How Often Should Your Food Manufacturing Company Sanitize High-Touch Equipment?

In food manufacturing facilities across St. Paul, Minneapolis, and the Twin Cities, small hygiene mistakes can lead to big problems. One major risk is the spread of germs through high-touch surfaces, which are any items or areas that are frequently touched by hands. These include not just food-contact equipment, but also shared tools, touchscreens, control panels, delivery crates, door handles, light switches, and even office items like keyboards and phones.

Because these surfaces are touched so often, they can easily spread germs and cause cross-contamination, especially when staff move between raw ingredients, processing, packaging, and break areas. Even surfaces that don’t touch food directly, such as a restroom door handle or breakroom fridge, can become bridges for bacteria if not cleaned properly.

To protect your facility, it’s important to identify all high-touch areas, not just the obvious ones, and include them in your cleaning schedules such as SSOPs and Master Cleaning Schedules. Overlooking these spots can compromise your entire sanitation plan.

Risks of Inadequate Sanitization

Failing to properly clean and sanitize high-touch surfaces can lead to serious consequences for food manufacturers in St. Paul, Minneapolis, and the Twin Cities. It puts public health at risk, costs your company money, and damages your reputation.

Foodborne Illness Outbreaks and Public Health Impact

Poor cleaning practices can lead directly to foodborne illness outbreaks. These outbreaks harm customers and seriously damage a company’s reputation and ability to stay in business. According to the World Health Organization (WHO), one in ten people globally get sick from contaminated food each year, and children under five account for 40% of these cases. A tragic example is the Listeria outbreak linked to a Boar's Head plant, where improper cleaning led to 10 deaths and 60 hospitalizations.

Product Recalls, Financial Losses, and Brand Damage

Inadequate cleaning often leads to product recalls, which are costly and damaging. Companies face expenses for retrieving recalled items, replacing them, and dealing with lawsuits. For example, Baskin-Robbins recalled ice cream due to plastic and metal pieces, OSI Industries recalled beef patties for metal contamination, and Nestlé recalled Hot Pockets due to plastic and glass. These cases highlight the financial losses and injuries caused by lapses in sanitization. On top of that, customer trust drops, leading to lower sales and long-term damage that’s difficult and expensive to fix.

Regulatory Non-Compliance and Legal Trouble

Food manufacturers in the Twin Cities must meet strict standards from agencies like the FDA and USDA, as well as local health departments. Failing to comply can result in heavy fines, losing your license, or being shut down. If unsafe practices cause illness or injury, your company could face lawsuits. Poorly maintained equipment makes things worse by providing places for bacteria, chemicals, or foreign materials to build up and spread.

Even a small oversight, like missing a high-touch surface during cleaning, can allow germs to spread. If contamination isn’t caught quickly, it can move through your facility by way of employees, equipment, air, or water. What starts as a minor issue can lead to widespread contamination. That means people get sick, regulatory agencies step in, and your company ends up paying massive costs for recalls, legal action, and lost trust.

In short, cleaning isn’t just a task or expense. It’s a critical part of protecting your customers, your reputation, and the future of your business.

The Benefits of a Strong Sanitation Program

Following food safety regulations is essential, but a strong cleaning program does much more. It turns sanitation from just a cost into a smart investment for food manufacturers in the Twin Cities.

Preventing Contamination and Microbial Growth

Effective cleaning stops contamination from bacteria, chemicals, and physical debris. It prevents the growth of harmful microbes like Listeria, Salmonella, yeast, and mold, all of which can cause illness or spoilage. Regular cleaning of equipment, tools, and facility surfaces, combined with proper temperature and humidity control, keeps these threats under control. Ongoing environmental monitoring also helps catch contamination early so it can be dealt with quickly.

Improving Product Quality and Shelf Life

Clean environments lead to better-quality products. Contaminants can ruin a food’s taste, texture, or appearance, making it unappealing to customers. A clean processing space ensures products stay consistent and high quality. It also helps extend shelf life, since fewer microbes mean slower spoilage and less food waste.

Being Audit-Ready and Protecting Your Brand

Working with a professional service like EIDS Cleaning & Consulting in the Twin Cities helps keep your facility ready for audits at all times. This reduces the stress of inspections and lowers the risk of non-compliance. Expert cleaning services also help remove biofilm, a tough layer of bacteria that’s hard to get rid of with basic cleaning. With consistent sanitation, you protect your brand from recalls and health issues, build trust with customers, and avoid major financial losses.

When you add up these benefits, it’s clear that cleaning is more than a routine chore. It reduces waste, cuts downtime, prevents spoilage and recalls, and improves product quality. Over time, this creates stronger customer loyalty and a more competitive position in the market. It also helps you stay compliant and avoid fines or legal trouble.

What the Authorities Expect

Food manufacturing facilities in St. Paul, Minneapolis, and throughout the Twin Cities must follow strict rules about cleaning and sanitizing. These rules are in place to maintain food safety and prevent the spread of germs.

FDA Food Code Guidelines

The FDA Food Code outlines when and how to sanitize surfaces and tools that come into contact with food to prevent cross-contamination:

• General Food-Contact Surfaces: Must be cleaned and sanitized after handling raw foods and before working with ready-to-eat foods. This also applies between raw fruits/vegetables and foods that require time and temperature control (TCS). Surfaces must also be sanitized before using food thermometers, when contamination is likely, and before switching between types of raw animal products (unless the cooking temperatures increase in sequence).
• Temperature-Based Cleaning in Prep Areas:
  • 41°F or lower: Clean every 24 hours
  • 41–45°F: Clean every 20 hours
  • 45–50°F: Clean every 16 hours
  • 50–55°F: Clean every 10 hours
• TCS Food Contact Surfaces: Clean at least every 4 hours. Exceptions:
  • Storage containers: Clean when emptied
  • Serving containers (e.g., salad bars): Clean every 24 hours
  • Utensils stored in hot water: Clean every 24 hours or more often
• Non-TCS Surfaces: Clean when contaminated. Some items have set schedules:
  • Iced tea dispensers and self-serve utensils: Every 24 hours
  • Condiment dispensers: Before refilling
  • Enclosed equipment parts (like ice bins or nozzles): As often as needed or per manufacturer’s instructions
• Sanitizing Methods:
  • Hot water: Soak manually at 171°F for at least 30 seconds or use commercial machines with specific rinse temps
  • Chemical sanitizers (like chlorine, iodine, or quats): Must meet exact temperature, strength, and time requirements

USDA FSIS Guidelines for SSOPs

Facilities regulated by the USDA (handling meat, poultry, or eggs) must have written Sanitation Standard Operating Procedures (SSOPs). These must:

• List steps to prevent contamination before and during operations
• Assign responsibility to specific staff
• Be signed and dated by the onsite manager
• Be followed exactly as written and reviewed daily
• Be documented with daily logs, including any corrections or fixes

If contamination isn’t prevented, corrective actions must be taken. This includes cleaning, handling affected products properly, and preventing repeat issues. Records must be kept for 6 months and shown to FSIS within 24 hours if requested.

Minnesota-Specific Guidelines

In Minnesota, proper cleaning includes a three-step process: wash, rinse, sanitize - and always air-dry. Towels are not allowed, as they can spread germs.

Facilities must use either:

• A three-compartment sink for manual washing, or
• A dish machine that operates per manufacturer instructions

If using chemical sanitizers, follow label directions for strength and contact time. Always use a test kit to confirm the solution is effective. Common sanitizers include bleach, iodine, and quats. Sanitizer water in manual sinks must be changed at least every 4 hours or sooner if it’s overused or diluted.

The University of Minnesota Extension recommends five steps: dry cleaning, wet cleaning, rinsing, sanitizing, and drying.

Going Beyond the Minimum

The FDA and USDA set the baseline, but your facility may need more frequent or customized cleaning. Some equipment should be cleaned "as needed", which depends on how it’s used and your facility’s conditions.

For example, if your facility has high production, complex equipment, or higher humidity, you may need to clean more often than required. Food safety isn’t just about checking boxes. It’s about ongoing assessment, risk management, and doing what’s right for your unique operations.

The 4-hour rule for TCS surfaces is a good place to start but not always where you should stop.

The following table summarizes key regulatory sanitization frequencies for food contact surfaces:

Key Factors Influencing Your Sanitization Frequency

• Time: How long you clean depends on the method, the amount and type of dirt, and the equipment. For chemical sanitizers, longer contact time usually means better cleaning, but always stick to the manufacturer's limits to avoid problems.
• Action: This is the physical force used to remove dirt and germs. It can be scrubbing by hand, heat, machine force, or high-pressure water. The method and intensity must match the dirt and surface.
• Concentration: Using the right amount of sanitizer is crucial. Too little won't kill enough germs, making it useless. Too much can be toxic, damage equipment, leave bad smells or tastes, and is wasteful. Always use test kits to make sure sanitizer levels are correct throughout the day.
• Temperature: Temperature greatly affects how well cleaning chemicals and sanitizers work. Each product has an ideal temperature range. Chemical sanitizers generally work best between 55°F (13°C) and 120°F (49°C), but always check the manufacturer's advice. For example, chlorine doesn't work well above 115°F (46°C) and can release dangerous gas if used in hot water.
• Water Quality: The quality of your cleaning water is very important. Hard water, for instance, can make some cleaners and sanitizers less effective (like Quats). You should test your water for hardness to pick the right cleaning agents. Only use clean, drinkable water for rinsing and mixing solutions.
• Individual (Personnel): The skill and care of the person doing the cleaning are vital. They must be properly trained on every cleaning step, understanding not just how to do it, but why each task is important.
• Nature of Soil: The type of food you make determines the kind of dirt and residue (like fats, proteins, minerals, sugars). This directly affects which cleaning methods and chemicals you'll need to remove that specific dirt.
• Surface Material: The material of your equipment (like stainless steel, plastic, rubber) also affects which cleaning process and chemicals you choose. Some chemicals can damage certain surfaces or won't work on them.

Specific Sanitizer Considerations

Different chemical sanitizers have unique qualities that affect how and when you use them:

• Chlorine: This is the most common sanitizer in food factories. Its effectiveness depends on water clarity, concentration, contact time (two minutes is usually enough on clean surfaces), water temperature (best at 72°F/24°C; ineffective and potentially dangerous above 115°F/46°C due to chlorine gas), and pH (best at 6.5-7.0). Chlorine is unstable, so you need to make fresh solutions often (store for a maximum of 24 hours), and it doesn't mix well with most other chemicals, especially detergents.
• Iodine/Iodophors: These sanitizers kill a wide range of germs and are less affected by dirt and hard water than chlorine. However, they have a limited effective temperature range (75°F-93°F / 24°C-34°C) and work best at low pH (2.5-3.5). A downside is they can stain surfaces.
• Quaternary Ammonium Compounds (Quats): Unique because they keep working for a while, Quats are often used on surfaces that sit idle longer, like floors, walls, and drains. They don't corrode, are odorless, don't stain, and work on porous surfaces over a wide pH range. But they become less effective in hard water and don't mix with common detergents or chlorine sanitizers.
• Peroxyacetic Acid (PAA): PAA effectively kills many types of germs, even at lower temperatures (41°F-104°F / 5°C-40°C) and higher pH (up to 8.0). It breaks down into safe substances (vinegar, water, oxygen, carbon dioxide) and is often used for fresh-cut produce and after harvesting, especially where a lot of organic matter would make chlorine less effective. You usually don't need to rinse after using it.

Implementing an Effective Sanitization Schedule

The Essential 7-Step Cleaning and Sanitizing Process

This structured order is key to getting things truly clean before sanitizing can effectively reduce germs. Every step is important and none should be skipped:

1. Remove Debris (Dry Cleaning): Start by physically removing large dirt, food bits, and other residues from food contact surfaces using tools like lint-free cloths, scrapers, or brushes. This first dry cleaning step saves water and lowers the risk of spreading germs from water spray.
2. Rinse: Use warm, clean water (less than 120°F/48.9°C) to rinse equipment. Using hotter water could make dirt stick to surfaces. High-pressure hoses are generally not recommended to avoid spraying dirt and chemicals, which could recontaminate clean areas or damage equipment.
3. Apply Detergent: Apply chemical cleaners specifically made to remove fats and proteins. Make sure detergents are mixed correctly according to the manufacturer's instructions for dilution and contact times. Not knowing this information is a big food safety risk.
4. Give a Thorough Rinse: Before sanitizing, do a final rinse with clean water to completely remove all detergent and residue.
5. Take a Closer Look: Visually check the equipment for any visible residue or detergent and clean spots as needed, paying close attention to hard-to-reach areas. For commercial food equipment with food zones that can't be cleaned by hand, Clean-in-Place (CIP) procedures are used, where detergent, water, and sanitizing solutions are circulated mechanically through the equipment. CIP procedures must be approved by food safety experts and re-checked if any facility changes happen.
6. Sanitize or Disinfect: Apply an effective sanitizing or disinfecting chemical that is approved for use in food and beverage processing to safely reduce bacteria. Follow the manufacturer's instructions for applying the sanitizer, ensuring it's spread evenly and has enough contact time. Use test strips to confirm the correct sanitizer strength, store them cleanly, and change them regularly. After sanitizing, inspect the production line for cleanliness and record the whole process, including date, time, and test results, keeping records for at least one year.
7. Dry: If you used a sanitizer or disinfectant that needs rinsing off, remove it completely with a clean water rinse. Air drying is the best way to prevent re-contamination from wiping. For areas that must stay dry or can't air dry, use a leave-on sanitizer or disinfectant and follow its label directions for drying times.

SSOPs and Master Cleaning Schedules

Sanitation Standard Operating Procedures (SSOPs) and a Master Cleaning Schedule are the core documents for any strong cleaning program. SSOPs give detailed, step-by-step instructions for cleaning specific surfaces, equipment, or tools. They include how often to clean different areas (e.g., daily for production lines, weekly for storage) and who is responsible. The Master Cleaning Schedule is a clear, actionable plan showing how often each area and piece of equipment in your facility needs cleaning. It sets aside shifts or times for deep cleaning to avoid disrupting production and assigns special tasks.

Verification and Monitoring Systems

Regular checking and verification are vital to ensure you meet hygiene standards. This includes Environmental Monitoring Programs (EMPs) where you take samples from various surfaces to find germs like Listeria and Salmonella. ATP testing gives quick, real-time feedback on how much organic matter is left after cleaning. Regular visual inspections, often with a flashlight, are also essential to spot any visible dirt or detergent. Data from these tests should be recorded and analyzed to find ongoing issues and improve your procedures.

Comprehensive Employee Training

Employees are the first line of defense in a cleaning program, so proper and continuous training is essential. Training should cover personal hygiene (proper handwashing, protective clothing), safe chemical handling (understanding safety data sheets, correct mixing), and specific tasks for critical equipment. Training employees in different tasks is also good for flexibility. All employees, even if they don't directly clean, should understand why cleaning is important and how their actions affect keeping things clean.

The Role of Professional Cleaning and Consulting Services

For food manufacturing companies in St. Paul, Minneapolis, and the wider Twin Cities, partnering with professional cleaning and consulting services like EIDS Cleaning & Consulting can greatly improve your cleaning program. These experts provide:

• Customized Sanitation Programs: They create master cleaning schedules and custom-mix chemical cleaning solutions specifically for your facility's needs, product types, and environmental conditions.
• Audit Readiness Assurance: Professional services ensure your facilities are always ready for audits, consistently meeting the tough cleanliness and sanitation standards for inspections, which reduces stress and potential problems.
• Reduced Risk of Foodborne Illness: By using proven cleaning methods and effectively getting rid of biofilm they significantly lower the risk of bacteria that cause foodborne illness and outbreaks.
• Technical Support and Expertise: Companies get unmatched technical support, including auditing and consulting for food safety and quality programs, and help with cleaning problems. This expertise helps set up SSOPs, GMPs, provides multi-level customer training, and conducts yearly cleaning audits.
• Specialized Solutions: Professional services offer a full range of detergents, cleaners, and EPA-registered disinfectants and sanitizers, along with the "best available technology" for applying them, including advanced equipment and single-step cleaning solutions that can save time and labor.

How often should you sanitize high-touch equipment in your Twin Cities food plant? The answer isn’t one-size-fits-all. While guidelines from the FDA, USDA, and Minnesota Department of Health give helpful minimums, real food safety depends on your specific risks. These include the types of food you process, how often you produce, what equipment you use, and even the building’s temperature and humidity.

Meeting the minimum requirements isn’t always enough. To truly protect your business, staff, and customers, you need a smarter and more flexible approach.

Using the TACT WINS framework can help. This means considering Time, Action, Chemical concentration, Temperature, Water quality, the Individual doing the work, the Nature of the soil, and the Surface material. Each factor matters, and changing one can affect the others.

A strong cleaning program should include clear procedures (SSOPs), regular testing like sanitizer checks, and solid employee training. When done well, cleaning becomes more than a task, it becomes a valuable investment. It prevents outbreaks, product recalls, and costly downtime, while also improving product quality and shelf life.

For food manufacturers in the Twin Cities, partnering with experts like EIDS Cleaning & Consulting provides the customized support and solutions needed to stay ahead of risks and be ready for audits.