Allergen Control
Manufacturing with Allergens
SG Systems is delighted to announce the latest innovation for FSMA Allergen Control Measures – the V5 Traceability ‘Allergen Control System’. Available as standard on Professional and Enterprise versions, the Allergen Plan enhancement is designed to provide a software-based Allergen Management Program designed to meet your company-based Allergen Control Policy without handwritten records / paper-based systems.
The premise of the Allergen Control System is simple. Using shop floor software screens and advanced allergen labeling, Operators at warned at every touchpoint that they are about to handle Allergens and then present the best way to control them. In turn, V5 Traceability records who, what, where, and when the Allergens were handled.
V5 Traceability will ensure Allergen labeling is automated (from the receiving stages, batching processes, and finished product creation). It will ensure the Allergen Management Program is visible using operator screens. It will guarantee operator confirmation (Pin code or SSO) at every handling stage. Moreso – each Allergen Control Measure is logged in a database for immediate retrieval in the event that an issue arises requiring immediate investigation.
Allergen Management Program Concept
First, you must setup your Allergens Control System in V5 and link your associated commodities. Commodities can belong to multiple allergen groups.
The main Allergens are already preloaded ( Milk, Eggs, Fish, Crustacean Shellfish, Tree Nuts, Peanuts, Wheat and Soy) but you can add more and built your commodity associations.
Allergen Labeling Setup
All System generated labels have the necessary data fields to meet the Allergen Control Plan. Lots of label choices exist but in principle, labels are generated to identify incoming inventory, batch production, any WIP or submix assemblies and finished products.
Warehousing Allergens
V5 Traceability will detect at the point of receiving that a PO contains a commodity that belongs to one of the Allergen Groups. The Software will automatically;
1) Warn the Operator that they are about to handle an Allergen (requiring a confirmation that they have seen the message that they are handling Allergens).
2) Generate a label (pallet or item level) that contains the Allergen Group(s)
3) Guide the operator to a put-away location (using the predefined warehouse setup) that allows the Allergen. The system will ensure Allergen control measures are enforced to meet the Allergen Management Policy. I.e. Allergens belonging to different groups cannot be stored on top of one another.
This prevents cross-contamination of Allergens. The Allergen Control Measures apply to the finished goods too, enabling an Allergen Management Policy that spans the whole warehousing operation.
Scheduling Production and Allergen Sequencing
The purpose of Allergen Sequencing is to optimize the production schedule to minimize the number of clean downs required for product changeover. V5 traceability allows the user to create a production run that establishes formulations containing ingredients marked as Allergens. The software then schedules them using the Allergen Pyramid method within the Allergen Control Plan routine.
In this example, the Allergen Sequencing software would look to see the most common Allergens – in this case, Wheat. Then schedule the jobs so that the Allergen complexity grows without cross-contamination prior to the cleardown. It will attempt to prioritize the largest run first.
The result will appear as:
CLEARDOWN
Formula A – Wheat
Formula D – Wheat, Egg
Formula C – Wheat, Egg, Nuts
CLEARDOWN
Formula B – Nuts
Formula D – Nuts, Egg
Benefits of the Allergen Control System include a) fewer clean downs b) reduced risk of cross-contamination c) optimized production output.
Batch Production
At the production floor level, production operators will be in automatic compliance with the Allergen Control Policy. They will be able to view the schedule on the V5 Formula Control System terminal without having to think about the sequence of clean downs and the priority of jobs. The system will remove the guesswork and ensure Allergen Control Measures are correctly adhered to.
The Formula Control System will organize the operators, then prompt them for each of the ingredients in the formulation ensuring tolerances are met and correct quantities are added. Any Allergens that require warnings will be displayed on screen and require operator confirmation.
Allergen Management Program
FSMA requires controls to prevent allergen cross-contact. Incorrect allergen content declaration, a potentially life-threatening situation, remains the primary reason for recalls in the USA and Canada. An effective allergen cross-contact prevention program requires a multi-disciplinary approach during development and implementation, and ongoing validation of the effectiveness of the practices. Employees must understand and follow the controls, then leverage V5 Traceability Software to capture and record their activities automatically.
Manufacturing with Allergens FAQ’s
What is the Allergen Control System by SG Systems? The Allergen Control System is a software-based Allergen Management Program designed to assist in implementing company-based Allergen Control Policies, replacing handwritten and paper-based systems. It employs shop floor software screens and advanced allergen labeling to warn operators about handling allergens and suggest control methods.
How does the Allergen Control System improve allergen labeling? The system automates allergen labeling from receiving stages to finished product creation, ensuring visibility of the Allergen Management Program and requiring operator confirmation at each handling stage.
What are the steps to set up the Allergen Control System in V5? To set up the system, initialize your Allergen Control System in V5 and link your associated commodities. These commodities can belong to multiple allergen groups. The system includes main allergens and allows for the addition of more and building of commodity associations.
What types of labels are generated by the system? The system generates various labels essential for the Allergen Control Plan, identifying incoming inventory, batch production, work-in-progress, submix assemblies, and finished products.
How does the system handle the receipt of allergens? Upon receiving a PO containing a commodity from an allergen group, the system warns the operator, generates a label indicating allergen groups, and guides to a suitable storage location.
How does the system prevent cross-contamination of allergens? The system’s Allergen Control Measures extend to finished goods, implementing an Allergen Management Policy that spans the entire warehousing operation to prevent cross-contamination.
What is Allergen Sequencing in this system? Allergen Sequencing optimizes the production schedule to minimize clean downs for product changeovers, establishing formulations with allergen ingredients and scheduling them to avoid cross-contamination.
What are the benefits of the Allergen Control System? The system offers benefits like fewer clean downs, reduced risk of cross-contamination, and optimized production output.
How does the system assist production floor operators? Operators automatically comply with the Allergen Control Policy, viewing schedules on the Formula Control System terminal, ensuring adherence to Allergen Control Measures.
What role does the Formula Control System play in allergen management? The Formula Control System organizes operators, ensuring ingredient tolerances and correct quantities, displaying allergen warnings, and requiring confirmation.
Is the Allergen Control System customizable for different allergens? Yes, the system is preloaded with main allergens but allows for the addition of more allergens as per specific requirements.
Can the Allergen Control System integrate with existing warehouse setups? The system is designed to work with predefined warehouse setups, guiding operators to appropriate storage locations for allergens.
How does the system ensure operator compliance? The system requires operator confirmation at various stages, ensuring compliance with the Allergen Management Policy.
What is the importance of allergen sequencing in production? Allergen sequencing is crucial for minimizing clean downs and preventing cross-contamination in production schedules.
How does the system contribute to food safety? By managing allergens effectively, the system reduces the risk of incorrect allergen content declaration and potential recalls.
What support does the system provide in case of an allergen-related issue? The system logs each allergen control measure, allowing for immediate retrieval of data for investigations.
How does the system help in optimizing production output? By scheduling production runs considering allergen complexity, the system helps in optimizing the overall production output.
Can the system handle multiple allergen groups simultaneously? Yes, the system can handle commodities belonging to multiple allergen groups and ensures their proper management.
How does the system impact the overall efficiency of a production facility? The system enhances efficiency by reducing manual tasks, automating allergen management, and optimizing production schedules.
Is the Allergen Control System compliant with industry regulations? The system is designed to meet industry regulations and requirements for allergen control and management in food production.
Summary
Effective allergen management within the food industry is crucial to ensure consumer safety and regulatory compliance. This involves the implementation of a robust allergen control program that includes a detailed allergen control plan, outlining specific measures to prevent cross-contamination during food manufacturing processes. Companies should establish allergen control systems that are guided by a clear allergen management policy, ensuring that all allergens in food manufacturing are identified, managed, and communicated to the end consumer.
Under the Food Safety Modernization Act (FSMA), specific allergen control requirements are in place to safeguard public health. Likewise, the Food and Drug Administration (FDA) mandates certain standards, encapsulated in the FDA allergen control program, to ensure that food allergen control practices meet the necessary safety criteria. It is imperative for food industry entities to consistently review their allergen control measures to adapt to new challenges and to maintain a high standard of allergen control management, thereby reducing the risks associated with food allergens.
Existing User? Need Help with Allergen Control Plan & Setup?
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