By Adel Makdesi, M.S., TS and Development Leader, Food and Beverage North America, Enviro Tech Chemical Services Inc.

In an industry where safety and compliance are not just priorities but also necessities, the introduction of Food Safety Modernization Act (FSMA) Section 204 has set new benchmarks. As the deadline of January 2026 inches closer, the need for a comprehensive and effective approach to achieving compliance is paramount. Enter FoodReady—your ultimate partner in not just meeting, but also excelling, in FSMA 204 compliance.

Harmful pathogens are a critical concern for food production facilities. Plant sanitation and safety have been in the news: the U.S. Food and Drug Administration (FDA) estimates more than 48 million cases of foodborne illness in the U.S. each year.¹

Antimicrobial treatments with chemistries like peracetic acid (PAA) are among the most effective methods for controlling microbial contamination in food production facilities.

Diligent cleaning and sanitizing are essential for safe food processing, preparation, and manufacturing. However, cleaning and sanitizing your food plant can be complex and multifaceted. Improperly cleaned and sanitized surfaces can result in foodborne pathogens—such as Listeria monocytogenes, Salmonella, and Escherichia coli—contaminating food processing areas. These contaminants can then make their way to other surfaces and, ultimately, into the food being produced.

The most effective way to remove these harmful pathogens is to destroy them where they breed, especially on floors and other surfaces (Figure 1).

Plant Sanitation Challenges

Keeping an entire food processing plant clean requires specific tools and procedures, along with a proper understanding of how to eliminate and control foodborne pathogens. Plants face ongoing challenges with sanitizer rotation and preventing microbial resistance. Overuse of quaternary ammonium sanitizers, for example, has led to resistant strains of Listeria in some facilities.

A 2023 study² published in the Journal of Food Protection found that commonly used sanitizers, like quaternary ammonium compounds and chlorine-based products, effectively reduced bacterial loads on food contact surfaces. Still, their antimicrobial efficacy was significantly reduced in the presence of organic matter. 

Operators must implement robust sanitizer rotation programs, using different chemical classes, to prevent this issue. An integrated approach that considers facility design, ingredient controls, process controls, sanitation, and verification testing is needed to effectively manage biocontamination risks in food and beverage processing. Cutting-edge, state-of-the-science biocidal formulations like PAA can help food and beverage producers ensure they are using practical and efficient sanitation methods.

The PAA Advantage

Another effective way to keep food supplies safe is through the use of PAA formulations for every stage of the food production process. New PAA-based formulations are being produced that ensure even better sanitation results than traditional methods.

For example, Enviro Tech recently launched PeraGuard^®, the world's first patented dry PAA sanitizer, specifically designed for use in food and beverage processing facilities. This innovative product addresses the unique challenges manufacturing facilities face in maintaining environmental biosecurity and sanitation.

This innovative product utilizes patented controlled-release technology, activating upon contact with moisture or water. Its powerful oxidation capabilities make it effective against a wide range of microorganisms and spores, including harmful pathogens like E. coli O157:H7, L. monocytogenes, and S. enterica. PeraGuard^® promotes water savings and is particularly effective in dry processing areas, making it a versatile solution for various food production settings.

Dry PAA formulations provide:

• A novel approach to boot, floor, and surface sanitization, activated by moisture or water to release peracetic acid.
• High effectiveness in dry processing areas, where traditional liquid sanitizers may introduce unwanted moisture. Dry PAA formulations can be applied during food production shifts without requiring drains where applied.
• Controlled-release technology, providing long-lasting sanitizing effects until activated. This helps prevent cross-contamination between processing areas over extended periods.
• A peroxygen-based chemistry, breaking down into harmless byproducts [sodium carbonate (soda ash), glycerin, water, CO₂, and oxygen]. This makes them environmentally friendly and safe for use in food-grade manufacturing settings.
• A better solution for water conservation efforts in food and beverage plants, as dry PAA formulations require less water for application compared to traditional liquid sanitizers.

Dry PAA Formulations

Dry PAA formulations offer numerous advantages for food and beverage plants. They are highly concentrated, odorless, and dustless, making them easy to apply and use during production cycles. The product uses only peroxygen chemistry, does not contain quaternary ammonium compounds, and produces no hazardous byproducts. This makes dry PAA safe to use in sensitive food-grade manufacturing settings without impacting wastewater treatment systems.

PeraGuard^® is particularly effective in areas where conventional biocides may fall short, such as boots (Figure 2), floors, and drains, where pathogens often hide. Its patented controlled-release technology allows it to be activated by water or moisture, making it a versatile solution for various food processing environments.

Dry PAA can be used in various food processing settings, including U.S. Department of Agriculture-inspected meat, poultry, and seafood plants, as well as wineries, breweries, cheese, beverage, and dairy processing facilities. It is also suitable for packaging rooms, refrigerated trucks, and food cooler areas, addressing critical sanitation needs throughout the food production chain.

One of the key benefits of dry PAA for food and beverage plants is its safety profile. Additionally, PeraGuard^® is non-slip even on smooth floors, enhancing workplace safety. Its ability to be applied during production cycles and its long-lasting effectiveness until activated further contribute to its efficiency in maintaining high sanitation standards in food and beverage processing facilities.

Using PAA in Food and Beverage Facilities

The future of plant sanitation in food and beverage processing facilities is likely to see increased adoption of PAA as an alternative sanitizer. PAA offers several advantages that make it well-suited for modern food safety challenges. It is highly effective against a broad spectrum of microorganisms, including bacteria, yeasts, molds, and viruses, even at low temperatures and in the presence of organic matter.

Since PAA breaks down into harmless byproducts, it addresses growing concerns about chemical residues and environmental impact. Its efficacy at lower temperatures also aligns with energy-saving initiatives in many plants. As food and beverage manufacturers seek more sustainable and efficient sanitation solutions, PAA-based systems are likely to become more prevalent.

PAA's role in the future of food and beverage plant sanitation is secure and expanding. Innovative formulations, such as PeraGuard^® from Enviro Tech, are expected to have an increasing positive impact on food and beverage plant safety.