Allergen Management in the Food Industry

Allergens form a separate risk category within food safety. Not because of microbial growth or spoilage, but because even small amounts can trigger reactions in sensitive consumers.

In food production environments, different ingredients and product lines often come together. That is why allergen management is a standard part of quality management, hygiene procedures and traceability.

Allergens and Food Allergies

For consumers with a food allergy, exposure to an allergen can lead to various physical reactions. In milder cases, this includes skin irritation, itching, swelling, or gastrointestinal issues. In more severe cases, a reaction can rapidly develop into breathing problems or an anaphylactic reaction, where immediate medical attention is required.

Because reactions can occur even at very low concentrations and sensitivity varies greatly between individuals, strict allergen control is essential.

In manufacturing environments, not only visible contamination must be prevented, but also residual allergenic protein traces. Therefore, verification methods are used to assess the effectiveness of cleaning, such as rapid protein tests and allergen swabs that indicate whether surfaces are truly free from residues.

These checks help show whether cleaning procedures are actually removing allergen residues effectively.

An allergen is a protein that can trigger an adverse reaction in some consumers. The reaction occurs when the immune system interprets a normal food ingredient as harmful. Even very small amounts of an allergen can be enough to cause symptoms, which is why accurate ingredient control and clear communication are so important in food safety.

In food safety, allergen management is therefore not about food quality in the traditional sense, but about consumer protection and providing accurate information. Recalls due to allergen contamination are reported weekly in the news and have significant consequences for both products and consumers.

In the European Union, fourteen allergens must be legally declared when they are present as ingredients in a food product. EU regulation 1169/2011 (Food Information to Consumers) establishes this list and provides the legal framework for allergen labelling across the European Union.

The main allergens are:

• Gluten-containing cereals (such as wheat, rye, barley, oats, spelt, and khorasan)
• Crustaceans
• Eggs
• Fish
• Peanuts
• Soy
• Milk and milk-based products (including lactose)
• Nuts (such as almonds, hazelnuts, walnuts, cashews, pistachios)
• Celery
• Mustard
• Sesame
• Sulphites (>10 mg/kg)
• Lupin
• Molluscs

This list forms the basis for labelling and allergen management in Europe. For some highly refined ingredients, specific exceptions apply within the legislation, but the obligation to provide information remains a key principle for producers.

Although allergens are biologically classified as proteins, they are often treated as a chemical hazard in food safety systems such as HACCP. This is because allergens do not grow or multiply like microorganisms. Within allergen management, a number of recurring points require attention.

Separation of Ingredient Streams
In manufacturing environments where multiple recipes are processed, there is a risk that allergenic ingredients may unintentionally end up in other products. This is generally referred to as cross-contamination.

This can occur, for example, via shared production equipment or product residues left in pipes, mixers, or dosing systems. Additionally, conveyor belts, work surfaces, and tools can contribute to cross-contamination when different product streams use the same infrastructure. Even small amounts are relevant.

To mitigate this risk, companies implement various control measures, such as physical separation of product streams, separate storage, and, in some cases, visual aids like colour coding.

Product Integrity and Labelling
Another key point is correct labelling. When an allergen is present in a product but not listed on the packaging, this can lead to severe incidents and, in many cases, a recall.

European food recalls often show that allergen incidents are related to labelling issues. These can range from incorrect packaging or label rolls to errors in formulation management or product mix-ups during the packaging process.

Process Organization
Allergen management typically involves multiple disciplines within an organization. Formulation management, production planning, and cleaning policies are part of it, as well as personnel practices, documentation, and traceability.

In practice, allergen control usually relies on a combination of organisational and technical measures.

In the food industry, allergen incidents often arise from labelling errors. For example, a fish snack may be withdrawn from the market because of an incorrect label on the packaging. This leads to the omission of allergens such as fish and gluten, even though they may be present in the product.

For consumers with an allergy or intolerance, this can result in health risks. For this reason, a company may initiate a recall, removing the product from the market as a precaution.

This type of incident is not uncommon. In European food safety reports, two primary causes often recur: missing allergen information on labels and cross-contamination during product changes on shared lines. For instance, when a product containing milk ingredients is followed by a dairy-free product and residue is left behind.

Allergen incidents therefore occur not only due to recipe management but also due to labelling, process transitions, and insufficiently removed product residues.

In day-to-day production, cross-contamination can occur through surprisingly simple routes. For example, by moving ingredients between production lines.

Tools can also be used in multiple locations, or work surfaces may not be fully cleaned in between uses. As a result, employee behaviour plays an important role in allergen management.

Many food manufacturers apply hygienic zoning, where production areas are categorized based on risk, such as low care, high care, or high-risk zones. By separating product flows, staff, and materials, the risk of allergen cross-contamination is reduced.

Zoning includes both physical separation and organizational measures, such as clothing changes, tool management, and zone-specific cleaning.

Colour Coding and Visual Separation

Colour coding can be used as a practical visual aid to separate materials and tools by allergen flow. For example, by assigning a specific colour to cleaning materials, tools, or storage racks, visual control is created. This reduces the likelihood of materials being exchanged between allergenic and non-allergenic product flows.

In some manufacturing environments, colours are even linked to specific allergens or allergen zones. This makes it immediately clear which materials belong to which zone.

In practice, colour coding can be applied to:

• Production lines with specific allergens
• Cleaning materials for specific zones
• Temporary production campaigns

The system varies by organisation. Some companies use colour coding for hygiene zones, while others link colours to specific allergen flows.

Allergens are protein structures that can adhere to surfaces. As a result, depending on the product type and process, they can sometimes be relatively difficult to remove. In production processes involving fatty ingredients, dough-like mixtures, or sticky sauces, protein residues can bind firmly to surfaces.

This means that surfaces, machines, and tools must be thoroughly cleaned to remove allergenic protein residues. Disinfection alone is not sufficient. Cleaning focuses on removing product residues and protein remnants, while disinfection is intended for microbiological control and does not remove allergens. Therefore, the focus is on effective cleaning and demonstrable removal of residues.

Some manufacturing companies make cleaning materials used for allergenic product flows specifically identifiable or store them separately. This prevents brushes, scrapers, or other tools that have come into contact with allergens from being used later in areas where no allergens are present.

In addition to cleaning procedures, the design of tools and equipment is also an important consideration. This is why many manufacturers choose materials with a hygienic design, such as smooth surfaces and without hard-to-clean corners or seams. This makes it easier to effectively remove product residues and allergenic protein traces.

Scope and Relevance

Allergen management becomes particularly important in production environments where speed and product variation go hand in hand. Companies that produce multiple recipes simultaneously, combine ingredient flows, or use flexible production lines are at a greater risk of cross-contamination.

This applies to bakeries, pastry manufacturers, dairy processors, meat and deli product producers, sauce and meal component manufacturers, snack makers, and industrial meal producers. Allergen management also plays a role in packaging, repackaging, and logistics activities. For example, when products with different ingredient profiles are processed in the same space.

Post-Cleaning, Verification, and Audits

In quality management systems, verification is an important tool to demonstrate that allergen management is effective. Organizations use various forms of control, ranging from visual inspections to protein detection tests, allergen swabs, and allergen tests in the form of rapid tests, which often provide results within approximately 5 minutes. In some cases, specific analytical techniques are applied, such as ELISA tests or PCR-based methods for allergen detection.

During audits, such as those according to BRCGS, IFS Food, and FSSC 22000, allergen management is routinely assessed as part of the risk assessment and process control.

Some companies work with different monitoring zones. Surfaces are categorized based on their proximity to the product, such as food contact surfaces, nearby equipment, and peripheral environmental surfaces. This principle is applied not only for microbiological monitoring but also for targeted allergen residue checking.

In many cases, such methods are used to verify cleaning procedures and, where necessary, validate them in advance. Validation focuses on proving that a method effectively removes allergens, while verification is intended to routinely check whether the process continues to function.

During food safety audits, multiple elements are examined. For example, allergen risk analysis within the HACCP system, product and ingredient specifications, label checks, and the validation of cleaning methods. Production planning and product changeover records are often also part of this assessment.

Together, these documentation and verification activities give auditors insight into how organizations demonstrate that allergen risks are systematically controlled.

Despite extensive control measures, allergen incidents continue to occur regularly. Typical causes include:

Unintentional Product Mix-up
At high production speeds or during frequent product changes, incorrect packaging or label rolls may be used.

Insufficient Separation of Raw Materials
Storage areas where allergenic and non-allergenic ingredients are stored close to each other increase the risk of cross-contamination.

Employee Behaviour
Employees often move between production lines, warehouses, and production zones. Without clear hygienic routines, transfer can occur via clothing, gloves, or tools.

Personal Hygiene
Personal hygiene is essential in preventing allergen transfer. Hand cleaning and disinfection are basic measures, and disposable protective equipment must be replaced on time to prevent cross-contamination.

Recipe Changes
When ingredients are adjusted without labels being updated in time, incorrect allergen information can arise. Additives, flavourings, spice mixes, and other composite ingredients can also unexpectedly contain allergens.

Incomplete Cleaning
Especially with complex machines or hard-to-reach parts, product residues can remain.

In allergen management, organizations use PPE and hygiene products as part of overall hygiene and risk management.

Disposable protective equipment is clean, hygienic and easy to replace, for example during shift changes, breaks or task changes.

These products help minimize transfer via employees, tools, and work surfaces.

Examples include:

• Disposable gloves
• Protective workwear
• Hairnets
• Beard covers
• Overshoes
• Cleaning materials with colour coding

Allergen tests are a practical way to check whether allergen residues are still present after cleaning. hese rapid tests provide a reliable result within 5 minutes after cleaning.

For allergen detection and food safety, Safety Products B.V. works with Neogen test methods. With Neogen’s reliable rapid tests, you get quick results so production can resume without delay.

Soy

Sesame seeds

Crustaceans

Peanut

Mustard

Coconut

Hazelnut

Gluten

Egg

Tree nut

Almond

Milk