Food Allergens and New Product Development

1
Food Allergens and New Product Development

• Sydney
• 16 February 2006

2
Food Allergens and New Product Development

• 1. Raw Materials
• 2. Production process
• 3. Impact

3
New Product
4
Raw Materials

• Approved suppliers are used
• Allergens considered as part of the approval
  process
• Supplier information (MAD form)
• What allergens?
• What concerns?

5
Raw Materials

• New allergens?
• Type of allergen oil, starch, protein
  containing material
• Cross contact at the supplier
• Type of cross contact

6
Raw Materials

• Assess the product allergen profile to understand
  impact
• Approval from head office to introduce new
  allergens

7
Raw Materials
8
Production Process
9
Production Process

• Preliminary HACCP
• Include QA, Technologists, Engineers, Production
  etc.
• Consider segregation and storage of the raw
  material

10
Production Process

• Assess the impact of the product on the product
  line
• Will products manufactured on the same line need
  precautionary labelling?
• If you need to change the labels then consider
  alternatives for the trials
• Equipment used
• New equipment hygienic engineering

11
Production Process

• Assess the product schedule
• If a new allergen is introduced consider when
  and where to produce the trial
• Consider the type of raw material particulates,
  powder, liquid
• At the end of production run followed by a clean

12
Production Process

• Consider also containers and tools used
• Manual addition of minor ingredients may avoid
  cross-contact
• Rework like-into-like policy
• Evaluate the rework matrix
• Validate the cleaning where used to remove new
  allergens
• Commence trial only when pHACCP is approved

13
Impact

• Labelling of product trials
• CCP for allergen labelling
• Double sign-off of allergen labelling from
  original information provided
• Sensory panellists need to be advised

14
Impact

• Documentation of procedures
• Communication with operators when a new allergen
  is introduced
• Awareness is not enough all parties must have
  the right attitude

15
Impact

• Consider alternative manufacturing sites if
  introducing a new allergen
• Source another raw material
• Precautionary label all other products affected
  by the new allergen before running the trial

16
Food Allergens and Product Development

• Consider raw materials
• Look at the production process at all stages,
  including the warehouse
• Impact
• Labelling products sensory panellists
• Attitude
• Manage the changes