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How to Perform an Operations Washdown in a Food & Beverage Manufacturing Facility
A Practical Guide to GMP Cleaning, 5S, and Equipment Protection
Whether you produce beer, spirits, wine, kombucha, dairy products, soft drinks, or prepared foods, cleaning does not stop when the tanks are empty.
An effective operations washdown removes product residues, reduces contamination risks, protects equipment, and ensures the next production run starts in a clean, organized environment. It is a fundamental part of Good Manufacturing Practices (GMPs) and can improve food safety, employee safety, equipment reliability, and production efficiency.
Many facilities invest heavily in Clean-In-Place (CIP) systems but overlook the importance of routine operations cleaning. Floors, conveyors, drains, workstations, equipment exteriors, and storage areas all require regular attention. Even the best CIP program cannot compensate for poor housekeeping or a disorganized production floor.
If you're looking to clean the inside of tanks, piping, and process equipment, read our Complete Clean-In-Place (CIP) Guide. This article focuses on cleaning the production environment surrounding your equipment.
This guide explains the principles of operations washdowns, how they differ from Clean-In-Place (CIP) and Clean-Out-of-Place (COP) cleaning, and how simple organizational practices such as 5S can help create a cleaner, safer, and more efficient facility.
Understanding CIP, COP, and Operations Cleaning
Cleaning in a food or beverage facility generally falls into three categories. Although they work together, each method serves a different purpose.
No single cleaning method replaces another. An effective sanitation program combines Clean-In-Place (CIP), Clean-Out-of-Place (COP), and routine operations washdowns to protect product quality, equipment, and employee safety.
Clean-In-Place (CIP)
Clean-In-Place (CIP) is the process of cleaning the inside of process equipment without taking it apart. Tanks, pipelines, pumps, heat exchangers, and fillers can be cleaned by circulating water, detergents, acids, and sanitizers through the system.
CIP is designed to clean product-contact surfaces efficiently while reducing manual labour and production downtime.
Clean-Out-of-Place (COP)
Some equipment cannot be cleaned effectively while assembled. Butterfly valves, tri-clamps, spray balls, gaskets, sample valves, and other removable components should be disassembled, cleaned separately, inspected for damage, and reassembled before production resumes.
This process is known as Clean-Out-of-Place (COP).
Operations Cleaning (Washdown)
Operations cleaning, often called a washdown, focuses on the production environment surrounding the equipment rather than the internal product-contact surfaces.
A typical operations washdown includes cleaning:
- Floors
- Drains
- Equipment exteriors
- Conveyors
- Work tables
- Walls
- Storage racks
- Hoses
- Tools
- Waste bins
Unlike CIP or COP, operations cleaning is about maintaining the overall production environment. A clean facility reduces contamination risks, discourages pest activity, improves employee safety, and makes it easier to identify leaks, damaged equipment, or maintenance problems before they become larger issues.
All three cleaning methods are essential. A tank may complete a successful CIP cycle while sticky syrup remains on the floor around it, creating a slip hazard and attracting pests. Likewise, a spotless production floor does not guarantee the inside of a process vessel is microbiologically clean.
Effective sanitation requires Clean-In-Place (CIP), Clean-Out-of-Place (COP), and routine operations cleaning working together.
Using 5S to Improve Cleaning and Food Safety
Many food and beverage manufacturers organize their cleaning programs using a workplace organization system known as 5S. Originally developed as part of Lean Manufacturing, 5S helps create workplaces that are cleaner, safer, and more efficient.
While 5S is often associated with improving productivity, it also supports Good Manufacturing Practices (GMPs) by making cleaning easier, reducing contamination risks, and helping employees identify problems before they affect production.
Rather than treating cleaning as something that only happens at the end of the day, 5S encourages operators to maintain a clean and organized workplace throughout the production process.
Sort (Seiri)
Remove anything that is not needed for production. Empty ingredient bags, damaged packaging, unused tools, scrap materials, and unnecessary equipment all make cleaning more difficult and can create places for dirt, pests, and contaminants to accumulate.
A clutter-free production area is faster to clean and easier to inspect.
Set in Order (Seiton)
Everything should have a designated storage location. Hoses, brushes, squeegees, cleaning chemicals, PPE, and production tools should be stored where employees can easily find and return them.
Proper organization reduces wasted time, prevents equipment damage, and helps ensure cleaning tools remain clean between uses.
Shine (Seiso)
Shine refers to cleaning and inspecting equipment at the same time. During every washdown, employees should look for leaks, damaged hoses, worn gaskets, loose fasteners, corrosion, and other maintenance concerns.
Cleaning often provides the best opportunity to identify equipment problems before they result in unexpected downtime.
Standardize (Seiketsu)
Develop written cleaning procedures, schedules, checklists, and visual standards so every employee performs cleaning consistently. Standardization reduces variation and helps ensure that important cleaning tasks are not overlooked.
Photographs, floor markings, shadow boards, and equipment labels can all help maintain consistency.
Sustain (Shitsuke)
The final step is making 5S part of your company culture. A successful cleaning program relies on consistency rather than occasional deep cleaning. Small improvements performed every day are often far more effective than major cleanups performed only when problems become visible.
Regular training, routine inspections, and employee involvement help maintain long-term success.
5S and Operations Washdowns
An effective operations washdown incorporates all five principles. The goal is not simply to remove visible dirt. A successful washdown leaves the production area clean, organized, easy to inspect, and ready for the next production run.
Combined with effective Clean-In-Place (CIP) procedures and appropriate Clean-Out-of-Place (COP) cleaning, 5S helps build a complete sanitation program that supports food safety, equipment reliability, and efficient production.
Steps to Perform an Operations Washdown
A successful operations washdown follows a clear order. Removing waste first, cleaning from high areas to low areas, and inspecting the workspace at the end can reduce cleaning time and prevent important tasks from being missed.
1. Preparation and Safety
Before cleaning begins, stop production and make sure the area is safe to enter and wash.
Employees should wear the personal protective equipment required for the cleaning chemicals and equipment being used. Depending on the task, this may include:
- Safety glasses or goggles
- Chemical-resistant gloves
- Protective aprons or clothing
- Slip-resistant footwear
- Face protection
Review the chemical label and Safety Data Sheet before use. Never mix cleaning chemicals unless the manufacturer specifically instructs you to do so.
Equipment should be shut down, isolated, and locked out when cleaning could expose employees to moving parts, stored energy, hot surfaces, electricity, or other hazards. Follow your facility's established lockout and safety procedures.
Remove exposed ingredients, packaging materials, finished products, and portable equipment from the washdown area. Gather the required brushes, hoses, detergents, squeegees, waste containers, and other cleaning tools before starting.
2. Remove Waste and Clutter
Begin by removing anything that does not belong in the production area. Cleaning around clutter is not effective cleaning.
Remove items such as:
- Cardboard and paper
- Plastic wrap
- Empty ingredient containers
- Damaged packaging
- Broken pallets
- Unused tools
- Scrap materials
- General waste
This step supports the Sort principle of 5S. Removing unnecessary materials makes surfaces easier to reach, reduces places where dirt and pests can collect, and prevents packaging debris from being washed into floor drains.
3. Dry Clean Before Using Water
Whenever possible, remove dry material before using a hose.
Sweep, vacuum, scrape, or collect loose residues such as:
- Flour
- Sugar
- Grain and malt dust
- Coffee grounds
- Powdered ingredients
- Fruit skins and pulp
- Labels and packaging fragments
Water can turn dry ingredients into sticky pastes that are much more difficult to remove. Dry cleaning also reduces the amount of material entering the wastewater system and prevents solids from blocking drains.
Use dedicated tools for different areas where required. For example, tools used to clean drains should not also be used on equipment, work tables, or other higher-risk surfaces.
4. Apply the Correct Cleaning Chemical
Once loose material has been removed, apply a detergent that is suitable for the residue and the surface being cleaned.
Different cleaning problems may require different products:
- Alkaline detergents are commonly used for fats, proteins, sugars, and other organic residues.
- Acid cleaners may be used to remove mineral scale and other inorganic deposits.
- Neutral detergents may be appropriate for routine cleaning or surfaces that can be damaged by stronger chemicals.
Always confirm that the cleaner is compatible with the equipment, flooring, seals, metals, coatings, and other materials in the washdown area.
Follow the manufacturer's instructions for concentration, temperature, contact time, and rinsing. Using more chemical than recommended does not necessarily improve cleaning and may create safety, corrosion, wastewater, or residue problems.
Like Clean-In-Place procedures, operations cleaning depends on a balance of time, mechanical action, chemical strength, and temperature. If one factor is reduced, another may need to increase to achieve the same cleaning result.
5. Use Mechanical Action
Cleaning chemicals help loosen and break down residue, but they do not always remove it by themselves.
Mechanical action may include:
- Scrubbing with a brush
- Wiping with a cloth or pad
- Using a floor scrubber
- Scraping heavy buildup
- Using controlled water flow
Pay particular attention to corners, joints, equipment feet, guards, brackets, and other areas where residue can collect.
Cleaning tools should be suitable for the surface. Brushes and pads that are too aggressive can scratch stainless steel, remove protective coatings, or create damaged surfaces that become harder to clean in the future.
6. Clean Equipment Exteriors
Clean equipment from the top down so loosened residue does not fall onto surfaces that have already been washed.
Equipment exterior cleaning may include:
- Tanks and vessel exteriors
- Tank legs and supports
- Pumps and piping supports
- Conveyors
- Fillers and cappers
- Machine frames and guards
- Work tables
- Handles and operator touchpoints
Do not assume every machine can be cleaned with a hose or pressure washer. Electrical enclosures, motors, bearings, sensors, control panels, and other components may require controlled spraying, wiping, covering, or another cleaning method.
Always follow the equipment manufacturer's cleaning instructions and confirm the washdown rating of electrical and mechanical components before applying water.
7. Clean Floors and Drains
After equipment and elevated surfaces have been cleaned, wash the floors.
Move water and residue toward the appropriate drain using squeegees or approved floor-cleaning equipment. Remove solid material before it reaches the drain whenever possible.
Pay attention to:
- Areas underneath equipment
- Floor-wall joints
- Tank feet
- Conveyor supports
- Low spots where water collects
- Cracked or damaged flooring
Standing water should not be treated as a normal condition. It can create slip hazards, encourage microbial growth, attract pests, and hide damaged floors or blocked drains.
Drains require their own cleaning tools and procedures. Simply flushing product residue into a drain may move the problem rather than remove it.
8. Rinse and Sanitize Where Required
After detergent cleaning, rinse surfaces as required to remove loosened residue and cleaning chemical.
Some surfaces may also require sanitizing, particularly where there is a risk of product contact or contamination. Cleaning and sanitizing are different steps:
- Cleaning removes soil, residue, grease, and other physical material.
- Sanitizing reduces microorganisms on a surface that has already been cleaned.
Sanitizer should not be used as a replacement for cleaning. Dirt and product residue can reduce its effectiveness.
Follow the sanitizer manufacturer's instructions for concentration, contact time, temperature, compatibility, and whether a final rinse is required.
9. Return Tools and Materials to Their Designated Locations
Once cleaning is complete, return hoses, brushes, squeegees, buckets, tools, chemicals, and personal protective equipment to their designated storage areas.
This supports the Set in Order principle of 5S. Proper storage makes equipment easier to find, protects it from damage, and makes missing or dirty tools easier to identify.
Hoses should be drained and stored off the floor. Brushes, squeegees, and other cleaning tools should be cleaned, allowed to dry, and stored in a way that prevents cross-contamination.
10. Perform a Final Inspection
Before the washdown is considered complete, perform a final walkthrough as if you were the next employee arriving to begin production.
Check for:
- Remaining product residue
- Standing water
- Leaks or dripping connections
- Garbage or packaging left behind
- Tools that were not returned
- Open chemical containers
- Damaged hoses or gaskets
- Loose guards or fasteners
- Blocked drains
- Equipment that is not ready for production
Document the cleaning according to your facility's procedures. Any maintenance, safety, or sanitation concerns discovered during the washdown should be reported and corrected before the equipment returns to service.
Protecting Equipment During Cleaning
Cleaning equipment is essential, but using the wrong cleaning method can shorten equipment life, damage sensitive components, and lead to costly repairs. Before using a hose or pressure washer, understand how the equipment was designed to be cleaned.
Food and beverage equipment often includes electrical components, bearings, sensors, motors, pneumatic systems, and control panels that require special consideration during cleaning. Always follow the equipment manufacturer's cleaning recommendations whenever possible.
Not Every Machine Should Be Pressure Washed
A common misconception is that higher water pressure results in better cleaning. While pressure washers can be useful for floors, drains, and certain heavily soiled equipment, they are not appropriate for every application.
Washdown Tip: Water-resistant does not mean pressure-washer safe. Before cleaning electrical equipment, bearings, motors, sensors, or control panels, verify the manufacturer’s cleaning instructions and the equipment’s NEMA or IP rating. High-pressure water can force moisture past seals that would withstand normal splashing or lower-pressure washdowns.
High-pressure water can:
- Force water past seals and gaskets.
- Wash lubricant from bearings and moving components.
- Damage sensors and electrical connectors.
- Drive contaminants into areas that are difficult to clean.
- Increase wear on painted and coated surfaces.
- Create aerosols that spread contamination throughout the production area.
Whenever practical, begin with the least aggressive cleaning method that will effectively remove the soil. Brushes, foaming systems, low-pressure rinse hoses, and appropriate detergents often clean more effectively than excessive water pressure alone.
Understanding NEMA and IP Ratings
Many food processing machines include electrical enclosures designed to resist water, but "water resistant" does not mean they can withstand every cleaning method.
Electrical equipment is commonly rated using either NEMA (National Electrical Manufacturers Association) or IP (Ingress Protection) standards. These ratings describe how well an enclosure protects its internal components from dust and water.
| Rating | Typical Protection | Typical Applications |
|---|---|---|
| NEMA 4 | Protection against rain, splashing water, and hose-directed water. | General washdown equipment. |
| NEMA 4X | Same protection as NEMA 4 with additional corrosion resistance. | Food and beverage processing environments. |
| IP65 | Dust-tight and protected against low-pressure water jets. | General industrial equipment. |
| IP66 | Dust-tight and protected against powerful water jets. | Heavy-duty industrial environments. |
| IP69K | Designed for high-pressure, high-temperature washdowns. | Equipment specifically designed for aggressive food processing sanitation. |
Important: A NEMA 4 or IP65 enclosure is not automatically designed to withstand close-range, high-pressure pressure washing. Directing a pressure washer at seals, cable entries, push buttons, or display screens can force water past seals, even when the enclosure is correctly rated.
Protect Sensitive Components
During every cleaning procedure, pay particular attention to:
- Electrical panels and junction boxes.
- Operator touchscreens (HMIs).
- Photoelectric sensors and proximity switches.
- Electric motors.
- Bearings and lubricated components.
- Pneumatic valves and air regulators.
- Variable frequency drives (VFDs).
Some components are best cleaned by wiping with a damp cloth or using low-pressure water rather than direct spraying. Always follow the equipment manufacturer's recommendations.
Inspect While You Clean
Cleaning is also one of the best opportunities to inspect equipment for early signs of wear or damage.
Look for:
- Damaged hoses or fittings.
- Worn or cracked gaskets.
- Loose fasteners.
- Oil, air, or product leaks.
- Corrosion.
- Damaged conduit or electrical connections.
- Missing guards.
- Unusual vibration or noise.
Identifying these issues during routine cleaning allows maintenance to correct small problems before they become expensive repairs or unplanned production downtime.
Cleaning should protect your equipment—not shorten its service life. Choosing the appropriate cleaning method for each surface helps maintain food safety while maximizing the life and reliability of your production equipment.
Choosing and Using Cleaning Chemicals Safely
Selecting the right cleaning chemical is just as important as selecting the correct cleaning method. Different soils require different cleaners, and not every chemical is compatible with every piece of equipment.
The objective is to remove the soil without damaging the equipment, creating a safety hazard, or leaving residues that could affect product quality.
Choose the Right Cleaner for the Job
Cleaning chemicals are generally designed to remove specific types of contamination.
- Alkaline cleaners are commonly used to remove organic soils such as proteins, fats, sugars, and carbohydrates.
- Acid cleaners help dissolve mineral deposits such as beerstone, milkstone, hard water scale, and other inorganic residues.
- Neutral detergents are often used for lighter cleaning applications or where more aggressive chemicals may damage equipment.
- Sanitizers reduce microorganisms after cleaning but should never be used as a substitute for removing visible soil.
Before changing chemicals, make sure they are compatible with your equipment and suitable for the residue being removed.
Always Follow Manufacturer Recommendations
Both the chemical supplier and the equipment manufacturer provide important information about safe cleaning procedures. Always review their recommendations before introducing a new cleaning chemical or changing your cleaning process.
Pay particular attention to:
- Recommended concentration.
- Water temperature.
- Required contact time.
- Material compatibility.
- Whether rinsing is required before returning equipment to service.
Using higher concentrations or extending contact times beyond the manufacturer's recommendations rarely improves cleaning performance. Instead, it may increase chemical costs, damage equipment, create unnecessary safety hazards, or leave unwanted residues behind.
Bleach and Chlorine-Based Cleaners
Bleach and other chlorine-based cleaning products deserve special attention. While they can be effective cleaning and sanitizing agents, they can also damage stainless steel and other materials if used incorrectly.
High concentrations, excessive contact times, inadequate rinsing, or repeated exposure may contribute to staining, pitting corrosion, and premature equipment failure. This is particularly important for stainless steel equipment, where chloride-induced corrosion can permanently damage product-contact surfaces.
If bleach or chlorine-based cleaners are recommended, carefully follow both the chemical manufacturer's operating instructions and the equipment manufacturer's cleaning procedures. Pay close attention to required rinse times and maximum contact times before returning equipment to production.
Chemical Compatibility Warning: Bleach and other chlorine-based cleaners can damage stainless steel if used incorrectly. Always follow both the chemical manufacturer's instructions and the equipment manufacturer's cleaning recommendations, paying close attention to concentration, contact time, and rinse requirements. More chemical or longer exposure does not necessarily improve cleaning—it can increase the risk of corrosion and shorten equipment life.
Never Mix Cleaning Chemicals
Cleaning chemicals should only be mixed when specifically instructed by the manufacturer. Mixing incompatible chemicals can produce dangerous reactions, reduce cleaning effectiveness, or damage equipment.
For example, mixing bleach with acidic cleaners can release hazardous chlorine gas, while combining certain detergents may reduce the effectiveness of both products.
Always prepare cleaning solutions according to the manufacturer's instructions and use appropriate personal protective equipment.
Store Chemicals Safely
Once cleaning is complete, return chemicals to their designated storage area.
Keep containers clearly labelled, tightly sealed, and stored according to the manufacturer's recommendations. Store incompatible chemicals separately and ensure Safety Data Sheets (SDSs) remain readily available for employees.
Proper chemical selection, handling, and storage protect both your employees and your equipment while helping maintain a consistent, effective sanitation program.
Common Operations Cleaning Mistakes
Even experienced facilities can develop cleaning habits that reduce effectiveness, damage equipment, or create food safety risks. Recognizing these common mistakes can improve sanitation while reducing cleaning time and maintenance costs.
Using Water Before Removing Dry Debris
Water should not be the first step in every cleaning procedure. Dry ingredients such as flour, sugar, coffee, grain dust, and powdered products are often easier to remove before water is applied.
Removing loose material first reduces wastewater, prevents blocked drains, and avoids creating sticky residues that are more difficult to clean.
Using Sanitizer Instead of Cleaning
Sanitizers reduce microorganisms, but they do not remove dirt, grease, proteins, or product residues.
Cleaning and sanitizing are separate steps. Surfaces should always be cleaned before sanitizer is applied.
Using Too Much Cleaning Chemical
More chemical does not necessarily result in better cleaning. Excessive concentrations may increase costs, damage equipment, leave residues, and require additional rinsing.
Always prepare cleaning solutions according to the manufacturer's recommendations.
Pressure Washing Everything
Pressure washers are valuable tools, but they are not appropriate for every surface. Bearings, electrical enclosures, sensors, motors, and operator interfaces may require lower-pressure cleaning or manual wiping.
When in doubt, follow the equipment manufacturer's cleaning recommendations.
Ignoring Hard-to-Reach Areas
Residue often accumulates underneath conveyors, around equipment feet, behind guards, beneath piping, and inside floor drains.
These hidden areas should be included in routine inspections and cleaning schedules.
Using the Same Cleaning Tools Everywhere
Cleaning tools can become a source of contamination if they are used throughout the facility without consideration for risk.
Many facilities colour-code brushes, squeegees, and other cleaning equipment to separate drains, floors, production equipment, and food-contact surfaces.
Leaving Standing Water Behind
Standing water creates slip hazards, encourages microbial growth, and may indicate blocked drains or uneven flooring.
A successful washdown removes water as well as soil.
Skipping the Final Inspection
Before production resumes, perform one final walkthrough.
Look for remaining residue, forgotten tools, chemical containers, damaged equipment, standing water, or anything else that could delay production or affect food safety.
Small issues identified during cleaning are often much easier and less expensive to correct than problems discovered after production has started.
Daily Operations Washdown Checklist
Every facility has different cleaning requirements, but a consistent checklist helps ensure important tasks are completed before production resumes. The following checklist can be adapted to suit breweries, distilleries, wineries, dairies, beverage manufacturers, and food processing facilities.
Before Cleaning
- ☐ Production has stopped safely.
- ☐ Required PPE is being worn.
- ☐ Cleaning chemicals have been prepared correctly.
- ☐ Ingredients and finished products have been removed or protected.
Production Area
- ☐ Garbage, cardboard, and packaging have been removed.
- ☐ Loose powders and debris have been dry cleaned.
- ☐ Equipment exteriors have been cleaned.
- ☐ Floors have been washed.
- ☐ Drains have been cleaned.
- ☐ Standing water has been removed.
Equipment Protection
- ☐ Electrical equipment has been cleaned using the appropriate method.
- ☐ Bearings, sensors, and motors have not been exposed to unnecessary high-pressure water.
- ☐ No leaks or equipment damage were observed during cleaning.
5S and Organization
- ☐ Hoses have been drained and stored correctly.
- ☐ Brushes, squeegees, and tools have been cleaned and returned to their designated locations.
- ☐ Chemicals have been sealed and stored safely.
- ☐ The production area is organized and ready for the next production run.
Final Inspection
- ☐ No visible product residue remains.
- ☐ No standing water remains.
- ☐ Drains are clear.
- ☐ Equipment is clean and ready for use.
- ☐ Maintenance concerns have been reported.
- ☐ Cleaning has been documented according to facility procedures.
A consistent cleaning routine supports Good Manufacturing Practices (GMPs), reduces contamination risks, improves equipment reliability, and helps ensure every production day begins with a clean, safe, and organized workplace.
Conclusion
Effective operations cleaning is about much more than keeping a facility looking clean. A well-planned washdown program helps reduce contamination risks, improve employee safety, extend equipment life, and prepare the production area for the next manufacturing run.
Combined with effective Clean-In-Place (CIP) procedures, proper Clean-Out-of-Place (COP) cleaning, and a strong 5S program, routine operations cleaning becomes an essential part of Good Manufacturing Practices (GMPs).
Every facility is different, and your cleaning procedures should reflect your products, equipment, and regulatory requirements. Always follow the recommendations provided by your equipment manufacturers and cleaning chemical suppliers, and regularly review your cleaning program to identify opportunities for improvement.
At Gorman & Smith, we work with breweries, distilleries, wineries, beverage producers, and food manufacturers across North America to supply sanitary process equipment, cleaning accessories, and technical expertise. Whether you're designing a new production facility or improving an existing sanitation program, we're here to help.
Looking for more technical resources? Explore our growing library of articles covering Clean-In-Place (CIP), sanitary fittings, valves, process equipment, and best practices for food and beverage manufacturing.
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