Case Study Food Processing Sanitation - Sublimate Technologies

Oven and Conveyor Sanitation for a Regional Bakery Operation

How chemical-free dry ice blasting delivered USDA-aligned sanitation in half the time — with zero water, zero chemical residue, and zero wastewater.

Key Results

~50%

CLEANING TIME

Faster than chemical wash cycle

Zero

WASTEWATER

No water used in the process

Zero

CHEMICAL RESIDUE

Nothing to rinse or verify

The Situation

A regional commercial bakery operating in Central Indiana produces high-volume bread, roll, and baked snack products across multiple production lines. The facility runs continuous oven systems with steel-mesh conveyor belts, dough forming equipment, packaging conveyors, and exhaust hoods — all subject to USDA and FDA sanitation requirements and third-party food safety audits.

Over weeks of continuous production, the equipment accumulates layers of baked-on carbon, caramelized sugar residue, grease, dough buildup, and allergen traces (wheat, soy, dairy, and egg proteins from different product runs). These deposits affect heat transfer efficiency in the ovens, create contamination transfer risk between product changeovers, and present findings during sanitation audits.

The Challenge

The facility’s standard deep-cleaning protocol involved:

Oven cool-down period (2–4 hours depending on oven bank)
Manual scraping of baked-on carbon from oven interiors, conveyor frames, and heating elements
Application of caustic cleaning chemicals and degreasers
Pressure washing and rinse cycles to remove chemical residue
Drying time before re-energizing electrical components and ovens
Post-clean chemical residue verification swabs
Oven reheat to operating temperature before production restart

Total downtime for a full deep-clean: 10–14+ hours per oven system. The process consumed a full overnight maintenance window and frequently ran over schedule, delaying the next production shift. Water from pressure washing created slip hazards on the floor, drove moisture into conveyor bearings and insulated panels, and generated contaminated wastewater requiring proper disposal.

The sanitation team also reported inconsistent results from manual scraping — baked-on carbon in corners, seams, and behind conveyor supports was difficult to reach and often survived the cleaning cycle, leading to re-clean requests and audit findings.

How We Work

1. Pre-Clean Assessment and Sanitation Plan

Sublimate Technologies conducted an assessment of the oven systems, conveyor configuration, contamination types, and the facility’s sanitation requirements (USDA alignment, allergen protocol, documentation needs). A custom sanitation plan was developed specifying equipment-specific techniques, nozzle configurations, and a cleaning sequence designed to minimize total downtime and maximize the overnight maintenance window.

2. Systematic Equipment Cleaning

Starting with the oven interiors and moving outward to conveyor sections, forming equipment, and packaging lines, the crew worked through the sanitation plan in a sequenced order. Oven interiors were cleaned with pressure and media settings calibrated for carbon removal on steel and stainless surfaces. Conveyor belts and frames were cleaned on both sides — product-contact surfaces and the underside where buildup accumulates unnoticed.

3. Allergen-Sensitive Areas

Particular attention was given to areas identified in the facility’s allergen control plan: product changeover zones, conveyor transitions, forming equipment contact surfaces, and areas around ingredient hoppers. The dry, residue-free cleaning process removed allergen deposits without introducing water that could spread proteins or create moisture conditions for microbial growth.

4. Exhaust Hood and Ductwork

Grease-laden exhaust hoods above the oven banks were cleaned using dry ice blasting rather than traditional chemical foam and pressure wash. This eliminated chemical fumes in the production area and removed the need for floor-level water containment during hood cleaning.

5. Containment and Documentation

Removed contaminant (carbon, grease, food residue) was captured using floor-level containment methods. Before and after photos were taken at each station. Scope completion documentation was provided for the facility’s sanitation records, HACCP logs, and audit trail.

Results

Cleaning Time: Approximately 50% Faster

The full sanitation scope — oven interiors, conveyors, forming equipment, packaging lines, and exhaust hoods — was completed within the standard overnight maintenance window with time to spare. The elimination of chemical application, rinse cycles, and drying periods was the primary time savings driver. Oven reheat could begin immediately after cleaning without waiting for moisture to evaporate.

Zero Water Used

No pressure washing was performed during the dry ice blasting sanitation. This eliminated wastewater generation, floor slip hazards, moisture intrusion into bearings and electrical components, and the need for post-clean drying time.

Zero Chemical Residue

No caustic chemicals, degreasers, or cleaning solvents were used. This eliminated chemical residue verification steps, chemical purchasing and storage costs, worker chemical exposure, and chemical disposal requirements.

More Thorough Clean

Dry ice blasting reached areas that manual scraping and chemical wash could not effectively clean: behind conveyor supports, inside oven seams, around bolt heads and bracket connections, and underneath conveyor rollers. The facility’s sanitation supervisor noted visibly cleaner results in areas that had historically been problematic during audits.

Audit-Ready Documentation

Before/after photographic records and scope completion notes were provided in a format ready for insertion into the facility’s HACCP records, sanitation logs, and third-party audit documentation. This reduced the administrative burden on the sanitation team following the clean.

Key Takeaways

Dry ice blasting provided USDA-aligned, chemical-free sanitation for ovens, conveyors, and packaging equipment

Total cleaning time reduced by approximately 50% vs. the chemical wash and pressure rinse protocol

Zero water, zero chemicals, zero wastewater — eliminating multiple cost and compliance factors

Reached areas manual methods could not, improving audit readiness in historically problematic zones

Custom sanitation plan developed around the facility's specific equipment, allergen protocol, and maintenance schedule

Full documentation provided for HACCP, sanitation logs, and third-party food safety audits

Ready to bring chemical-free, residue-free sanitation to your processing facility?

Contact us for a free sanitation assessment. We will evaluate your equipment, contamination, and compliance requirements and recommend a custom approach.