A Key Cause of Allergen Recalls
Incorrect or missing allergen information on food packaging is a serious issue. It puts people with food allergies at risk and can lead to costly product recalls. This guide helps food businesses—especially small manufacturers—spot and fix problems before they happen.
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Why This Matters
If allergens aren’t clearly listed on packaging, people with food allergies can become seriously ill. Businesses may also face expensive recalls, damage to their reputation, and legal consequences.
Common Reasons for Allergen Recalls
Most allergen-related food recalls happen because of simple but serious mistakes. These include allergens not being listed at all, listed incorrectly, or not clearly highlighted on the label. Sometimes, products end up in the wrong packaging, or claims like “free from nuts” are made when the product actually contains traces of allergens. Another common issue is failing to warn consumers about the risk of cross-contact—when a product might unintentionally contain allergens due to shared equipment or facilities. All of these errors can put people with serious allergies in danger and lead to expensive recalls, lost customer trust, and reputational damage for the business.
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Allergens not being listed or listed incorrectly -
Products in the wrong packaging
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Incorrect “free-from” allergen claims
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Missing warnings about possible cross-contact (e.g. “may contain soya”)
How to Manage Allergen Risks
A strong allergen risk management system should cover every stage of production. If something goes wrong, it’s important to investigate properly and take steps to prevent it happening again.
Fishbone (Ishikawa) Diagram
Looks at factors like people, equipment, methods, and materials to find the cause of a problem.
Five Whys
Asks “why?” repeatedly until the real cause is discovered. Can be combined with the fishbone method.
When Allergens Aren’t Listed Properly
What Can Go Wrong?
Allergens can be left off the label entirely or written in the wrong language, which puts allergic consumers at serious risk. Problems can also arise from poorly designed artwork or incorrect labels. Information may not match across different platforms, such as packaging and websites, especially when updates aren’t managed carefully.
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Approve and regularly review ingredient specifications with suppliers
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Check that packaging matches the product’s allergen profile
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Keep ingredient data in one central system
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Ensure all staff understand allergen rules and labelling requirements
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Use technology (e.g. barcode scanners) to track ingredients
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Regularly review labels and allergen declarations
Mismatched Product and Packaging (Mispacking)
What Can Go Wrong?
A product might be packed into the wrong packaging, or a label from an older version may be applied by mistake. This can happen easily if packaging materials aren’t clearly separated or if old labels are still in circulation. Such mix-ups can cause consumers to unknowingly eat allergens not listed on the label.
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Keep packaging and raw materials well organised and separated
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Double-check packaging matches the product
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Clear production lines between product runs
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Use barcode or scanner systems to reduce mistakes
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Regularly audit your processes and train your staff
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Dispose of old packaging properly so it can’t be reused
Incorrect “Free-From” Allergen Claims
What Can Go Wrong?
A “free-from” claim on a product can be dangerous if the product actually contains the allergen—either as an ingredient or through unintentional cross-contact. These mistakes mislead allergic consumers into thinking a food is safe when it isn’t.
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Thoroughly check all ingredient specifications
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Test products regularly to confirm “free-from” claims
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Train staff on accurate allergen labelling
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Make sure artwork and labels go through strict approval checks
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Audit your suppliers and verify their allergen controls
Not Declaring Possible Cross-Contact (“May Contain”)
What Can Go Wrong?
Sometimes, a product can accidentally be contaminated with allergens during production, but there’s no warning on the label. This is often due to shared equipment, poor cleaning, or cross-contact during storage and handling.
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Ask suppliers to confirm cross-contact risks
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Store allergen ingredients separately
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Plan production schedules to reduce risk of cross-contact
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Clean equipment properly and verify it’s allergen-free
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Use colour-coded tools or containers to keep allergens separate
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Work with accredited labs for allergen testing
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Train all staff regularly on allergen handling
Building a Culture of Allergen Safety
Food allergen safety is essential—not optional. Even small mistakes can put lives at risk. By building strong systems, working closely with suppliers, and keeping your teams informed, your business can help keep customers safe and avoid costly recalls.