ALLERGEN MANAGEMENT

Considerations

Food allergies are on the rise, and therefore must be prevented as they can lead to death:

 

Good habits:

Product development

• Minimize the use of allergenic ingredients in formulas

• Attempting to produce/handle the allergens at the end of the process/workday

• Use of affordable and easy-to-clean equipment to eliminate allergens between productions

• Test production lines with cross-contamination tests

• Ensuring that allergens are easily identifiable on finished product labels

• Isolate allergen addition points (eg weighings)

• Dedicate unique rework systems

• Eliminate crosses and enhance product isolation

• Dedicate production systems and/or install modules in parallel for non-washable units (eg flours)

 

Raw material

• Assess allergens in all raw materials

• Audit suppliers and partners and help develop plans

• Insist with vendors com  allergen statements

• Be aware of specification and ingredient changes

• Review possible sources of contamination from other raw materials eg. recycled/reused containers

 

Production schedule

• Dedicate production systems

• Longer runtimes / minimize swaps

• Produce products with allergens at the end of the production sequence

• Control  each allergen separately from other allergens

• Allow full cleanup time between runs

• Confirm packaging suitability

 

labeling and packaging

• Ensure the label reflects the formula in use

• Assiduous review of the mentions on the labeling when there is a change / substitution of ingredients

• Proper management of packaging inventory/stock in order to avoid the accumulation of packages with obsolete mentions

• Separate packaging material for similar formulas with and without allergens

 

Rework

• Clearly record all reworks (including in flowcharts)

• Make sure the feed systems can be cleaned and dedicated

• Post and communicate instructions on the use of rework

• Immediately report any misuse of rework

• Audit rework periodically to ensure proper identification

 

Sanitation

• Allow proper cleaning between runs

• Manually dismantle and sanitize equipment that cannot be completely sanitized on site

• Properly clean tools or accessory equipment (spoons, boxes, hoppers, etc.)

• Avoid purchasing  hard-to-clean equipment

• Use alternative cleaning measures where wet washing (with water)   is not feasible (eg salt or sugar)

 

Training and Communication

• Establish a compilation of documentation and records capable of guaranteeing an allergen management plan, for example with

• training manuals

• Policies,  procedures and work instructions

• Certifications (eg Gluten Free)

• Identification of locations in the layout

• Restricting access to labeling software

• Internal audit reports

 

Summary of  Entries for the Allergen Management Plan

• supplier control

• Characteristics of raw materials and supply chain management

• Identification

• Reception, storage and handling of Goods

• Product Formulation and Development

• Production and Programming Project

• operations

• Marketing

• Recall Plan

• Top management involvement

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