mix them incorrectly. Problems can also occur if you guess the amounts or use dosing systems that are not properly calibrated.

Practical fixes:

• Whenever possible, use automatic dosing or proportioning systems.
• Regularly inspect and calibrate manual mixing tools such as measuring cups and pumps.
• Place laminated mixing charts at each chemical station.
• During regular sanitation checks, use test strips to verify chemical concentrations.

Skipped Verification Checks

Sanitizing without first looking over the area or using an ATP test just assumes it is clean. If you do not check, there is a greater chance that something dirty could get into the product.

Practical fixes:

• Make verification steps a required part of SSOPs instead of leaving them optional.
• Have a supervisor or QA sign off before any equipment is released.
• Use ATP testing on surfaces that are high-risk or have had previous issues.
• If a check fails, re-clean the area right away instead of waiting to address it during an audit.

Overlooking Non-Contact Areas

Paying attention only to food contact surfaces and ignoring floors, drains, walls, equipment frames, and other areas not touching food. Non-contact surfaces often hold pathogens. They can spread them back to food contact areas through splashes, airborne particles, or people walking by.

Practical fixes:

• Set up sanitation plans for each zone and make sure to specify how often each area should be cleaned.
• Use specific tools and colors for non-contact areas to help prevent cross-contamination.
• Clean drains and wet areas more often, rather than less.
• Make sure non-contact areas are part of environmental monitoring and trend reviews.

Most sanitation failures happen not because people aren’t trying. They happen because of missed steps in how tasks are done and checked. Using clear procedures can make cleaning programs stronger and lower the risk of expensive food safety problems.

Bottom Line

Effective cleaning and sanitation are not just separate tasks. They are essential systems that help ensure food is produced safely, meets regulations, and stays reliable. This guide has shown that good sanitation depends on clear definitions, organized procedures, documented SSOPs, and strong verification and validation. 

Cleaning and sanitation in the food industry follow HACCP prerequisite programs and GMP requirements. This helps create a preventive system for cleaning and sanitation.

Successful programs are built on consistency and accountability. This is done by following the 7 steps of sanitation and using area-specific controls and verification tools. 

Avoiding common sanitation mistakes and addressing them with practical solutions ensures that sanitation systems remain effective consistently, not only during audits.

FAQs

How often do you need to review and update sanitation procedures?

Review sanitation procedures at least once a year, and also whenever products, equipment, chemicals, facility layout, or regulations change. It is also a good idea to review them after audits, contamination events, or repeated sanitation problems.

Who approves sanitation procedures and SSOPs?

Sanitation procedures need approval from QA or food safety leaders, with input from the sanitation, operations, and maintenance teams. Getting everyone involved helps make sure the procedures meet food safety standards and work well in practice.

Why are sanitation procedures considered prerequisite programs in HACCP?

Sanitation procedures help keep the environment clean so that HACCP controls can do their job. If cleaning and sanitation are not done well, hazards might appear before Critical Control Points can handle them.

Are sanitation activities considered Critical Control Points (CCPs)?

Usually, the answer is no. Cleaning and sanitation are considered prerequisite programs rather than CCPs. Still, if sanitation fails, it can cause problems with HACCP and lead to food safety issues.

How often should food contact surfaces be cleaned and sanitized?

Clean and sanitize food contact surfaces as often as needed based on risk. This usually means after each production run, when changing products or allergens, or at the end of each shift.