Spotless Food Processing Floors: Safety & Compliance Made Easy

When it comes to food processing—cleanliness is always top of mind. For food processors, there are federal and state regulations to ensure that the food being produced is safe and healthy for consumption. As consumers, we are regularly checking expiration dates and staying aware of recall information to ensure the food we eat and feed our families is safe. When it comes to food safety, how it is processed, packaged, stored, and prepared is always top of mind; but have you ever thought about the floors?

For food processors, proper floor care is a must for keeping food and staff safe. While food products should never come in contact with the floors—we know that bacteria can easily transfer from the floor to our food, especially in a busy processing facility. Bacterial contamination is a leading cause of FDA recalls¹, and it can easily be transferred from the floor to food contact surfaces through dust or water droplets on employee’s shoes or rolling carts.

Maintaining a clean and safe environment in food processing plants isn't just about meeting regulations; it’s about safeguarding the entire food production process. A clean floor reduces the risk of cross-contamination, which can occur when pathogens like Listeria or Salmonella are transferred from the floor to equipment, food contact surfaces, or even the food itself. So, how can food processing plants ensure their floors are clean and compliant?

Build Your Cleaning Program

Regular floor cleaning and sanitizing are essential in any food processing plant. Scheduling consistent cleaning prevents the buildup of dirt, debris, and food particles that can harbor bacteria, and regular sanitizing reduces the number of bacteria and microorganisms to levels considered safe for human health. Wet floors can also present a slipping hazard to workers, so cleaning schedules should account for both cleanliness and safety.

The first step to having clean and safe floors is choosing the right cleaning equipment, tools, and chemicals. Industrial floor scrubbers and sweepers are a must-have for food processing facilities. With so many options available, choosing the right equipment for your facility can be tricky. Our experts are here to help. Contact us today to schedule a consultation about your floor care needs.

Steps to Clean + Sanitize

Once you have the right equipment, you need to choose the best chemicals to keep your floors clean and sanitized. When cleaning floors in a processing facility, you want to ensure that the products you are using are safe for use in a food environment. These cleaning agents need to be tough enough to eliminate bacteria and pathogens but safe enough to be used around food.

While various regulatory bodies and food safety programs will have some variations to recommendations of how to best clean and sanitize floors, food contact surfaces, and equipment in food processing facilities, in general, the following steps are recommended according to NSF (National Sanitation Foundation)²:

Remove Debris

Using push mops, brushes, vacuums, or wipes, remove soil and other residue from the floors. In this first step, you want to focus on removing the large deposits you can see on the floors, so that the surfaces are clean for disinfecting and sanitizing.

Rinse the Floors

Using warm, potable water, all the floors should be rinsed. It’s discouraged to use high-pressure hoses because a high-pressure rinse could aerosolize debris onto areas that may have already been sanitized. For dry food processors, a rinse is not recommended, as dry food products need to stay moisture-free to prevent mold and bacteria growth. In these situations, it’s recommended to thoroughly wipe down floors with a pad or brush and a food-safe cleaning solution.

Apply Chemicals

Now you’re ready to use chemicals to remove food proteins and fat from the floors. Be sure to follow manufacturer guidelines for dilution rates and contact times. 

Rinse Again

After applying chemicals, foaming agents, and scrubbing, it’s time to rinse the floors again. You want to completely remove the chemicals and residue before you start sanitizing. Most detergents are alkaline, and sanitizers are acidic, so without a good rinse, you run the risk of neutralizing your sanitizer!

Double Check the Floors

Take a moment to inspect the floors and ensure no residue or detergent is left behind. If necessary, spot clean these areas before proceeding to the next step.

Sanitize or Disinfect

To prevent bacteria, you’ll want to apply a food-safe sanitizer or disinfectant. Disinfectants kill more bacteria than sanitizers, but they typically take longer to work. Disinfecting chemicals are typically stronger, but some are safe for food-contact situations. It’s really important to check labels and ensure that you are using chemicals that are clearly indicated for your intended use. 

The Role of Floor Drains

A commonly overlooked aspect of food processing plant floor care is the importance of floor drains. Drains are essential to prevent water from pooling, but they can also become hotspots for bacterial growth if not properly maintained. Clean drains are critical to maintaining hygiene standards, as dirty or clogged drains can release bacteria-laden water back onto the floor. Regular drain cleaning should be incorporated into the overall sanitation routine to ensure wastewater is efficiently removed from the environment.

Choosing the Right Flooring Material

In addition to routine cleaning and drain maintenance, the type of flooring in a processing plant can significantly affect cleanliness. Floors should be made of non-porous, easy-to-clean materials, such as epoxy coatings or sealed concrete, which prevent bacteria and food particles from embedding themselves into the surface. Food-safe flooring options are designed to withstand constant moisture, heavy foot traffic, and the movement of equipment, ensuring long-lasting hygiene and durability.

Employee Training and Monitoring

Even the most sophisticated cleaning protocols will fail if employees aren’t properly trained. Ensuring that workers understand the importance of cleaning floors and adhering to a cleaning schedule is vital for overall food safety. Training programs should emphasize the correct use of cleaning products, proper disposal of waste, and steps to take in the event of a spill or contamination incident.

Finally, ongoing monitoring and inspection are crucial. Regular audits of cleaning practices and floor conditions help identify problem areas before they lead to contamination. Monitoring ensures that cleaning is thorough, that proper materials are used, and that the plant always maintains the highest safety standards.

While food processing floors may not be the first thing we think of when considering food safety, they play a pivotal role in keeping our food clean and safe. By implementing a comprehensive cleaning routine, ensuring proper drainage, using appropriate flooring materials, and providing employee training, processing plants can greatly reduce the risk of contamination. While no one should be eating off of these floors, ensuring they are clean can certainly help prevent foodborne illnesses from making it onto our plates.

How can I implement a floor cleaning program in my food processing facility?

At BradyPLUS, we will listen to your business objectives, ask the right questions, and help you find food processing solutions that keep your floors clean, your food safe, and your plant productive.

Contact us today ⬇️, and our food processing experts will get to work.

1. Summary of Recall and PHA Cases in Calendar Year 2023 - Food Safety and Inspection Services
2. Seven Steps to a Clean and Sanitized Food Processing Facility