Don’t Let Mold Ruin Your Packaging Line

by | Jun 17, 2025

When it comes to food safety, bacteria like Listeria and Salmonella get most of the attention. But mold is an equally serious threat—often underestimated, yet responsible for recalls, health risks, and persistent contamination issues in food processing facilities.

Recent product recalls highlight the risk. In 2020, Hostess was forced to recall Raspberry Zingers® due to mold growth [source]. And just last year, Martinelli’s pulled over 170,000 bottles of apple juice after routine FDA testing detected elevated levels of Patulin, a mold-related toxin [source].

To find out why mold is such a persistent problem, we spoke with John Glynn II, XENON’s North American Sales Manager.

How common is mold in food products?

John works with many food companies to provide Pulsed Light solutions for food safety. He sees mold issues quite often—even in those companies that take great precautions.

“Mold spores cling to surfaces, survive many cleaning methods, and can grow in sealed packaging under the right conditions,” John explains. Spores can enter during filling, settle from the air before sealing, or hitch a ride on ingredients. Even well-sealed containers aren’t immune—microscopic leaks or pressure changes can allow spores to enter or survive inside.

Companies are usually surprised to discover mold problems, especially if they’ve been conscientious about safety. “We’re working with a company now that’s been experiencing mold contamination between hot fill and capping,” he says. “It’s a narrow window of opportunity, but it’s enough for spores to get in and cause issues. Our Pulsed Light solution fits seamlessly into their line and eliminates the problem without slowing production.”

Another case involves a baby food manufacturer struggling with recurring mold despite rigorous cleaning protocols. “We’re talking with their team about adding Pulsed Light to the conveyor line,” John says. “It’s a practical step that could help them address the issue quickly and safely.”

XENON Pulsed Light systems integrate into conveyor lines, filling stations, and other process points without slowing production. As long as the package has a wide enough opening for light to reach all surfaces, Pulsed Light can be applied to trays, containers, lids, and more.

For example, John says that in one West Coast facility, XENON Pulsed Light is being used to pre-treat packaging trays just before filling—a simple step that helps ensure product integrity down the line.

Why is Pulsed Light so effective?

Many packaging materials—like plastic, cardboard, and paper—are inherently tough to sanitize. Bleach and other chemicals may kill spores, but they require thorough rinsing and can leave residue, especially problematic for absorbent or porous surfaces. Heat is another option, but it’s impractical for many materials and too slow for production speeds.

XENON’s Pulsed Light systems offer a powerful, chemical-free solution. And unlike single-wavelength UV treatments that target only one threat, Pulsed Light delivers intense, broad-spectrum light that disrupts DNA and RNA in all pathogens–including mold, bacteria, and viruses–without generating heat.

It’s time to say goodbye to mold

Mold has been a persistent problem in food packaging, but it doesn’t have to be that way. XENON Pulsed Light provides a solution that’s proven and FDA-approved for use in food processing.

Why wait until mold costs you customers or even triggers a product recall? To find out how you can use XENON Pulsed Light to improve your food safety, contact XENON today.