SANITATION Snapshot: “Cleanrooms were initially certified for pharmaceutical and electronics industries and are generally classified in accordance with standards such as the International Organization for Standards or the Federal Cleanliness Standards,” says Stuart Jernigan, director of preconstruction. “There are levels of cleanliness detailed in each standard but they both refer to allowable number and size microns of particulate per cubic foot of air. The lower the classification, the cleaner the space. The classification level of a cleanroom can greatly affect the overall cost, so a good deal of science and subsequent design/engineering is required to determine the suitable level of cleanliness and air quality required for the product,” he notes.

The term “cleanroom” is now used in the food industry for specially controlled environments, but may or may not receive a classification. However, design is very similar to those in other industries, Jernigan notes.

SANITATION Snapshot: Dave Watson, baking and snack expert, says that sanitation and food safety has been a significant concern of most bakers over the years. “FSMA, followed by the COVID-19 pandemic, has elevated these concerns to a higher level. Food companies want to know that the products they are producing are safe for the consumer. Past sanitation practices suddenly became ineffective from some types of pathogens,” he says.

“Outbreaks of Salmonella have created much more public awareness of foodborne pathogens, as well,” says Watson. The ready-to-serve and meat/poultry industries have traditionally followed stricter guidelines, but other industries are now adopting similar protocols. “Bakeries now realize that they need to provide better and safer environments during the manufacturing of their products,” he says.

“Typically a cleanroom is required in the prebake portion of the plant,” says Watson. These include processes ahead of the oven—before the kill step. “Once the bakery products have been baked, they are no longer as susceptible to contamination as they are in the raw state,” he says.

SANITATION Snapshot: In general, cleanroom technology can be applied to all baked goods that demand controlled environmental conditions and the highest hygiene standards, says Kantha Channaiah, director of microbiology, regulatory.

“Cleanroom technology is particularly beneficial in manufacturing allergen-free finished food products,” says Channaiah. “Other applications include frozen bakery foods, chocolate and candy, confectionary and snacks, and gluten-free and lactose-free products.” Proper design, training, certification and testing, and monitoring are critical to keep the cleanroom technology in compliance, he adds.

SANITATION Snapshot: “Allergen-free items benefit from cleanroom technology, as this is a way to ensure that no external contamination can make its way into the product, even when made in a factory that processes allergens,” says Pablo Coronel, Ph.D, director of food processing and food safety, process authority. “Just imagine making gluten-free cookies in a normal bakery,” he says.

“Intermediate-moisture, preservative-free, ready-to-eat foods that are made with no preservatives are also well-suited to production in a cleanrooms environment. Both product types must be isolated to prevent microbial contamination that can spoil or cause outbreaks. Cleanrooms provide a perfect environment with controlled temperature and air filtration to prevent contaminations that may decrease shelf life.”

SANITATION Snapshot: “From Gray’s perspective, all snack and bakery facilities should include a cleanroom environment, especially in mixing areas as well as after baking and prior to packaging. Cleanrooms help prevent micro issues in this instance,” says Jeremy Bruner, senior project manager.

Greg Janzow, director, food safety, says cleanrooms are meant to address these activities in an operation where small particles can adversely affect the manufacturing process or product performance. Conducting a thorough hazard risk analysis is a necessary approach in establishing perspective on a cleanroom application for a facility.