Food Recalls: Causes and How to Prevent Them

Types

Food recalls are categorized based on the severity of the health risk posed to food safety. These categories are as follows:

Class I Recall

Class I recalls are the most critical and involve products that may cause serious health problems or death. For example, dangerous pathogens like E. coli, Salmonella, or Listeria are present in food products.

Class II Recall

Class II recalls indicate a lesser risk than Class I and involve products that might cause temporary or medically reversible health problems. Examples include undeclared allergens (e.g., peanuts, gluten) or incorrect labeling.

Class III Recall

Class III recalls are considered the lowest level of risk, with products unlikely to cause any significant adverse health effects but still violating FDA regulations. While posing the least risk, cases that call for this recall are still concerning and a threat to food and general safety.

Common Reasons for Food Recalls

Food recalls can happen due to many different reasons, such as the following: . Here are some of the most frequent causes:

Undeclared Allergens

In 2023, undeclared allergens were the primary reason for food recalls in the US—a 27% increase from the previous year. The most common undeclared allergens included sesame, wheat, shellfish, eggs, fish, peanuts, milk, tree nuts, and soybeans. Sesame alone caused 13 recalls in 2023. Pet food recalls also increased that year, with undeclared Salmonella being the primary cause.

Product Contamination

Contamination is another leading cause of food recalls and can occur during various production, processing, or distribution stages. The three types of product contamination that can lead to recalls are:

• Biological: Harmful bacteria, viruses, or parasites like E. coli and Salmonella, including mold and yeast growth.
• Chemical: Contamination from pesticides, antibiotics, or heavy metals.
• Physical: Foreign objects like metal, glass, or plastic that can cause injury if ingested.

Misbranding or Mislabeled Products

Mislabeling or incorrect labeling of food products can also lead to recalls. This can include:

• Misbranding: Incorrect or misleading label information, such as false claims about ingredients or nutritional content.
• Missing Information: Expiration dates, barcodes, or other crucial labeling information required by regulatory standards not being present.

Production Failures

Production failures occur when a product does not meet safety standards due to processing, manufacturing, storage, or transportation errors. For example, failure to maintain proper temperature control during storage and shipping can result in the growth of harmful bacteria and cause foodborne illnesses.

Packaging Defects

Issues with packaging that lead to  leaking, breakage, or improper sealing can also be a cause of food  recalls. These defects can allow bacteria and contaminants to enter the food items, making it unsafe for consumption.

Disease Outbreak Investigations

Foodborne illness outbreaks are also a common reason for food recalls. When an outbreak occurs, investigative agencies will trace the source of contamination and recall any products that may be associated with it to prevent further spread.

Impact

Food recalls can significantly impact public health, manufacturing companies, and the food industry. Here are the most commonly affected aspects of society affected by such recalls:

Public Health

Food recalls are primarily initiated to protect consumers from health risks associated with contaminated or mislabeled products. Contaminated food can cause foodborne illnesses, with symptoms varying from mild stomach issues to severe conditions needing hospitalization or resulting in death.

Manufacturing Companies

Food recalls also have significant economic consequences for manufacturing companies. Some of the most common aspects of a business affected are the following:

• Direct Costs: This includes expenses related to product retrieval, disposal, logistics, regulatory notifications, and halting production for decontamination.
• Indirect Costs: Companies may face increased insurance premiums, legal fees from lawsuits, and significant losses in consumer trust.
• Operational Disruptions: Recalls can halt production lines, resulting in lost revenue and higher operational costs.

Broader Food Industry 

Recalls can also have effects on the food industry as a whole, including the following:

• Decreased Consumer Confidence: Recalls often lead to public mistrust in the safety and quality of food products, affecting sales for all companies.
• Increased Regulatory Scrutiny: Frequent or severe recalls may result in increased regulatory scrutiny and stricter enforcement of safety standards.

Role of Government Agencies

Government agencies oversee and safeguard the safety of food products. Some of the key agencies involved in food recalls include the following:

FDA

The FDA regulates approximately 80% of the US food supply, including nearly all food products. It possesses the authority to mandate recalls of food products within its jurisdiction when they present a significant health risk. However, this authority does not extend to meat and poultry.

USDA

Under the USDA, the FSIS ensures the safety of meat, poultry, and processed egg products. The FSIS can recall these products if they are deemed unfit for consumption.

CDC

The US Centers for Disease Control and Prevention (CDC) is the lead federal agency responsible for investigating foodborne illness outbreaks. Here are some of the CDC’s primary responsibilities related to food recalls:

• Detects and tracks patterns of foodborne illnesses through surveillance systems
• Investigating outbreaks to determine the source of contamination
• Providing food safety guidelines to institutions, public health agencies, and consumers during food recalls.

Prevention Strategies

While recalls are necessary for protecting public health, prevention should always be a priority. Here are some ways that companies can do to reduce the risk of recalls:

1. Implement Robust Food Safety Management Systems (FSMS)
   • Establish a comprehensive Food Safety Plan using a HACCP (Hazard Analysis and Critical Control Points) approach or preventive controls
   • Develop and maintain Good Manufacturing Practices (GMP)
   • Establish a comprehensive Standard Operating Procedures (SOP) for food safety
   • Conduct regular compliance training and education for all employees
2. Ensure Traceability and Visibility
   • Use an updated ERP system that allows for maximum traceability capacity to quickly identify affected lots in case of a recall
   • Automate reports by utilizing IoT (Internet of Things) devices and sensors
   • Push traceability back into the supply chain by demanding timely and accurate feedback from suppliers
3. Leverage IoT Technology for Early Detection
   • Utilize Sensors to automatically monitor food storage conditions
   • Use digital checklists and audits to improve inspection processes

Implement Robust Food Safety Management Systems (FSMS)

Food safety management systems are procedures and controls to ensure food products’ safe handling, preparation, and storage. Companies can establish these systems by implementing the following:

1. Hazard Analysis and Critical Control Points (HACCP): A systematic method for identifying and controlling food safety hazards during production.
2. Good Manufacturing Practices (GMP): Guidelines for ensuring hygienic manufacturing processes, preventing contamination, and maintaining proper safety standards.
3. Standard Operating Procedures (SOPs): Detailed instructions for specific tasks that employees

Ensure Traceability and Visibility

Food traceability means tracking a product’s history and location throughout its supply chain. Companies should have systems to trace products from raw materials through production, distribution, and retail. This enables quick identification and isolation of affected products during a recall.

Companies should also have strong visibility within their supply chain to track products effectively. This means:

• Using Enterprise Resource Planning (ERP) systems to aggregate and analyze data from various sources;
• Automating reports to track and document the movement and condition of products; and
• Utilizing IoT (Internet of Things) devices and sensors to provide real-time product status and location data

Leverage IoT Technology for Early Detection

Companies can also utilize IoT technology to detect potential food contamination issues early on. Sensors embedded in food handling equipment or packaging can detect abnormalities like temperature, humidity, or chemical levels that could indicate a possible safety issue.

Why Use IoT Technology

Leveraging IoT technology can help companies prevent recalls in several ways by improving the following:

• Temperature and Humidity Monitoring: IoT sensors can continuously and consistently monitor the temperature food is stored in and alert users if they go beyond safe ranges.
• Traceability and Transparency: IoT devices provide real-time product location and condition data throughout the supply chain, enabling quick identification and recall of affected products.
• Compliance and Reporting: IoT technology helps companies monitor critical factors like temperature and humidity to comply with food safety regulations, aiding in reporting and audits.
• Enhanced Quality Control: IoT can identify potential quality issues in real time, allowing companies to take corrective action and prevent recalls, saving time and resources while protecting consumers.