Safe Handling and Use of Detergents and Sanitizers in Dairy Plants

Cleaning and sanitization are non-negotiable in a dairy plant – but the chemicals that make it all possible can be seriously hazardous if mishandled. Detergents and sanitizers used in milk processing range from strong alkalis and acids to chlorine-based compounds, all of which can cause severe burns and equipment damage when used incorrectly. Safe and effective sanitation, therefore, depends not just on choosing the right products, but on handling them the right way – every single time.

Why safe chemical handling matters in dairy plants 🔗

A dairy plant is a food production environment where hygiene and safety overlap constantly. The same chemicals that destroy pathogens on processing equipment can injure workers, corrode machinery, or leave harmful residues in milk products if used without care. Failure to follow documented chemical handling protocols is dangerous to workers and damaging to the company – and the consequences can range from a contaminated batch of milk to a hospitalized employee. Establishing clear, consistently followed instructions for the use of detergents and sanitizers is, therefore, a core operational responsibility in any dairy facility.

Understanding and following the Safety Data Sheet (SDS) 🔗

Every chemical used in a dairy plant – whether an alkaline detergent, an acid cleaner, or a chlorine-based sanitizer – must be accompanied by a Safety Data Sheet (SDS), formerly known as the Material Safety Data Sheet (MSDS). The SDS is a standardized document that contains crucial occupational safety and health information, including chemical properties, physical and health hazards, recommended protective measures, and safety precautions for handling, storage, and transport.

The SDS is structured into 16 sections, covering everything from hazard identification and first-aid measures to exposure controls, PPE requirements, handling and storage precautions, and disposal guidelines. For dairy plant personnel, the most immediately relevant sections are those on first-aid measures, accidental release procedures, PPE requirements, and safe storage.

Keeping SDS accessible and current 🔗

OSHA’s Hazard Communication Standard requires that SDS be readily accessible during each work shift to employees when they are in their work area. In a dairy plant, this means SDS files – whether physical binders or digital records – must be stored where all staff can reach them during working hours, not behind locked doors or on password-protected devices that workers cannot access. Electronic copies must also have a backup option in case of power failure.

It is equally important that SDS records are kept current. The SDS master file should be used to conduct a yearly audit of all process operations to ensure that only approved chemicals are being used, and any chemicals taken out of service should be recorded for a permanent usage history.

Selecting chemicals compatible with equipment 🔗

Not all detergents and sanitizers are suitable for all types of dairy equipment. Chemical cleaners, when improperly used, have damaged equipment and hospitalized staff. Dairy plants use a wide variety of materials – stainless steel, rubber gaskets, plastic components, and specialized coatings – each of which responds differently to different chemicals.

For instance, chlorine-based sanitizers are widely used but can corrode certain metals over time, particularly when used at incorrect concentrations. Some sanitizing compounds lose strength with time in storage, while others are not compatible with hard water or are unstable at higher temperatures. Acid cleaners, similarly, can degrade rubber seals if used at the wrong concentration or temperature.

Before introducing any new chemical into a cleaning program, plant managers should verify compatibility with all equipment materials. Equipment manufacturers typically provide compatibility charts, and chemical suppliers should be consulted when selecting detergents for specialized systems. One cannot overemphasize the need to consult your detergent supplier and follow their recommendations for selection and concentration of detergents.

Never mix incompatible chemicals 🔗

Mixing the wrong chemicals together is one of the most dangerous mistakes in dairy sanitation. Never blend acid with caustic, never blend acid with chlorine, and never add water to a chemical concentrate – always add chemicals to water. These rules must be communicated clearly to every employee who handles cleaning products, and they should be displayed prominently in chemical preparation areas.

Safe storage of detergents and sanitizers 🔗

Where and how chemicals are stored directly affects both worker safety and product integrity. Detergents and sanitizers must be stored in a dedicated area, physically separated from the milk processing zone, ingredients, packaging materials, and any food-contact items. Cleaners and sanitizers should never be stored above or close to ingredients, packaging supplies, single-service items, or product contact items – they should be stored in a separate location from production, properly labeled.

All chemicals and lubricants shall be stored in locked and properly labeled facilities, clearly marked with signage that states “Authorized Personnel Only” and that hazardous materials are stored in this location. Storage containers should be kept tightly sealed to prevent vapor release into the surrounding air.

Ventilation in chemical storage areas 🔗

Adequate ventilation in chemical storage rooms is a non-negotiable safety requirement. Chemicals can release dangerous fumes even when stored safely, and inhaling chemical vapors can have a devastating impact on worker health. OSHA standards specify that every inside chemical storage room must be provided with either a gravity or mechanical exhaust ventilation system, designed to provide a complete change of air within the room at least six times per hour.

In practical terms, this means chemical storage rooms in dairy plants should have functioning exhaust fans or ventilation systems that run continuously during working hours, with proper airflow directed away from food production areas. The storage room should be on the cooler side and should be lighted so that labels can be read clearly. Storage drum openings should be kept tight to prevent chemical dissipation into the air, and containment pallets or spill-control devices should be in place to manage any leaks.

Personal protective equipment (PPE) for chemical handling 🔗

Personnel who handle, dilute, or apply detergents and sanitizers must always wear appropriate personal protective equipment (PPE). Equipment shall include, but need not be limited to: eye protection, gloves, aprons, and boots. Breathing gear may be necessary. Equipment shall be inspected regularly to ensure that it remains in good condition.

The type of PPE required varies by chemical. The SDS for each product specifies what protection is needed. Acid-resistant gloves, chemical splash goggles, and full-length aprons are typically required when handling concentrated alkalis or acids. Detergent-acid resistant gloves and proper safety eye protection or a face shield are essential when working with concentrated dairy cleaning chemicals.

PPE should be stored near the chemicals it is intended for, or in an easily accessible nearby location. A real-world caution: a well-documented case from a sanitation workshop described a cleanup crew member who nearly lost his sight when he got caustic cleaner in his eyes because he was not wearing the required eye protection – even though he had attended a safe chemical handling session that specifically addressed that chemical. Attending training is only the first step; consistent, daily PPE use is what actually protects workers.

Training personnel in chemical safety 🔗

All personnel who work with or around cleaning chemicals must receive formal, documented training before they begin handling those chemicals. Employers must provide information and training to workers who might be exposed to hazardous chemicals. New workers must be trained before they first work with a hazardous chemical, and all workers must be trained when a new hazard is introduced to the workplace.

Training should cover the following areas: how to read and use the SDS; correct dilution ratios and mixing procedures; compatible and incompatible chemicals; PPE requirements for each product; emergency procedures for spills, skin contact, or accidental ingestion; and the location of eyewash stations and first-aid equipment. Practical applications may include the safe dilution of cleaning agents or the correct use of PPE when handling corrosive substances.

Records of all training sessions must be maintained in employee personnel files. This documentation is important not only for regulatory compliance but also for identifying gaps – if an incident occurs, training records help determine whether instructions were provided and followed.

Refresher training and supervision 🔗

Initial training is not enough on its own. Chemical handling practices can become careless over time, especially when nothing seems to go wrong. Regular refresher sessions, visual reminders in the workplace, and active supervisory oversight are all necessary to maintain consistent standards. Regular refresher training reinforces safe practices and ensures that updates – such as changes in chemical products or new equipment – are communicated to all relevant staff.

Handling chemical spills and emergencies 🔗

Despite precautions, spills and accidents do happen. Every dairy plant should have a clear, rehearsed response plan for chemical spills or accidental exposure. The SDS for each chemical specifies the correct spill containment and cleanup procedures, as well as first-aid measures for skin contact, eye exposure, and ingestion.

Any clothing contaminated by chemical detergent should be removed immediately and the affected area flushed thoroughly. Medical assistance should be obtained at once. Eyewash stations and emergency showers should be located close to chemical use and storage areas, regularly inspected, and clearly signposted. Empty chemical containers must also be thoroughly rinsed and disposed of in accordance with local environmental regulations – they should never be reused for other purposes.

Disposing of chemicals responsibly 🔗

Proper disposal of spent or expired chemicals is the final link in the safe handling chain. Diluted cleaning solutions used in standard CIP or manual cleaning cycles are generally disposed of through drain systems, but concentrated or unused chemicals require a different approach. Old or waste chemicals should be disposed of by generating a work order to the physical plant, with proper documentation that the chemicals have been properly eliminated. The SDS and supplier documentation for each chemical describe the correct disposal method, including neutralization requirements and local regulatory requirements that must be met.

Responsible disposal also protects the surrounding environment. Plant efficiency and the need for sanitary, high-quality milk products mandate the wise use of various cleaning chemicals, and that wise use extends to how they leave the facility.

What do you think? How confident are you that every person in your dairy plant who handles cleaning chemicals has received proper training and has access to the relevant SDS at any given moment? And when was the last time your chemical storage area was inspected for compliance with ventilation, labeling, and separation requirements?

References

1. https://www.bccdc.ca/resource-gallery/Documents/Educational%20Materials/EH/FPS/Food/DairyProcessingCleaning.pdf
2. https://www.food-safety.com/articles/10967-safe-chemical-handling-and-storage
3. https://chemicalsafety.com/sds-search/
4. https://danielstraining.com/the-sixteen-16-sections-of-the-safety-data-sheet-sds/
5. https://ehs.research.uiowa.edu/chemical/safety-data-sheets-sdss
6. https://www.thedairysite.com/articles/686/cleaning-and-sanitizing-milking-equipment
7. https://health.maryland.gov/phpa/OEHFP/OFPCHS/Milk/Shared%20Documents/DPC029_Cleaning_Sanitizing_Fluid_Milk_Plants.pdf
8. https://www.foodprotection.org/upl/downloads/publications/other/free-pdf-file.pdf
9. https://eldridgeusa.com/blog/chemical-processing-storage-industrial-fans-and-ventilation/
10. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.106
11. https://ohioline.osu.edu/factsheet/aex-892229
12. https://blog.foodsafety.ca/from-msds-to-sds-understanding-whmis-safety-data-sheets-in-the-food-industry