FOOD PRODUCTION FACTORY CLEANING & HYGIENE AUDIT SUPPORT

ROHA Group - Caldicot, Monmouthshire, South Wales, NP26 5PX

Client's Challenge

Following the commissioning of new plant and equipment, ROHA UK required a comprehensive food production factory cleaning programme at their Caldicot facility.

The site needed to meet strict food hygiene, health & safety, and audit requirements, including the sanitisation of machinery, production lines, high-level structures, and internal surfaces. The cleaning programme had to support an upcoming audit while ensuring the facility could continue operating safely as a live food production environment.

The client also required guidance on improving cleaning efficiency, chemical usage, and long-term compliance across production areas.

Assessment & Planning  

APT ICC completed a full cleaning survey across all production and processing areas, assessing:

• Contamination risks associated with new equipment commissioning
• Heavily soiled zones and hard-to-reach high-level areas
• Hygiene risks linked to machinery, floors, walls, and services
• Audit requirements and inspection deadlines
• Operational constraints within a live food production facility

A tailored RAMS package and phased cleaning schedule were developed and agreed with plant management to align with audit deadlines and production requirements.

    Methodology

    APT ICC implemented a structured, food-safe deep-cleaning methodology:

    1. Factory deep cleaning
    Comprehensive cleaning of production areas following new equipment installation.

    2. High-level cleaning
    Removal of dust and contamination from ceilings, steelwork, pipework, and services using specialist access equipment.

    3. Machinery and production line cleaning
    Detailed cleaning and sanitisation of machinery and food-contact surfaces.

    4. Surface sanitisation
    Walls, floors, and internal surfaces cleaned to food-safe standards.

    5. Process optimisation
    Review of existing in-house cleaning products and procedures to improve efficiency, compliance, and cost control.

    Site Access & Logistics

    Equipment
    • Specialist lift access equipment for high-level cleaning
    • Commercial cleaning machinery suitable for food production environments

    Chemicals
    • UltraClean MB - bactericidal cleaner and sanitiser for stainless steel
    and food-safe surface hygiene
    • Phos Clean - food-plant descaler used for removal of limescale staining on stainless steel surfaces

    Chemicals supplied via APT Commercial Chemicals.

    The Results
    • Grade A food hygiene audit achieved
    • Machinery, production lines, and high-level areas sanitised to audit standard
    • Works completed within agreed timeframe
    • Improved cleaning efficiency and compliance
    • Adoption of UltraClean MB as a single-source cleaning chemical
    • Reduced chemical usage and improved cost control
    • Future maintenance cleaning programme proposed

    The programme delivered measurable hygiene improvements while supporting
    long-term operational and compliance objectives.