Detection of sesame residues in cookies sold in pastry shops and examination of employees' food allergy knowledge and awareness

Undeclared or mislabeled allergen residues on food product labels can cause life-threatening allergic reactions for sensitive consumer groups. Sesame seeds (Sesamum indicum) are one of the most common and significant food allergens and are frequently used in baked goods and pastries. This study was conducted to determine the current status of allergen management in pastry shops by jointly evaluating the presence and levels of sesame residues in cookie samples sold unpackaged and without labeling in various pastry shops operating within the borders of Istanbul, together with the food allergy knowledge and awareness of the personnel working in these pastry shops. This study is the first scientific study in Türkiye to examine sesame residue and contamination in packaged and unpackaged bakery products on a large scale. The increasing prevalence of food allergies as a health issue necessitates an assessment of allergen management in bakeries from a gastronomic perspective. Accordingly, this study aims to identify the potential risks that sesame allergens may pose to consumer health and contribute to a better understanding of the current conditions in the sector by employing a mixed-method approach combining quantitative and qualitative methods. This study presents findings that serve as a guide for the industry, legislation, and scientific research; it contributes to the gastronomy literature by systematically revealing the current situation regarding sesame allergens and cross-contamination risks in Türkiye. For the purpose of the study, a total of 80 pastry shops from different districts of Istanbul were included, and 258 unpackaged cookie samples labeled as 'sesame-free' were collected. The samples were divided into three groups—plain, cocoa/chocolate, and filled/fruit-flavored—and the levels of sesame allergen were determined using the ELISA method. RIDASCREEN® FAST Sesame (Art. No. R7202) test kits, compatible with the ELISA device, were used. Sesame residues were detected at levels below 2.5 ppm in 53% of the samples, between 2.5–20 ppm in 24%, and above 20 ppm in 23% of the samples. The analysis results indicated that sesame allergen levels were particularly higher in filled/fruit-flavored and cocoa/chocolate cookies. While plain cookies generally contained low levels of sesame, filled/fruit-flavored cookies were considered the highest-risk group due to their elevated residue levels. Statistically significant differences in sesame residue levels were observed among the three cookie groups (P < 0.05). The qualitative findings of the study revealed that, despite the high level of awareness among pastry shops employees regarding food allergies, their knowledge levels were inconsistent. There was a significant lack of knowledge, particularly regarding sesame allergens, with only a portion of participants aware that sesame is an allergen. This situation, consistent with the high levels of sesame residues identified in the quantitative findings, reveals that the knowledge level of employees directly impacts the production process and the risk of cross-contamination. The findings indicate that the preparation of sesame-containing and non-containing products on the same equipment and production lines, combined with inadequate cleaning practices and insufficient control of cross-contamination points in production areas, poses significant health risks, particularly for sensitive consumer groups with sesame allergies. This indicates the absence of a comprehensive and systematic allergen management system in the pastry sector. Accordingly, the study provides recommendations for the industry, scientific research, regulatory and policy makers, as well as consumers. Among these recommendations, concrete and feasible measures such as preventing cross-contamination during production, strengthening allergen management systems, raising employee awareness, ensuring accurate allergen labeling for unpackaged products, and enhancing regulatory and inspection mechanisms are emphasized. In this respect, the study fills a gap in the literature on sesame allergen and contamination in Türkiye, providing an original and meaningful contribution to the field of food allergies and allergen management.