Food allergen safety is a critical component of prepared meal manufacturing that should never be undervalued. Manufacturing prepared meals typically involves a variety of ingredients across the different types of meals you create. You may even have different meal lines that cater to different dietary preferences or food allergies.
Having the correct food allergen safety protocol in place is essential for navigating common food allergies that consumers may have.
In this article, we will discuss the food allergen safety standards that prepared meal companies should implement, such as creating food allergy safety zones. We will also discuss the importance of disclosing ingredients so that consumers can navigate common food allergies.
Common Food Allergies: What Prepared Meal Manufacturers Need to Know
There are many common food allergies that prepared meal manufacturers need to be aware of. Part of the danger of food allergies is that they vary significantly in severity. For some people, food sensitivity may be very minimal, while for others, it could be life-threatening.
Prepared meals manufacturers have an obligation to protect consumer safety by being aware of these safety risks.
Although there are hundreds of different types of food allergies, there are a few that have been recognized as being more prevalent, such as:
- Dairy: Although not usually a severe allergy, dairy is a common allergen that can create significant discomfort.
- Gluten: Some people have a gluten sensitivity or an outright allergy that can result in uncomfortable side effects. Keep in mind that a gluten sensitivity or allergy is not the same as diagnosed celiac disease.
- Nuts: One of the most common and severe allergies is a nut allergy. This can include different types of nuts, such as tree nuts and peanuts, all of which can result in potentially life-threatening reactions.
- Fish & Shellfish: Another common and dangerous food allergy is an allergy to fish or shellfish. Both can be potentially life-threatening even if the exposure is only due to cross-contamination.
- Eggs: Egg allergies are common in children and can create a variety of side effects, whether the exposure is to the egg white or yolk.
- Sesame: Sesame is one of the most common allergens and can pose various risks to consumers, whether they are consuming the seeds or oil.
The Importance of Proper Ingredient Disclosure
In the United States, prepared meals manufacturers must follow specific legal regulations regarding ingredient disclosure. These regulations exist to ensure consumers know exactly what their food is made of.
Consumers need clear information about the ingredients they’ll be exposed to so they can make safe and informed decisions. For instance, those with severe food allergies that could trigger life-threatening reactions may not want to consume food produced in a plant that handles those allergens. By properly disclosing ingredients, you are allowing them to make these decisions for themselves.
Generally speaking, all food ingredients must be included on the packaging label. There should also be disclosure regarding any common allergens that the food may have been exposed to within the same manufacturing plant. This information needs to be clear, easy to read, and easily accessible to the consumer.
How to Create Food Allergy Safety Zones in Manufacturing
Now that you know about the most common allergens to be aware of, how can you create food allergen safety zones? When manufacturing prepared meals, you may need to create safety zones as a way of preventing cross-contamination. Although this can feel challenging when working in the same manufacturing plant, it is not impossible.
The size of the safety zone will depend on the type of allergen and the potential cross-contamination risks. Here are some aspects of safety zones to consider to prevent allergen cross-contamination.
Segregated Conveyor Lines
One of the main steps in creating safety zones for allergens is to establish segregated conveyor lines. Prepared meals that use any type of allergen must be separated and produced on a different line from other meals. At Quantum, we offer a variety of multi-line conveyors that are perfect for keeping products separate. Most of our conveying lines are also highly integratable, allowing you to add additional lines to your current system as you create more products.
Keep in mind that for most food allergens, segregated conveyor lines are not enough to make a safety zone. You may need to zone off your entire manufacturing plant to prevent airborne contamination.
Personnel Movement
One aspect of food allergy safety that is often overlooked is personnel movement. Even if you are using automated food production equipment that doesn’t require many employees, you still need to have safety standards for personnel movement in the manufacturing plant.
For example, you may have safety zones set that keep common food allergens far away from one another to prevent cross-contamination. However, if you have employees who are moving throughout the plant, they could be creating cross-contamination.
To prevent this, your safety zones need to include personnel movement, ideally with certain teams working in those designated zones. All of your employees should also go through safety training so that they are better aware of the safety standards they need to maintain.
Equipment Sanitation
Another very important aspect of maintaining food safety is food production equipment sanitization. One of the best ways to prevent cross-contamination between different types of ingredients is to maintain sanitization standards for all of your equipment.
You can invest in equipment with a sanitary design, such as the QTCC series offered at Quantum. It is also a good idea to look for equipment that is easy to clean and washdown compatible.
Invest in Safer Food Production Equipment From Quantum
Do you want to create food allergy safety zones in your manufacturing company? At Quantum, we offer a variety of food production equipment specifically designed for prepared meals companies. This equipment can help you improve food allergen safety by creating safety zones, reducing cross-contamination, and improving hygienic standards. Contact our team today to learn more.