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The annual State of Manufacturing Survey from Food Engineering Magazine is now available, and it highlights both progress and areas needing improvement in the food industry. Despite some positive developments last year, there’s still significant room for growth. This year’s survey reveals that 72% of respondents have a food safety management system in place, while 69% report having a recall plan.
Although having a food safety management system is not the same as being fully FSMA-compliant, the numbers show an upward trend. In 2014, only 38% of those surveyed followed FSMA recommendations, and that rose to 41% in 2015.
One major development is the increased adoption of Global Food Safety Initiative (GFSI) programs such as BRC, SQF 2000, and FSSC 2200. These programs include strict audit protocols, helping manufacturers prepare for potential FDA audits and ensuring they follow best practices. Many facilities are implementing measures like color-coding systems to prevent cross-contamination and using durable tools to reduce the risk of foreign body contamination.
However, despite these improvements, allergen controls appear to be on the decline. According to Food Safety Magazine, 34% of recalls between 2009 and 2012 were due to undeclared allergens, and this number remained at 33% in 2015. This suggests that the industry hasn’t made much progress in managing allergen risks. With more consumers suffering from food allergies than ever before, it's critical that companies don't neglect allergen control measures.
Another concerning trend is the sharp drop in lot-level traceability. While it's possible that this functionality has been integrated into ERP or inventory systems, the survey doesn’t capture this. The 15% decrease in its use is especially surprising given the over 450 food recalls reported by the FDA this year.
Looking ahead, it's unclear whether some safety measures have become redundant or if plants are simply focusing on the bare minimum to meet regulations. It’s important to ensure that safety and efficiency continue to go hand in hand rather than one taking precedence over the other. As the industry moves forward, maintaining strong food safety practices will remain essential.