Foreign body contamination continues to be a major threat in food production – damaging brand reputation, triggering costly recalls, and most importantly, risking consumer safety.

The solution? A “prevention before detection” mindset. This is the concept of reducing contamination risks at the source, before they have the chance to reach your products or ingredients.

In the following article, we will explore six of the most common foreign body contaminants, offering expert advice on what you can do to keep them out of your food products.

Plastic contamination is often linked to utensils or packaging, but small tools like pens are frequently overlooked. Cheap, brittle pens can shatter on impact, shedding undetectable fragments into your products. In contrast, Retreeva Detectable Pens are made using shatter-resistant, food-grade material. This means they will only ever break under extreme and unusual force, and even then they won’t splinter into small fragments. Colour-coding is also essential when it comes to managing plastic contaminants. That is why Retreeva Pens typically feature blue housing, as blue is a colour rarely found in natural ingredients, making it easier to spot if an incident occurs. For many of the Retreeva pen designs, there are other colours available (green, yellow, and red).

It’s important that your site doesn’t rely solely on metal detection, as depending on the frequency of your detector, it may not be triggered by small items like metal springs. This is especially relevant to sites that manufacture high-moisture products that emit a high background signal.

The best way to reduce the risk of metal contamination is to choose smart, compliant tools. For example, Retreeva Detectable Pens have a unique cartridge suspension system that provides a firm writing experience, without the need for metal springs. They are also manufactured using the minimum number of small components, further reducing the risk of a foreign body incident.

Stones will often enter the food production process via raw agricultural ingredients like grains or pulses. To manage this risk effectively, ingredients should be thoroughly screened before entering your production line.

Many sites use stainless steel EuroBins with mesh inserts to sieve large quantities at once, while others rely on x-ray machines and mechanical sorting.

Regardless of your method, it’s essential that any incidents involving stones are reported and documented. This will allow you to raise concerns with your suppliers and push for improvements in their own control processes.

Glass is often used for essential instruments like thermometers and probes, so it’s not always possible to entirely remove this material from your site. This makes regular integrity checks all the more important, particularly for any glass equipment that comes into direct contact with your product.

Your team should be trained to identify early signs of damage or weakness, such as chips, cracks, or stress marks. You should also have clearly documented Glass Breakage SOPs that outline the correct steps for containing and cleaning up incidents. These procedures should be supported by regular training, with dedicated Glass Incident Kits easily accessible across the factory floor.

Contaminants like cardboard fibres, plastic wrap, and paper labels often originate from packaging areas located too close to an active production line. To prevent this from happening, the layout of your site should keep packaging zones clearly separated from food preparation and production areas.

It’s also worth reviewing your customer complaint data. If you notice recurring issues – such as plastic wrapping found in finished products or cardboard shavings in sealed packs – this can highlight areas where your packaging materials may need to be upgraded or replaced with more durable, food-safe alternatives. Even seemingly minor packaging changes can lead to significant risk reduction.

Hair, jewellery, and even fingernails are a common cause of contamination, particularly when hygiene policies aren’t properly followed or enforced. The BRCGS Global Food Safety Standard (Issue 9) contains several clauses covering this exact topic. Clause 7.2.1 restricts the use of false nails and jewellery, Clause 7.2.3 requires coloured plasters to be used to cover cuts, and Clause 7.4.2 sets expectations around hair nets and beard snoods. Ongoing training is essential, not just to explain the rules, but to help your team understand the consequences of non-compliance. This training can be supported with visual reminders in changing rooms, along with custom mirrors that reinforce dress codes and hygiene expectations.