COP (Cleaning Out of Place) Protocol for Surfaces and Utensils

The COP (Cleaning Out of Place) protocol is the cleaning and disinfection procedure for parts that are dismantled from equipment: blades, grids, hoppers, trays, moulds, plastic crates and hand utensils. Unlike CIP, which cleans closed circuits by recirculation, COP is carried out in one or more immersion tanks, with manual brushing and control of dose, temperature and contact time. It is part of the cleaning and disinfection plan of the HACCP system (Regulation (EC) No 852/2004) in bakeries, butcheries, cutting rooms and cheese dairies.

Materials required

• Non-foaming alkaline detergent for the cleaning tank: Alcalino (dose 1-4 %, maximum temperature 60 ºC, suitable for aluminium)
• Alkaline degreaser for heavily greased stainless steel or plastic parts: Gras Foam (2-6 %, 20-60 °C, do not use on aluminium)
• Alkaline disinfectant for the disinfection tank: Bacter Alcalino (1 % or 5 % depending on the effect required)
• Combined-action disinfectant detergent, as an alternative to the two-tank process: Bacter (4-5 %) or Clor NF Pro (2-8 %, chlorinated alkaline, do not use on aluminium)
• Acid descaler for the periodic limescale cycle: Acid Pro (2-5 % by immersion, 40-70 ºC)
• Stainless steel immersion tanks with drain, one for detergent and one for disinfectant (or a single tank emptied and rinsed between stages)
• Probe thermometer and dosing system (dosing pump or measuring cup) to prepare the dilutions
• Colour-coded brushes and scouring pads, reserved for the cleaning area
• Hose with pressurised water for rinsing
• Drainer or perforated trolley and a clean drying area
• COP record sheet (product, dose, temperature, time, person responsible)

Step-by-step procedure

1. Dismantling and pre-cleaning: Dismantle the parts following the equipment manufacturer's instructions and group them by material: stainless steel, aluminium and plastic. Remove coarse residues (dough, fat, blood, cheese residues) dry with a scraper and paper, and pre-rinse with water to remove loose soil. Set aside parts with cracks, worn seals or corrosion.
2. Preparing the alkaline detergent tank: Fill the tank with water and dose the detergent. For mixed batches, or when there are aluminium trays and moulds, use Alcalino at 1 to 4 % and do not exceed 60 ºC. For heavily greased stainless steel or plastic parts (cutting rooms, fryers), Gras Foam can be used at 2 to 6 % at 20-60 °C, always with no aluminium in the tank. Record the actual dose and temperature on the record sheet.
3. Immersion and brushing: Fully submerge the parts, making sure no air pockets remain in tubes, threads and cavities. Allow the bath to act and brush grooves, threads and hard-to-reach areas with colour-coded brushes. Remove the parts when no soil remains visible or to the touch. Renew the bath if it becomes soiled or cools below the working temperature.
4. Intermediate rinse: Rinse all surfaces with pressurised water until the detergent is removed, especially from threads and corners where alkali is retained. Essential before disinfecting: detergent residues reduce the effectiveness of the disinfectant.
5. Periodic acid cycle (when scale is present): If the parts or the tank show a white film or limescale deposits caused by water hardness, carry out a bath with Acid Pro at 2-5 % by immersion at 40-70 ºC. Acid Pro removes limescale, mineral deposits and residues left by alkaline detergents, and does not attack chrome-plated or enamelled surfaces or rubber and plastic seals. Rinse with plenty of water before moving on to disinfection. Never mix acid products with chlorinated products.
6. Disinfection by immersion: Prepare the disinfection tank with Bacter Alcalino: at 1 % (10 g/l) with around 5 minutes of contact for bactericidal effect, or at 5 % (50 g/l) with around 15 minutes for bactericidal and virucidal effect. As an alternative, Bacter at 4 % (40 g/l) for around 5 minutes for bactericidal effect or at 5 % for around 15 minutes for virucidal effect. If a single cleaning and disinfection bath is preferred for plastic crates or micro-perforated steel moulds, Clor NF Pro at 2 to 8 % at 20-60 °C with 5-15 minutes of contact; do not use it on aluminium. The parts must remain fully submerged for the whole contact time.
7. Final rinse: Rinse with plenty of water (Bacter, Clor NF Pro) or with pressurised water (Bacter Alcalino) until all disinfectant residue is removed, and check that no product odour remains. On food-contact surfaces, this rinse is mandatory unless the product data sheet states otherwise.
8. Draining, drying and storage: Place the parts on the drainer or perforated trolley with cavities facing down and allow to air-dry in a clean area. Do not dry with reusable cloths. Store the dry parts protected from splashes and off the floor; do not reassemble them until they are completely dry. Record end time, person responsible and any incidents.

Verification and control

Verification relies on three layers. First, visual and tactile inspection of the dry parts: no residues, no white film, no product odour. Second, recording the process parameters on the COP sheet: product, dose prepared, bath temperature, contact time and person responsible, checking that they fall within the ranges of the technical data sheet (for example, 1-4 % for Alcalino or 1 % / 5 % for Bacter Alcalino). Third, microbiological verification according to the HACCP plan (surface swabs or ATP), at the frequency set by the quality manager. Any deviation (dose out of range, exhausted bath, insufficient contact time) is documented and requires the cycle to be repeated for the affected part.

Safety and PPE

• Chemical-resistant gloves, safety goggles and a waterproof apron while preparing the tanks and handling wet parts.
• Non-slip boots: the floor of the COP area is usually wet.
• Always add the product to the water, never the other way round, and using the intended dosing system.
• Never mix acid products (Acid Pro) with chlorinated products (Clor NF Pro): empty and rinse the tank between one cycle and the next.
• Food-industry disinfectants (Bacter Alcalino, Bacter, Clor NF Pro) are biocides regulated by Regulation (EU) No 528/2012; the technical data sheet states that they are to be applied by professional personnel.
• Consult the safety data sheet (SDS) of each product before first use and keep an eye-wash station within reach.

Recommended Instaquim products

Alkaline cleaning: Alcalino, a non-foaming detergent with corrosion inhibitors suitable for aluminium, at 1-4 % and a maximum of 60 ºC; Gras Foam, a degreaser for heavily greased surfaces (cutting rooms, meat plants), by immersion at 2-6 % at 20-60 °C, on all metals except aluminium. Disinfection: Bacter Alcalino, a chlorine-free bactericide and virucide based on tertiary amines, at 1 % (5 min) or 5 % (15 min); Bacter, with triple detergent, bactericidal/virucidal and deodorising action for equipment and utensils, at 4 % (5 min) or 5 % (15 min); Clor NF Pro, a non-foaming chlorinated alkaline disinfectant detergent for tanks, circuits, utensils, plastic crates and micro-perforated moulds, at 2-8 % at 20-60 °C for 5-15 minutes. Acid cycle: Acid Pro, a controlled-foam acid descaler, at 2-5 % by immersion at 40-70 ºC.

Applicable regulations: the cleaning and disinfection plan is one of the prerequisites of the HACCP system established by Regulation (EC) No 852/2004 on the hygiene of foodstuffs and, in meat and dairy establishments, by Regulation (EC) No 853/2004. The disinfectants mentioned are biocides subject to Regulation (EU) No 528/2012 and hold a registration number for use in the food industry; their classification and labelling are governed by Regulation (EC) No 1272/2008 (CLP) and the detergents by Regulation (EC) No 648/2004.

Frequently asked questions

What is the difference between COP and CIP cleaning?

COP (Cleaning Out of Place) is the cleaning of dismantled parts by immersion in a tank, with manual brushing; CIP (Cleaning In Place) cleans closed circuits by recirculation without dismantling. Some products serve both: Alcalino is indicated for the automatic cleaning of utensils and trays and also for CIP circuits, and Acid Pro has different doses for immersion (2-5 %) and for CIP (1-3 %).

Can I immerse aluminium trays and moulds in the alkaline tank?

Only with an alkaline formulated for it. Alcalino contains corrosion inhibitors and can be used on aluminium. By contrast, Gras Foam and Clor NF Pro must not be used on aluminium surfaces: reserve them for stainless steel and plastic.

What dose and temperature should I use in the alkaline detergent tank?

Alcalino is dosed at 1 to 4 % at a maximum temperature of 60 ºC. Gras Foam, for very greasy soil, is used at 2 to 6 % at 20-60 °C.

How long must the disinfectant remain in contact with the parts?

It depends on the product and the effect required. Bacter Alcalino: 1 % for around 5 minutes for bactericidal effect, or 5 % for around 15 minutes for bactericidal and virucidal effect. Bacter: 4 % for around 5 minutes (bactericidal) or 5 % for around 15 minutes (virucidal). In both cases the parts must then be rinsed with water.

Can I clean and disinfect in a single bath?

Yes, with a chlorinated alkaline disinfectant detergent such as Clor NF Pro, diluted at 2 to 8 % at 20-60 °C, leaving it to act for 5-15 minutes and rinsing with plenty of water. It is practical for plastic crates and micro-perforated moulds, but not for aluminium; with heavy soiling, the two-stage process is safer.

How often should the acid cycle be carried out?

Whenever a white film or limescale appears on parts or in the tank itself, and periodically depending on water hardness. Acid Pro removes limescale and residues left by alkaline detergents; by immersion it is used at 2-5 % at 40-70 ºC. Never mix the acid bath with the chlorinated one.

Which efficacy standards do the disinfectants mentioned comply with?

Bacter Alcalino, Bacter and Clor NF Pro comply with standard UNE-EN 13697 (bactericidal and, for Clor NF Pro, also fungicidal) and UNE-EN 14476 (virucidal) against the organisms listed in their technical data sheets, and hold a registration number as biocides for use in the food industry (HA). Consult the technical data sheet and the safety data sheet before use.