Sanitizers are crucial in controlling pathogens, improving public health and allowing those in the dairy industry to be stewards of the environment.

The industry has seen several clear shifts in how it is evaluating sanitization methods, most notably the move away from hot water sanitizing, which was historically one of the more common sanitization methods in dairy processing environments.

“Processors are increasingly embracing chemical sanitizing because it delivers on multiple fronts,” said Hannah Rollinger, marketing manager, food and beverage, for St. Paul, Minn.-based Ecolab. “It supports cost savings and sustainability performance by reducing energy and water usage compared to methods that require hot water.”

Chemical sanitizing can also boost productivity by eliminating the need to wait for water to reach high temperatures. Plus, it generally calls for shorter contact times.

Ecolab also noticed a shift away from chlorine toward peracetic acid (PAA) sanitizers.

“These PAA alternatives are more compatible to core facility equipment and eliminate the risk of creating chlorine-related byproducts,” Rollinger said. “As regulators in the EU and beyond continue to apply heightened scrutiny to chloramines, chlorates and other chlorine residuals, PAA sanitizers are increasingly attractive to dairy processors looking to achieve an effective clean without these chlorine risks.”

More recently, there has been a move away from sanitizers containing quats. Quats are known for their residual activity and can persist on surfaces after application. These characteristics have given some dairy processors pause that quats could impact products that rely on food cultures.

“There are also growing concerns around quats’ potential environmental impact, mostly related to wastewater,” Rollinger said. “Researchers are conducting studies right now to bring more clarity to the validity and severity of these concerns, but this scrutiny has caused many in the dairy industry to proactively cut down on their use of quats.”

An evolution

There has been an evolution in sanitizer usage, primarily driven by heightened regulatory standards, emergence of new pathogens and the desire to extend shelf life.

Jason Huff, commercial executive director at Nelson-Jameson, a distributor for the dairy industry based in Marshfield, Wis., noted more and more, the industry emphasizes adherence to certifications such as NSF approval and EPA registration.

“Sanitizer manufacturers have responded to the increasing complexity of foodborne illness challenges by developing products that meet the evolving regulatory landscape.

“As a result, the dairy industry now relies on sanitizers that are specifically designed to combat a broader spectrum of pathogens, ensuring a safer and more hygienic production environment,” Huff said.

There also has been a trend in sanitizers formulated to extend shelf life by targeting specific spoilage causing microorganisms.

That’s why more decision makers in the dairy industry are looking for EPA-approved claims against a number of different food safety risks – Avian Influenza (H5N1), COVID-19, Cronobacter, Listeria, biofilms, etc. Companies want to be able to feature these claims on their products’ packaging.

“Many times, the interest in these claims follow specific recall or health events,” Rollinger said. “For example, a recent cronobacter recall in powdered infant formula brought new information to light — and increased the industry’s knowledge of and scrutiny on what effective cleaning looks like for their unique facilities. Increasingly, these dry formula processors are coming to us specifically looking for sanitizers that mitigate the spread of cronobacter.”

New tools

The escalating consumer emphasis on food safety and hygiene has significantly influenced the sanitizing equipment market within the dairy industry. Driven by the desire for cleaner and safer dairy products, consumers are demanding higher standards from producers. This increased scrutiny has led to a surge in sanitizer usage across the industry.

“To meet this heightened demand, sanitizer manufacturers have expanded their product applications, creating versatile solutions that can be used on a wider range of equipment and surfaces,” Huff said. “This trend not only simplifies cleaning procedures, but also enhances overall sanitation efficacy. As a result, dairy processors can achieve a higher level of cleanliness while optimizing resource utilization.”

Recognizing the increasing regulatory demands and complexity of foodborne pathogens, Nelson-Jameson strategically partnered with leading sanitizer manufacturers to offer a comprehensive range of products that meet the highest industry standards.

“By aligning closely with our suppliers, we ensure that our customers have the information they need to make informed decisions,” Huff said. “Our diverse product portfolio, encompassing a wide array of sanitizer options, allows us to cater to the unique requirements of different dairy operations. This customer-centric approach, combined with our expertise in the industry, positions Nelson-Jameson as a trusted partner in maintaining optimal sanitation standards.”

For 33 years, SuperKlean Washdown Products has been supplying DuraFlow nozzles for the food processing industry. Among the DuraFlow line is the company’s new custom-built, stainless steel dairy milking parlor nozzle that offers superior results for chemicals pre- and post-dip.

Bob Rudy, vice president of sales and marketing for the Burlingame, Calif.-based company, explained the durable teat dip gun ensures thorough application of disinfectant solutions, promoting optimal udder hygiene and reducing the risk of mastitis.

“This is a specific nozzle for the dairy industry that is chemical and bacteria resistant, and you end up with healthier cows because you have better coverage,” he said.

SuperKlean will also soon introduce a line of specialty tank cleaning nozzles that will cover the dairy industry, with a series of spray balls and spray spinners designed to help clean tanks and tools.

Dairy processors understand that cleaning and sanitization is not a one-size-fits-all proposition, which is why Ecolab supports the dairy industry with a broad array of solutions that processors can use to meet their specific needs.

“We are among the first to develop EPA-approved products — Synergex and Active OX+ — that kill biofilms on food contact surfaces,” Rollinger said. “This powerful capability addresses a persistent and pernicious source of contamination for dairy processors and greatly increases processors’ ability to reduce the risk of costly quality and food safety issues.”

The company’s dry-cleaning products such as Boost Tread Defense QF, deliver powerful quat-free sanitization in facilities that require low- or no-moisture solutions.

“Our digital solutions like 3D TRASAR Technology for CIP also enable better real-time visibility into C&S, which helps dairy processors streamline their operations and take a more sustainable approach to resource management,” Rollinger said.

Moreover, the industry is witnessing advancements in sanitizer formulations that minimize dry time.

“This is crucial for optimizing cleaning processes, reducing equipment downtime and improving overall operational efficiency,” Huff said. “By accelerating the drying process, these sanitizers enable dairy processors to maintain a high level of sanitation while increasing productivity.”

Health and safety

The dairy industry is subject to rigorous health and safety standards that continually evolve in response to emerging threats and consumer expectations. These standards serve as a catalyst for innovation in sanitizer development.

“As regulatory requirements become more stringent, manufacturers adapt their formulations to meet the new standards,” Huff said. “This focus on compliance not only ensures product efficacy but also reinforces consumer confidence in the safety of dairy products.”

The cronobacter-related recalls of 2021 were a stark reminder of the importance of rigorous C&S in dry-cleaning environments. For the infant formula providers who were most immediately impacted by the cronobacter recall, it served as a pivotal learning moment.

“In general, these developments in high-sensitivity products and applications are having a broad impact on the dairy industry as a whole,” Rollinger said. “There is an overall push to consider alternative approaches to cleaning and sanitization that deliver smarter, more efficient and more effective cleans.”

The COVID-19 pandemic was also a catalyst for advancements in dairy equipment sanitization.

In the past, Rollinger noted the industry was more content to rely on broad-spectrum sanitizers that didn’t necessarily make risk-specific claims.

“There is now a heightened awareness of the importance of meticulous cleaning, particularly in hard-to-reach areas,” Huff said. “Additionally, sanitation frequencies have increased to mitigate the risk of contamination. The pandemic underscored the necessity of comprehensive sanitation protocols to protect both employees and consumers.”

These changes led to a more robust and proactive approach to sanitation in the dairy industry, ultimately enhancing food safety and public health.

Smart technology

The conductivity of certain sanitizers makes it easier for dairy processors to validate the efficacy of their protocols.

“Smart technologies help confirm that sanitization cycles are being implemented for the right amount of time and that chemistries are applied at the correct concentrations,” Rollinger said. “This level of real-time visibility helps increase the speed of troubleshooting when issues arise and has a meaningful impact on food safety and quality assurance overall.”

When it comes to sanitation in the future, expect more manufacturers to turn to solutions that can do more with less, deliver more effective cleans while also supporting accelerating sustainability goals and food safety standards.

“The demand for sanitizers is projected to increase steadily as the industry expands and regulatory standards become more stringent,” Huff said. “Additionally, we expect to see advancements in technology that enhance sanitizer application and efficacy. Sustainability will also be a driving force in the future, with a focus on developing environmentally friendly sanitizers that minimize environmental impact.”