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The annual State of Manufacturing Survey by Food Engineering Magazine is now available, and it highlights both progress and areas for improvement within the industry. Despite significant positive developments last year, there's still a lot of room to grow. This year’s survey shows 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 a clear trend. In 2014, only 38% of those surveyed followed FSMA recommendations, and that number increased slightly to 41% in 2015.
One of the most encouraging developments is the growing adoption of Global Food Safety Initiative (GFSI) programs such as BRC, SQF 2000, and FSSC 2200. These programs include rigorous audit protocols, helping facilities prepare for potential FDA inspections and ensuring they follow best practices. Many plants are implementing measures like color-coded zones to prevent cross-contamination and using durable tools that reduce the risk of foreign body contamination.
However, despite these improvements, some critical areas are showing signs of decline. Allergen controls, which could help prevent recalls like the 2016 Oreo incident involving undeclared allergens, have reportedly been used less frequently. According to Food Safety Magazine, 34% of all recalls between 2009 and 2012 were due to undeclared allergens, and that number remained at 33% in 2015. This suggests that the industry has not made much progress in managing allergen risks, even though more consumers are suffering from food allergies than ever before.
Another concerning trend is the sharp decline in the use of lot-level traceability. This process, often done through adhesive labeling, tracks products from farm to table. While it's possible that this functionality has been integrated into ERP or inventory systems, the survey doesn't account for that. The 15% drop in usage is surprising, especially given the nearly 450 food recalls reported by the FDA in 2023.
As the industry moves forward, it's important to ask whether some safety measures have become redundant or if plants are simply meeting the minimum requirements under stricter regulations. Are safety and efficiency truly aligning, or is there still a gap? The answers to these questions will shape the future of food manufacturing and its ability to protect consumers effectively.