Innovative Technology for the Inactivation of Allergenic Compounds on Component Surfaces of a Prototype Processing Line for the Manufacture of Products with Controlled Allergenicity

Abstract The study aimed to develop and validate effective procedures for cleaning and allergen deactivation in a prototype processing line for crisp-coated meat products. Reliable cleaning methods are critical for ensuring food safety and preventing cross-contamination when conventional and allergen-controlled products are manufactured on the same line. Critical points along the processing line were identified through preliminary assessments. At these points, allergen residues were monitored using immunoassay-based tests targeting major food allergens, including gluten, soy, milk, nuts, sesame, and others. Several cleaning procedures were compared with regard to their ability to eliminate allergenic proteins from equipment surfaces. Lower-concentration protocols proved inadequate, particularly in high-risk areas such as cutting, mixing, and cooling zones. In contrast, the optimized procedure achieved complete removal of allergens at all critical points. This outcome was further confirmed during validation trials involving thirty pilot production batches, where no allergenic proteins were detected in environmental swabs or final products. The results demonstrate that carefully designed cleaning strategies can enable dual use of processing lines for both standard and allergen-controlled products. The validated procedure offers a cost-effective and practical solution for the food industry, supporting compliance with regulatory requirements and improved consumer safety.