Hello! I’m Tania, Co-founder and Director at Assured Food Safety Consulting (AFSC). With over 8 years of hands-on experience in the food safety industry, I have had the opportunity to work with various allergens, including gluten, sesame, mustard, dairy, and shellfish. I’ve built and implemented many HACCP plans and conducted allergen assessments across diverse manufacturing setups, presenting these programs to both auditors and inspectors. From these experiences, I’d like to share five practical tips for developing an effective allergen management program tailored to food manufacturing. Implementing these can help keep both your product and consumers safe.
- Identify and Control Allergen Cross-Contamination
Cross-contamination is a primary concern in allergen management. This involves allergenic ingredients unintentionally coming into contact with allergen-free products. Establishing dedicated production lines for allergen and non-allergen products is ideal, but not always feasible. In such cases, strict scheduling and thorough cleaning are essential.
Example: At a bakery where I once consulted, a cleaning protocol was established to address cross-contamination risks between batches of gluten-containing and gluten-free products. We implemented specific color-coded cleaning tools to prevent cross-contamination, and production was scheduled with non-gluten items processed first, followed by a thorough clean-down before introducing gluten-containing ingredients.
- Develop a Robust Allergen Labeling and Verification Process
Proper labeling is crucial in ensuring customers have the information they need. Make sure that allergen information is accurately represented on product labels and is regularly reviewed. Additionally, verify your suppliers’ allergen information, as even minor ingredient changes can introduce allergens.
Example: During an audit at a manufacturing plant that handled mustard and sesame, we uncovered inconsistencies in their supplier-provided allergen information. We worked closely with the suppliers to set up a quarterly verification check to ensure allergen information on incoming ingredients remained up-to-date and consistent with the plant’s allergen labeling on final products.
- Train Employees Regularly on Allergen Awareness
Employee awareness is fundamental to maintaining food safety, especially in allergen handling. Regular training sessions that cover allergen handling protocols, cross-contact risks, and emergency procedures ensure that staff are knowledgeable and vigilant. Allergen management should be everyone’s responsibility.
Example: In a seafood processing facility, we conducted annual allergen training sessions. We emphasized the importance of avoiding shellfish cross-contact and introduced quick response protocols if an allergen-related incident occurred. Training also included steps to handle incidents where allergens were found unexpectedly during production.
- Create Clear Allergen Storage and Handling Protocols
Clearly defined storage and handling procedures for allergenic ingredients can reduce the likelihood of accidental cross-contact. Separate storage areas for allergenic and non-allergenic ingredients, along with clear labeling, helps mitigate contamination risks.
Example: In one facility, we designated specific shelves for each allergen type and used large, visible labels to identify these zones. An inspection revealed that this setup significantly reduced the chance of accidental allergen mixing during ingredient selection for production.
- Conduct Routine Allergen Testing and Validation
Testing is a critical step in verifying the effectiveness of your allergen management program. Routine swabs and validation tests after cleaning can confirm the absence of allergen residues before production starts on allergen-free products. This not only reinforces internal protocols but also reassures clients and consumers of product safety.
Example: I worked with a plant producing both nut-free and nut-containing products on the same line. To mitigate risks, we implemented a rigorous allergen testing schedule with surface swabs and product testing. The tests provided the team with data to improve cleaning protocols, reducing allergen levels consistently below detectable limits.
Conclusion
Implementing a comprehensive allergen management program is essential to ensure food safety, meet regulatory standards, and build consumer trust. From identifying cross-contamination risks to routine allergen testing, each of these tips aims to fortify your allergen management efforts. Remember, consistent training, robust procedures, and verification practices will create a culture of allergen safety throughout your manufacturing operations.
Pro Tip: Hire a Food Safety Consultant
Developing Allergen Management Program or HACCP Plan can be a complex process, but hiring a food safety consultant can make it much easier. A qualified consultant brings expertise and experience to the table, helping you navigate regulatory requirements and ensuring that your facility meets all the necessary standards. They can assist with writing and implementing plan, guide you through audits, and provide ongoing support to maintain compliance. By investing in a consultant, you can save time, avoid costly mistakes, and achieve certification faster. Assured Food Safety Consulting’s certified SQF Consultant and Lead HACCP instructors have been helping food businesses since 2022. We provide food safety plan creation services and HACCP/GFSI training services. If you require assistance with your HACCP plan or SQF program, Contact us at tania@assuredfoodsafety.ca to request a quote.
