Example recall: undeclared allergen due to labelling error


When a new ingredient is added to a product, it’s critical that all teams involved—product development, production, and technical— are fully aligned. Here’s how a simple oversight can lead to a recall: A food manufacturer introduces a


new ingredient, such as almond flour, to enhance a product’s flavour. The internal team responsible for recipe changes notifies the labelling team, who create an updated version of the product’s packaging. However, there are now two versions of packaging artwork: one declaring almond flour and one without. Unfortunately, not


The rising number of food recalls


capability is invaluable during product recalls, enabling rapid identification and isolation of affected batches.


Automating Dough Mixing: In bakeries, the dough mixing process demands precision to maintain product quality and prevent contamination. OAL’s robotic dough mixing system automates this critical stage with advanced sensors and real-time monitoring, ensuring exact ingredient ratios, temperatures, and mixing times. By minimising human interaction, the system enhances food safety and reduces human error, such as miscalculations or improper handling. Its traceability features provide a full record of each batch, streamlining issue identification and corrective actions.


Precision Powder Weighing: Accurate weighing of powdered ingredients is another area where robotics excel. Traditional manual methods are prone to inaccuracies and cross-contamination, but OAL’s robotic systems measure and dispense powders with exceptional precision.


bakeryproduction.co.uk


in 2024 highlights the need for the food industry to adopt innovative solutions to mitigate risks”


With real-time data analysis, manufacturers


gain complete oversight of the production process, enabling proactive adjustments and minimising downtime. By ensuring consistent ingredient quantities, these systems safeguard product quality and help avoid costly recalls.


The role of AI in food safety AI technology is emerging as a game-changer in food safety. OAL’s AI-driven solutions integrate with ERP systems to streamline processes, minimise errors, and improve traceability. Powerful AI cameras can complete complex checks like seal and product integrity. It’s imperative the data driving these systems is


all of the old packaging is disposed of, and an operator accidentally brings the outdated version to the production line. The error goes unnoticed until the product has already been shipped to retailers. A consumer reports an issue, triggering a costly recall. OAL’s automated label and date code verification systems prevent issues like this by ensuring complete artwork version control. Using technologies like 2D barcodes, we track packaging changes and prevent the use of outdated materials on the production line by verifying every label with cameras.


accurate and up to date. However, as Nic Sharman cautions:


“Technology must be supported by a culture of accountability. Robust systems and ongoing maintenance are key to long-term success. It’s imperative that teams create a culture that maintains these systems and doesn’t switch them off!” The rising number of food recalls in 2024 highlights the need for the food industry to adopt innovative solutions to mitigate risks. OAL’s advanced automation systems offer transformative solutions for reducing human error, enhancing ingredient traceability, and ensuring compliance with food safety standards. These systems not only protect manufacturers from the financial and reputational damage of recalls but also pave the way for a more efficient and reliable food production process. As technology continues to evolve, integrating


AI and robotics into food manufacturing processes will become increasingly essential. For manufacturers looking to stay ahead of the curve, OAL’s automation solutions provide a proven path to success.


For more information on preventing recalls with automation please visit www.oalgroup.com.


Kennedy’s Bakery Production December/January 2024/25 15


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