What Does Open Plant Cleaning Include in a Food Factory?
In the food processing industry, cleaning is not a single activity—it is a structured system. Understanding the distinction between different cleaning methods is essential for food safety professionals, auditors, and plant managers. One term that frequently appears in food factory cleaning protocols is Open Plant Cleaning (OPC).
What Is Open Plant Cleaning (OPC)?
Open Plant Cleaning, abbreviated as OPC, stands for "Open Plant Cleaning" —a term commonly used in the food and beverage industry to describe the cleaning of external surfaces of equipment, machinery, walls, floors, and other open areas within a production facility.
Unlike CIP (Clean-In-Place), which involves circulating cleaning fluids through enclosed pipes and tanks, or COP (Clean-Out-of-Place), which requires disassembling and removing parts for cleaning, OPC focuses on the external and visible surfaces of the plant.
As explained in industry training materials: "Today we only talk about this machine as an open cleaning machine. Open cleaning, we remember its simplest concept, is cleaning the outside of the machine."
The Four Essential Elements of OPC
Effective open plant cleaning relies on four critical factors, often referred to as the "Four Elements of Cleaning" :
Element | Role in Open Plant Cleaning |
Temperature | Heat enhances the chemical activity of cleaning agents, helping to break down grease and organic soils more effectively. |
Chemical Action | Detergents and cleaning agents chemically react with soils, emulsifying fats and dispersing solids for easy removal. |
Mechanical Force | In OPC, this is primarily provided by high-pressure water (typically 20–25 kg/cm²) and foam application. |
Time | The cleaning agent must remain in contact with the surface long enough to work. In foam cleaning, 10–15 minutes of contact time is standard. |
Key Components of an OPC Program
1. High-Pressure Rinsing
The first step in most OPC procedures is a pre-rinse using high-pressure water to remove loose debris and wet the surface. In food factories, pressures of 20–25 kg/cm² are common, significantly higher than standard water supply pressure (about 3 kg/cm²).
2.Foam Cleaning
Foam cleaning is the hallmark of OPC. A specialized foam cleaning agent (typically alkaline for grease removal) is mixed with water and compressed air to create a thick, clinging foam. The foam is sprayed onto vertical and horizontal surfaces, where it:
- Provides long contact time due to its clinging ability
- Allows visual confirmation of coverage (white foam is easily seen)
- Delivers uniform chemical action across complex surfaces
3.Disinfection
After cleaning, a disinfectant is applied to kill remaining microorganisms. In OPC, this is often done using a low-pressure spray system, ensuring thorough coverage of all treated surfaces.
4. Final Rinse (Optional)
Depending on the facility's protocol and the chemicals used, a final rinse with potable water may follow disinfection.
Equipment Used in OPC
Modern OPC programs rely on specialized equipment such as:
- Multi-functional foam cleaning stations (e.g., EFC-325) that integrate high-pressure water, foam generation, and disinfection into one unit
- Mobile foam cleaning trolleys for flexibility across different production zones
Color-coded nozzles and wands to prevent cross-contamination between cleaning modes
Therefore, Open Plant Cleaning is a comprehensive approach to maintaining hygiene on the external surfaces of food processing equipment and facilities. By combining temperature, chemical action, mechanical force, and time—delivered through high-pressure rinsing, foam cleaning, and disinfection—OPC ensures that every visible surface in the production environment meets food safety standards.
For food factories seeking compliance with BRC, SQF, or FSSC 22000, a well-defined OPC program is not optional—it is essential. Understanding what OPC includes is the first step toward building a defensible, effective cleaning protocol.
Contact
Leave your information and we will contact you.
WONE Hygiene Technology Co., Ltd.
WONE Hygiene Technology Co., Ltd.
Products
Products
Application Industry
Application Industry
Contact
Contact
Whether you're building a new food factory, upgrading your production line, or undergoing factory audits and renovations, we can provide you with cleaning and disinfection equipment and hygiene planning support tailored to your industry needs.
Meat processing
Poultry food
Dairy processing
Bakery and confectionery
Seafood & fish processing
Pet Food Manufacturing
Central kitchens
Beverage and alcohol production
Sauce and seasoning manufacturing
Contact Person: Dean Li
008618028007427
W008618028007427
WhatsApp
微信
其他