Stop allergen product recalls with packaging automation
With allergen-related product recalls on the rise, food manufacturers are under increasing pressure to ensure products are correctly labelled. But why do these errors occur in the first place and how do we stop them? We spoke to Faye Louch, OAL Connected’s Trainer, to understand the problems and how automation can help.
Why is the risk increasing?
1. Frequent packaging updates
Modern food packaging is updated regularly, often for new promotions, artwork refreshes or regulatory changes.
Each new version introduces a risk. Even a small mistake, such as a missed allergen declaration or incorrect code, can lead to a recall.
2. Changing product recipes
When recipes are reformulated, even slightly, new allergens can be introduced where there were none before.
If packaging does not change, these allergens can be missed during artwork updates, creating a hidden risk that often escapes manual checks.
3. Similar packaging designs
Walk any supermarket aisle and you’ll see how similar products can look.
Retailers often use consistent, eye-catching designs across a range but this makes it hard for operators to distinguish between allergen-containing and non-allergen variants on the line.
Mismatch example. Tomato soup pot with vegetable soup sleeve.
How automation prevents allergen errors
OAL’s Connected packaging verification system automates the control and setup of packaging line devices to ensure the correct packaging and date code are applied every time.
Automatic line setup
The system draws from a master database managed by your technical team.
Each product record includes the artwork version code, so when a product is selected, the system tells the camera what to expect.
If the camera detects anything else, even a small discrepancy, the line stops immediately to prevent incorrect packaging from leaving the factory.
The scanner will give a mismatch and stop the line instantly if it sees anything other than this information. Preventing incorrect packaged product leaving the factory.
Codes contain letters and numbers and the information must be printed exactly, including capitalisation e.g. P or p.
During the artwork process occasionally letters and numbers can be missed or incorrectly capitalised causing a mismatch within the system.
The mismatch is an indicator that something is wrong in the information that the scanner has seen and requires investigation prior to any product leaving the manufacturing facility.
Why 2D codes matter
Many manufacturers still rely on 1D barcodes, which only identify the product type for retailers.
However, the 1D code does not change when artwork versions change, creating a gap in traceability.
That’s why more food businesses are moving to 2D codes such as GS1 Digital Link.
1D barcodes: Used for stock and sales
2D barcodes: Enable version control and link each artwork to a specific product release
OAL’s Connected system reads every 2D code, ensuring the version on the pack matches the product in production.
This removes the element of human error and dramatically reduces the risk of allergen-related recalls.
Faye’s top tips for better allergen control
1. Get the artwork right
Allergen control starts long before production,” says Faye.
“Make sure your artwork team understands how 2D codes work. Size, white space and print clarity all matter.”
Checklist for 2D code quality:
Correct dimensions
Clear print and contrast
Adequate white zone
Accurate data and capitalisation
Small errors here cause the majority of scanning mismatches.
2. Print allergens directly on the pack
If your product uses sleeves, consider adding allergen information to the lid film itself.
That way, if a wrong sleeve is applied or removed later in the supply chain, the allergen data stays visible.
OAL’s Connected system can automate this using a two-stage print process:
Stage 1: Prints allergen information directly onto the product film
Stage 2: Prints the date code information
“It’s a failsafe,” says Faye.
“Even if the sleeve comes off, the allergen warning stays with the product.”
Automation that protects your brand
Automation doesn’t just stop mistakes. It protects your reputation, ensures compliance and gives retailers confidence in your quality processes.
By combining OAL Connected with robust 2D barcode verification, food manufacturers can achieve 100% packaging accuracy and eliminate the risk of allergen-related product recalls.
Learn more about packaging verification with OAL Connected →
