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Proactive Cleanliness: Anticipating Challenges in Open Plant Cleaning


Factories and manufacturing plants vary from small, manageable concerns to vast open spaces where production lines run 24/7. Maintaining cleanliness in these larger facilities presents a unique set of challenges, but proactive open plant cleaning solutions can form an integral part of maintaining these levels of hygiene.


Unlike the sterile, controlled environments of laboratories and hospitals, these large concerns contend with dust, debris, oil and food spills, fluctuating weather conditions, and even wildlife, all of which can threaten hygiene and production efficiency. Fortunately, by adopting a proactive approach to open plant cleaning, these challenges can be effectively mitigated, ensuring a safe and productive working environment.


Today, the leading cleaning equipment suppliers at Pescatech will explore the three most common challenges encountered in open plant cleaning and offer practical solutions and strategies to anticipate and overcome them.


3 Most Common Challenges in Open Plant Cleaning


Here are three common challenges you need to be aware of:

Open Plant Cleaning

  1. Challenge: Dust, Dirt, and Debris Management


Large facilities are susceptible to dust, dirt, and debris accumulation from various sources, including:


  • Production Processes: Grinding, sanding, welding, and other activities generate airborne particles that settle on surfaces.
  • External Elements: Wind, rain, rodents, and even birds can introduce dirt and contaminants by entering through open doors and windows.
  • Foot Traffic: Personnel movement across the workspace tracks dust, dirt, grime, and debris onto floors and equipment.




  • Implement Zoned Cleaning: Divide the plant into high-, medium-, and low-dust zones based on activity levels. Allocate cleaning resources accordingly, focussing on high-dust areas more frequently.
  • Invest in Industrial Air Filtration Systems: These systems capture airborne particles before they settle, improving air quality and reducing dust buildup.
  • Utilise Quality Floor Cleaning Equipment: Ride-on sweepers, scrubbers, and vacuums specifically designed for industrial environments can efficiently remove debris from floors and walkways. However, consider colour-coded, hand-held equipment like brooms, brushes, buckets, and mops for different departments to prevent cross-contamination
  • Control Access and Egress Points: Implement measures like doormats, hand sanitation stations, and boot cleaners to minimise dust, debris, and germs tracked in from the outside.


  1. Challenge: Cleaning Around Sensitive Equipment and Processes


These plants often house delicate equipment and ongoing production processes that require careful cleaning considerations:


  • Risk of Damage: Harsh chemicals or abrasive cleaning methods can harm sensitive machinery and equipment.
  • Production Downtime: Shutting down production lines for open plant cleaning can be disruptive and costly.
  • Contamination Risks: Cleaning chemicals must be compatible with the manufactured products to avoid contamination.




  • Develop Detailed Cleaning Procedures: Outline specific cleaning methods and products for each type of equipment and process, considering compatibility and potential risks.
  • Utilise Specialised Cleaning Tools: Invest in tools designed for delicate equipment, such as microfiber cloths. If your business is related to the F&B sector, consider cleaning equipment that is HACCP compliant.
  • Implement Scheduled Shutdowns: Coordinate open plant cleaning with planned production downtime to minimise disruptions.
  • Communicate Effectively: Ensure clear communication between janitorial staff and production teams to avoid accidental contamination or equipment damage.


  1. Challenge: Training and Compliance


Ensuring consistent and effective cleaning across a large open plant requires a well-trained and compliant workforce:


  • Lack of Knowledge: Improper cleaning techniques can be ineffective and even harmful to surfaces, equipment, and machinery.
  • Non-Compliance with Safety Regulations: This can lead to on-duty injuries, accidents, and health hazards, even expensive hospital bills and legal claims.
  • Motivation and Engagement: Maintaining a high level of commitment to cleaning standards can be challenging.




  • Provide Comprehensive Cleaning Training: Educate personnel on proper cleaning procedures, safety protocols, and the importance of their role in maintaining a clean working environment.
  • Regularly Monitor and Audit Cleaning Practices: Identify areas for improvement and ensure compliance with established procedures.
  • Make Use of Colour-Coded Equipment: Colours transcend words, language barriers, and misunderstandings. Make use of colour-coded cleaning equipment to separate sections or even differentiate between machinery, floors, kitchens, and ablution facilities to avoid confusion. Also, using colour-coded, picture-based posters may help for both training and operational functionality.


Ultimate Cleaning Solutions through Pescatech


At Pescatech, we offer you the ultimate combination of cleaning solutions. We have a comprehensive approach to assisting our valued customers achieve their cleaning and sanitation goals. We have travelled the world sourcing only the most superior-quality cleaning products and equipment.


We have drawn on our suppliers’ vast experience and applied everything we have learned to the local industry. Subsequently, we have developed unique, 360° open plant cleaning solutions and provide products, equipment, and services for the South African marketplace.


If you need expert advice, knowledgeable opinions, and unsurpassed pre-and post-sales service, view our catalogue or simply contact us. We can assist in the planning, installation, and implementation of all your open plant cleaning needs.


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