“The cheese processing company has five
‘high care areas’ that require daily cleaning and sanitising after production.”
Cheese without the chemicals
In this Case Study, JS Bailey becomes UK’s first food manufacturer to install non-chemical cleaning system.
JS Bailey is extremely proud of its heritage, as well as its locality – based in a region (Cheshire) which has an undisputed reputation for cheese making. As a leading supplier to the food services industry, JS Bailey describes itself as the ‘home of homemade cheese’ – churning out high quality goods from its state-of-the-art production facility.
High standards are everything and JS Bailey does not compromise on any aspect, injecting £3m of capital investment into the business in 2019 – funding that has created a new production and storage unit allowing it to significantly increase production volume. This combines with the introduction of three additional grating lines, increasing the capacity of the business and allowing further growth into the food service, manufacturing and export markets.
Such is the commitment to growth and maintaining exceptional levels of production, that no stone is left unturned in the manufacturing process. The cheese processing company has five ‘high care areas’ (areas of food preparation), that require daily cleaning and sanitising after production. Areas of operation include grating, re- milling, cutting and processing out of specification cheese.
Understandably, the issue of cleanliness is vital around food preparation areas, in order to combat micro- organisms like Listeria, mould and spores, especially as cheese is a natural produce.
Due to its location, JS Bailey does not have mains drainage; it has its own on-site water treatment system. And that was why it’s even more important that cleaning chemicals aren’t allowed to seep into the treatment tanks – these being alkaline detergents and chlorine-based sanitisers.
52 | FEATURE: CASE STUDY
James Beattie, Director at DEB Disposables and cleaning products supplier to JS Bailey, explained: “This problem led to the research and trial of the Toucan Eco – the hypochlorous-based bio cleaning solution. As a company wanting to improve their environmental credentials but having issues finding the right solution, they contacted me and asked, ‘Can you help?’. It was then that we introduced them to Toucan Eco.”
David Chesworth, QA Manager at JS Bailey, commented: “After trialling the effectiveness of hypochlorous solution, as a sanitiser in our production facility, and finding it to be at least as effective as the chemicals that were in current use, we purchased the Toucan Eco system in October 2019.
“The hypochlorous solution now accounts for 99% of the sanitiser used in the production facility and since implementing the change-over from a chemical- (chlorine) based sanitiser, there have been no failures of swabbing results.
“A major advantage of the solution as a sanitiser over chemicals is that microbes can build a resistance to chemicals over time and so higher concentrations are required to maintain effectiveness. This does not apply to hypochlorous acid as the solution destroys the cell wall of the microbes.”
JS Bailey invested in a Toucan Eco Active (10 litres) for factory use, together with a Toucan Eco III (1 litre) unit. The solution, which is made in only 20 minutes, effectively kills 99.999% of bacteria, destroying micro-organisms, both quickly and comprehensively, while providing protection to water, surfaces, fabrics and people.
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