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1. Ensuring efficient cleaning processes which reduce the need for labor intensive re cleaning while minimizing the amount of expensive sanitation chemicals needed to properly sanitize equipment Providing rapid results on site allowing for immediate corrective action that can prevent expensive product recalls and delayed production Reducing the required amount of environmental monitoring lab costs and labor expenses Provides brand protection by Increasing product quality and shelf life Preventing food borne illness and health violations that can compromise the brand image Demonstrating to clients and auditors that food safety is a priority 1 5 Other applicable uses for the SystemSURE Plus ATP Detection System In addition to routine ATP hygiene monitoring there are also other useful applications for the SystemSURE Plus ATP Detection System Troubleshooting ATP testing with your SystemSURE Plus provides a way to expose microbial contamination and other issues that might be causing higher than normal plate counts in environmental testing It may also be useful in determining the factors affecting end product screening results such as product inconsistency or spoilage Randomized testing The SystemSURE Plus system can be used to audit cleaning efficacy by doing random spot checks of designated testing locations A large number of test locations are set up Of these locations a select number are tested daily or weekl
2. d Pass forany RLU reading that is less than or equal to the Pass limit A pass result indicates the surface is clean Caution for any RLU reading that is greater than the Pass limit but less than the Fail limit A caution result indicates the surface may not have been adequately cleaned x Fail for any RLU reading that is equal to or greater than the Fail limit A fail result indicates the surface is dirty or contaminated For information on what steps should be taken after obtaining Pass Caution or Fail results see Corrective action procedures in section 2 5 19 2 4 When to perform ATP testing Once control points have been established and ATP threshold levels have been set you should develop a sampling frequency plan Sampling frequency should be based on the level of contamination risk associated with the control point being tested Factors determining the level of risk include surface robustness and susceptibility to contamination degree of difficulty to clean frequency of contact with product for food processors number of types of food being processed on a machine which increases the potential for cross contamination and allergens Critical high risk control points should be tested on a daily basis after each cleaning You may also choose to test after product line changes after daily employee shift changes and or any time prior to start up Lower risk control points may not need to be tes
3. Calibration Control Rod Kit results are consistently outside of the recommended range There may be a problem with your luminometer Contact your Hygiena distributor or Hygiena s Head Office see Contact Hygiena section 3 5 Positive Control Kit results are consistently outside of the recommended range There may be a problem with your swab devices or the luminometer Contact your Hygiena distributor or Hygiena s Head Office see Contact Hygiena section 3 5 ATP test results are inconsistent There is a large discrepancy between readings at the same location Review cleaning and testing procedures Some factors affecting consistency of results include poor or inconsistent adherence to standard cleaning procedures faulty detergent concentration or inconsistent sampling technique 24 3 2 Glossary ATP adenosine triphosphate ATP is a chemical compound used by all living organisms to fuel metabolic processes such as muscle function and reproduction ATP is found in living organisms including bacteria and other microorganisms as well as once living material such as food Detection of ATP on a surface indicates the presence of either microbial contamination or food residue that has the potential to support microbe growth Bioluminescence Bioluminescence is a chemical reaction that produces light when ATP comes into contact with the enzyme luciferase The Ultrasnap Sample Testing
4. ATP hygiene monitoring and are based on plate count and ATP correlation studies They may or may not suit the standards at every facility To determine independent ATP thresholds follow the Routine Cleaning or Vigorous Cleaning options described above a Easy to clean surfaces SystemSURE Plus Easy to Clean Surfaces General Thresholds Pass Caution Fail RLU lt 10 11 19 gt 20 PASS Less than 10 RLU CAUTION Between 11 and 19 RLU FAIL Greater than 20 RLU b Hard to clean surfaces SystemSURE Plus Hard to Clean Surfaces General Thresholds Pass Caution Fail RLU lt 10 11 29 gt 30 PASS Less than 10 RLU CAUTION Between 11 and 29 RLU FAIL Greater than 30 RLU 18 2 3 3 Storing and viewing threshold data Once threshold levels are established they can be programmed into DataSure II and then uploaded from the software to the SystemSURE Plus luminometer For information on how to do this see Managing and tracking your data with DataSURE II Software in section 2 5 Threshold data can also be manually entered into the luminometer consult your SystemSURE Plus User Manual for details Once thresholds have been entered into the luminometer upper 1 and lower 4 threshold limits are displayed numerically on the screen for each PROG location After completing an ATP test Pass Caution Fail results will display on the SystemSURE Plus luminometer as follows
5. ATP testing 2 2 1 Establishing your facility s test locations control points Before sample tests are taken you need to identify areas within your facility that are at risk for contamination from product residue or microbe growth These areas should be designated as control points in your hygiene monitoring plan A control point should provide reliable feedback on the cleanliness of a particular piece of equipment or area during testing It s important that ATP testing is routinely performed on all control points including product contact areas direct and indirect and hard to clean sites on your processing and handling lines Ifyou currently have HACCP or SSOP programs in place or if you conduct environmental testing you may choose to use the same test locations established for these programs as your control points for ATP monitoring Ifyou haven t previously established test locations you need to determine where your facility s areas of contamination risk are This can be done by swabbing multiple areas on equipment and production line surfaces after routine cleaning ATP levels will be higher in those spots that are harder to clean spots that are missed in your current cleaning procedure and spots that have developed biofilms These areas should be established as control points for routine testing and monitoring 2 2 2 Types of contact areas Your ATP testing plan should include the following locations a Direct
6. Of contact areas aise cwisesstiseniedseesnteresdewsnddeetivaass eeeeteeane 12 2 2 3 Diagram of typical production floor control poimts eee 14 2 2 4 Monitoring individual control points eee eeeeeeeee eee eeeeeeeeeeeeeeeeees 15 2 3 Determining ATP threshold levels for your facility secceeeseesseees 16 2 3 1 Options for setting up ATP threshold levels nnnnnaosnnnnnnneeeeaenne 16 2 3 2 General Pass Caution Fail levels EE 18 2 3 3 Storing and viewing threshold data ccecceeeeeeeeeeteeeeeeeeeeeeeee 19 2 4 When to perform ATP testing cssseeeeeeeeenseeseeeeeeeeeeeeseeeeeeneeeeeeeeeeennenees 20 ii 2 5 Corrective action procedures c ssecccceseseeeceeseeeeeeeeeseeeeeesseeneeeesseeeeeesees 21 2 4 Continuous improvement rertrtrnnnnnn nn nn nn nn 23 SECTION 3 Further helbiiit asisuu son rak 24 GO e e elt BE 24 3 2 GOS SONY cna ssp O DD Peara sc PEA aaee E SPEKTA Nai ERNE AEM ASEAK ESE EaR TTE 25 3 3 Appendix A Typical ATP threshold guidelines nsnnnsnnnnnnnnnnnnnnnnnnn 26 3 4 Other Hygiena products cessecccceeeseeeeeeeeeeeeeneeeeeeeeseeeeeeeessseeeeeeeseneneeeees 27 3 5 Contact e e UE EE 28 bp Egger ee Ee 28 Hygiena Jeer aiecccceev ees asda rio nade tos et tenet ae EES EE gege Spades 28 Hygiena web site interactive demos 2 ccccceeeeeseseeeceeeeeeeeeneeeeeeeeees 28 111 QUICK START GUIDE Sampling Procedure using the Syst
7. To determine the Pass limit Calculate the average RLU for each location based on the 5 10 test results To do this add all test results then divide the sum by the number of tests taken The resulting number is your average RLU This number is your Pass limit 5 To determine the Fail limit Multiply the Pass limit by 3 The resulting number is your Fail limit 6 To determine the Caution limit The area between the Pass and Fail thresholds is the Caution zone NOTE In some cases test results from individual control points within a facility or specific area are consistently within a similar range of each other In this case the user may choose to apply a single Pass Caution Fail standard to all control points within that area or facility 16 b Vigorous Cleaning 1 2 Identify control points in your facility Clean all surfaces thoroughly 2 or more times to achieve the maximum level of cleanliness possible This may include a total production line disassembly Conduct an ATP test at each location Take 5 10 replicate tests at each location over the course of several days To determine the Pass limit Calculate the average RLU for each location based on the 5 10 test results This average RLU is considered to be the Pass level To determine the Fail limit Multiply the Pass limit by 2 for easy to clean areas and by 3 for harder to clean areas To determine the Caution limit The area between the Pass and Fail
8. and when to test control points set Pass Caution Fail thresholds follow corrective action procedures upload results to the DataSure II database for storage and analysis 2 1 Proper sampling procedure Before collecting a sample for testing the surface should be visibly clean If any soiling or residue is apparent re clean the work area before testing 2 1 1 Collecting samples with the Ultrasnap device 1 Remove the Ultrasnap device from the package Next remove the outer tube by holding onto the double ring base of the Snap Valve while pulling down on the tube The swab tip comes pre moistened with a detergent that breaks down biofilm on the test surface Condensation may be visible on the inside of the swab tube This is normal Do not touch the swab tip or shaft with fingers or anything else as this will contaminate the test Discard any swabs that accidentally get tainted or activated NOTE For optimal performance swabs that have been removed from cold storage should stand for 10 minutes at room temperature before use 2 Collect a sample with the Ultrasnap device using the guidelines below Be careful not to overload the swab bud with too much sample The Ultrasnap device is designed to detect trace amounts of contamination therefore no sample residue should be visible on the swab An excessive amount of sample may interfere with the bioluminescence reaction and produce an inaccurate test result For a definition of
9. biofilm please see the Glossary section of this guide a Regular surfaces Swab a 10 x 10 cm 4 x 4 in square on the test surface Rotate the swab as the sample is collected while applying firm pressure to break through any biofilm This will create a slight bend in the swab shaft b Irregular surfaces Where 10 x 10 cm square sampling is not feasible swab as much of the surface as possible Be sure that a slight bend in the shaft is achieved and an adequate sample is collected c Water sampling Dip the swab for 5 to 10 seconds into a 20 mL sample of the water being tested If the water is not homogenous or contains sediment mix it thoroughly before sampling NOTE Ultrasnap swabs are designed primarily for surfaces but can be used for some types of water samples Contact a Hygiena representative to find out if water testing with Ultrasnap is applicable for you A more sensitive water testing device is also available Contact Hygiena for more information Re insert the swab into the tube Ultrasnap is now ready to be activated or it can be left inactive for up to 4 hours in this state In some facilities users prefer to sample each location write the sample location on the swab tube and run all tests in a laboratory rather then at the test location or they may choose to run each test right after collecting their sample If testing occurs at the sampling location turn on the SystemSURE Plus luminometer and
10. contact areas Direct contact areas are surfaces where the presence of any contaminant will taint the product These are high risk areas that should be tested frequently Examples conveyor belt wash bucket cutting board slicers and utensils A direct contact surface such as a conveyor belt should be _ Swab Arees tested in a few different places to verify total cleanliness Conveyor Belt 12 b Indirect contact areas Indirect contact areas are locations where splashed product or contaminants can be dropped drained or transferred onto the product These areas are often overlooked as sources of contamination and should be routinely tested Examples sink drain side walls and additional machine parts Swab Areas Indicated areas of the sink are examples of indirect contact points where ATP testing should be conducted Sink c Hard to clean contact areas Hard to clean areas have a high potential to harbor bacterial growth and should be tested regularly Examples hoses O rings nozzles areas with irregularly shaped surfaces corners grooves cracks and joints Swab Areas The suggested sampling technique for a hose nozzle is to swab around the outer nozzle threads twice and then swab around the inside lip once Apply firm pressure while swabbing 13 2 2 3 Diagram of typical production floor control points Below is an example of a typical food processor s production floor plan Direct contact
11. scroll through the program numbers PROG to find the one that correlates to the location being tested This action can also be taken prior to swabbing This is up to the user For more information see Establishing your facility s test locations section 2 2 1 Surface Swab Areas E a 4 Holding the device upright activate the Ultrasnap by bending the bulb at the top until the plastic Snap Valve breaks then bend once more in the opposite direction Squeeze the bulb twice to expel the liquid stable reagent contained in the bulb and allow it to flow to the bottom of the tube 5 Gently shake the device with a side to side motion bathing the swab bud in the liquid stable reagent The test is now activated and the bioluminescence reaction is taking place For optimal results the reading should be taken on the SystemSURE Plus luminometer within 5 to 60 seconds of activation 2 1 2 Measuring ATP with the SystemSURE Plus luminomete 1 Open the lid on the SystemSURE Plus luminometer and insert the activated Ultrasnap device into the reading chamber Close the lid making sure to keep the machine upright 2 Press OK on the SystemSURE Plus to initiate measurement of RLU output Results are displayed on the screen in 15 seconds 2 1 3 General precautions and warnings If the Ultrasnap device accidentally gets activated do not use Avoid collecting large amounts of sample on the swab bud Hold the Syste
12. thresholds is the Caution zone The following table uses example data to illustrate average RLU and Pass Caution Fail thresholds Test i02 03l 4 5l 61748 9 140 EL Pass Caution Fail Routine ig 15 8 19 10 13 17 4 15 11 13 2 13 14 35 36 cleaning Vigorous cleaning 4 3 0 2 1 103 la lol 14 2 1 2 3 4 easy to clean Vigorous cleaning 6 3 8 4 7 5 8 4 5 4 5 4 5 6 14 15 hard to clean NOTE Different surfaces have different levels of risk and therefore may reguire different thresholds For example porous plastic or rubber surfaces may be more difficult to clean than stainless steel surfaces and therefore produce higher ATP test results In this case the user may choose to 1 set thresholds higher for those harder to clean areas or 2 intensify cleaning to bring ATP test results on those surfaces in line with other control points This is up to the user NOTE The Caution zone is useful for trend analysis and providing early warnings However users may opt to forgo the Caution zone and set the Fail limit 1 RLU more than the Pass limit Any result over the Pass limit is then considered a failed result 17 2 3 2 General Pass Caution Fail levels For facilities that opt not to set their own ATP thresholds Hygiena offers two general guidelines for threshold levels based on the type of surface being tested These are common levels used for
13. Bi ge A Guide To AIP Hygiene Monitoring SS 7 hygiena TABLE OF CONTENTS QUICK START GUID EN V Flow chart Cleaning Testing and Corrective Action Procedures V INTRODUCTION WE 1 The SystemSURE Plus ATP Detection Program rrerrrnnnnnnnnnnnnnnnnnnenn 1 Components of the SystemSURE Plus ATP Detection System 000 2 Overview of this guldes i 2 202 220501001 nail inna 2 SECTION 1 An overview of the SystemSURE Plus ATP Detection Program 4 Aes Eege ege ees 4 1 2 Measuring ATP with bioluminescence technology eeeeeeeeeeeeseen 4 1 3 Interpreting results on the SystemSURE Plus luminometer 5 1 4 Benefits of routine ATP testing 0 20 cece ee eeeennnneeeeeeeeeeeeeneneeeeeeeees 5 1 5 Other applicable uses for the SystemSURE Plus ATP Re Re EE 6 SECTION 2 Using your SystemSURE Plus ATP Detection System 7 2 1 Proper sampling procedure cicisiisciscsees ce ecdiisiindsentiwcneisicecnsenceecdcededidendeansnaies 7 2 1 1 Collecting samples with the Ultrasnap device oooonononnnnnn 7 2 1 2 Measuring ATP with the SystemSURE Plus luminometer 9 2 1 3 General precautions and wammimngs nn 10 2 1 4 Ensuring correct results with calibration controls reeee 11 2 2 Where to do ATP Teen zeugiekueeceugeERKN ENER kona 12 2 2 1 Establishing your facility s test locations control points 12 2 2 2 Types
14. Device uses bioluminescent technology combining ATP with luciferase to produce a light output that can be detected and measured by the SystemSURE Plus luminometer Light output during the Ultrasnap reaction is directly proportional to the amount of ATP on the sample RLU Relative Light Units RLU is the unit of measurement for light output during a bioluminescent reaction The SystemSURE Plus luminometer expresses ATP test results in RLU RLU numbers are directly proportional to the amount of ATP on the test sample therefore a high RLU indicates a large amount of ATP present which in turn indicates a high degree of contamination Low RLU indicates low levels of ATP and low level of contamination Biofilm Biofilms occur when microorganisms work together as a population and secrete a sticky polymer to form a solid matrix attached to a surface Once a biofilm is established it is very difficult to eliminate Biofilms can cause poor product quality and or lost product due to contamination HACCP Hazard Analysis and Critical Control Points HACCP is a widely accepted systematic approach to the identification evaluation and control of significant food safety hazards in the food manufacturing and processing industries SSOP Sanitation Standard Operating Procedures Sanitation procedures in food production plants They are considered a basic requirement in a HACCP program Control Points CP Control points are direct and indirect contact are
15. adequately cleaned You may choose to proceed to sanitizing or re clean and re test A control point with a Caution reading should be noted and monitored for future problems Caution The control point surface is dirty or contaminated and must be cleaned again and re tested until a Pass or x Fail Caution level is achieved A control point with a Fail reading should be noted and monitored for future problems According to the needs of the facility the user has the option of setting up a more extensive corrective action plan For example it may be decided that control points which produce Fail results should be re tested until 3 consecutive days of Pass results are achieved If the control point does not successfully achieve 3 consecutive days of Pass results cleaning procedures or thresholds are required to be re evaluated A flow chart on the next page illustrates general recommended cleaning and corrective action procedures 21 Flow Chart Suggested Cleaning Test and Correction Action Procedures Check detergent concentration is within specification Proceed with cleaning Control Points CP u Pan tn Perform rapid ATP hygiene confirmation Sanitizing routine 22 2 4 Continuous improvement The SystemSURE Plus ATP Detection Program is designed to aid organizations striving for continuous improvement of standards Continuous improvement ensures excellence in product quality whi
16. as where potential contamination hazards can be identified controlled and monitored 25 3 3 Appendix A Typical ATP threshold guidelines The following guidelines are typical of those found in the food and beverage sectors and are based on stainless steel surfaces Other surfaces may be more difficult to clean and consequently may require a higher Pass Fail level to be set These guidelines represent those typically used in the sectors listed These should only be used for guidance in establishing Pass Caution and Fail thresholds for similar surfaces and products High Risk Product Surfaces CIP Clean In Place systems PRODUCTION PASS CAUTION FAIL ENVIRONMENTS resi cream products SS 19529 SS Juice products lt 15 16 29 gt 30 Water bottling lt 15 16 29 gt 30 Shine ERA lt 15 16 29 gt 30 Sta lt 5 6 9 gt 10 Typical Product Surfaces PRODUCTION PASS CAUTION FAIL ENVIRONMENTS Raw meat Abattoirs lt 100 101 199 gt 200 Butchery lt 50 51 99 gt 100 Cooked meat products Meats amp all product w meat Low risk lt 50 51 99 gt 100 High risk lt 25 26 49 gt 50 Fish products lt 30 31 59 gt 60 Shellfish lt 100 101 199 gt 200 Cheese processing lt 25 26 49 gt 50 General food processors Low risk lt 30 31 49 gt 50 High risk lt 10 11 29 gt 30 Vegetable processing Low risk lt 50 51 74 gt 75 Hig
17. ater samples A key feature of the SystemSURE Plus ATP Detection System is its use of bioluminescence technology to identify and measure adenosine triphosphate commonly known as ATP 1 1 What is ATP ATP is an energy molecule found in all plant animal and microbial cells It fuels metabolic processes such as cellular reproduction muscle contraction plant photosynthesis respiration in fungi and fermentation in yeast All organic matter living or once living contains ATP including food bacteria mold and other microorganisms The detection of ATP on a surface therefore indicates the presence of biological matter that may not otherwise be visible to the eye In industries where hygiene control is crucial ATP testing is an excellent tool for detecting and measuring biological matter on surfaces and in water Hygiena s SystemSURE Plus ATP Detection System uses ATP bioluminescence technology to measure extremely low levels of organic residue 1 2 Measuring ATP with bioluminescence technology The Ultrasnap ATP Sample Testing Device contains a natural enzyme found in fireflies This enzyme called luciferase produces a simple bioluminescence light producing reaction when it comes into contact with ATP Using bioluminescence technology the SystemSURE Plus luminometer can measure extremely low levels of ATP collected with the Ultrasnap device Measuring the amount of bioluminescence from an ATP reaction provides a good indication of s
18. emSURE Plus ATP Detection System 1 Identify the location to be tested and turn on the SystemSURE Plus luminometer Remove the Ultrasnap swab from the outer tube Pressing firmly down on the swab tip collect a sample from a 10 x 10 cm 4 x 4 in area Use a side to side and up and down motion while rotating the swab tip 2 Place the swab back into the swab tube The Ultrasnap device is now ready to be activated or can be left inactive for up to 4 hours in this state 3 To activate break the plastic valve at the top of the device by bending backward and forward Squeeze the bulb twice to expel the liquid in the bulb to the bottom of the tube 4 Bathe the swab bud in the liquid by shaking gently in a side to side motion for 5 seconds 5 Place the entire swab device into the SystemSURE Plus luminometer and close the lid This step must be done within one minute of activation iv 6 Holding the SystemSURE Plus luminometer in a vertical position press OK to initiate reading The test result will appear on the screen in 15 seconds Flow chart Cleaning Testing and Corrective Action Procedures Perform rapid ATP hygiene confirmation Check detergent concentration is within specification Proceed with cleaning Control Points CP Standard cleaning routine Post cleaning visual examination Sanitizing routine Re clean surface vi INTRODUCTION The SystemSURE Plus ATP Detection Pr
19. ers with location for easy reference during sampling This legend can be attached to the key ring holder on the luminometer 15 2 3 Determining ATP threshold levels for your facility Setting correct Pass Caution and Fail levels is a fundamental part of running a successful ATP hygiene monitoring program These threshold levels may vary depending on the type of product being manufactured or processed as well as the surface or liquid being checked However the formulas used to determine Pass Caution and Fail levels are always the same There are two different standards by which to set up Pass Fail levels Routine Cleaning and Vigorous Cleaning The Vigorous Cleaning setup option is used by facilities requiring extremely high hygiene standards and or which have easy to clean surfaces Both methods produce similar results with slight variation Hygiena also provides general recommended threshold levels which meet most manufacturers hygiene standards Examples of some typical threshold guidelines specific to the food and beverage industry can also be found in Typical ATP threshold guidelines in Appendix A 2 3 1 Options for setting up ATP threshold levels a Routine Cleaning 1 Identify control points in your facility 2 Clean product surfaces to the level that daily sanitation programs should achieve 3 Conduct an ATP test at each location Take 5 10 replicate tests at each location over the course of several days 4
20. h risk lt 10 11 29 gt 30 Baked products Low risk lt 30 31 49 gt 50 High risk lt 10 11 29 gt 30 For recommended thresholds in other environments such as food service hospitality government education pharmaceutical and healthcare contact Hygiena 26 3 4 Other Hygiena products SnapShot A universal ATP swab designed for luminometers from other manufacturers No need to change threshold settings on the luminometer being used Made with a unique liquid stable reagent to yield more accurate and consistent results Aquasnap A user friendly self contained ATP water sampling device used with the SystemSURE Plus and Pi 102 luminometers Pi 102 An affordable multifunctional luminometer using traditional photo multiplier tube technology For use with cuvettes or all in one reagent devices such as Ultrasnap or Snapshot Suitable for bioluminescence and chemiluminescence assays Biomass Control Kit An easy to use system for real time monitoring of water quality and product contamination Comes with sample tubes that can be read in the Pi 102 SpotCheck A surface hygiene swab that detects glucose when food residue is present Requires no instrumentation The self contained reagent turns from clear to green SpotCheck Plus SpotCheck Plus detects lactose and glucose residue in under 60 seconds Presence of either substance is indicated by a color change of a self contained reagent Requires no instru
21. ing correctly Each kit contains a Positive rod and a Negative rod The Positive rod emits a very low level of radiation producing a constant light output that can be measured in RLUs to verify proper calibration of the unit The Negative Rod produces low light or zero 0 RLU and is used to check that background light is not entering the instrument while ensuring that the light detector is calibrating correctly For instructions on how to use the Calibration Control Rod Kit as well as how to interpret results consult the product insert Positive Control Kit Part CK25 The Positive Control Kit is used for validating the efficacy and quality of the Ultrasnap ATP Sample Testing Device It comes with 25 sealed glass vials each of which contain an identical amount approx 5 x 10 moles of freeze dried ATP and sugars to provide a predictable result if Ultrasnap devices are used and stored correctly Each vial provides a sample which produces a positive result when tested with the Ultrasnap Positive Controls should be used to test one device in each bag of 25 devices or whenever there is concern about the product s storage temperature or shelf life Incorporating the Positive Control Kit into the overall Quality Control program will validate results of the SystemSURE Plus and the Ultrasnap For instructions on how to use the Positive Control Kit as well as how to interpret results consult the product insert 11 2 2 Where to do
22. l Included with it is a flow chart that illustrates the basic steps involved in cleaning testing and corrective action procedures Section I An overview of the SystemSURE Plus ATP Detection Program This section discusses what ATP is how it s used in rapid hygiene bioluminescence testing as well as the benefits of an ATP monitoring program and other applicable uses for the SystemSURE Plus System Section II Using your SystemSURE Plus ATP Detection System This section provides step by step practical instructions for how to use the SystemSURE Plus ATP Detection System as part of your hygiene monitoring program It includes information on how to properly collect and test samples where and when to do ATP testing determining Pass Fail levels taking corrective action and using the DataSURE II software package to manage and track test results over time Section III Further help Section III offers Troubleshooting information a Glossary of Terms useful Appendices as well as information on how to contact Hygiena SECTION 1 An overview of the SystemSURE Plus ATP Detection Program The SystemSURE Plus ATP Detection Program is a rapid hygiene monitoring program designed to help organizations achieve optimal hygiene status within their facilities The Program combines the three part SystemSURE Plus ATP Detection System with a comprehensive monitoring plan to test record and track biological contamination on production surfaces and in w
23. le reducing inefficiencies avoiding recalls and showing due diligence and compliance to auditors Analysis of ATP test result trends is key to the evaluation and ongoing improvement of the sanitation system in place Using the DataSURE II Data Analysis software you can monitor and assess ATP test results perform trend analysis identify trouble zones correct improper cleaning procedures and eliminate risk If trends show high numbers of Caution and Fail results in ATP testing SSOPs should be reviewed by experts for ways to improve protocols If low numbers of Caution and Fail results are obtained Pass Fail thresholds should be reviewed and lowered to maintain high standards and ensure continuous improvement Pass Caution and Fail thresholds should also be re evaluated every year and whenever procedural changes are made As sanitation procedures become more efficient and effective thresholds should be adjusted to ensure your facility is operating to its maximum potential 23 SECTION 3 Further help 3 1 Troubleshooting Problem Solution You are ready to insert the activated Ultrasnap device into the luminometer but the screen on the luminometer says CAL with numbers counting down The SystemSURE Plus luminometer automatically performs a 60 second self calibration CAL upon startup Always be sure to turn the luminometer on and wait for self calibration to finish BEFORE activating the Ultrasnap device
24. mSURE Plus upright when taking readings Hold the Ultrasnap device upright when activating Read the Ultrasnap sampling device within one minute of activation Keep the Ultrasnap device out of direct light when possible 7 To ensure shelf life for up to a year Ultrasnap sampling devices should be refrigerated at 2 8 C 35 46 F Sample devices will tolerate room temperature lt 25 C for 4 weeks Refrigerated sampling devices should be left out at room temperature for 10 minutes before being used 10 2 1 4 Ensuring correct results with calibration controls To help ensure the accuracy of test results the SystemSURE Plus luminometer is programmed to automatically self calibrate every time the instrument is turned on During the 60 second calibration it checks the light sensor and adjusts to temperature and humidity To further verify test result accuracy Hygiena offers two calibration kits that are recommended for periodic use with your SystemSURE Plus ATP Detection System the Calibration Control Rod Kit for testing the luminometer and the Positive Control Kit for testing Ultrasnap devices Calibration Control Rod Kit Part PCD4000 It s recommended that you verify calibration of the SystemSURE Plus luminometer with the Calibration Control Kit once a month Incorporating the Calibration Control Kit into your overall Quality Control program will confirm that the instrument is within specifications and operat
25. mentation PRO Clean PRO Clean detects protein residues left on a surface after cleaning PRO Clean quickly validates the hygiene of a surface allowing immediate corrective action to be taken if necessary Q Swab Increase productivity and efficiency while reducing lab costs by using Q swab for your environmental monitoring needs Q swab comes with multiple 1ml buffer formulations for optimal recovery of bacteria No need for broth preparation QD Loop All in one sterile system for accurate and convenient volumetric dilutions Designed with patented Snap Valve technology Devices are calibrated for 1 10 1 100 or 1 1000 dilutions 27 3 5 Contact Hygiena For any questions about the SystemSURE Plus ATP Detection Program or for more information on Hygiena products please contact Hygiena at Hygiena Americas 941 Avenida Acaso Camarillo CA USA 93012 Tel 1 805 388 8007 x 300 Fax 1 805 388 5531 info hygienaUSA com Hygiena International Unit 11 WENTA Business Centre Colne Way Watford Hertfordshire WD24 7 ND UK 44 0 1923 818821 tel 44 0 1923 818825 fax enquiries hygiena net Hygiena web site interactive demos You can find additional information about Hygiena as well as interactive product demos at www hygiena net 28
26. ogram In today s market impeccable hygiene control is an increasingly critical issue for industries involved in the manufacturing and distribution of consumable products Hygiena s SystemSURE Plus ATP Detection Program offers a state of the art solution for organizations looking to advance the hygienic status of their facilities Recognized worldwide for accuracy ease of use and affordability the SystemSURE Plus ATP Detection System is used extensively throughout the food and beverage processing industries as well as healthcare and pharmaceutical industries hospitals restaurants supermarkets and other facilities where rapid detection of contamination is crucial The SystemSURE Plus ATP Detection System enables organizations to Instantly assess the cleanliness of production surfaces allowing immediate corrective action to be taken Reduce the use of conventional microbiological testing methods that are slow labor intensive and costly Monitor water quality Enhance sanitation training as well as verify efforts of sanitation personnel Record and track test results to identify problem areas make improvements and show due diligence and compliance with HACCP Sanitation Standard Operating Procedures SSOPs and industry regulations Optimize the use of sanitation chemicals Protect brand image by increasing product quality and avoiding recalls The guidelines detailed within this manual are applicable to multi
27. ous page Prog Location Group Lower Upper 0 Calibration Control Point Calibration Control Point 10 30 1 Line A Dump 10 30 2 Line A Hopper 10 30 3 Line A Elevator Belt 10 30 4 Line A Reject Bins 10 30 5 Line A Lower Belt 10 30 6 Line A Top Belt 10 30 7 Line A Up Conveyor 10 30 8 Line A Blades 10 30 9 Line A Flume 10 30 10 Line A Shaker 10 30 11 Line B Dump 10 30 12 Line B Hopper 10 30 13 Line B Up Belt 10 30 14 Line B Slicer 10 30 15 Line B Reject Chute 10 30 16 Line B Inspection Table 10 30 17 Line B Cut Table A 10 30 18 Line B Cut Table B 10 30 19 Line B Up Conveyor 10 30 20 Line B Flume 10 30 21 Line B Shaker 10 30 22 Line C Finish Conveyor 10 30 23 Line C Cut Table C 10 30 24 Line C Cut Table D 10 30 25 Line C End Conveyor 10 30 26 Crate 1 Crate 10 30 27 Crate 2 Crate 10 30 28 Bin Cart 1 Bin Cart 10 30 29 Bin Cart 2 Bin Cart 10 30 30 Bin Cart 3 Bin Cart 10 30 31 Bin Cart 4 Bin Cart 10 30 32 Hand Washing Station On Off Mechanism 10 30 33 Hand Washing Station Basin 10 30 34 Drain 1 Drain 150 250 35 Drain 2 Drain 150 250 36 Drain 3 Drain 150 250 37 Drain 4 Drain 150 250 For further information about the installation and use of DataSURE II software see Managing and tracking your data with DataSURE II Software in section 2 5 You may wish to create a legend that matches PROG numb
28. ple business sectors including but not limited to Food and Beverage industry Food Service Hospitality Government Education Pharmaceutical and Healthcare fields Components of the SystemSURE Plus ATP Detection System The SystemSURE Plus ATP Detection System includes three components SystemSURE Plus Luminometer a user friendly handheld light reading unit that provides precise on site hygiene test results Used with the Ultrasnap sample testing device extremely low levels of contamination can be detected in just 15 seconds Ultrasnap Sample Testing Device a convenient all in one ATP sampling device that is activated with a simple swab snap and squeeze action DataSURE II Data Analysis Software a powerful software program that allows users to upload test results to a database analyze trends and generate reports Hygiena s luminometer sample testing devices and software are all designed for ease of use and reliability enabling both technical and non technical staff to operate the SystemSURE Plus ATP Detection System without difficulty Overview of this guide This guide is designed to assist users in setting up and operating their own ATP hygiene monitoring program using the SystemSURE Plus ATP Detection System The contents of this manual include Quick Start Guide A quick reference on how to use the SystemSURE Plus ATP Detection System the Quick Start Guide is included at the beginning of this manua
29. surfaces are indicated with a diamond and indirect ones with a circle p d ti F direct ro U C 0 n oor indirect Line A 1 Dump 2 Hopper 3 Elevator Belt 1 AA TT 3 4 Reject Bins SAARI GE WWW WEE H Line A H Wi 12 3 Wad Wad Wha Wh HHEH V H 11111114 EE RE Te GEN mb 15 Reject Chute mji D PUP UP UP 4 J 16 Inspection Belt A hal lal A a 18 H 28 U Gut Table A d e Ta z B A G weg LI Line B e th EP Oe ee 22 Finish Conveyor N A Cut Table a ER SE Num 7 5 25 End Conveyor CRATES 547 amp A V Line wi SARIS Se x z a 2 HHS EC Kr l LML ct E C LL d ARIAL DRAINS 14 2 2 4 Monitoring individual control points Once control points have been identified this information should be entered into the DataSURE II software In DataSURE II you can assign each control point a program PROG number that will correspond to a PROG number on the SystemSURE Plus luminometer Program locations can also be identified by name and group in DataSURE II Test results from individual control points can now be uploaded from the SystemSURE Plus luminometer to the DataSURE II database for recording tracking and analysis purposes Below is an example of a spreadsheet created with the DataSURE II software The program PROG numbers correspond to the control points illustrated in the Diagram of typical production floor test locations shown on the previ
30. ted as frequently NOTE ATP testing should be done prior to the application of a sanitizer if possible Take ATP test Ee A E gt Swabbing should be done after cleaning a surface but prior to the application of a sanitizer By doing it in this order you can remove any residue detected by the SystemSURE Plus with proper cleaning before applying sanitizer The sanitizer is most effective when surfaces are free of all residue This ensures microorganism removal when the sanitizer is used at its normal working strength Following this Clean Test Sanitize procedure prevents wasting time money and chemicals on re cleaning and re sanitizing upon a failed result NOTE Some sanitation procedures may require ATP testing be done after sanitizing e g CIP Clean In Place systems In such cases allow the sanitizer to fully evaporate before ATP testing For a list of sanitizers that could affect the ATP bioluminescence reaction contact Hygiena 20 2 5 Corrective action procedures Implementing a corrective action plan is an essential part of the SystemSURE Plus ATP Detection Program Corrective action procedures provide clear instructions for what steps should be taken following Pass Caution Fail results Recommended corrective action procedures are as follows ATP TEST RESULT CORRECTIVE ACTION The control point surface has been adequately cleaned Proceed to sanitizing J Pass The control point surface may not have been
31. urface cleanliness or water quality because the quantity of light generated by the reaction is directly proportional to the amount of ATP present in the sample The RLU bioluminescence reaction is immediate so results can be processed in seconds at the testing site by inserting the swab device into the SystemSURE Plus unit Results are then expressed numerically on the SystemSURE Plus screen as Relative Light Units RLU 1 3 Interpreting results on the SystemSURE Plus luminometer The relationship between the amount of ATP on the sample and the RLU result reading on the luminometer is simple High contamination Low contamination improper cleaning proper cleaning Large amount Small amount of ATP of ATP More light produced Less light produced in Ultrasnap reaction in Ultrasnap reaction High RLU reading Low RLU reading on SystemSURE on SystemSURE Plus Plus The RLU reading is directly proportional to the amount of ATP collected from the sample A high RLU reading indicates a large amount of ATP at the test location This in turn indicates improper cleaning and the presence of contaminants Cleaning properly results in less ATP at the location Less ATP results in less light output during the bioluminescent reaction and consequently a lower RLU reading 1 4 Benefits of routine ATP testing Routine ATP testing with the SystemSURE Plus ATP Detection System offers a number of benefits to the end user Saves money and time by
32. y on a randomized or rotating schedule Production line disassembly During a routine full line disassembly and reassembly it is recommended to do copious amounts of ATP testing to find and clean all areas of machinery that have the potential to harbor harmful bacteria Validation of hand cleanliness ATP testing can be used to verify proper washing techniques and cleanliness of employees hands when used directly on skin When doing this type of testing it is important to identify appropriate pass fail levels taking into account naturally occurring ATP levels in skin cells To find out more about using ATP testing to verify hand cleanliness contact a Hygiena sales representative Training The SystemSURE Plus ATP Detection System is an effective tool for teaching sanitation crews proper cleaning procedures since it gives them on the spot feedback SECTION 2 Using your SystemSURE Plus ATP Detection System Proper sampling at critical test locations correct use of the luminometer and sampling devices and accurate data management are crucial components of the SystemSURE Plus ATP Detection Program Consistency in the procedures used ensures accurate results Effective record keeping and documentation of results allows for helpful analysis and data retrieval during an audit This section will explain how to collect a sample using the Ultrasnap device use the SystemSURE Plus luminometer to measure ATP determine where

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