Top 7 Mistakes Brands Make in Gluten-Free Food Manufacturing

The demand for “better-for-you” and gluten-free foods continues to rise, and so do consumer expectations. Today’s buyers aren’t just skimming labels for buzzwords. They’re digging deep for trustworthy, safe, and reliable gluten-free brands. And when you're marketing to individuals with celiac disease or gluten sensitivity, the margin for error disappears.

We’ve worked with enough brands to know: gluten-free isn’t a simple box you check. Whether you're launching your first gluten-free SKU or scaling up a product line, here are the biggest mistakes we see with gluten-free food manufacturing — and how to steer clear of them.

#1. Assuming “Wheat-Free” Means Gluten-Free

Just because an ingredient list doesn’t mention wheat doesn’t mean the product is gluten-free. Gluten can also be found in barley, rye, malt, brewer’s yeast, and even hiding out in natural flavors or seasoning blends. Even oats, if not certified, can pose a risk due to cross-contact during farming or processing. It’s a small oversight that can lead to big consequences.

How to Avoid It: Don’t rely solely on the absence of wheat. Vet every ingredient and sub-ingredient. Ask suppliers about processing environments and potential for cross-contact. Work with a manufacturer that understands gluten-free compliance at every level, from sourcing to finished goods.

#2. Skipping Dedicated Gluten-Free Equipment or Space

Cross-contact is one of the biggest risks in gluten-free production. If your product runs on shared lines, even trace amounts of gluten left behind can trigger serious health issues — and costly recalls. Cleaning shared equipment may reduce risk, but it doesn’t eliminate it.

How to Avoid It: Use a dedicated gluten-free facility like ZoRoCo’s GFCO-certified plant. With isolated production zones, strict allergen zoning, and no gluten-containing ingredients allowed in the space, you eliminate the gray area and keep your brand protected.

#3. Overlooking Other Allergens in Gluten-Free Products

Many consumers who shop gluten-free are also managing additional allergens like dairy, soy, nuts, or sesame. If your product is gluten-free but still contains other “Big 9” allergens, it may not be seen as truly safe, especially in school settings or allergy-conscious households.

How to Avoid It: Think beyond gluten. Decide early whether you want to pursue a broader “allergen-friendly” or “school-safe” claim, and choose a manufacturer who can help you meet it. ZoRoCo’s plants are 100% peanut-free, and one of our plants is completely Big 9 allergen-free, which offers brands even more flexibility and claim power.

#4. Underestimating the Importance of Staff Training

Even with perfect ingredients and the right equipment, all it takes is one missed glove change or unlabeled container to cause a gluten exposure. Human error is one of the most common sources of contamination — and one of the most overlooked.

How to Avoid It: Choose a food manufacturing partner with a culture of food safety and built-in compliance. We recommend that protocols are reinforced through routine training, daily checklists, and a quality assurance process that starts at the top and carries through every shift.

#5. Treating Gluten-Free Like a Simple Line Extension

Swapping wheat flour for a gluten-free alternative isn’t enough. Gluten affects structure, moisture, and shelf life, especially in baked goods. Without proper formulation, your product might turn out dry, crumbly, or flavorless, which can leave a bad impression on consumers.

How to Avoid It: Treat gluten-free product development as its own innovative process. At ZoRoCo, we’re happy to help clients test, reformulate, and fine-tune gluten-free recipes for optimal performance in both baking and packaging — so you’re proud of what hits the shelf.

#6. Overlooking Packaging and Post-Production Handling

Even if your mix and bake are compliant, gluten can sneak in during packaging — from shared bins and scoops to conveyor belts or boxing tables. These final steps are often where cross-contact risks go unnoticed.

How to Avoid It: Confirm that your co-man has allergen controls in place through every stage, including packaging. At ZoRoCo, our gluten-free products are processed, packed, and sealed within dedicated zones, and we offer multiple packaging formats — from peel-and-go cups to stand-up pouches — that all meet our allergen-free standards.

#7. Picking the Wrong Food Manufacturing Partner

Last but not least, here’s the big one: If your co-man doesn’t take gluten-free seriously, your product is at risk. Some food manufacturers prioritize their own brands, delay production for higher-margin clients, or operate behind closed doors, giving you little visibility into what’s really happening on the floor.

How to Avoid It: Work with a co-man who offers true transparency and zero conflicts of interest. For example, here at ZoRoCo we don’t own any in-house brands, which means we grow when you do. From live ERP access to weekly production calls, we give you complete visibility and act as an extension of your team.

Gluten-Free Manufacturing Done Right

At ZoRoCo, gluten-free food manufacturing isn’t a side hustle — it’s a core capability. We’ve invested in infrastructure, people, and processes to do it the right way every time. Here’s a quick breakdown of what that looks like:

• Dedicated gluten-free, peanut-free plant (GFCO-certified) and Big 9 allergen-free dedicated plant

• No in-house brands — your product is always the priority

• Wide variety of packaging formats in secure zones

• Commitment to stringent certification requirements

• Regular staff training and robust safety protocols

• Live ERP portal access for total client transparency

• Weekly and monthly calls to align on inventory, production, and forecasting

Whether you're looking to scale your GFCO Gluten-Free brand, or seeking reliable, high integrity claim oriented co-man services, ZoRoCo is here to help you do it safely, efficiently, and transparently. Reach out to our team to see how we can make a difference as your gluten-free contract food manufacturer.