If a process line is used to produce both products with and without allergens at different times, the schedule sequence should run unique allergens toward the end. For example, candy bars without peanuts might be scheduled first, followed by bars with peanuts, followed by bars with peanuts and almonds. If the next scheduled product does not contain an allergen, the line should be cleaned and sanitized.
Suppose during your hazard analysis you identified a potential allergen hazard from producing products with no allergens and products with allergens on the same line at different times. Your Hazard Analysis might look like this.
|PRODUCT:||PAGE ___ OF ____|
|Ingredient or processing step||Hazard||Preventive control required||Justify your decision||Preventive controls||Applied at this step?|
|Roasting||Undeclared allergen in candy bar||X||Products with allergen are produced on the same line as products no or different allergens (peanut, almond). Allergens cause illness in susceptible individuals.||Run non-allergen product first, schedule peanut or almond roasting after non-allergen product. Clean and sanitize roaster when switching to other nut or non-nut product.||X|
This example only shows the roasting step. Subsequent steps in the production process would also require cleaning.
Now that we have defined how to control for the potential allergen, we need to create a row in the Allergen Process Preventive Controls form.
Allergen Preventive Control form
|PRODUCT:||PAGE 1 of ___________|
|Allergen Control||Hazard(s)||Critical Limits||Monitoring||Corrective Action||Verification||Records|
|Scheduling to prevent cross-contact of allergens with non-allergen product||Undeclared peanut or almond in candy bar||Line equipment exposed to allergen cleaned and sanitized before change to a different allergen or non-allergen product||Line equipment and conveyors||Visual and ATP swabs for cleanliness||Every change of product||Line operator and supervisor||Segregate all allergen product run on uncleaned line||Review and sign-off when switching to another product||Production schedule|
|Schedule and cleaning||Review schedule and cleaning records||Reclean line||Cleaning records|
|Corrective action records|
DOWNLOAD A BLANK VERSION OF THIS ALLERGEN CONTROLS FORM
The verification column in this form shows the actions taken to control the hazards, including monitoring, have been done correctly.