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It is essential to keep comprehensive records of all recipe batches and production schedules to verify the effective control of allergens.
The control of the use and storage of packaging is important to reduce possible cross-contamination by allergens.
Incorrect storage of packaging can introduce allergens into the product. Packaging that is meant to contain “allergen free” products should be securely stored away from other packaging.
The most common problem in allergen control is the placing of product into incorrect packaging. Special emphasis should be placed on process control when there is a change in a product’s recipe on the production line. Measures must be put in place to ensure that the product is placed in correct packaging.
Controls at the packaging stage of the product are extremely important.
Allergens can contaminate products when cleaning is not done competently. Cleaning within the factory should be carried out on a comprehensive cleaning schedule with subsequent monitoring for effectiveness.
Allergen-dedicated cleaning equipment should be used to clean all areas that pose a contamination risk.
As a food safety manager, you are responsible for developing an effective cleaning schedule that minimizes the risk of all possible allergen contaminants on equipment and the factory environment. Your emphasis should be placed on equipment that requires dismantling for effective cleaning to ensure all allergen contaminants are removed before reuse.
Your staff should be aware that any spillages must be cleaned immediately.
Production processes and schedules have a significant influence on the control of food allergens.
Where possible, foodstuffs that contain allergens should be processed on specific equipment or in specific areas of the factory to reduce the risk of possible cross- contamination But other measure should also be used to control food allergens. For example, installing physical barriers such as doors between processing rooms reduces the risk of cross- contamination.
Dedicated utensils that are used just for specific foodstuffs will help reduce allergen contamination; for example, utensils that are color-coded for use on products that contain nuts should not be used for any other foodstuff.
The movement of materials and equipment within your factory will also help reduce the risk of allergens contaminating products.
Production scheduling is a key in the control of food allergens. Scheduling sufficient time for effective cleaning, for example, will reduce the risk of allergen contamination.
Reworking a product back into the production line is a high-risk process because the identity and status of the product can be lost if the control measure are not in place. The loss of identity means allergens can easily be put into a product that is not labeled to indicate the presence of an allergen.
Because of the severity of the food allergen, it is essential to take corrective action as soon as you are aware of any contamination or incorrectly labeled product.
The product should be quarantined in the factory and a decision made on the use or disposal of the product. However, if the product is already in the distribution system and could be consumed by the buyers, actions to effect product recall must be initiated.
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