Overview

In this post, our food safety and sanitation specialists at MWAC explain why water-free sanitation or dry cleaning is often essential for certain food production environments. You will learn when introducing water poses safety and quality risks, how dry cleaning methods are performed, and how to validate these strategies against microbial, allergen, and contamination concerns.

Highlights

Introduction

In food production, not all cleaning is created equal. While wet cleaning is standard in kitchens and wet food plants, introducing water to dry food processing, such as cereal, spices, or powdered ingredients, can pose serious risks. Moisture left behind can support microbial growth, damage equipment, and compromise product quality. That’s why waterless sanitation, also called dry cleaning, is often mandatory.

When Is Water a Hazard in Food Production?

In many food processing environments, water is essential. However, in dry production systems where ingredients are low in moisture or processed in powder form, water can quickly turn from a cleaning aid to a serious threat. Here’s when and why moisture becomes hazardous in these settings.

Water Encourages Microbial Growth

Dry production environments are typically inhospitable to microbial life until moisture is introduced. Even a small amount of water can allow bacteria like Salmonella or Listeria to grow, especially if residue is left on equipment or in hidden crevices. Once bacteria become established, they’re far harder to eliminate, and dry foods lack the natural barriers that kill or suppress pathogens during processing.

Moisture Can Trap Contaminants

When water mixes with dry product dust or residue, it forms a paste that sticks to surfaces and equipment. This makes it harder to remove and increases the risk of spreading contamination to other parts of the plant. Scrubbing or rinsing may even push bacteria deeper into seams or areas that are difficult to reach with standard tools.

Water Risks Damaging Sensitive Equipment

Many systems used in dry production, such as conveyors, blenders, and electrical controls, are not built to withstand heavy exposure to water. Wet cleaning can lead to rust, electrical failures, or premature equipment wear. Worse, water trapped inside complex machinery can go unnoticed and lead to long-term sanitation issues or shutdowns.

Residual Moisture Delays Production

Even when water is used carefully, it sometimes has to be completely dried before production resumes. That often means extra downtime for fans, heaters, or disassembly to ensure no moisture remains. This slows down operations and increases labor hours, all without adding any additional cleaning benefit in a dry environment.

What Dry Cleaning Methods Are Used?

Dry cleaning in food production uses a range of moisture-free techniques to maintain hygiene without introducing water into sensitive environments. The method chosen depends on your facility’s layout, the type of residue present, and the safety risks associated with water.

Manual Cleaning and Vacuum Systems

Most dry cleaning begins with the physical removal of visible debris. Workers use tools like food-grade brushes, scrapers, and brooms to loosen and collect dry material. This step is essential before any sanitizing takes place.

HEPA-filtered vacuums are commonly used to capture fine dust, allergens, or powdered residues. These vacuums prevent airborne contamination and are often used alongside controlled compressed air to clean tight spaces.

Targeted Sanitizing Without Moisture

Once debris is removed, dry sanitizing techniques are used to reduce microbial risk without adding moisture.

These include:

  • Alcohol-based wipes for contact surfaces and disassembled parts
  • Evaporative sanitizers that kill bacteria without leaving residue

These options are especially helpful on flat surfaces or high-touch equipment where water would introduce more risk than benefit.

Advanced Waterless Cleaning Methods

Some facilities use specialized systems for deep sanitation where manual methods aren’t enough.

These might include:

  • Dry steam cleaning: Produces vapor with minimal moisture, making it effective against microbes without requiring full drying afterward
  • Dry ice blasting: Uses CO₂ pellets to lift soil and contaminants without abrasion or residue, ideal for sensitive electronics or allergen control

Both methods offer strong sanitation outcomes while preserving equipment integrity in dry environments. We’ll take a closer look at these later.

Benefits of Waterless Sanitation in Food Processing

Dry cleaning methods offer essential benefits for facilities where moisture can cause damage, contamination, or downtime. In dry food production environments, using waterless sanitation practices helps preserve product quality, protect equipment, and support compliance with food safety regulations.

Preserves Product and Ingredient Integrity

Dry environments are sensitive to moisture. Even minimal water exposure can cause clumping, spoilage, or microbial growth in products like powders, grains, and spices. Waterless sanitation helps maintain the integrity of these ingredients by eliminating moisture-related risks.

Key product-related benefits of waterless sanitation include:

  • Prevents rehydration or spoilage of dry goods
  • Reduces microbial risk by eliminating moisture that supports growth
  • Avoids ingredient loss or contamination during cleaning
  • Maintains allergen control by reducing cross-contact opportunities

By keeping water out of the equation, manufacturers can protect both their product and their reputation.

Protects Equipment and Boosts Efficiency

Many machines in dry production aren’t designed for wet cleaning. Water can corrode parts, damage sensors, or create long-term sanitation challenges by becoming trapped in small crevices.

Operational benefits include:

  • Minimizes risk of rust, corrosion, or electrical damage
  • Reduces equipment downtime by eliminating drying periods
  • Extends the life of processing machinery
  • Supports continuous production cycles with faster sanitation turnaround

Waterless cleaning helps keep lines running efficiently without compromising sanitation standards. By integrating dry sanitation into your standard operating procedures, you improve both food safety and production performance without introducing new risks.

Advanced Waterless Options for When Regular Methods Aren’t Enough

While manual dry cleaning and basic sanitizers are sufficient for many production lines, certain situations demand a higher level of cleaning performance. Whether you’re dealing with allergen cross-contact, persistent biofilms, or hard-to-reach surfaces, advanced waterless cleaning technologies can provide deeper sanitation without compromising equipment or product integrity.

Dry Ice Blasting for Deep, Moisture-Free Cleaning

Dry ice blasting is one of the most effective non-abrasive and waterless cleaning methods available. It involves propelling small pellets of solid carbon dioxide at high speeds toward the target surface. Upon contact, the pellets sublimate, transforming from solid to gas, leaving no moisture or secondary residue.

Dry ice blasting is beneficial because it’s:

  • Ideal for sensitive electrical components, motors, or control panels
  • Effective at removing sticky, baked-on, or allergen-rich residues
  • Non-abrasive, making it safe for stainless steel and plastic surfaces
  • Quick and efficient, eliminating the need for drying time

This method is especially valuable in allergen-controlled facilities or post-contamination scenarios where precision and minimal disruption are critical.

Superheated Dry Steam Vapor for Biofilm Control

Dry steam vapor systems generate superheated vapor using minimal water, typically less than 6% moisture. These systems deliver high temperatures capable of breaking down biofilms, denaturing proteins, and killing bacteria without soaking equipment or surfaces.

Dry steam vapor systems are often used to:

  • Clean hard-to-access areas like crevices, joints, and hollow rollers
  • Eliminate microbial threats without chemicals or rinse steps
  • Complement allergen control programs with heat-based sanitation
  • Support faster changeovers between product lines

This technique bridges the gap between traditional wet sanitation and dry cleaning, offering flexibility and microbiological safety in one solution.

Chlorine Dioxide Gas for Facility-Wide Disinfection

In rare cases, such as after contamination events or during deep cleaning shutdowns, facilities may use chlorine dioxide gas to sanitize entire rooms or processing zones. This method involves carefully controlled gas concentrations that inactivate bacteria, viruses, and molds even in places unreachable by manual tools. It’s allowed under the Canadian Environmental Protection Act, provided certain conditions are met.

While not a day-to-day cleaning solution, chlorine dioxide gas can:

  • Penetrate every corner, crevice, and shadowed area
  • Eliminate pathogens without the need for scrubbing or moisture
  • Be precisely monitored and vented to ensure safe application
  • Help revalidate spaces after contamination or product recall

Due to its complexity, this method requires professional handling, monitoring systems, and strict safety protocols. However, it offers unparalleled coverage and microbial control in critical situations.

Why Dry Sanitation in Food Processing Matters More Than Ever

In dry food production environments, introducing water can create more harm than good. That’s why dry sanitation is a core part of keeping products safe, equipment protected, and operations running smoothly. From manual scrubbing and HEPA vacuums to advanced methods like dry ice blasting or chlorine dioxide gas, waterless cleaning offers powerful, flexible solutions for high-risk and low-moisture settings alike.

When implemented consistently and validated correctly, dry cleaning methods help food processing facilities meet regulatory demands while preventing microbial contamination and product recalls.

Need Support With Dry Cleaning Protocols?

MWAC specializes in food safety and sanitation services tailored to the unique needs of dry food processing environments. Our team understands the risks water can introduce and delivers targeted, compliant solutions that keep your facility clean, dry, and audit-ready. Whether you need routine allergen control, emergency contamination support, or advanced sanitation like dry steam, we have the tools and expertise to get the job done right.

Call (905) 846-7796 today to schedule a consultation and see how we can support your food safety program.