Abbott’s closed infant formula factory in Michigan to resume production

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Abbott Nutrition resumes production at its shuttered infant formula plant in Sturgis, Michigan on Saturday, offering hope that a nationwide shortage that had left parents scrambling to find food for their children could ease in the coming weeks.

The company said it was resuming production “after meeting initial requirements” specified by a May consent decree with the Food and Drug Administration.

“We understand the urgent need for infant formula, and our top priority is getting safe, high-quality formulas into the hands of families across America,” Abbott said in a statement. “We will increase production as quickly as possible while meeting all requirements.”

The plant was closed five months ago after an FDA inspection revealed allegedly unsanitary conditions. The plant produced most of the country’s supply of powdered Similac and was the main producer of specialty formulas, so its closure drastically reduced supplies.

The company previously said it would take two weeks for production to fully resume and another six to eight weeks to get the product on store shelves. The plant will prioritize production of EleCare, a specialized amino acid-based formula for children with multiple allergies, before ramping up production of its consumer products. On Saturday, Abbott said it plans to launch EleCare “to consumers starting on or around June 20.”

The crisis has caused panic among many parents who rely on infant formula to feed their children and has raised questions about the fragility of the supply chain of an essential food source. Four major companies control 90% of the infant formula supply in the United States: Abbott, Gerber, Mead Johnson and Perrigo Nutritionals. Congress and others have sharply criticized FDA leadership, Abbott executives, and even the White House for failing to avert the crisis.

Biden says he was late hearing about formula shortage

FDA Commissioner Robert M. Califf questioned when the Sturgis facility would likely be operational, telling lawmakers May 19 that could be as soon as the following week. In a hearing last week, however, he said the issues his agency had uncovered were “out of reach” and may require more extensive remediation.

The February inspection came after two infants fell ill and two other infants died after consuming contaminated infant formula. Abbott says there is no clear evidence the contamination came from the factory. Inspectors found Cronobacter sakazakii bacteria in samples they took outside the main formula production area. They found standing water on the floor due to leaking valves, as well as dampness and condensation in dry powder infant formula production areas. They found cracks and holes in the dryers as well as tape and debris on the floor.

Abbott says it has made a number of upgrades, including replacing a leaky roof and installing non-porous, easy-to-clean and hygienic floors to eliminate the risk of standing water. In addition, Abbott has updated its education, training and safety procedures for employees and visitors, as well as its cleaning and maintenance procedures on site.

The reopening of the establishment will not immediately lead to fully stocked grocery shelves. Even with Operation Fly Formula bringing in millions of bottles from Australia, the UK and Germany, data research firm IRI reports that store stocks were still slightly worse in recent weeks compared to early May. Parents continue to report difficulty finding the formula they need, with some traveling long distances and others paying a premium to buy it online.

One of the reasons the shortages persist despite efforts to increase production is that domestic producers, including Abbott, have focused on increasing the availability of specialty formulas for children with allergic and digestive disorders. Air bridges of formulas from abroad are largely distributed via pediatricians’ surgeries and hospitals. Califf said part of the shortage also stems from parents hoarding formula out of fear of running out.

FDA reaches agreement with infant formula factory to resume production

Abbott said the EleCare product could reach stores in about 16 days, but it could take weeks for the Sturgis-made formula to fully hit shelves due to the time it takes for the formula to be dried and tested for safety. The factory makes the type of formula that comes in powder form and needs to be mixed with water before feeding. Batch testing adds days to the production process.

On May 16, Abbott reached an agreement with the FDA to address safety issues at the plant. Under the consent decree, Abbott agreed to clean and sanitize its facilities and all equipment, and to keep an independent expert on site to ensure the plant is in compliance with FDA rules. It also includes requirements for testing products, as well as for ceasing production and immediately notifying the FDA if contamination is detected.