The Big 9: A Guide to Allergen-Free Food Manufacturing

Food allergies aren’t going anywhere — and neither is the growing consumer demand for safer, cleaner, allergen-free options. Today, an estimated 33 million Americans live with at least one food allergy, including approximately 6% of both adults and children. That’s about two students in every classroom, and countless families making daily decisions based on what’s safe to eat. 

Whether you’re building the next great allergen-free snacks or expanding your current product line, if you want to carry an allergen-free claim, your contract food manufacturer better be up to the challenge.

At ZoRoCo, we’ve been partnering with companies for years to manufacture 100% allergy-free snacks. We know anything less puts your customers, your brand, and your reputation at risk. Here’s what companies need to know about allergen-free manufacturing, and how to find the food manufacturing partner to do it right.

What Are the Big 9 Allergens?

The “Big 9” allergens are the most common culprits behind serious allergic reactions in the U.S. According to the FDA, these nine ingredients are responsible for around 90% of all food allergy-related medical emergencies. That’s a statistic you can’t afford to ignore if your brand is aiming to make allergen-free, school-safe, or free-from claims.

Here’s the full list of Big 9 allergens:

1. Dairy

2. Eggs

3. Tree nuts (like almonds, walnuts, cashews)

4. Peanuts

5. Wheat

6. Soybeans

7. Fish (like cod, bass, flounder)

8. Crustacean shellfish (like shrimp, crab, lobster)

9. Sesame (officially added in 2023)

These allergens are tricky for a few reasons. For one, many of them appear in unexpected ingredients. Think about lecithin, casein, or “natural flavors” — they can all contain hidden allergens. To make matters worse, some facilities process these ingredients on the same lines used for other products, which creates the risk of cross-contact. 

What Is Cross-Contact?

Cross-contact happens when a food allergen is accidentally transferred to a product that isn’t supposed to contain it. Unlike cross-contamination (which deals with bacteria or pathogens), cross-contact involves the presence of tiny traces of allergens. Even traces can be dangerous or life-threatening for someone with a food allergy.

Cross-contact can occur in ways that aren’t always obvious, such as:

• Shared equipment that hasn’t been fully cleaned

• Airborne particles in a shared production space

• Bulk ingredient scoops or storage bins used across multiple lines

• Packaging lines that handle multiple product types

Here's the challenge: it's not just about what's in the product — it's about the entire ecosystem around it. For example, the equipment, the air, the storage rooms, and the cleaning process. That’s why trusted allergen-free manufacturing requires more than just good intentions. It requires a facility purpose-built to prevent cross-contact at every stage.

What Allergen-Free Really Means

There’s a big difference between a brand that slaps on a “free-from” label and a food manufacturing partner that’s built its infrastructure around protecting consumers with food allergies.

True allergen-free manufacturing requires:

• Dedicated equipment that has never processed Big 9 allergens

• Isolated production lines and zones with controlled access

• Validated cleaning protocols and allergen swab testing between every run

• Ingredient traceability and documented supplier verification

• Consistent training for operators and QA teams

At ZoRoCo, we take it a step further with our dedicated Free-Free plant. We’ve invested in scratch baking capabilities for allergen-free cookies, muffins, brownies, and granolas. Plus, we do it all in a GFSI BRC A+ rated environment with the most rigorous food safety standards in place.

Because when your product is headed into a school lunchbox or a retail shelf with a bold allergen-free claim, you can’t afford anything less.

Red Flags to Watch for When Choosing an Allergen-Free Food Manufacturer

Not all contract food manufacturers are created equal. And just because they say they "can do allergen-free" doesn’t mean they’re doing it right.

Here are a few red flags we encourage every brand to look out for:

• Shared lines or partial separation – If a facility is using the same equipment for allergen-containing and allergen-free products, even with cleaning protocols in place, that’s a major risk.

• No live access to production data – If the food manufacturer can't show you inventory levels, cleaning logs, or ingredient traceability in real time, that’s a red flag. True transparency means you see what they see.

• In-house brands – Many food manufacturers prioritize their own products, pushing smaller client SKUs to the back of the line. This can mean inconsistent quality, lack of flexibility, and delayed timelines.

• Unclear documentation or QA processes – If the answers around allergen management feel vague or inconsistent, follow your gut.

Why Companies Trust ZoRoCo for Allergen-Free Food Manufacturing

We’re proud to work with some of the most innovative brands in the "better-for-you" space — and they don’t choose us just because we’re 100% allergen-free. They also choose us because we’re a true partner in growth.

Here’s what makes us different:

• Purpose-built allergen-free plants, not retrofitted add-ons

• Capacity to scale, from small-batch test runs to national retail rollouts

• Expertise in multiple formats of packaging, including vertical form fill and seal, stand-up pouches, grab-and-go cups, and club packs

• Scratch baking capabilities with continuous and rack ovens for ready-to-eat, allergen-free cookies, brownies, muffins, and more

• No competition with in-house brands, so your product gets the priority and attention it deserves

• Hands-on collaboration, including weekly production calls, monthly leadership reviews, and quarterly strategy sessions

• Access to a custom-built ERP portal, offering live visibility into production, inventory, shipping, and more

We also help brands navigate certifications like GFCO, Non-GMO Project Verified, OU Kosher, and USDA Organic — plus “school-safe” labeling and allergen claim support. Whether you're targeting lunchboxes, vending machines, or the freezer aisle, we’ll help you build a product that’s safe, scalable, and shelf-ready.

Building a Safer Future, One Allergen-Free Snack at a Time

If you're serious about allergen-free food manufacturing, you need more than a supplier. You need a partner who’s just as committed to your product’s safety and success as you are. At ZoRoCo, that’s exactly what we offer.

From purpose-built, Big 9 allergen-free plants to real-time transparency and unmatched flexibility, we’ve created a system designed to protect your brand, your consumers, and your growth. Whether you’re baking delicious allergen-free cookies or scaling an allergen-free snack line to change the game, we’re here to make sure it’s done right, every step of the way.

Let’s build something safer, smarter, and stronger — together. Reach out to our team to learn how we can help with your food manufacturing needs!