Volume 6, Issue 7, July – 2021 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Options for Prevention of Product Cross-

Contamination in Logistic Processes
Marieta Stefanova
Department of Management and Logistics,
Naval Academy “N. Y. Vaptsarov”,
Varna, Bulgaria,

Abstract:- Over the past few years there have been These two methods can be fulfilled by applying an integrated
frequent cases of cross-contamination within the logistics management system and by using it for effective management
supply chains. This paper examines the options for of the processes [15, 16].
preventing cross-contamination by the application of an The purpose of this study is to ensure the reduction,
integrated product quality and safety system. An analysis prevention or elimination of the food safety risks as a means to
of the factors contributing to the prevention or protect consumers by applying a cross-contamination risk
minimisation of the risk of cross-contamination is management model in logistics organisations.
presented. The application of the method allows
assessment of the risk of cross-contamination by II. METHODS
identifying the probability of each hazard, its severity and
the likelihood of detecting it before the product reaches The 11-step model (presented in figure 1) was applied in
the consumer. It has been concluded that despite the this study for identification, prevention and reduction of all
numerous risks of cross-contamination in the logistics significant risks of cross-contamination in logistics
chain, the introduction of a quality management system organisations. The model was used as part of the quality and
has the potential to minimise this risk. safety management system in the companies where it was
applied. The analysis based on the model indicated on figure 1
Keywords:- Logistical Processes, Cross-Contamination. was applied in 5 logistics organisations. Significant risks were
defined as the risks that could adversely impact the systems
I. INTRODUCTION and are very likely to result in an overall failure of the system.
The application of the model took place based on the
Over the past few years the cases of product withdrawals following key stages:
and recalls from the retail chains and the end users have  Formation of a team of experts for introduction of the
become more frequent as a result of detected cross- model;
contamination [1, 2, 3, 4, 5], the highest risk being the one  Analysing the existing risk management system in the
related to cross-contamination with allergens [6, 7]. This studied logistical processes;
implies the need to seek further means for prevention,  Dividing the system into subprocesses, constituents and
reduction or elimination of the risks of cross-contamination in stages of the processes related to unpacking, packaging,
the logistics chain. The purpose of the introduction of wrapping or repackaging of the products;
integrated management systems is to control the risks  Identification of the primary and secondary functions of
associated with food safety and quality by helping identify and each process and identification of the possible risks;
manage them through the introduction of adequate control Application of the 11-step model;
during each step of the processes that are part of the food  Second analysis of each of the indicated stages of the
chain. model;
 Identification of the planned measures in the model for
There are two ways to seek prevention of cross- compensating and preventing the risks.
contamination in the logistics chain. One of them is to ensure
the introduction of a procedure for controlling the more
accurate product label declaration of ingredients [8, 9] that
could be present as a result of cross-contamination in the
logistics chain, so that those suffering from allergies could
avoid the relevant food products [10, 11]. The second way is
through the application of a product quality and safety
management system to exercise effective control [12, 13] in
order to ensure that when the occurrence of a specific
contaminant due to negligence can be identified in case of
cross-contamination, its amount in the product is not in levels
that would create a risk for people suffering from allergies and
that the product will be safe for human consumption [14].

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Volume 6, Issue 7, July – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
III. RESULTS
1. Existing cross-contamination risk management system
The elimination of all possible risks of product cross-
contamination in the logistics chain is virtually impossible due
to the wide variety of products handled in this chain. The
possible effects can be sought in the reduction of the risks and
2. Identification of a list of input commodities and materials that are minimising their impact through an analysis that is adequate to
subject to repackaging and relabelling in the logistics organisation. the actual situation and effective management of the logistics
processes. The most significant risks of cross-contamination in
the chain are associated with the reverse logistics, when
consumers or customers return the goods that had already been
3. Identification of the suppliers of the input commodities and delivered to the logistics warehouse for some reason. The
materials mentioned in point 2. cross-contamination management model was applied as a
series of 11 steps (figure 1), starting with the identification of
inputs and products containing ingredients that pose risk of
cross-contamination (allergens, microbiological
4. Identification of the end products that were repackaged, finished contamination, etc.), identification of the risks based on the
with additional packaging and returned after claims from customers. actual conditions in the logistics warehouses and the
implemented processes and defining appropriate control
measures for the actual conditions in the logistics warehouse
to be set in the process management programmes as part of the
5. Analysis and verification of the process flow and the possibilities quality management system. These stages are detailed in the
for cross-contamination. next part of the paper.

A. Analysis of the existing cross-contamination risk

management system
The logistics organisations examined in this paper have
6. Analysis of the risk of cross-contamination in the logistics chain.
cross-contamination risk management procedures in place.
The introduced procedures allow a certain level of control on
the probability of accidental or deliberate product
contamination. The risk from the processes associated with
7. Creation and introduction of a procedure for prevention of cross- reverse logistics was not assessed in any of the studied
contamination during repackaging. companies.

B. Identification of a list of input commodities and materials

that are subject to repackaging and relabelling in the
8. Staff training for prevention, elimination or minimisation of the logistics organisation
risk. This stage involves creation of a list of all input and
output products for each individual logistics warehouse. The
list should be completed with all used inputs and materials that
could cause cross-contamination. There should be a focus on
the products with complex composition that could also be used
9. Control on the processes introduced.
as ingredients in the packaging and repackaging of the
products. After the creation of the list, the collected
information was analysed and summarised in a special form
created for this purpose.
10. Validation and verification of the process management.
C. Identification of the suppliers of the input commodities
and materials mentioned in point B
During this step all suppliers of input commodities and
materials were identified. The risk was analysed with focus on
the goods exposed to a higher risk of cross-contamination with
End of process
the suppliers. Attention was paid both on the possible
omissions in the labelling of the goods and on the possible
Cross-contamination risk management model during
Fig. 1. risks of deliberate or unintentional cross-contamination. The
the packaging and repackaging of products in the logistics team conducting the analysis reached to a consensus on the
companies. (Source: Own research) clear distinction between high-risk and low-risk products. The
possible decisions with respect to high-risk products that
should be taken were identified as follows:

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Volume 6, Issue 7, July – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
 Effective auditing on the supplier and undertaking plans F. Assessment and analysis of the risk of cross-
for corrective actions in case of established non- contamination in the logistics chain
conformities during the audit; This stage involved a risk assessment. During the
 Appropriate labelling of the products with signs and analysis all goods were divided into three groups based on the
symbols to inform the consumer about the possible risks of assessment given by the experts and the consensus reached
cross-contamination; between them.
 Implementing steps for minimising the risk of  Products with a very low risk class that should be managed
contamination in the new supplier selection procedure. by using the introduced customary control measures.
 Products with a moderate risk class that should be
D. Identification of the end products that were repackaged, managed by using the operational programmes for
finished with additional packaging and returned after claims management of the specific risk and the relevant control
from customers. measures.
During this step of the process all end products exposed  Products with a significant risk of contamination that
to a risk of cross-contamination were identified. After the should be managed by introducing plans for control of
identification a list was created summarising the details about cross-contamination. These products could be potentially
the possible potential and actual risk of contamination of the contaminated with other products, the staff protective
finished products. The focus was on the products that were clothing, by dispersing and spilling liquids and powder
part of the processes implemented in the warehouse for mixtures or as a result of inadequate cleaning.
packaging, repackaging and products returned by customers
after claims. G. Creation and introduction of a programme for prevention
of cross-contamination during repackaging
E. Analysis and verification of the process flow and the The cross-contamination risk management programme
possibilities for cross-contamination. introduced in the logistics also involved measures for
This stage included confirmation of the place of the protecting the products handled. There were numerous rules in
process flows of inputs and materials in the logistics this programme, with the most important of them being:
warehouse from the moment of receiving the inputs and goods  To clean and disinfect the warehouse premises, the staff
to the time of shipping the finished product to the customer, as changing rooms and the equipment immediately after
well as the warehousing of the products returned by the handling high-risk products and after the end of the
customers. All process stages with identified high risk of warehouse working day, if possible;
cross-contamination were considered in detail and all the  To avoid the temporary storage of unpacked products in
necessary subprocesses and operations were identified to bulk or in a liquid state;
allow analysis of all secondary activities:  To introduce zoning between high-risk and low-risk
 Inputs used by the goods suppliers which could products, as well as clear identification of these zones and
contaminate the supplied products; the relevant warning pictograms;
 The processes for procurement of goods and the  To designate a zone in the warehouse for storage of
possibilities for cross-contamination of flows during the products returned after claims, which should be physically
implementation of operations that are exceptional and not distant from the zone of the high-risk products that are
foreseen in the routine operation of the warehouse; subject to packaging and repackaging;
 The processes of storing inputs and products where  To prevent the simultaneous packing and unpacking
incorrect storage compatibility is possible during periods operations of two high-risk products of different
of peak overloading of the warehouse premises; composition and type;
 The processes of handling the goods in case of damage of  To make a distinction between zones for high-risk products
the warehouse equipment; and zones for cleaning and disinfection chemicals;
 Storage of the materials used during the packaging and  To exercise appropriate effective control to ensure that the
repackaging of the product; waste from the packages of the unpacked products will not
 The processes of temporary storage and handling of the create conditions for cross-contamination;
intermediary product;  To minimise any unnecessary movement of equipment,
 The presence of persons external to the organisation in the inputs and materials.
warehouse who are servicing or handling the product;
 Rules for wearing protective clothing by the warehouse H. Staff training for prevention, elimination or minimisation
staff; of the risk
 The processes related to cleaning and disinfection of the The necessary trainings for preventing cross-
warehouse premises; contamination in the logistics operations should cover the
 The processes of management of products that are not fit entire staff present, including the temporarily hired warehouse
for consumption, products past their expiration date and workers. Training is the most appropriate method for
waste during the operational work; familiarising the staff with the newly introduced programmes
for risk management and risk minimisation and mitigation to
acceptable levels.

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Volume 6, Issue 7, July – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
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