We are starting the process of revamping our (anemic) allergen control program. I am going in circles trying to identify a system that is both cost effective and practical while at the same time sufficient to manage the risks present in the facility. I am specifically wanting to have better risk control over in-process and sanitation cleaning utensils just to give an idea of my aim.
The complexity of the plant is what is giving me a little bit of a headache. Our facility has both RTE and non-RTE production areas, a USDA meat prep room, warehousing, and (not exaggerating) every major US allergen on-site AND many combinations of allergens from product to product.
I have contemplated both ends of the complexity spectrum from assigning color codes for different allergens/combos and using bands to denote production area type (which I think is physically impossible) to simply having allergen and non-allergen color coding with generic "allergen" utensils undergoing sanitation/allergen validation on a set frequency post sanitation.
I am pretty deep into this one so I may be missing the forest for the trees so extra eyes on the situation are greatly appreciated.