Chemical Control

Chemical Usage Requirements

All pesticides, sanitisers, cleaners, polishes, lubricants, and other toxic and non-toxic chemicals used in the food business must be:

• Necessary for the operation of the establishment. Unnecessary chemicals should not be found anywhere in the establishment;
• Used properly according to the manufacturers’ label and SDS instructions;
• Properly labelled when chemicals are removed from the original container and put into a working container. Food containers should not be used as working containers for chemicals;
• Considered against the legal requirements for chemical handling and use. The use of some chemicals must only be conducted by specially licensed persons. Legal requirements also commonly include requirements for PPE to be worn.

Chemical Approvals

Food business chemicals must be approved for use in the food establishment. Some products, such as food-grade lubricants, may contain statements by the manufacturer as being approved for use within the food industry or a specific industry sector. Before use within a food business, a confirmation must be received that chemical products are approved for a specific use, and will not potentially contaminate foods. Pesticides and other regulated chemicals must only be applied by persons licensed or certified under local regulatory requirements. Regulatory approvals may also be required for the use of some chemicals within food businesses.

Food Grade Chemical Confirmation

Where a chemical may come into contact with food, food contact surfaces, or packaging, the supplier should confirm in writing that it is suitable for that use. This commonly applies to lubricants, cleaning and sanitising chemicals used on food contact surfaces, and processing aids.

Food grade confirmation should be received before the chemical is first used, kept with the Safety Data Sheet, and recorded on the approved chemical listing. Confirmation should be reviewed when the chemical, its formulation, or its supplier changes.

Safety Data Sheets (SDS)

A current Safety Data Sheet should be held for every chemical used within a food business. Safety Data Sheets are commonly supplied by the chemical manufacturer or supplier and describe the hazards, safe handling, storage, first aid, spill response, and disposal requirements for each chemical.

Safety Data Sheets should be:

• Checked against the approved chemical listing and chemical inventory listing;
• Readily available to team members who handle or use the chemical;
• Reviewed for currency on a scheduled basis and replaced when the supplier issues a revised version;
• Used as the source for first aid, spill response, and PPE requirements within chemical usage procedures.

Chemical Decanting and Labelling

Decanting is the transfer of a chemical from its original container into a working container. Where chemicals are decanted, diluted, or mixed, the working container should be fit for purpose, clean, and clearly labelled so that it cannot be mistaken for another product.

Labels on working containers should generally include:

• The product name;
• The main hazards and any required PPE;
• The dilution ratio or intended use where applicable;
• The date prepared, where the mixture has a limited useful life.

Food and drink containers must never be used as working containers for chemicals. Decanting should follow the directions on the Safety Data Sheet and the manufacturer’s label.

Chemical Storage, Segregation and Security

Chemicals used within food businesses must be properly stored and segregated. Insecticides and rodenticides must be stored separately from cleaning compounds and other chemicals. All chemicals and pesticides must be stored separately from food, food contact surfaces, and single-use and single-service articles. In this context, the term separate does not include storage of toxic chemicals above food, food contact surfaces, single-use articles, or single-service articles.

The storage of chemicals must also meet local regulatory and environmental protection requirements.

Where necessary, adequate facilities for the storage and handling of food, ingredients, and non-food chemicals, including cleaning chemicals, pest control chemicals, lubricants, and other maintenance chemicals, must be provided.

Where appropriate, food storage and handling facilities should be designed and constructed to:

• Permit adequate maintenance and cleaning;
• Avoid pest access and harbourage;
• Enable food to be effectively protected from contamination during storage and handling;
• Where necessary, provide an environment that minimises the deterioration of food through controls including temperature and humidity.

The type of facilities required will depend on the nature of the food items being stored and handled by a food business. Where necessary, segregated and secure storage facilities should be provided for cleaning chemicals, pest control chemicals, lubricants, and other maintenance chemicals. Storage facilities for ingredients, packaging, and other materials should also be appropriately secured and adequately ventilated. Further guidance is available within Storage and Handling Requirements.

Chemical Dosing Units

Chemical dosing units are commonly fitted to ensure the appropriate dilution of chemicals with water and other liquids where required. Where chemical dosing units are fitted, they must be regularly calibrated to ensure their accuracy. The calibration of chemical dosing units should be scheduled and documented, just as the calibration of items such as thermometers or scales. See Calibration of Measuring and Testing Equipment for further guidance.

Chemical suppliers commonly manage this function within food businesses, often using titration methods to show that the output from the dosing unit contains the chemical at the correct concentration. Outcomes of calibration activities should be recorded and reviewed on an ongoing basis to reconfirm the avoidance of product contamination.

Chemical Handling and Usage Training

Specific chemical training is a standard requirement for persons involved with the use of chemicals within food businesses. Chemical training should be tailored to the specific requirements of the chemicals being used, to ensure that foods do not become contaminated by such usage.

Chemical handling and usage training should be completed before persons are left unsupervised to use chemicals within a food business. Competency against chemical handling and usage training requirements should also be verified before unsupervised use. See Training, Competency and Resources Requirements for further guidance.

Specific chemical handling and usage training should be developed, scheduled, conducted, and recorded to demonstrate compliance for functional chemicals used as food additives or processing aids. The use of such chemicals should be well controlled. It is common for chemicals such as nitrites and sulphites to be stored in secure areas and be accessible only to authorised persons, so that accidental or intentional misuse is unlikely to occur.

Chemical Inventory Listings

It is common for food businesses to develop, document, implement and maintain chemical inventory listings to track the usage and location of chemicals within the business. This activity not only provides evidence of appropriate chemical usage but also assists in controlling the costs of purchasing chemicals. An added benefit is the ability to confirm chemicals received against the chemical inventory listing, to ensure the chemical has not changed from its original specification and active ingredients.

Chemical inventory listings commonly include the following details:

• Chemical Supplier;
• Chemical Name;
• Chemical Unit Size;
• Date Received;
• Batch or Lot Number;
• Active Ingredients;
• Nominated Dilution Ratio;
• Intended Dilution Ratio;
• Currency of SDS;
• Date Use Started;
• Date Use Finished.

Detergents

Detergents are used to remove dirt particles. They are not designed to kill microorganisms, although their pH levels can affect microbial growth and survival. Detergents are chemicals that usually contain a surfactant, which makes the removal of dirt from surfaces easier. The most appropriate time to clean surfaces with detergents in solution, or as recommended, is immediately after use. This removes food particles before they harden and become more difficult to remove, and before they support microbial growth. The strength of a detergent regarding its cleaning power is reflected in its alkalinity. The use of hot water as a component of cleaning and sanitising routines, where appropriate, can dramatically improve the capability of the system to control microorganisms. See Cleaning and Sanitation for further guidance.

Sanitisers

Sanitisers are generally not good at removing dirt but do kill microorganisms if used according to the conditions of use. The majority of food poisoning bacteria are killed if they are exposed to heat, chemical sanitisers, or a combination of both. Sodium hypochlorite (chlorine bleach) is one of the most commonly used chemical sanitisers in the food industry today. Commercial bleach typically contains around 10% available chlorine, while the domestic variety is commonly around 4%. High-risk areas to be sanitised should use a solution at a concentration of up to 100 parts per million of available chlorine. Other areas and applications may require a solution of around 50 parts per million. Concentrations should always follow the supplier’s directions and your validated cleaning and sanitation procedures.

Choosing a Detergent or Sanitiser

Chemical sanitising generally requires greater controls than sanitising with hot water or steam. The following factors must be considered to obtain effective sanitation by chemical methods:

• Amount of water used;
• pH of the water: The pH and hardness of the water being used must be determined. Should the water supply be from a municipal supply, the water supplier may adjust the hardness of the water through processing controls. If the water is from other sources, it may need to be tested periodically to ensure ongoing appropriate outcomes;
• Temperature of the water;
• Contact time;
• The concentration or dilution rates: Cleaners and sanitisers should be supplied with a Safety Data Sheet or SDS. This sheet, along with the directions for use on the supplied container or accompanying documentation, will outline the requirements for using the product for its maximum benefit in the cleaning and sanitation process;
• Exposure time: Detergents and sanitisers need to be exposed to surfaces for long enough to be effective. Exposure times can also be found on the documentation accompanying the product.

The factors that determine the performance of a particular detergent or sanitiser include:

• The type of substance that is to be removed, as different types of detergents are more adept at removing specific substances. Fats, sugars, and proteins are the three main types of substances that detergents are developed to remove. Dirt reduces a sanitiser’s ability to kill microorganisms because the microorganisms can shelter in and beneath dirt where they are difficult to reach;
• The water temperature used in conjunction with the detergent or sanitiser: Most detergents and sanitisers are designed to work at their best in either hot or cold water. Using a product as per the manufacturer’s directions will produce the best outcomes in cleaning and sanitising.

Obtaining Correct Chemical Sanitising Ratios

When not using an automated chemical dosing system, chemical sanitiser instructions call for a given amount of chemical sanitiser per litre of water. This ratio of chemical sanitiser to water is important to ensure ongoing appropriate outcomes for the sanitation process.

If manual chemical sanitiser measuring and mixing methods are used, the processes involved must follow procedure and be verified on an ongoing basis.

Staff involved in applications where they are required to manually measure and mix chemicals must be trained and deemed competent in the required tasks.

If your food business supplies foodstuffs manufactured to a customer’s specifications, consider any specific Chemical Control Development requirements in relation to their items.