Segregating the Allergens: The smart way to reduce the risk of cross contamination

Food allergies have been in the headlines recently, and for good reason.

Here in the UK, it’s estimated that around 2 million people have a food allergy, a number that is only going up. It’s more important than ever to keep track and declare any allergen if you’re a food manufacturer; if one slips through the net, it could put your customers in danger and, with it, the future of your business. Most are pretty good with listing the common food allergies on their packaging, but it is cross-allergen contamination that poses a big risk.

What is allergen cross-contamination?

Cross-contamination is when an allergenic ingredient, not included in the food product recipe, enters the manufacturing process. Undeclared allergens within the product pose potential health risks. There are approximately ten deaths every year in the UK due to food induced anaphylaxis*, mostly due to undeclared allergenic ingredients; each of these could be avoided by having a robust allergen segregation process and clear labelling.

*Food Standard Agency ‘Food Allergy Facts’

What is an effective allergen control strategy?

Processes that were seen as suitable five years ago no longer cut the mustard. Procedures now need to be more robust and future-ready. There’s a system known as Horizon Scanning which is employed by a number of the largest corporations in the world, as well as Her Majesty’s Government. They describe this process as ‘not about making predictions, but systematically investigating evidence about future trends’.

Trying to anticipate potential upcoming risks is the easiest and most cost-effective way to proactively improve your allergen segregation policy. Keeping an eye on alerts from the Food Standards Agency can help keep you ahead of the game and any possible new legislation that could be on its way. It’s also worth remembering that while there are only 14 allergens that have to be declared, almost any food can cause an allergic reaction; something isn’t risk free just because it isn’t in the legislation.

Ten ways to improve your allergen segregation

Horizon Scanning is great and should definitely be part of your plan going forward, but what should you be doing now?

Here are ten simple ways to help to reduce your risk of cross-contamination.

1. Check your suppliers’ processes

If you’re using external suppliers, you need to know what is happening at their sites. Ask them about the allergenic content, what ingredients are affected, and the proportion of the raw material the allergen comprises. Also find out if they process different allergens that may not be part of your product but could cross-contaminate before it gets to you. If you’re in any doubt, presume that their ingredient does have the allergens. Try to make sure ingredients and raw materials are delivered pre-segregated, and don’t be afraid to reject a delivery if there are any signs of cross-contamination.
2. Label all the allergens on your site

Any allergenic ingredient used on your site should be labelled; it sounds obvious, but it can be overlooked easily. There’s a number of ways to do this, such as tagging the allergens with a specifically coloured label (think yellow for egg, green for nuts, and so on), or having all 14 allergens on the tag and ticking the ones present. It's also a good idea to ensure clear storage container/dispenser identification too (IndeliMarking is great for this). Whichever way you go, just make sure you stick to it.
3. Isolate allergens during storage

Have dedicated, separate storage areas for different allergens, regardless of whether they are there for months or minutes. Do not allow any cross contamination of allergenic ingredients. Clause 5.3.4 in BRCGS's Food Safety Standard Issue 8, specifies 'physical or time segregation while allergen-containing materials are being stored, processed or packed', and also, 'systems to restrict the movement of airborne dust containing allergenic material'. Many factories have found SegriScreens useful for physical segregation of both production and storage areas, which can also be printed with visual messaging where required.
4. Show allergens visually

Consider using an image of a peanut instead of using the word when flagging it as an allergen. It’s quicker for the brain to process and easier to understand in today’s multi-national, multi-lingual workforce. Images can be applied to labels or directly onto equipment using Klipspringer’s permanent IndeliMarking process.
5. Use colour

Colour coding is a universal language, so look to introduce different coloured production utensils and PPE for different uses and allergen types. This helps prevent cross contamination by making it easier to identify that the correct utensils are used.
6. Store hygiene and production equipment properly

Equipment being incorrectly stored - or not stored at all - is a quick way to the wrong utensil being used in the wrong place, risking contamination. Simple solutions such as colour-coded shadow boards make it quick and easy to see where equipment should be stored, or if there is something missing.
7. What if colours alone are not enough?

Although the EU legislation details 14 allergens that must be controlled, often companies are supplying to customers globally and their allergen requirements may be very different. So, colour alone may not be sufficient to ensure adequate segregation. With IndeliMark, a permanent mark, (symbol or wording) can be used to identify the utensil to a specific allergen type or ingredient.
8. Have designated spill control equipment and stations

Allergen spills happen, but it’s how you deal with them that matters. Efficient and effective management starts with having the right equipment in the right places. Consider installing specialist spill stations at strategic points across your business which are designated homes for spill kits containing the necessary utensils and process information.
9. Train your staff on your allergen strategy and give them specific responsibilities for it

Ensure all staff know the process and protocols for your allergen segregation strategy. Rehearse different scenarios and prepare them so that they know how to react when something does go wrong. Explain to them the importance of why they are doing it as then they are more likely to follow procedure. Show them how it links to consumer safety and therefore your company success. Once trained, all staff need to get behind the process, but specific team members should have specific responsibilities. Ensure all areas and all shifts across the business are covered.
10. Carry out an allergen audit on yourself

Audit your own process regularly to ensure it is still working for your business. If it isn’t – improve it. Revisit it whenever you change suppliers or your product lines. Consider asking external specialists to help with audits to ensure you aren’t missing something due to over familiarity. Address shortcomings and recognise that this is an ongoing process.

Allergen segregation is such a key component in food manufacturing. Getting on top of it is essential to the well-being of your customers and your business, so the time to is now. Klipspringer is here to offer solutions to help you achieve compliance with confidence. To find out what we can do to help prevent cross contamination in your facility, get in touch with a member of our friendly team of experts.

What is allergen cross-contamination?

1. Check your suppliers’ processes

2. Label all the allergens on your site

3. Isolate allergens during storage

4. Show allergens visually

5. Use colour

6. Store hygiene and production equipment properly

7. What if colours alone are not enough?

8. Have designated spill control equipment and stations

9. Train your staff on your allergen strategy and give them specific responsibilities for it

10. Carry out an allergen audit on yourself

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