Food Safety
search
cart
facebook twitter linkedin
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Safety
  • NEWS
    • Latest News
    • White Papers
  • PRODUCTS
  • TOPICS
    • Contamination Control
    • Food Types
    • Management
    • Process Control
    • Regulatory
    • Sanitation
    • Supply Chain
    • Testing and Analysis
  • PODCAST
  • EXCLUSIVES
    • Food Safety Five Newsreel
    • eBooks
    • FSM Distinguished Service Award
    • Interactive Product Spotlights
    • Videos
  • BUYER'S GUIDE
  • MORE
    • ENEWSLETTER >
      • Archive Issues
      • Subscribe to eNews
    • Store
    • Sponsor Insights
  • WEBINARS
  • FOOD SAFETY SUMMIT
  • EMAG
    • eMagazine
    • Archive Issues
    • Editorial Advisory Board
    • Contact
    • Advertise
  • SIGN UP!

Allergen control and training for snack and bakery production

Companies rise to the challenge of allergen control

By Liz Parker
sanitation
January 21, 2020

In every level of snack and bakery production, allergen control is of utmost importance. Training operations staff on best practices is vital, and systems to keep personnel continually on track are also essential.

 

Training staff

“Allergen management training of employees in the food industry must be at the same intensity of training employees on the management of pathogens,” says Kathy Knutson, independent consultant, EAS Consulting Group, Alexandria, VA.

Facility management is responsible for the development and implementation of a training program for the prevention of both cross-contamination of pathogens and cross-contact of allergens, says Knutson. “Training starts with the on-boarding of new employees, seasonal workers or temporary hires before the worker goes to their first position on the production floor. From the first day of employment, the worker must be trained on the hazard of undeclared allergens, the facility’s color code for labeling of allergenic ingredients, use of personal protective equipment (PPE), and encouraged to report concerns or hazards associated with allergens. Facility management creates the food safety culture inclusive of allergen management and conducts refresher training as needed.”

All new hires and plant personnel should have training on what allergens are and how they affect the food industry, says Bret Zaher, manager, operations, Americas, AIB International, Manhattan, KS. “A list of known allergens at the plant should be provided to everyone and displayed at numerous locations around the facility. Allergen training should also include gluten training and training on specific allergens for any country the plant may export to,” he adds.

Establishing safe storage and handling practices are a must to prevent possible cross-contamination, Zaher notes. “It is a best practice that receiving personnel have a list of materials that contain allergens and these items are clearly labeled with allergen identification stickers (color-coded is best practice). There should be dedicated storage locations for the allergens, preferably on the bottom rack to prevent spillage. Like allergens should be stored over like allergens,” he explains.

It is also suggested that divider walls be provided in the storage slots to further assist in containing the allergens, Zaher adds. “Dedicated and/or color-coded containers and utensils should be used for handling these items. Dedicated and/or color-coded cleaning utensil should also be provided. Many sites have sectioned off allergen product lines from the other lines and have dedicated uniforms and color-coded hairnets for workers on those lines. Positive air pressure and dust collection systems in the pre-scale and mix areas are a must for dry ingredients that are allergenic.”

Employee traffic patterns should also be considered to prevent cross-contamination, too, Zaher says. “Risk assessments should also be conducted for any possible lunch room allergens being brought in by employees and ensuring that these are restricted to designated areas.  Many sites do not allow certain allergens, like peanuts in a peanut-free facility, to be brought into the lunch room.”

 

Staying on track

Zaher gives some examples of scenarios where software could be useful in allergen control, including altering staff when a line requires sanitation, alerts to prevent cross-contamination, and protocol for testing for allergies.

“Manufacturers can help keep personnel on track with allergen control through computer programs. Many plants are also sending out automatic email and text messages to their supervisory staff when allergen change-overs are due,” says Zaher. “ELISA-specific protein testing is the best way to validate that a company’s allergen cleaning is effective. A comprehensive food contact testing program should take place as well.”

Knutson recommends performing an allergen clean validation as part of SSOPs. An allergen clean is used to remove allergens on food contact surfaces after the production of one product and before starting production of a second product without the allergens.

“Despite not being required by FDA’s Preventive Controls for Human Food rule, 21 CFR 117, validation of an allergen clean is highly recommended. Validation of an allergen clean is a research project that is done once using allergen swabs on a multitude of difficult to clean food contact surfaces. Following the validation study, cleaning can be verified with lower-cost protein swabs at a frequency determined by the facility,” explains Knutson.

The validation study, allergen clean procedures, and swab procedures must be written along with the use of associated records for documentation of the allergen clean and verification, Knutson says. “Electronic programs to alert employees for the requirement of an allergen clean can be developed, and electronic recordkeeping can demonstrate that an allergen clean was completed and verified. Employees, equipment and utensils on a line with a unique allergen must be dedicated during use. Employees on a line with a unique allergen can be provided with color-coded hairnets or other PPE to show supervisors that they are at the correct work station. If the employee is moved off one line and to another line, the employee must leave the production area, remove all PPE and don new PPE to prevent cross-contact.”

Knutson says she spoke with the managers of a company that has a nut line and a nut-free line. In that example, employees have electronic key cards to access the line where they are to work. The employee will not have access to a line, if the employee is not scheduled to work on the line. “Traffic patterns for all personnel, wheeled equipment such as forklifts and garbage cans, and maintenance personnel and their tools must be controlled to prevent cross-contact,” she notes. “Tools and utensils brought to a line must be cleaned and sanitized before use. Allergen training for specific tasks should be verified by supervisors and documented in personnel files following the documentation of onboarding training.” 

This article was originally posted on www.snackandbakery.com.
KEYWORDS: allergens sanitation workforce development

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Liz200

Liz Parker is the Senior Editor of Candy Industry and Snack Food & Wholesale Bakery and the former Managing Editor of Food Safety Magazine. She has written for CBS Detroit, as well as for her own blogs. She earned a B.A. degree in Creative Writing from the University of Michigan.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • people holding baby chicks

    Serovar Differences Matter: Utility of Deep Serotyping in Broiler Production and Processing

    This article discusses the significance of Salmonella in...
    Contamination Control
    By: Nikki Shariat Ph.D.
  • woman washing hands

    Building a Culture of Hygiene in the Food Processing Plant

    Everyone entering a food processing facility needs to...
    Management
    By: Richard F. Stier, M.S.
  • graphical representation of earth over dirt

    Climate Change and Emerging Risks to Food Safety: Building Climate Resilience

    This article examines the multifaceted threats to food...
    International
    By: Maria Cristina Tirado Ph.D., D.V.M. and Shamini Albert Raj M.A.
Manage My Account
  • eMagazine Subscription
  • Subscribe to eNewsletter
  • Manage My Preferences
  • Website Registration
  • Subscription Customer Service

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the Food Safety Magazine audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of Food Safety Magazine or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • mold
    Sponsored byIFC

    Tackling Mold Remediation in Food Processing Plants

  • a worker in a food processing plant
    Sponsored byLPS® DETEX®

    How a Beverage Facility Improved Food Safety and Compliance with Detectable Packaging Solutions

  • Two men standing in a produce storage facility having a discussion.
    Sponsored byOrkin Commercial

    Staying Compliant With FSMA

Popular Stories

carton of dozen brown eggs

Salmonella Outbreak Linked to Eggs Ends With One Dead, 38 Hospitalized

close-up shot of nickel metal

New EU Maximum Levels for Nickel Now Apply to Dozens of Foods

blue iced donuts next to pie of sugar with blue written in it

FDA Authorizes Use of Fourth ‘Natural’ Food Dye, Gardenia Blue

Events

July 22, 2025

Beyond the Binder: Digital Management of Food Safety

Live: July 22, 2025 at 3:00 pm EDT: During this webinar, attendees will learn best practices for the use of digital food safety management systems across industry and regulatory agencies.

August 7, 2025

Achieve Active Managerial Control of Major Risk Factors Using a Food Safety Management System

Live: August 7, 2025 at 2:00 pm EDT: From this webinar, attendees will learn about changes to the FDA Food Code, which now includes a requirement for FSMS. 

May 11, 2026

The Food Safety Summit

Stay informed on the latest food safety trends, innovations, emerging challenges, and expert analysis. Leave the Summit with actionable insights ready to drive measurable improvements in your organization. Do not miss this opportunity to learn from experts about contamination control, food safety culture, regulations, sanitation, supply chain traceability, and so much more.

View All

Products

Global Food Safety Microbial Interventions and Molecular Advancements

Global Food Safety Microbial Interventions and Molecular Advancements

See More Products
Environmental Monitoring Excellence eBook

Related Articles

  • QA/QC and process validation in cannabis edibles and beverages production

    QA/QC and process validation in cannabis edibles and beverages production

    See More
  • Best practices for maintaining an allergen-free snack or bakery facility

    Best practices for maintaining an allergen-free snack or bakery facility

    See More
  • Effective control of birds and pests across the food chain

    Effective control of birds and pests across the food chain

    See More

Related Products

See More Products
  • 9781032369990 (1).webp

    Food Safety Quality Control and Management

  • 1119053595.jpg

    Food Safety for the 21st Century: Managing HACCP and Food Safety throughout the Global Supply Chain, 2E

  • 1119160553.jpg

    Food Safety: Innovative Analytical Tools for Safety Assessment

See More Products

Events

View AllSubmit An Event
  • May 14, 2025

    Proven Practices for Allergen Management

    On Demand: This session tackles the importance and impact of allergen management in product development, production, and labeling. 
View AllSubmit An Event

Related Directories

  • Bakery Machinery & Fabrication (BMF/Cookie & Cracker Machinery)

    Engineering/Designing/Manufacturing of Cookie, Cracker, Snack Food & Pet Treat equipment. From unit machines to turnkey systems ranging from flour handling through wrapping. Equipment development for new products that are not capable of being produced on conventional equipment. We're your competitors' best kept secret!! Get the Baking Edge!!
  • Responsible Training

    Responsible Training has been a trusted leader in compliance education since 1999, providing accessible and reliable training solutions for businesses across highly regulated industries. With deep local expertise in Texas and a nationwide reach, we specialize in helping kitchens across industries get tailored, regulation-focused content that ensures businesses seamlessly meet their compliance requirements. Contact us for more information about our Food Manager Certification, Food Handler Courses, Alcohol Server and Cannabis Vendor courses.
×

Never miss the latest news and trends driving the food safety industry

eNewsletter | Website | eMagazine

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Instagram
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing