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How to manage allergens in confectionery production
In this article, originally published in *Candy Industry* on June 16, 2017, and updated for 2021, Remco’s Amit Kheradia highlights the critical importance of allergen management in confectionery production. For individuals with food allergies, even a small amount of an allergen can lead to severe and potentially life-threatening reactions. Symptoms such as hives, swelling, difficulty breathing, and anaphylaxis can occur rapidly, making it essential for manufacturers to take proactive steps to prevent cross-contamination.
According to the Food Allergy Research & Education (FARE), approximately 15 million Americans suffer from food allergies, and the economic burden of these allergies in the U.S. is around $25 billion annually. Undeclared allergens are one of the leading causes of food recalls, with data showing that in 2014, nearly half of all FDA recalls were due to this issue. In fact, undeclared allergens accounted for almost the same number of reports as Salmonella, highlighting the severity of the problem.
An allergen is a substance that triggers an overactive immune response in sensitive individuals. While any protein-based ingredient has the potential to cause an allergic reaction, eight major foods account for about 90% of all food allergies: milk, eggs, peanuts, tree nuts, wheat, soy, fish, and shellfish. Managing these allergens in confectionery production is not just a regulatory requirement but a vital part of ensuring consumer safety.
To effectively manage allergens, manufacturers must implement comprehensive training programs for employees. This includes understanding how to identify allergens, avoid cross-contact during handling, and follow strict sanitation protocols. Color-coding systems—such as using white tags for milk and green for peanuts—can help track ingredients and reduce the risk of mix-ups.
Storage and handling practices also play a key role. For example, storing wheat and soy flours side by side rather than stacked can minimize cross-contamination risks. Operators should also avoid puncturing ingredient bags to prevent accidental mixing. Proper recordkeeping ensures accountability and improves traceability, which is crucial in case of a recall.
Sanitation is another critical factor. High-risk areas require thorough cleaning, and tools used for cleaning should be color-coded to prevent cross-contamination between different allergen zones. ATP swabs or allergen-specific test kits can quickly verify if surfaces are free from allergens, offering an extra layer of assurance.
Supervision and clear visual cues—like color-coded uniforms and equipment—help reinforce allergen control measures. Employees should be trained to change protective gear when moving between processing zones and to wash hands thoroughly.
Production scheduling is also important. Processing non-allergenic products first, followed by those with fewer allergens, can help reduce contamination risks. After handling allergenic items, a full sanitation cycle is necessary before switching to other products.
Beyond the factory floor, labeling plays a crucial role in protecting consumers. Many people are unaware of scientific names like "sodium caseinate" or "whey," which are derived from milk. Labels should clearly state all allergens, even if they appear in minor amounts. Additionally, flavorings, spices, and preservatives may contain hidden allergens, so transparency is key.
International regulations also vary. For instance, Canada recognizes mustard and sesame as allergens, which means manufacturers must be aware of these when exporting products.
With the global confectionery market expected to reach $275.8 billion by 2025, the cost of allergen-related recalls will continue to rise. By implementing a robust allergen management program and educating their workforce, manufacturers can significantly reduce these risks and ensure the safety of their customers.
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