Preventing and Responding to Food Allergies in Processing Facilities

Even trace allergen exposure can trigger life-threatening reactions. Food processors must pair strict cross-contact prevention with first-aid readiness to safeguard both workers and consumers.

• By Mia Barnes
• Sep 23, 2025

Food allergies are a serious concern in food processing environments. Even trace amounts of an allergen can cause life-threatening reactions, so safety protocols must be precise, consistent and strictly enforced. For workers and employers, knowing how to respond quickly and effectively is just as important as preventing cross-contact in the first place.

Recognizing Allergic Reactions

Allergic reactions can range from mild to severe. In some cases, a person may only develop hives or stomach cramps, while in others, they might experience swelling of the face or throat, dizziness or difficulty breathing. The most dangerous reaction is anaphylaxis, a rapid and potentially fatal condition that requires immediate intervention.

Due to the urgency involved, workers must be trained to recognize the symptoms and react without hesitation. Even a moment of delay can make the difference between recovery and a medical emergency.

Emergency First-Aid Response

When an allergic reaction occurs inside a processing facility, every second counts. Here’s what you should do.

Call for Emergency Medical Help

The first and most critical step is to dial emergency services. Even if symptoms appear mild, reactions can escalate quickly. A written and visible protocol for who makes the call prevents confusion in stressful situations.

Administer Epinephrine

If the affected person has been prescribed an epinephrine auto-injector, use it right away and don’t wait for the reaction to worsen. Epinephrine is the only medication that can halt the progression of anaphylaxis. Facilities should consider keeping additional auto-injectors on-site in case of emergencies, with staff trained in their proper use.

Position and Comfort the Person

While waiting for medical help, keep the individual calm. They should remain lying down unless breathing becomes difficult, in which case sitting upright may help. This simple step can reduce stress on the body and ease symptoms until professional care arrives.

Monitor Breathing and Circulation

CPR may be required if the individual loses consciousness or shows no signs of breathing. Training employees in CPR ensures there’s always someone ready to respond, even before paramedics arrive.

Safe Handling and Allergen Control

While first aid is essential, the ultimate goal is to prevent allergic reactions. One of the most effective tools for food processing facilities is the Hazard Analysis and Critical Control Points (HACCP) system. HACCP is a structured approach that identifies where hazards are most likely to occur and establishes strict checkpoints to control them.

These systems are critical. Foodborne illnesses and allergen cross-contact remain a major public health issue. In fact, it’s estimated that approximately 48 million people in the United States get sick from foodborne illnesses each year, showing the scale of what’s at stake when safety controls fail. The foundation of allergen safety in processing plants lies in consistent, disciplined practices:

Clear Labeling and Segregation

At least 33 million people in the U.S. have at least one food allergy. To prevent reactions, allergenic ingredients such as peanuts, tree nuts, dairy and shellfish should be clearly labeled and stored separately from non-allergenic items. Using distinct containers, storage zones and signage minimize the chance of accidental mix-ups.

Dedicated Equipment and Cleaning Protocols

Whenever possible, dedicated equipment should be assigned for handling allergenic ingredients. If shared equipment is unavoidable, thorough cleaning protocols are critical. Validated cleaning procedures, including testing for allergen residues, ensure surfaces and tools are safe for use with other products.

Routine Training and Education

Employees at all levels should understand the basics of food allergens and cross-contact risks. Training shouldn’t be a one-time event. Regular refreshers and scenario-based drills keep knowledge fresh and prepare staff to react confidently under pressure.

Personal Protective Equipment

Gloves, aprons and face masks are important layers of protection when handling allergenic ingredients. PPE protects the worker and reduces the chance of transferring allergens to other surfaces or products. Ensuring proper use and regular replacement is part of building a reliable control system.

Building a Culture of Safety

Policies and checklists only work if people follow them. To create a truly safe environment, food and processing facilities need a culture where everyone feels responsible for allergy safety. This means encouraging open communication, rewarding vigilance and treating mistakes as opportunities to strengthen procedures rather than to assign blame.

When employees feel empowered to speak up about a potential issue — whether it’s a mislabeled container or a skipped cleaning step — it can prevent risks before they become problems. Regular drills, updated signage and transparent communication foster accountability at every level of the workforce.

Safety Is Everyone’s Responsibility

Food processing plants don’t just manufacture products — they protect public health. These facilities are responsible for protecting people from allergic reactions and foodborne illnesses. By combining swift first-aid practices, rigorous HACCP-driven procedures and a workplace culture that prioritizes safety, plants can protect their workers and the consumers who trust their products.