Managing Allergen Risk: What Good Looks Like in Food Manufacturing

If you work in food safety, you are likely to be familiar with the following statistic: around 40% of global product recalls are linked to allergen mismanagement. And here in the UK, the figure is almost exactly the same. It’s a sobering reminder that allergens remain one of the most persistent and preventable risks in our industry. 

In one of our allergen podcasts recorded in 2025, I sat down with two of Intertek’s experts - Deborah Matthews and Heather Hayward - to explore what “good” looks like when it comes to allergen control in food manufacturing. We focused on the areas businesses can control: their own production sites, processes, and people. 

Here’s what we uncovered. 

Start with Risk Assessment 

Heather started the session with the foundation of any effective allergen strategy: a comprehensive risk assessment. That means identifying every allergen on site and mapping out how they are managed, how they are used, and potential areas of cross-contamination. 

From Goods Receipt to Dispatch, every step needs scrutiny. It’s not just about listing allergens; it’s about understanding how they move through your food production facility and identifying potential risks. 

Food Production Controls 

Dedicated lines and equipment for high-risk allergens like peanuts are ideal. Physical zoning – separate areas and PPE protocols – add another layer of protection.  

Also, do not underestimate the power of scheduling. Scheduling products which do not present an allergen risk for production before those containing key allergens, can significantly reduce risk. In addition to this, deep cleaning overnight ensures that the line is free of allergenic residues for the first run in the morning. 

Mislabelled or undeclared allergens are one of the top causes of food product recalls. That is why label checks and reviews at the dispatch stage are critical, especially during production line changeovers. For example, a fish pie in a cottage pie sleeve is not just a mix-up; it’s a serious health risk. 

While suppliers may seem outside of food manufacturers’ control, there are tools to help. In the session, I highlighted the value of Intertek’s Horizon Scan, a platform we manage which updates global food safety issues daily. It allows the user to configure alerts for specific commodities and regions, giving businesses early warnings on emerging risks like undeclared allergens or contamination events. 

Cleaning, Testing, and Verification 

It’s not just overnight cleaning that is essential; performing validated cleaning procedures between production runs is essential. Visual inspections, swab tests, and rapid protein tests help verify effectiveness. While this can be done in-house, third-party verification provides independent evidence of cleaning efficacy and creates a testing history of compliance for due diligence purposes. 

At Intertek we offer lab testing for swabs, raw materials, and finished products, helping businesses build a comprehensive allergen testing programme. It is not only about verifying cleaning controls, but also ensuring that raw materials do not present a separate allergen risk.  

People: Your Strongest Defence 

The key to good site controls are people – they are your frontline defence. Heather and Deborah emphasised the importance of training throughout the session. Whether it’s classroom sessions, virtual modules, or on-demand courses through platforms like Intertek’s Wisetail, staff need to understand allergen risks, the value of cleaning protocols, and how to handle ingredients safely. 

However, allergen awareness cannot be just about delivering training. It’s about creating a food safety culture where good practices become the norm. The latest version of the Codex Alimentarius emphasises food safety culture as a prerequisite to good hygiene, and allergen awareness is a key part of that. 

Documentation: “If It’s Not Written Down, It Didn’t Happen” 

Heather’s point on documentation is key to an effective quality management system. Like all risk assessments, an allergen plan needs to be documented, integrated into your HACCP or food safety management system, and backed by traceability records. From cleaning logs to test results, everything should be recorded and accessible. 

If you want to go further, the BRCGS allergen module offers a structured way to assess your allergen controls. In our session, Deborah explained how it can be bolted onto your existing audit; no extra visits, just deeper insight. 

Emerging Risks: Don’t Let Urgency Undermine Safety 

One final point I raised in our discussion was about sourcing. Climate change, geopolitical unrest, and supply chain disruptions often force businesses to find new suppliers or enter new markets quickly. But urgency can introduce risk, especially if allergen controls aren’t properly assessed. 

That’s why we launched SupplyTek at Intertek. It’s a holistic service that helps businesses assess end-to-end risk when sourcing or expanding. We listen to your goals and tailor our support to your specific situation. 

Allergen management isn’t just a compliance exercise—it’s a commitment to customer safety and brand integrity. From risk assessment to safety culture, testing to documentation, every step matters. 

If you’d like to learn more about allergen testing, training, or how SupplyTek can support your sourcing strategy, visit intertek.com/food or intertek.com/supplytek. Or just reach out—we’re always happy to talk.