FOOD SAFETY
CONTAMINATION PREVENTION IN PLANT-BASED FOOD
Kati Hope, Global Account Manager, Mettler-Toledo Product Inspection, outlines the importance of a holistic approach to contamination
prevention, especially in plant-based food production
lant-based food – the trend that shows no signs of slowing. Like it or loath it with a passion, the fact remains that over 1.5 billion people globally are vegetarian. Another huge trend on the rise is flexitarian, with over 72 million households in the US alone identifying as “social omnivores”. This means that food manufacturers in recent years have had to massively up their game in terms of the plant-based food they are producing, and the level of quality and safety checks they are applying to each type of food produced. The ongoing threat of physical toxins and foreign bodies invading food products is a near constant risk and a very serious threat, despite technological advances and the close attention paid to food safety procedures. This is especially true for plant-based food as the raw ingredients come direct from the field. Among the 132 food recalls in the UK from January 2022 to December 2022, 28% were associated with the potential presence of foreign objects, including plastics, metal and glass. Such incidents underscore the imperative need for all food manufacturers, including plant-based, to proactively address, detect and eliminate physical contaminants to maintain the integrity of their products. The consequences of contamination are not only immediate but can have enduring impacts. Factors such as the severity of a product recall, post-recall efforts and the brand equity of the company influence consumer perceptions.
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The story of plant-based food begins where soil meets seed, it is here, where legumes, grains, nuts and vegetables flourish, that a complex narrative of potential contaminants emerges. Within the vastness of these agricultural landscapes, it is easy to see how metals and rock particles find their way into the plant-based production process. Detecting these contaminants becomes
38 MARCH 2025 | PROCESS & CONTROL
tricky due to differences in size and density, especially when a contaminant matches the density of the product or its packaging - a challenge for traditional inspection methods. Each product and application require a unique detection solution, adding layers of complexity. Plant-based food manufacturers, must understand the subtle nuances of size, density and the stealthy entry of foreign elements into our green food. Food safety risks from physical
contamination can occur anywhere along the production line, from the raw material stage to packaging. The good news is that there are formal frameworks available to aid food businesses in evaluating their manufacturing methods and the most vulnerable points to foreign body contamination.
Hazard Analysis and Critical Control Point (HACCP) and Hazard Analysis Risk-based Preventive Controls (HARPC) audits are intended to assist manufacturers in identifying these vulnerable potential points of contamination. While HARPC aids in planning to mitigate against situations like intentional adulteration, food fraud and terrorist activities, HACCP assists in identifying the danger of infection. The earlier a hazard can be discovered throughout the production process, the better.
All manufacturers will be able to set up control points so that checks and systems are properly positioned to help remove food safety hazards based on the findings of these audits. These are referred to as Preventative Control Points (PCPs) and Critical Control Points (CCPs), respectively. A strategy to reduce the risks of physical contamination can be put in place by understanding how contamination happens and identifying weak spots in the production process.
Establishing robust defences against foreign body contamination is pivotal and demands a
strategic approach across diverse production stages. The plant-based food manufacturing process necessitates a three-tiered defence. Commencing at the initial stage of raw material inspection, early detection involves scrutinising incoming materials and ingredients for plant-based ready meals. Detecting physical contaminants at this juncture not only helps with the purity of the raw materials but also shields downstream processing equipment from potential harm caused by undetected contaminants, such as stones in a batch of potatoes. This proactive step aims to eradicate foreign bodies before value-adding production processes begin, minimising the risk of contaminants reaching advanced stages of production and escalating costs.
The second line of defence operates during the production process, specifically inspecting bulk or loose-flow products. This stage is crucial for virtually eliminating debris that might be generated as a by-product of grinding, pulping or blending. A meticulous inspection at this phase leads to contaminants being intercepted before becoming integral components of the final product. This proactive approach not only maintains the product's integrity but also reduces the chances of contamination- related breakdowns during subsequent processes.
End-of-Line Inspection is essential but should not serve as the sole line of defence. This inspection serves as a last-resort measure, identifying any contaminants introduced during the packaging process, such as glass splinters from capping. However, reliance solely on this stage can prove less cost-effective. Manufacturers should prioritise identifying weak points in the production process early on.
The selection of inspection technology is
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