Dairy Processing - March/April 2023 - 51

because most sanitization processes won't eliminate allergen
threats like they do with biological contaminants.
" Often sanitizers or other 'kill' processes are relied upon
to remedy situations where cleaning is not consistent or
reliable, " Downer said. " This is where focusing on the proper
cleaning or removal of the allergens is critical. "
In order to best handle allergens, Downer recommended
eliminating all potential for variability and increasing the
active monitoring of the cleaning that takes place in areas
where allergen hazards exist. For example, he called manual
cleaning " fundamentally rife with inconsistency " and lacking
true traceability.
He instead suggested using an automated cabinet
washer, because with that technology the cleaning " recipe "
is repeatable and comes with the added benefit of full
traceability, with verification that can be accessed in real time.
PREVENTIVE PROTOCOLS
Available approaches to handling allergens can be different
for smaller manufacturers than their larger counterparts. Eric
Garr, regional sales manager for Fortress Technology Inc.,
explained that larger processors will segregate production
areas that handle known allergens when possible, but that
may not be an option for smaller processors.
When separate production areas aren't available, Garr said
the emphasis must shift to hygiene and effective processes.
" In fact, where potential allergens are present or could be
present in some sets of ingredients but not in others, cleaning
must go well beyond normal hygienic requirements, " he said.
" Even where heat processing is involved, allergens can still
survive high temperatures. "
Among the several steps necessary for handling allergens in
such scenarios, Garr added, are equipment cleaning protocols
that are formalized and included in staff training. To make
sure a food safety plan works, each cleaning process also must
be verified and documented through regular testing - he said
swabbing of critical control points should be scheduled to
verify that specified areas are remaining allergen-free.
Additionally, Garr said all products containing known
allergens should have clear and legible labels to prevent
potentially life-threatening allergic reactions and ensure
regulatory compliance.
In facilities that use gravity metal detection systems for
powders and particulates, Garr said, product residues that
potentially include allergens can be " especially troublesome. "
" Routine risk assessments and audits help to control
the introduction of foreign material into products, " he
said. " External eyes provide a different perspective. Many
internationally recognized audits follow set standards and
provide a complete 360-degree review. "
A container of Aldean's Organic ice cream shows a
Certified Gluten-Free logo, meaning it has met strict
standards during production to ensure the product is free
of the common allergen.
COMMON PROBLEM AREAS
Avoiding allergen-related complications in a facility is a must,
especially when undeclared allergens in products routinely
lead to food recalls.
Within the dairy supply chain, Garr said companies
can reduce the risk of consumer exposure to allergens by
taking the greatest care when sourcing ingredients and by
auditing suppliers.
The Center for Dairy Research recommends that dairy
processing companies ask their suppliers each year for an
allergen statement on all products that are used. Per CDR,
such statements should include all allergens present in the
supplied product, as well as a notice if the product is made on
the same line as other allergens.
Downer credited the dairy industry with traditionally
doing a good job of keeping its fluid processes both well
designed and cleanable. For dairy processors, he said allergen
problems most commonly are encountered with processes
downstream, such as handling, cutting, filling and packaging.
He said those often are areas where a variety of products
can come in contact with common equipment. Plus, that
DAIRYPROCESSING.COM | MAR-APR 2023 51
Dave Gordon
http://www.DAIRYPROCESSING.COM
Dairy Processing - March/April 2023

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