A Professional Hygiene Guide for a Safe Restart in Production, Service and Packaging

After a long holiday period, annual leave or an extended production shutdown, restarting a food business is not limited to turning on machines or reopening the kitchen. Hygiene control must be re-established across food contact surfaces, processing lines, storage areas, floors, laboratories, packaging zones and chemical storage areas.

In facilities that remain closed or operate at low capacity for a certain period, several hygiene-related issues may occur. These may include dust accumulation on surfaces, stagnant water in equipment or pipelines, odor formation in drainage points, slippery floors, microbial risks on food contact surfaces, damaged packaging in storage areas, and possible organic or chemical residues in process lines.

For this reason, the first cleaning and disinfection procedure after a holiday shutdown should be handled differently from routine daily cleaning. The objective is not only to remove visible dirt, but also to ensure that the facility is hygienically ready for production, service or packaging operations.

1. First Inspection After the Holiday: General Hygiene Assessment Before Operation

In food businesses, the post-holiday cleaning plan should not start directly with chemical application. The first step should be a visual and sensory assessment of the overall condition of the facility. This inspection helps determine which cleaning approach is required for each area.

Key points to check during the initial inspection

• Is there any unpleasant odor or moisture in closed areas?
• Are there oil residues, dust, stains, slipperiness or sticky surfaces on the floor?
• Is there any odor, sediment or accumulation in drainage channels and floor drains?
• Is there dust, staining or residue on benches, equipment and filling surfaces?
• Is there any packaging damage, spillage or contamination in cold storage, dry food storage or packaging areas?
• Could there be stagnant water or product residues in CIP/SIP lines, tanks or piping systems?
• Are the cleaning and disinfection chemical containers intact and properly labeled?

The purpose of this stage is to classify the facility’s cleaning needs correctly. In food businesses, not every area should be cleaned with the same product. Food contact surfaces, floors, drains, equipment, filling lines and storage areas each have different hygiene requirements.

2. Food Contact Surfaces: Benches, Equipment and Preparation Areas

Food contact surfaces are among the most critical areas to be evaluated after a holiday shutdown. Benches, cutting boards, mixers, vessels, filling nozzles, conveyor belts, packaging machines, preparation tables and all equipment that comes into contact with food require a separate cleaning and disinfection approach.

On these surfaces, not only visible dirt but also microbial load, organic residues, oil-protein films and possible chemical residues must be considered.

Recommended general procedure for food contact surfaces

1. Physical pre-cleaning: Dust, crumbs, food particles and coarse dirt are removed.
2. Cleaning with a suitable detergent: The appropriate cleaning chemical is selected according to the type of oil, protein, carbohydrate or organic residue.
3. Rinsing: The cleaning chemical is removed from the surface.
4. Disinfection: A suitable disinfectant is applied with attention to the required contact time.
5. Residue control when necessary: Especially on food contact surfaces, rinsing efficiency and residue risk should be verified.

When selecting products for food contact surfaces, surface compatibility, use concentration, contact time, rinsing requirements and internal facility procedures should be evaluated together.

Products that may be considered for food contact surfaces

• ULTRACOL FOOD/OX – Food Contact Surface Cleaner: May be considered for food contact surfaces where a peroxide-based hygiene approach is required.
• ULTRACOL FOOD/AC – Food Contact Surface Cleaner: May be preferred for surfaces where a citric acid-based cleaning approach is suitable.
• ULTRACOL FM/AC – GMP and HACCP Compatible Peracetic Acid-Based Washing Agent: May be considered for food process hygiene and surface disinfection applications.

3. Post-Holiday Hygiene in Filling Lines and Packaging Areas

Filling and packaging areas are critical sections directly related to the final product in terms of food safety. Post-holiday inspection in these areas should not be limited to checking whether the equipment is operational. Filling nozzles, conveyors, packaging contact surfaces, capping units and product transfer points must also be evaluated from a hygiene perspective.

Key points to check in filling and packaging areas

• Are there any product residues or dried films on filling nozzles?
• Is there dust, oil or stickiness on conveyor belt surfaces?
• Are there packaging residues, cardboard dust or film particles on packaging surfaces?
• Is there stagnant product or water residue on the line?
• Has a surface disinfection procedure been applied before filling?
• Has an inspection record been created before the first production run?

Incorrect chemical selection in filling and packaging lines may create risks for product quality and packaging safety. Therefore, both hygiene performance and surface compatibility should be considered when selecting chemicals.

Peracetic acid-based products may be considered as a strong option in food process hygiene when used at the appropriate concentration and contact time. However, each facility’s application procedure should be determined according to product type, surface material, organic load, level of automation and rinsing requirements.

4. CIP/SIP Systems: Pay Attention to Stagnant Water and Residue Risks in Closed Lines

In food production facilities, CIP/SIP systems are among the most critical parts of hygiene management for tanks, pipelines, heat exchangers, filling systems and closed process equipment. After a holiday shutdown, stagnant water, residues from previous production, cleaning chemical residues or microbial risks may occur in these systems.

For this reason, performing only a routine CIP/SIP cycle before the first production may not always be sufficient. The condition of the lines should be assessed, and suitable pre-rinsing, cleaning, disinfection and, when necessary, residue control should be carried out.

Post-holiday checklist for CIP/SIP systems

• Is there stagnant water or product residue inside the line?
• Is there odor, film formation or sediment in tanks?
• Are dosing pumps and connections functioning properly?
• Is there a possibility of residue from previous cleaning chemicals?
• Is pre-rinsing required before the first cycle?
• Should active ingredient or pH control be performed after disinfection?
• Is there any foam, color, odor or conductivity change in the CIP return water?

Products that may be considered for CIP/SIP and process hygiene

• ULTRACOL FM/AC – GMP and HACCP Compatible Peracetic Acid-Based Washing Agent: May be considered for food process hygiene, CIP/SIP applications and equipment surfaces where a peracetic acid-based approach is suitable.
• ULTRACOL FM/AL – GMP and HACCP Compatible Hypochlorite-Based Disinfectant: May be used in processes where a hypochlorite-based disinfection approach is suitable.
• Peracetic Acid 5.0 | 5% PAA: May be considered for applications requiring oxidative hygiene and process disinfection.
• Peracetic Acid 10.0 | 10% PAA: May be considered for professional process applications requiring a higher active ingredient level.
• Peracetic Acid 15.0 | 15% PAA: May be preferred in industrial applications requiring a concentrated peracetic acid approach.

For peracetic acid-based products, use concentration and contact time must be determined according to the facility’s procedure. On food contact surfaces and closed process lines, proper rinsing and, when necessary, residue control are recommended after application.

5. First-Day Cleaning of Floors, Walls and Drainage Areas

In food businesses, floors, walls and drainage points are essential components of the hygiene chain. Although these areas may not come into direct contact with food, they are important in terms of internal microbial load, odor, slipperiness and cross-contamination risk.

After a holiday shutdown, unpleasant odors in drainage points, sticky floors, oil films, mineral deposits or moisture-related contamination may be observed in closed areas.

Cleaning approach according to contamination type on floors and walls

When cleaning floors and drainage areas, the suitability of the product for the surface and the rinsing procedure are important. Especially when strong alkaline or acidic products are used, rinsing and visual inspection should be performed to ensure that no residue remains on the surface.

6. Cold Storage, Dry Food Storage and Packaging Areas

Storage areas are among the sections that must be inspected after a holiday shutdown in food businesses. Cold rooms, dry food storage areas, packaging material storage and auxiliary material sections should be checked before production starts.

Key points to check in storage areas

• Is there water accumulation, odor or slipperiness on the cold room floor?
• Is there packaging damage, dust or spillage on shelves?
• Is there moisture, caking or external packaging contamination in dry food storage areas?
• Are packaging materials kept closed and in a clean area?
• Are cleaning chemicals stored separately from food products and in appropriate conditions?
• Are chemical product labels readable and containers intact?

Cleaning chemicals should be selected carefully for storage areas. Food, packaging and chemical storage zones should be separated; after cleaning, the area should be ventilated and allowed to dry properly.

7. Post-Holiday Opening Hygiene in Restaurants, Canteens and Catering Businesses

In restaurants, canteens and catering businesses, post-holiday opening hygiene should be managed with a practical and operational plan. Before service starts, preparation areas, cooking equipment, refrigerators, benches, dishwashing areas, floors and drains should be inspected.

Main areas to check before opening

• Preparation benches and cutting surfaces
• Cooking equipment and hood surroundings
• Dishwashing area and detergent residue risk
• Refrigerators and shelf surfaces
• Floors and drainage points
• Service equipment and transport containers
• Personnel handwashing and hygiene areas

The most common problems in these businesses include oil films, unpleasant odors, detergent residues, surface slipperiness and moisture-related contamination in cold areas. For this reason, product selection should be made according to each area’s specific cleaning need.

When selecting products for food contact surfaces, post-application rinsing and residue risk must be considered. A clean-looking surface alone is not sufficient; the surface should also be suitable from a food safety perspective.

8. Why Is Chemical Residue Control Important?

One of the most important topics in first cleaning and disinfection procedures after a holiday shutdown is the risk of chemical residues after application. Chemical residue control is especially important on food contact surfaces, CIP/SIP outlets, filling lines and dishwashing areas.

Areas where residue control is recommended

• Food contact surfaces
• CIP/SIP outlet waters
• Filling nozzles and line outlets
• Service equipment after dishwashing
• Surfaces with pH change after rinsing
• Areas treated with peracetic acid or hypochlorite-based products

Test kits that may be considered for control purposes

• Peracetic Acid Test Kit: May be considered for active ingredient control in peracetic acid applications.
• Peracetic Acid Percentage Test Kit: May be used for checking concentrated peracetic acid solutions.
• Peracetic and Hydrogen Peroxide Percentage Test Kit: May be considered for applications containing PAA and hydrogen peroxide.
• Hypochlorite Residue Test Kit: May be used as a residue control approach in hypochlorite-based disinfectant applications.

Residue control should not be considered only as a regulatory or procedural step. It is also a practical quality control tool that helps verify proper rinsing, correct dosage and appropriate contact time.

9. Post-Holiday Hygiene Reminder for Personnel

After long holiday periods, personnel should not be expected to return directly to the old routine without guidance. A short hygiene briefing on the first working day helps reduce the risk of incorrect product use and incomplete cleaning.

Recommended topics for personnel briefing

• Which area will be cleaned first?
• Which product will be used on which surface?
• Which products must never be mixed?
• How should rinsing be performed on food contact surfaces?
• Who will check the CIP/SIP cycle?
• How will cleaning records be maintained?
• In which situations will residue control be performed?
• What should be done in case of chemical spillage or incorrect use?

This short briefing makes the first-day hygiene procedure more controlled and traceable.

10. Practical Opening Checklist for Food Businesses After a Holiday Shutdown

11. Common Mistakes

Some mistakes during post-holiday cleaning in food businesses may reduce the effectiveness of the hygiene process or create safety risks.

• Starting disinfection directly without general cleaning
• Not performing proper rinsing on food contact surfaces
• Using alkaline and acidic products outside the defined procedure
• Mixing different chemical products
• Ignoring stagnant water in CIP/SIP lines
• Checking filling nozzles and conveyor surfaces only externally
• Neglecting drainage and floor drain points
• Not checking chemical containers and labels
• Not creating a cleaning verification record

To prevent these mistakes, a standard opening hygiene procedure should be applied inside the facility on the first working day after the holiday.

Conclusion: Safe Opening in Food Businesses Starts with Controlled Hygiene

After a holiday shutdown or any extended stoppage, general cleaning alone is not sufficient for food businesses to restart safely. Food contact surfaces, filling lines, packaging areas, CIP/SIP systems, floors, drainage points, storage areas and chemical stocks should all be evaluated together.

The correct approach is to first inspect the area, identify the type of contamination, select the appropriate cleaning chemical, apply disinfection when necessary, and verify the result with a control procedure at the final stage.

Colin Kimya’s ULTRACOL and Testonic product groups offer professional solutions for different needs in food businesses, including process hygiene, surface cleaning, CIP/SIP applications, floor and wall cleaning, and residue control.

Food safety is a continuous process. Applying the first cleaning and disinfection steps after a holiday shutdown in a controlled manner helps the facility begin the new operating period more safely, systematically and hygienically.