Baking & Snack - June 2019 - 105

OPERATIONS
Line Isolation

HOLD THE LINE

Strengthening production segregation can protect food - and consumers - from allergens.
by Charlotte Atchley

Allergens have been a growing concern for years in the
food industry. As the number of allergens - and people
affected by them - grows, so does concern about how
food is protected as it's being made. "Today's consumers
have a heightened sensitivity to allergens, and we have
a strong commitment to protect them," said Bart Child,
senior vice-president of commercial development of
Nellson, Anaheim, CA.
This heightened intolerance has revolutionized the
food manufacturing industry to not only prioritize
sanitation but also look at other ways to prevent crosscontamination. Companies that deal with many different allergens need stringent sanitation plans, strategic
production schedules and, in some cases, isolated production lines.
"The benefits of line segregation allow us to produce
products with multiple allergens on different lines at the
same time," Mr. Child said.
Line isolation can take on several forms, and it's important for a bakery to find the system that works best
for its customers, allergen matrix and production needs.

"Ultimate isolation is achieved with totally separated
facilities," said Greg Carr, senior director of project planning, The Austin Co. "A plan to meet ultimate regulatory
requirements could include selecting a big enough site
to accommodate a separate plant in the future."
When creating or expanding dedicated facilities, it
isn't just about shopping for a site with enough space,
but it's also about the neighborhood. "Austin's site location consultants will identify any nearby facilities that
may use allergens that could conceivably contaminate
new plant fresh air intakes," Mr. Carr explained. "Where
possible, Austin will request covenants that prevent future allergenic operations locating nearby."
Preventing cross-contamination within the same facility by separating lines requires more operational strategies as well as physical barriers to protect allergen-free
production. While dedicated plants may be closest to a
sure-thing in preventing cross-contamination, it's not always feasible for every company. "As a co-manufacturer
that manages all types of allergens, building dedicated
plants is not practical," Mr. Child said.

Levels of isolation

Choose a level

There are several types of line isolation to accommodate different plants' needs, be they floorspace, allergen
matrix, customer requirements or all three. A company
can have dedicated bakeries free from a specific allergen. They can also have lines physically separated in
the same building. Lines can exist in the same facility
with minimal physical separation. In these cases, strict
sanitation is a must.

Determining which level of isolation will work best for
a bakery requires a consideration of several variables including the facility's limitations, customer requirements,
current allergen matrix and future production needs.
To choose the appropriate level of isolation, bakers
must first identify what the risks for cross-contamination are and where opportunities for contamination exist in the process.

Heightened concern around
allergens has companies that
deal with many allergens, such
as bar producers, looking to
segregate production to prevent cross-contamination.
Craig Vander Lende

www.bakingandsnack.com / June 2019 Baking & Snack 105

http://www.bakingandsnack.com

Baking & Snack - June 2019

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