Preventing Cross-Contamination in Food and Beverage Manufacturing

The most important job of those who produce and process food is to ensure the product they produce is safe for the consumer. Pursuant to that end, legislation and processes/programs such as the FDA Food Safety Modernization Act (FSMA) and Hazard Analysis and Critical Control Point (HACCP) have come into being. A part of this includes the use of articles that are collectively known as Personal Protective Equipment (PPE). PPE in the food and beverage manufacturing industry refers to specialized gear and clothing designed to effectively mitigate food safety risks such as cross contamination. It also safeguards workers from potential hazards and ensures a safe working environment.

PPE and Cross-Contamination of Food

The proper use of PPE serves a two-fold purpose:

1. The first is to protect the product from accidental contamination from workers who may have pathogens or other contaminants on their skin, hair, or clothing. Food contamination can be defined as the “spoiling or tainting of food by another food item or material, making it no longer suitable for consumption.” Contamination is generally divided into three distinct types: Chemical, Biological, and Physical. Chemical contaminants could include residues from the farms, such as pesticides and herbicides, or chemicals at the plant, such as cleaners. Biological contaminants are probably the most strongly associated type of contaminant which includes bacteria, viruses, parasites, and blood. The final type of contaminants, physical contaminants, are more likely to cause immediate harm such as broken pieces of machinery or blades and fingernails.
2. The second purpose of PPE is to protect the workers from any potential hazards that the product or processing equipment may pose to them, such as pathogens, cuts, and burns, both thermal and chemical. Because PPE protects the employees as well as the materials they are handling, OSHA also has regulations requiring the use of PPE.

Types of PPE in the Food Industry

In food manufacturing plants, there are numerous hazards warranting the use of PPE and each hazard can require its own type of protective gear. Typical PPE used at such plants includes gloves, aprons, face masks/face shields, plastic sleeves, hair and beard nets, and proper footwear. Most of these also protect the product being processed as well as the employees who are wearing them, if worn correctly.

Gloves have multiple purposes, depending on what kind is being used. Latex, vinyl, and nitrile gloves are worn when handling the product. Latex is not frequently used anymore due to it being an allergen. When these gloves are worn and applied correctly, it protects the product from any contaminants that may have accumulated on the employees’ hands. These contaminants can include pathogens, skin, hair, and dirt. Also, if the material being processed is already contaminated, they can protect the employees from harm through chemical or pathogenic means. Nitrile gloves are especially good for chemical protection and are relatively resistant to tearing. Other types of gloves that find use in food processing plants include cutting and thermal gloves. Cutting gloves prevent employees from cutting themselves while using knives thus preventing skin and blood from potentially contaminating the food from a cut. Thermal gloves prevent injury from hot/cooked products and frozen items.

There is, however, a downside to the use of gloves, especially since the Covid-19 outbreak. One issue that the outbreak has brought to the forefront is the use of gloves that are lower cost and subsequently lower quality as the price of gloves has increased. These lower quality gloves tend to have more micro perforations that allow a “liquid bridge” to form and contaminate the product with what microbes may be present inside the glove, even if the employee sufficiently cleaned their hands before donning their gloves.

There is also the likelihood of cross contamination from dirty gloves as the tactile senses are diminished and through “thoughtless acts.” Such acts usually go unnoticed unless deliberately focused on as they tend to be more reflexive or habitual, like touching your face. Even changing gloves can increase the chance of contamination if not done properly with a hand washing step between removing the old gloves and donning the new ones. Finally, false assumptions/conceptions of gloves can result in contaminated products. Gloves can collect and transfer contaminants if not cleaned or replaced regularly, the general suggestion is every 30 minutes.

Aprons, lab coats, and plastic sleeves are worn over clothing and exposed arms to keep any potential contaminants brought in on the employees outside clothing and skin from getting into the food they are working on. Clothing from outside of the plant can contain allergens, pathogens, and other forms of contaminants, such as pet hair. Lint rollers can also be used to further decrease the likelihood of such tag-along contaminants from entering the work floor and getting into the product. Of course, many food processing plants can use chemicals that can be harmful to employees if it should get on them. Coats, aprons and plastic sleeves can help reduce risks associated with the use of such chemicals by preventing them from contacting the skin of the employee should a spill or splash occur.

Hair and beard nets should be worn by those who handle food to prevent hair and skin from entering the product. Hair nets can also protect employees from collecting pathogens in their hair and infecting themselves and others or spreading it to other products. Face masks and face shields should also be worn when handling ready-to-eat foods as it stops microdroplets from breathing, talking, coughing, and sneezing that could contain pathogens from contaminating the food that is being handled. They also stop the same pathogen laden particles from spreading to others in the workplace. The face shields also protect the wearer from chemical splashes that could cause serious harm.

Proper footwear and outer clothing are not only important for employee safety but to prevent contaminants from entering the production zones. Heavy equipment and machinery can necessitate the use of protective boots with steel or composite toes in the event of a heavy, or even sharp, piece falling on an employee’s foot. Many food processing plants have moisture on the floor, be it from sanitizers or cleaning the equipment, or potentially slippery materials, such as dropped or spilled produce or waste material, i.e. corn husks and melon rinds. As indicated by a study by University of Arizona, a primary route of contamination is the bottom of people’s shoes. ‘Cleaning footwear has become just as important as washing hands when coming into the facility.’ A boot sanitizing system, prior to entering the production rooms would reduce the risk of footwear as a cause for the spread of listeria, salmonella and other pathogens. Slip resistant shoes or shoe covers should be used to reduce the risk of slipping and injuring themselves, others, or damaging equipment. Shoe covers are designed to keep contaminants contained when worn over the shoes. They may be disposable or cleanable.

Facilities must have Standard Operating Procedures (SOPs) to prevent outer clothing such as frocks or smocks from spreading contamination. When clothing is soiled with food or dirt that could potentially transfer to food or food contact surfaces, employees must change their outer clothing immediately. Food, especially Ready-to-Eat (RTE) should not be held exposed against outer clothing, and outer clothing should not be worn anywhere other than the production zones.

Hearing Conservation Many food processing plants can be very loud due to the machinery that is constantly running, be it refrigeration units or other processing equipment. This constant exposure to excessive noise can cause permanent damage to an employee’s hearing. For such loud places, the use of ear protection is highly suggested. Such protective equipment can include ear plugs, earmuffs, or communication protectors.

Eye protection is also an important type of PPE to have around at food processing plants as well. Most are likely to use chemicals that can cause damage to an employee’s eyes. Aside from chemical splashes, there could be other particulate matter thrown up by machinery that could cause issues, like from a meat saw or pressurized fluid lines.

When is PPE Most Effective?

While PPE is generally regarded as a good thing to have, it is only effective when used and applied properly. To facilitate the proper use and implementation of PPE, establishing a culture of safety could prove invaluable. This would include continuous training, adherence to hygiene protocols, and inspection and replacement of PPE. The training ensures that all employees know when and where to wear their PPE as well as how to correctly use the PPE when necessary. If proper protocols aren’t followed, employees may view the use of PPE as something that is more optional and may not be as diligent in wearing their PPE or wearing it correctly. In addition to proper use and implementation of PPE, making sure that they are of sufficient quality is also important. Therefore, purchasing this equipment from a reputable supplier is a must. Some places to get PPE from include specialized safety equipment stores, industrial supply stores, health and safety retailers, safety consultants, and government-approved suppliers.

International Standards for PPE Guidance

Due to the global nature of the food industry, international standards have been established to ensure consistency in safety practices and the protection of food handling workers. There are several international standards that provide guidelines for PPE in the food industry. Some of the key standards recognized on an international scale are HACCP (Hazard Analysis and Critical Control Points), ANSI/ISEA Z87.1, ASTM F2413-18, EN 388, EN 407, ISO 22000, ISO 45001, ISO 16603 and ISO 16604.

Role of PPE in Preventing Cross Contamination

There are many potential hazards that could result in the contamination of the product being made and eliminate them all completely isn’t realistic. With the proper use of PPE, we can not only better protect our employees but also reduce several paths of accidental product contamination. Gloves, aprons, lab coats, plastic sleeves, and face shields can all protect from potential chemical injury or contact from spills and splashes while preventing pathogens and contaminants from the wearer’s skin, breath, and clothes from getting into the food products. Cutting gloves and proper footwear can help prevent injuries that could introduce skin and blood into the products. Hair and beard nets and face masks can reduce the amount of hair and skin contamination as well as inhibiting the spread of respiratory contagion between food and employees. This should demonstrate the importance of using the right PPE in the food production facility for the safety of the consumer as well as the employee.

The Importance of Food Safety Training

Food safety training is essential to protect consumers, maintain compliance, and safeguard your brand. Proper training ensures employees follow best practices in food handling, storage, and preparation to prevent foodborne illnesses.

Vector Solutions offers comprehensive food safety courses designed to meet industry regulations and equip your team with critical knowledge. With scalable online training and easy progress tracking, we help companies build a culture of safety and compliance. Explore our food safety training solutions today to protect your operations and customers.

About the Author

Angie Surtani is a results-oriented food industry leader with over 25 years of experience in food safety, quality assurance, and regulatory compliance. Angie specializes in maintaining robust food safety systems aligned with HACCP protocols, Preventive Controls, and GFSI standards (SQF, BRC, PRIMUSGFS). She has extensive expertise in FSMA requirements and works closely with management, production leaders, and plant employees to uphold compliance with FDA, USDA, and third-party regulatory agencies.

As a subject matter expert and food safety course author, Angie contributes to Vector Solutions’ online food safety training, helping frontline workers and industry professionals stay compliant, improve food safety culture, and meet regulatory standards.