In the food processing industry, preventing oil contamination is critical for product safety and quality.
Decades ago, food processing’s switch to using food-grade lubricants was associated by some manufacturers with a drop in performance and additional overheads. However, today’s generation of leading food-grade lubricants has shed this reputation; not only addressing product contamination but also being conducive to superior system performance.
In this article, we’ll look not only at the role played by food-grade lubricants in reducing contamination risk, but at other preventative measures that food manufacturers can take to protect consumer health and comply with food safety regulations.
Use designated food-grade lubricants
Oil contamination prevention begins with using appropriate lubricants. Food-grade lubricants are specifically formulated to be non-toxic if incidental contact with food occurs.
Food manufacturers should always select NSF registered lubricants for all equipment with potential food contact.
An updated inventory of all lubricants used in the facility must be maintained, with a colour-coding system used to distinguish food-grade from industrial lubricants.
It is important to store food-grade lubricants separately from other industrial oils to prevent cross-contamination. When using food-grade lubricants, dedicated dispensing equipment should be used.
Proper equipment maintenance
Regular maintenance is another essential that reduces the risk of leaks and equipment failure, which could lead to contamination.
Standard maintenance practices include scheduling routine inspections of seals, gaskets and bearings. When components become worn, it is important to replace them before they risk failing. Detailed maintenance logs should be maintained for all equipment.
It is vital for food manufacturers to follow manufacturer’s recommendations for lubrication intervals. The maintenance personnel who apply lubricants should be fully trained in proper techniques, in order to avoid over-greasing, which is the next area we will cover.
Training for staff
Well-trained employees form the first line of defence against oil contamination.
Firstly, an understanding of the health risks associated with oil contamination is important. Training programmes will typically cover proper handling and application of food grade lubricants, but also awareness of how to recognise signs that may indicate potential leaks or contamination. Once a risk is identified, it’s important for personnel to know the right reporting procedures.
In the case of an emergency, response procedures for significant spills or leaks are another common training element.
Cleaning procedures
Proper maintenance involves clear cleaning protocols. The main purpose of cleaning in relation to contamination prevention is the removal of oil residues.
Cleaning practices typically employed in food processing environments include; developing specific procedures for cleaning up lubricant spills; using food-safe degreasers for removing oil residues from equipment surfaces; implementing dry cleaning methods where appropriate to minimise spreading contamination; and establishing cleaning verification procedures through visual inspection and testing.
Minimise exposure points
One of the fundamentals of oil contamination is identifying and controlling potential contamination pathways.
Effective strategies include; installing drip pans and containment systems under critical equipment; using sealed or shielded bearings where possible; implementing closed lubrication systems where feasible; and utilising sight glasses for checking lubricant levels without opening systems.
Cleaning procedures
Proper maintenance involves clear cleaning protocols. The main purpose of cleaning in relation to contamination prevention is the removal of oil residues.
Cleaning practices typically employed in food processing environments include; develop specific procedures for cleaning up lubricant spills; using food-safe degreasers for removing oil residues from equipment surfaces; implementing dry cleaning methods where appropriate to minimise spreading contamination; and establishing cleaning verification procedures through visual inspection and testing.
Considering design features
Equipment design may be a big factor in oil contamination prevention. When selecting or upgrading equipment, opting for equipment with minimal lubrication requirements will reduce contamination risk.
It can also be beneficial to choose machinery with self-contained lubrication systems and choose designs that keep lubrication points away from food zones. Modern equipment with appropriate guarding and containment features offers a clear advantage in risk reduction.
Monitoring and testing
It’s not sufficient to simply trust oil contamination prevention systems to work effectively. For prevention systems to fulfil their purpose, regular monitoring and testing must be practised.
Monitoring practices typically implemented include scheduled oil testing and analysis to detect contamination early, as well as regular inspections of equipment to identify any leaks or oil residue.
ATP (adenosine triphosphate) swab testing is used on surfaces to detect invisible residues, and environmental sampling around critical equipment is also conducted. All test results are documented, and corrective actions can be taken when necessary.
Implementing a comprehensive program
As we’ve explained, successful oil contamination prevention demands a systematic approach.
Only by treating oil contamination prevention as an ongoing programme that incorporates the elements above – including creating a safety culture within which employees understand food safety – can risk reduction be achieved.
