Frequently Asked Questions About Industrial Cleaning

Recommended frequencies by area:

Area / Equipment	Minimum Frequency	Risk Level
Direct contact surfaces	Between each product change	High
Production lines	After each shift (minimum daily)	High
Cutting/processing areas	Every 4 hours during production	Critical
Cold rooms / chill chambers	Monthly deep clean	Medium-High
Floors and drains	Daily (minimum)	Medium
Packing areas	Daily	High
Storage zones	Weekly	Low-Medium
Elevated equipment	Monthly (deep clean)	Medium

Why this is critical for your plant:

• Regulatory compliance: FSANZ Standard 3.2.2 requires food contact surfaces to be cleaned frequently enough to minimise contamination risk
• Biofilm prevention: Regular cleaning prevents biofilm formation which can be up to 1000x more resistant to sanitisers
• Successful audits: 67% of HACCP audit non-conformances relate to inadequate cleaning frequency
• Equipment lifespan: Proper cleaning extends machinery life by up to 40%

Categories of approved chemical products:

1. Alkaline Degreasers (pH 11-14)

• Use: Removal of fats, oils, proteins from surfaces and equipment
• Examples: Sodium hydroxide (caustic soda), sodium carbonate
• Application: Production lines, industrial floors, processing equipment

2. Acid Cleaners (pH 1-3)

• Use: Removal of mineral deposits, scale, encrustations
• Examples: Nitric acid, phosphoric acid, citric acid
• Application: CIP equipment, heat exchangers

3. Approved Sanitisers

• Quaternary ammonium (Quats): Effective against Gram-positive bacteria
• Hydrogen peroxide: Broad-spectrum, degrades to water and oxygen
• Peracetic acid: Highly effective against biofilm
• Chlorine: Economical but corrosive on stainless steel

Chemical products PROHIBITED in food plants:

• ❌ Aromatic solvents (benzene, toluene, xylene)
• ❌ Products with non-approved fragrances
• ❌ Domestic cleaners not certified food-grade
• ❌ Products without clear ingredient labelling

Our Customised Approach to Pricing:

At KARL Support Services, we don't offer fixed pricing because every food processing facility has unique requirements, equipment configurations, and compliance needs. Each service is 100% personalised to meet your specific challenges.

Why we customise every quote:

• Facility-specific assessment: We evaluate your exact layout, equipment types, and production processes
• Compliance requirements: Different product types (meat, dairy, bakery) have different FSANZ requirements
• Scheduling flexibility: We work around your production calendar to avoid disruptions
• Service scope: Some clients need comprehensive cleaning, others specific areas only
• Frequency optimisation: We recommend the right cleaning frequency for your risk level

Factors that influence your investment:

• Production type: Meat/poultry plants require different protocols than dry product packaging
• Equipment complexity: Multiple dismountable components require more detailed work
• Service frequency: Regular scheduled services provide better value and consistency
• Timing requirements: We accommodate night shifts, weekends, and emergency response
• Special requirements: Pre-audit cleaning, biofilm elimination, allergen changeovers

The KARL Advantage: How We Protect Your Bottom Line

Additional benefits of working with KARL:

• Prevent costly recalls: Professional cleaning eliminates contamination risks worth hundreds of thousands in potential losses
• Avoid failed audits: HACCP audit failures mean business interruption, emergency remediation, and potential loss of contracts
• Extend equipment life: Proper cleaning prevents corrosion and buildup that damage expensive machinery
• Reduce downtime: Our efficient processes mean faster turnaround between production runs
• Eliminate training overhead: No need to certify or manage internal cleaning staff
• Lower insurance risks: Professional cleaning with full liability coverage reduces facility risk

What's included in every service:

• ✅ Qualified labour (White Card + Yellow Card + HACCP trained)
• ✅ All certified food-grade chemical products
• ✅ Specialised cleaning equipment
• ✅ Complete PPE for entire team
• ✅ Detailed cleaning documentation
• ✅ Transport within 50km from Brisbane CBD

How to get your customised quote:

1. Contact us: Call 0451 791 377 or email for initial consultation
2. Free site visit: We assess your facility and specific needs
3. Detailed proposal: Transparent pricing with clear scope of work
4. Flexible options: Choose between one-off or ongoing service agreements

Investment reality: Professional industrial cleaning isn't an expense - it's protection against recalls, audit failures, and equipment damage that cost 10-100x more than preventive cleaning.

What is biofilm and why is it dangerous?

Biofilm is a community of microorganisms that adhere to surfaces and produce a protective polysaccharide matrix. In food plants, biofilm:

• Is 10-1000x more resistant to sanitisers than planktonic bacteria
• Protects pathogens like Listeria, Salmonella, E. coli
• Regenerates rapidly if not completely eliminated (within 24-48 hours)
• Causes recalls: 80% of persistent contaminations associate with biofilm

Common biofilm locations in plants:

• 🔴 Drains and siphons: Wet areas with constant nutrient flow
• 🔴 Conveyor belts: Especially under rollers and joints
• 🔴 Valves and gaskets: Difficult-access areas with trapped moisture
• 🔴 Heat exchangers: Temperate zones ideal for growth
• 🔴 CIP tanks and pipes: Dead-legs and low-flow areas

Biofilm elimination protocol:

1. Pre-rinse (5-10 min): Hot water 60-70°C, pressure 1000-1500 PSI
2. Alkaline degreaser (15-20 min): 2-4% sodium hydroxide at 50-60°C
3. Mechanical action (10-15 min): Hard-bristle brushes, scrub affected areas
4. Intermediate rinse (5 min): Clean water to remove degreaser completely
5. Sanitisation (10-15 min): Peracetic acid 200-400 ppm or H₂O₂ 3-7%
6. ATP Testing: Target <10 RLU for direct contact surfaces

Signs you have biofilm:

• 🚨 Slimy or slippery layer on surfaces after regular cleaning
• 🚨 Persistent dark stains on floors, drains, or equipment
• 🚨 "Swamp" or putrid odour in specific areas
• 🚨 Recurring positive microbiological results at same points
• 🚨 Consistently high ATP testing (>100 RLU)

At KARL: We use biofilm-specific 6-step protocol, with mandatory ATP verification in critical areas.

Mandatory certifications in Queensland:

1. White Card - Certificate I in Construction (CPC10108)

• Requirement: Mandatory to access any industrial site
• Valid: For life (no renewal required)
• Content: Work Health & Safety, hazard identification
• ✅ KARL Status: All technicians certified

2. Yellow Card - Elevating Work Platform Licence

• Requirement: Necessary to operate boom lifts, scissor lifts up to 11m
• Valid: 5 years, renewable with refresher course
• Levels: WP (Working Platforms), WB (Boom), SL (Scissor Lift)
• ✅ KARL Status: SL/BL certified

3. Food Safety & HACCP Knowledge

• FSANZ Standard 3.2.2: Hygiene requirements for food premises
• HACCP Principles: Knowledge of 7 principles and CCPs
• Allergen Awareness: Cross-contamination management
• GMP: Personal hygiene and cleaning practices

4. Chemical Handling & Safety

• SDS Training: Interpretation of safety data sheets
• PPE Usage: Selection and correct use according to chemical
• Spill Response: Emergency procedures for chemical spills
• Dilution Protocols: Correct preparation at specific concentrations

Documentation the company must maintain:

• 📄 Public Liability Insurance: Minimum $10-20 million coverage
• 📄 Workers Compensation Insurance: For all employees
• 📄 ABN: Registered and active
• 📄 SWMS: Safe Work Method Statements for each type of work
• 📄 Chemical Registers: Complete list of products with SDS
• 📄 Training Records: Evidence of all personnel training

KARL Support Services - Complete Compliance:

• ✅ White Card (CPC10108) - All technicians
• ✅ Yellow Card (SL/BL) - EWPA Member #454941
• ✅ Public Liability $20M - Updated annually
• ✅ HACCP Training - All team trained
• ✅ Chemical Safety Training - Annual certificates
• ✅ Custom SWMS - For each client

Clear signs you need specialised cleaning NOW:

🚨 Critical Indicators (Immediate Action):

• Positive microbiological results: Presence of pathogens in environmental swabs
• HACCP audit non-conformances: Observations related to cleaning
• Visible biofilm: Slimy layer on equipment, floors, or drains
• Customer complaint: Contaminated product or foreign body reported
• ATP testing >100 RLU: On food contact surfaces
• Pre-certification audit: BRC, SQF, FSSC 22000 in 2-4 weeks

⚠️ Warning Indicators (Schedule Soon):

• Unexpected increase in microbiological counts
• Persistent odours after regular cleaning
• Stains that won't remove with standard cleaning
• Change in product you process (especially with allergens)
• Haven't had deep cleaning in 6+ months

Specific situations requiring specialised cleaning:

1. Production Changes / Allergen Changeover

• When: Changing between products with different allergens
• Example: From nut-containing → nut-free products
• Scope: Deep clean + swab testing to verify allergen absence

2. Equipment Installation or Replacement

• When: Before commissioning new equipment
• Why: New equipment has manufacturing oils, dust, contaminants
• Process: Initial cleaning + sanitisation + verification

3. Scheduled Shutdowns (>48 hours)

• When: Long weekend stops, holidays, annual maintenance
• Why: Ideal opportunity to access normally inaccessible areas
• Scope: Dismantle equipment, clean behind/underneath, height areas

4. Post-Contamination Incident

• When: After any contamination detection
• Scope: Identify source + deep clean area + verification testing
• Urgency: Critical - prevent recurrence

5. Audit Preparation

• Timing: 1-2 weeks before scheduled audit
• Focus: Areas auditor will review (floors, drains, equipment)
• Value: Investment in professional cleaning vs. risk of losing certification

Recommended deep cleaning frequency:

• High Risk (meat, dairy, RTE): Monthly
• Medium Risk (bakery, sauces, beverages): Quarterly
• Low Risk (dry snacks, packaging): Semi-annual

Comprehensive industrial cleaning service includes:

1. Production Lines & Equipment

• Disassembly of removable components
• Degreasing of conveyor belts, rollers, guides
• Cleaning of motors, gear boxes (external)
• Sanitisation of all food contact surfaces
• Reassembly and operational verification

2. Cold Rooms & Refrigeration

• Deep cleaning of walls, ceilings, floors
• Evaporator coil cleaning and sanitisation
• Door seal cleaning and inspection
• Drain line cleaning and verification
• Biofilm removal from chronic moisture areas

3. Floors & Drainage Systems

• High-pressure washing (1500-2000 PSI)
• Alkaline degreaser application
• Mechanical scrubbing of heavily soiled areas
• Drain cleaning with specialised tools
• Sanitisation of entire floor surface

4. Processing Equipment

• Mixers, blenders, grinders - complete disassembly
• CIP system verification (if applicable)
• Tanks, vessels - internal and external cleaning
• Pumps, valves - disassembly and deep clean
• Heat exchangers - scale and residue removal

5. Walls, Ceilings & Height Areas

• Boom lift access for elevated areas
• Removal of dust, cobwebs, accumulated residue
• Cleaning of light fixtures, air vents
• Inspection for pest entry points

6. Quality Verification

• ATP Testing: 10-20 critical points depending on plant size
• Visual Inspection: Complete pre and post-cleaning assessment
• Chemical Verification: Confirm correct concentrations used
• Final Sanitisation: Complete facility sanitisation

7. Documentation & Records

• Detailed cleaning records with times, chemicals, personnel
• ATP testing results with photos
• Before/after photographs of critical areas
• Signed completion certificate
• Corrective action recommendations (if applicable)

What's NOT included (but available as add-ons):

• Pest control services (we can coordinate with your provider)
• Equipment maintenance or repairs
• Painting or structural repairs
• Waste disposal beyond normal cleaning waste
• Microbiological lab testing (swabs sent to external lab)

Service execution process:

1. Pre-service consultation: Walk-through to identify priorities
2. Preparation: Your team removes products, isolates equipment
3. Execution: Our team performs complete cleaning (4-12 hours typical)
4. Verification: ATP testing and final inspection
5. Handover: Document review and recommendations

Typical service duration by plant size:

• Small plant (500-1000m²): 4-6 hours
• Medium plant (1000-3000m²): 6-10 hours
• Large plant (3000m²+): 10-16 hours (may require 2-day service)

Complete audit preparation timeline:

2-3 Weeks Before Audit:

• Schedule specialised deep cleaning service
• Review last audit report - identify previous non-conformances
• Order any replacement equipment (worn brushes, damaged seals)
• Schedule internal pre-audit inspection
• Update all cleaning SOPs if needed

1 Week Before Audit:

• Perform comprehensive deep cleaning (KARL recommended timing: 3-5 days before)
• Conduct ATP testing at all critical control points
• Review and organise all cleaning records (past 3-6 months)
• Verify chemical products have current SDS on file
• Check staff training records are up to date
• Inspect and repair any facility damage (peeling paint, broken tiles)

2-3 Days Before Audit:

• Conduct final walkthrough with management team
• Touch-up cleaning of commonly overlooked areas
• Organise documentation in audit-ready format
• Brief all staff about audit procedures
• Prepare conference room for auditor

Day Before Audit:

• Final visual inspection of entire facility
• Verify all lights working, areas well-lit
• Ensure cleaning equipment stored properly
• Print any documents auditor may request
• Confirm key personnel availability

Critical areas auditors always inspect:

High Priority Inspection Points:

• 🔍 Drains and floor surfaces: Most common non-conformance area
• 🔍 Equipment undersides: Conveyor belts, tables, processing equipment
• 🔍 Wall-floor junctions: Cracks, gaps, biofilm accumulation
• 🔍 Door seals and gaskets: Mould, damage, cleanliness
• 🔍 Cold room interiors: Condensation management, cleanliness
• 🔍 Hand wash stations: Soap, paper towels, proper signage
• 🔍 Chemical storage: Labelling, SDS availability, separation from food

Documentation Auditors Will Request:

• Master cleaning schedule with assigned responsibilities
• Completed cleaning logs (daily/weekly/monthly) - past 3-6 months
• Chemical product list with current SDS
• Staff training records (HACCP, GMP, food safety)
• ATP testing results and trend analysis
• Corrective action records for any cleaning failures
• Pest control records and service reports
• Supplier certifications for cleaning chemicals

Common audit non-conformances and how to avoid them:

Non-Conformance	Prevention Strategy
Incomplete cleaning records	Implement daily sign-off system, weekly supervisor review
Visible biofilm in drains	Weekly drain cleaning, monthly deep treatment
Damaged floor/wall surfaces	Monthly facility inspection, immediate repair schedule
Missing/outdated SDS	Annual SDS audit, supplier automatic updates
Equipment undersides not cleaned	Monthly equipment disassembly protocol
Staff unable to answer questions	Pre-audit briefing, regular HACCP refresher training

What to do if auditor finds issues during inspection:

• Stay calm: Accept feedback professionally
• Document immediately: Take photos, notes of issue identified
• Acknowledge, don't argue: Even if you disagree, discuss later
• Develop corrective action: On-the-spot if possible
• Set timeline: Commit to reasonable correction date

KARL's Pre-Audit Deep Clean Package includes:

• ✅ Complete facility deep cleaning (all areas, all equipment)
• ✅ ATP testing at 15-25 critical points (depending on plant size)
• ✅ Biofilm elimination protocol in identified areas
• ✅ Pre-audit walkthrough with recommendations
• ✅ Photographic evidence of cleaning completion
• ✅ Complete documentation package for auditor review
• ✅ Priority scheduling (24-48 hour turnaround available)

Success rate: 95% of our clients who complete pre-audit deep cleaning pass their HACCP audits without major non-conformances related to cleaning.

Key differences explained:

Aspect	Commercial Cleaning	Industrial Food Cleaning
Chemical Products	General-purpose cleaners, may contain fragrances	FSANZ-approved, food-grade, no toxic residues
Knowledge Required	Basic cleaning techniques	HACCP principles, GMP, allergen management
Equipment	Mops, vacuums, standard cleaners	High-pressure washers (1500+ PSI), industrial steam, ATP meters
Target Contaminants	Dirt, dust, general soiling	Biofilm, food residue, pathogens, allergens
Verification	Visual inspection only	ATP testing, micro swabs, documented verification
Documentation	Basic checklist or none	Complete records for HACCP audit trail
Staff Certification	No specific certifications	White Card, HACCP training, food safety knowledge
Compliance	Workplace safety standards	FSANZ, HACCP, BRC, SQF standards

Why commercial cleaners can't work in food plants:

1. Chemical Product Issues

• Commercial products may contain non-approved fragrances
• Surfactants may leave toxic residues on food contact surfaces
• No SDS specific to food safety requirements
• Sanitisers not validated against food-borne pathogens

2. Lack of HACCP Knowledge

• Don't understand Critical Control Points (CCPs)
• Can't identify cross-contamination risks
• Unaware of allergen management protocols
• Don't recognize biofilm or food safety hazards

3. Inadequate Equipment

• Standard mops spread contamination rather than eliminate it
• Low-pressure cleaners (500-800 PSI) insufficient for food residue
• No ATP testing capability to verify cleanliness
• Cleaning cloths/equipment not colour-coded for allergen prevention

4. Documentation Gaps

• Can't provide audit-compliant cleaning records
• No verification procedures or corrective actions
• Missing chemical concentration records
• No traceability for regulatory requirements

Real-world consequences of using commercial cleaners:

Case Study 1 - Meat Processing Plant (Brisbane, 2023):

• Used commercial cleaning company to save costs
• Listeria detected in routine environmental monitoring
• Root cause: Biofilm in drains not eliminated (commercial team used only surface cleaning)
• Result: 2-week shutdown, $180,000 lost revenue, $45,000 remediation costs

Case Study 2 - Bakery (Gold Coast, 2024):

• Commercial cleaner used fragranced product near production area
• Fragrance contaminated baked goods (customer complaints)
• Result: Product recall, loss of major retail customer

When commercial cleaning IS appropriate:

• ✅ Office areas (not connected to production)
• ✅ Administrative buildings separate from manufacturing
• ✅ External landscaping and car parks
• ✅ Staff amenities (if completely separated from production)

When you MUST use industrial food cleaning:

• 🏭 All production areas
• 🏭 Processing equipment and machinery
• 🏭 Cold rooms and temperature-controlled storage
• 🏭 Packaging areas
• 🏭 Ingredient storage and preparation areas
• 🏭 Any area where food is present, stored, or processed

Investment comparison - True value:

• Commercial cleaning: Appears cheaper upfront but risks are enormous
• Industrial food cleaning: Professional investment that:
• Prevents recalls (potentially $100,000-500,000+ each)
• Passes audits (certification worth $50,000+ in contracts)
• Avoids regulatory fines ($10,000-50,000+)
• Extends equipment life (saves 40% on replacement costs)

Value Reality: Investing in proper industrial food cleaning protects against issues that cost exponentially more than the service itself, making it the only responsible choice for serious food manufacturers.

Recommended booking timeframes:

Service Type	Recommended Advance Notice	Notes
Regular Weekly/Monthly Service	3-5 days	Standard production areas, established schedule
Deep Cleaning Service	2-3 weeks	Complete facility, equipment disassembly required
Scheduled Shutdown Cleaning	4-6 weeks	Christmas, Easter, annual maintenance periods
Pre-Audit Cleaning	2 weeks minimum	BRC, SQF, FSSC audits - ideally 3-5 days before audit
Emergency/Urgent Cleaning	24-48 hours	Contamination incidents, urgent audit preparation
One-Off Service (First Time)	1-2 weeks	Allows time for site assessment and quotation

Why advance notice matters:

For Regular Services (3-5 days):

• Ensures availability of certified technicians
• Allows coordination with your production schedule
• Time to prepare specialised equipment if needed
• Guarantees chemical stock availability

For Deep Cleaning (2-3 weeks):

• Requires larger crew allocation (3-6 technicians)
• Specialised equipment booking (boom lifts, industrial steam cleaners)
• Coordination with your shutdown schedule
• Potential need for overnight/weekend premium scheduling

For Scheduled Shutdowns (4-6 weeks):

• High demand periods (Christmas, Easter) book out early
• Multiple plants competing for same service dates
• Allows proper scope of work development
• Better planning for advance bookings

Peak booking periods in Queensland:

• 🎄 Christmas Shutdown (Mid-December): Book by early November
• 🐣 Easter Shutdown: Book 6-8 weeks in advance
• ☀️ Summer (January-February): Popular for deep cleaning during slower production
• 📊 Pre-June Audits (May): Many annual audits scheduled, high demand

Emergency service - When you can't wait:

Situations qualifying for 24-48 hour emergency service:

• 🚨 Positive pathogen detection (Listeria, Salmonella)
• 🚨 Customer complaint requiring immediate response
• 🚨 Audit scheduled within 3-5 days (and you weren't prepared)
• 🚨 Major contamination incident requiring deep cleaning
• 🚨 Regulatory inspection announced with short notice
• 🚨 Equipment failure resulting in product spillage/contamination

Emergency service details:

• Response time: Initial contact within 2 hours
• On-site time: 24-48 hours from approval
• Availability: 24/7 including weekends and public holidays
• Premium: Additional fees apply for urgent response

Benefits of monthly service contracts:

Guaranteed Scheduling:

• ✅ Pre-booked slots reserved specifically for your plant
• ✅ Same team, same day/time each service (consistency)
• ✅ Priority access for emergency/additional services
• ✅ Flexible rescheduling if production changes

Service Quality:

• ✅ Team learns your plant layout and specific needs
• ✅ Proactive identification of developing issues
• ✅ Continuous documentation trail for audits
• ✅ Account manager assigned for your facility

How to schedule with KARL Support Services:

Method 1 - Phone (Fastest for Urgent):

• 📞 Call 0451 791 377
• Speak directly with our scheduling team
• Immediate availability check
• Best for: Emergency services, complex scheduling

Method 2 - Email (Best for Advance Planning):

• ✉️ contact@karlsupportservices.com.au
• Include: Preferred dates, plant size, service type
• Response within 4 business hours
• Best for: Monthly contracts, shutdown planning

Method 3 - Online Contact Form:

• 🌐 karlsupportservices.com.au/contact
• Quick form with all relevant details
• Automated confirmation received
• Best for: Initial consultations, quotes

What information to have ready when booking:

• Plant size (m² or approximate dimensions)
• Type of production (meat, dairy, bakery, etc.)
• Preferred service dates and times
• Specific areas of concern (biofilm, difficult areas)
• Access requirements (keys, personnel escort needed?)
• Special considerations (height work, confined spaces)

Cancellation and rescheduling policy:

• Regular services: 48 hours notice for free rescheduling
• Deep cleaning: 1 week notice to avoid cancellation fee
• Monthly contracts: Flexible rescheduling within same billing period
• Emergency services: No cancellation fee if incident resolves