Overview

When you’re in charge of hygiene and sanitation at a food processing facility, avoiding contamination risks is part of your everyday job, but biofilms can complicate that. These microscopic communities of bacteria often go unnoticed and thrive in food handling, processing, and packaging environments. They resist standard cleaning methods and can cause product contamination, equipment damage, regulatory violations, and costly shutdowns.

In this blog, MWAC’s food plant cleaning specialists break down everything you need to know about biofilms, including what they are, where they tend to form, and what prevention efforts usually entail.

Highlights

• What biofilms are
• Why biofilms are a risk in food plants
• Where biofilms are most often found
• How to spot a problem with biofilms
• Cleaning methods that eliminate biofilms
• How to prevent biofilm regrowth
• Best practices for disinfecting food processing equipment
• Benefits of hiring licensed cleaners to tackle biofilms
• How often to inspect and treat biofilm threats
• Custom food-plant cleaning cost considerations

Introduction

In 2022, a Listeria outbreak linked to a major food processor in Pickering, Ontario, triggered a nationwide recall, costing millions and damaging consumer trust. The hidden culprit? Biofilms.

No one wants to consume food or beverages they can’t trust, especially if there’s a chance those products could cause illness. That’s why it’s critical to understand how biofilms quietly threaten your food processing facility. These microbial layers compromise product safety and can damage your brand’s reputation, erode employee confidence, and land your operation in serious trouble with regulatory bodies.

Let’s take a closer look at how to defend your operation against this silent threat and keep your products, reputation, and compliance intact.

What Are Biofilms?

Biofilms are structured communities of microorganisms (typically bacteria) that stick to surfaces and produce a slimy, protective matrix. In food processing environments, they form when organic material, moisture, and bacteria combine on surfaces like stainless steel, plastic, rubber seals, drains, or processing equipment. Once established, biofilms are incredibly difficult to remove.

Unlike free-floating bacteria, biofilms are embedded in a self-produced layer of polymers that shield them from sanitizers, water flow, and some antibiotics. This protective barrier allows them to survive cleaning routines that would otherwise eliminate surface bacteria, making them a persistent threat in any facility that handles food or beverages.

Even more concerning, biofilms can act as reservoirs for pathogens like Listeria monocytogenes, Salmonella, and E. coli, which can be released into your production lines and contaminate products long after the initial contamination happens.

Why Are Biofilms Dangerous in Food Plants?

Biofilms pose a significant threat to food safety and operational compliance. Their structure makes them incredibly resilient, allowing harmful bacteria to survive and spread in environments that are supposed to be sterile.

Once biofilms take hold in a food plant, they can:

• Contaminate products without visible signs, increasing the risk of foodborne illness outbreaks
• Trigger regulatory violations, leading to failed inspections, recalls, or even temporary plant closures
• Erode equipment performance, as the buildup can cause corrosion, clog drains, and reduce efficiency
• Compromise your facility’s compliance when hazardous biofilms are found, especially when they form in critical control points
• Damage your reputation, especially if product recalls or illness reports make headlines

Biofilms can persist for weeks (or even months) without detection. They pose an invisible threat that can escalate quickly. Facilities that don’t proactively identify and control biofilms are left vulnerable to serious consequences.

Where Are Biofilms Most Likely To Form in a Food Plant?

Biofilms thrive in damp, nutrient-rich, hard-to-reach places that are often common in food plants.

Typical hotspots include:

• Drains and floor cracks
• Processing equipment crevices, gaskets, and seals
• Undersides of conveyor belts and slicers
• Cooling units, evaporators, and humidifiers
• Dead zones in water lines and pipes
• Hard-to-access surfaces behind panels or guards

These areas are often missed during routine cleaning, allowing microbes to flourish undetected. Regular inspections and sanitation protocols targeting these trouble zones are essential for preventing outbreaks.

How Can You Tell if You Have a Biofilm Problem?

One of the biggest challenges with biofilms is that they often go unnoticed unless you’re actively looking for them. However, there are a few telltale signs you can consider as a warning. Recurring contamination or failed swab tests point to problems with these persistent microbes.

Slimy residues and odours that won’t go away are other indicators, and so are sudden spikes in microbial counts during testing and any visual signs of build-up you’ve noticed in hard-to-clean areas.

Since biofilms are often invisible to the naked eye, confirming their presence may require Adenosine Triphosphate (ATP) testing, microbial swabbing, or fluorescent dye tests. If standard cleaning isn’t solving the issue, you’re likely dealing with a biofilm.

Which Cleaning Methods Actually Work Against Biofilms?

Standard sanitizing methods are often ineffective because biofilms are shielded by that slimy matrix we discussed above.

Effective removal typically requires:

• Biofilm-targeted cleaners like enzymatic or oxidizing agents
• Mechanical action, such as scrubbing or high-pressure washdowns
• Extended contact times and proper dwell time for disinfectants
• Heat or steam cleaning in specific food-safe applications
• Validated cleaning protocols with follow-up testing

Using the right combination of chemical, mechanical, and thermal action is crucial. Simply increasing chemical concentration without an overall strategy won’t guarantee results.

How Do You Prevent Biofilm Growth?

Preventing biofilms starts with understanding how they form and addressing the conditions that let them thrive.

Proven prevention strategies include:

• Regular deep cleaning of vulnerable equipment and surfaces
• Routine microbial testing to catch early-stage buildup
• Proper drainage and moisture control throughout your facility
• Equipment design upgrades to eliminate crevices and stagnant zones
• Employee training to reinforce sanitation procedures and reporting

A proactive approach drastically reduces your risk of biofilms developing in your food processing equipment and on other surfaces.

What’s the Best Way To Disinfect Food Processing Equipment?

Effectively disinfecting food processing equipment (especially when targeting biofilms) requires the correct techniques, chemicals, and timing to break through the protective biofilm layer and eliminate the microbial load underneath.

The most effective disinfection processes include the following steps:

• Pre-rinse and surface cleaning: This step removes visible soil and organic material using detergents and mechanical action. It helps expose the biofilm.
• Application of a biofilm-targeted cleaner: A process that uses enzymatic, alkaline, or oxidizing agents specifically formulated to penetrate the biofilm matrix.
• Mechanical agitation: Involves scrubbing, brushing, or high-pressure spray systems to help physically break apart the biofilm structure.
• Dwell time: This means leaving disinfections on surfaces long enough to be effective. Different products have different dwell requirements. Rushing this step reduces the efficacy of even the most powerful agents.
• Rinse and sanitize: This encompasses a rinse and a final sanitizing step to kill any remaining microorganisms.

After this, validating and monitoring help verify that your plant’s disinfection efforts succeeded. To maximize results, periodically review and re-validate your facility’s cleaning protocols, especially after equipment upgrades, production changes, or inspection failures.

Remember, not all disinfectants are food-safe or effective against biofilms. Consulting with local food-processing sanitation experts for assistance in selecting the right products and techniques has many benefits.

What Are the Advantages of Hiring a Licensed Janitorial Company?

Partnering with a licensed janitorial company specializing in food processing sanitation brings several advantages. These are teams of licensed commercial and industrial cleaners trained to understand the strict hygiene requirements recognized by the Canadian Food Inspection Agency (CFIA), Global Food Safety Initiative (GFSI), and other regulatory frameworks that apply to food processing in Ontario.

These specialized cleaners also have access to industrial-grade cleaning tools, products, and techniques not typically available in-house.

Additional benefits of hiring a factory cleaning company include:

• Expertise in biofilm detection and removal: Trained crews know how to identify and treat biofilm-prone areas using validated, science-based methods.
• Customized cleaning protocols: Licensed companies assess your facility and develop tailored plans based on equipment, production schedule, and contamination risks.
• Regulatory compliance support: From documentation to audit preparation, janitorial experts help ensure your sanitation practices align with industry and government standards.
• Access to advanced cleaning technology: This includes ATP meters, steam sanitation, and food-safe biofilm cleaners proven to work in high-risk environments.
• Reduced downtime and fewer recalls: With professional support, your team can stay focused on production while ensuring sanitation is handled with precision and consistency.

How Often Should You Inspect and Treat for Biofilms?

There’s no one-size-fits-all answer. How often you should inspect your facility, treat for biofilms, and perform preventative maintenance depends on your facility’s layout, risk profile, and the types of products you handle.

However, best practices suggest incorporating monthly or quarterly deep cleans that target known biofilm hotspots into your commercial janitorial plan. Your facility will also benefit from weekly inspections of high-moisture and high-contact areas, frequent microbial swabbing in and around critical control points, and immediate follow-up when you detect or suspect a contamination risk.

Creating a routine monitoring schedule tailored to your production schedule and cleaning challenges is a smart way to stay ahead.

What Will a Custom Food Processing Cleaning Plan Cost?

Costs for custom food processing cleaning and biofilm remediation depend on the following:

• Facility size and layout
• Contamination level or risk
• Equipment accessibility and complexity
• Service frequency (one-time or ongoing)

While upfront costs vary, investing in a tailored cleaning program helps your business avoid much more expensive consequences, including product recalls, lost production time, and regulatory penalties.

Protect Your Facility: Schedule a Biofilm Inspection Today

Biofilms are among the food processing industry’s most persistent and under-recognized threats. Left unchecked, they can jeopardize product safety, equipment function, and your operation’s reputation. With early detection, proper sanitation techniques, and a proactive plan, you can keep your facility clean and compliant so it’s easier to operate at peak production and remain in good standing with consumers who depend on you.

Don’t wait until a routine inspection or product recall reveals a hidden problem. Contact MWAC at (905) 846-7796 to schedule a biofilm inspection and protect your facility with industry-approved sanitation solutions.