Keeping an (Electronic) Eye on Labels

According to research done by groups as diverse as the Food Safety and Inspection Service (FSIS) of the United States Department of Agriculture (USDA) and the baking industry’s information center AIB International, the number one reason for food product recalls is mislabeling, and especially mislabeling that omits allergens. According to the FDA, in 2008-2009 mislabeling that failed to identify major food allergens accounted for 43% of recalls.

In other words, attention to detail in preparing label information, and thorough inspection to ensure that labels are accurate, complete and are placed on the correct package would enable food manufacturers to avoid almost half of all recalls.

Consumers today read labels more often and with more attention to detail as concern about allergens has increased, and they rely on the label’s accuracy in making their purchase decisions. For the manufacturer who omits an allergen from a label, the recall he faces may be the least of his worries. A lawsuit as the result of anaphylaxis caused by an undisclosed allergen and the resulting publicity can cause much more severe damage to a company and to its brand image. And restoring a tarnished brand image is a very long and difficult process.

Even when the “undisclosed” allergen is not the result of omitting it from the ingredient list, but is caused by a wrinkle in a label that obscures the ingredient, the result is equally damaging and still puts the manufacturer at risk.

Yet, when research shows that 43% of recalls are due to mislabeling, many manufacturers are obviously not taking full advantage of the existing systems that can help eliminate the problem.

           

The sharpest eye

The days of the human package inspector are long gone. The speed of production and the complexity of packages and especially of labels today has made them ineffective. Today’s defects, from low fill levels and cocked caps to missing codes, are detected by machine vision systems that inspect with 100% reliability in the blink of an eye, then contact downstream rejecters to remove the faulty package.

This same technology can identify mislabeled packaging with equal accuracy and speed. By comparing a camera-viewed label with a stored file, the system can easily catch a missing, skewed or wrinkled label and can ensure that all labels on a package match. When fully integrated into a facility’s management system and properly operated, a vision system can go even further toward ensuring proper labeling. When the line manager enters a product code into the line control system, the vision system accesses the stored parameters for that product, confirms that the listed ingredients are on the label and rejects those packages that do not conform.

Vision systems are cost-effective to operate and can usually be installed within or over a line without line reconfiguration. Given the impact of the risks associated with not thoroughly inspecting labels, the investment in this company  “life insurance” is well worth it.


Written by: Robert Rogers Senior Advisor for Food Safety and Regulations METTLER TOLEDO Product Inspection