Food Recalls Surging: Key Challenges and Solutions

How to tackle the root causes of food recalls before they turn into bigger issues.

Proactive measures, continuous improvement and the integration of advanced technologies at key production stages can reduce recall risks and foster greater confidence in the safety of food products. © Khairil – stock.adobe.com

Another week, another headline: food recalls have become a troubling norm across America. In fact, the U.S. food manufacturing industry saw a sharp increase in recalls during 2023 — up 44% from the previous year, with 65 separate incidents leading to the removal of over 4 million pounds of product from the market, more than double the volume recalled in 2022.¹ This increase underscores common pitfalls in production and presents opportunities for adopting advanced technologies to mitigate risks. So, how can manufacturers tackle the root causes before they turn into bigger issues?

Labeling Mishaps

In 2024, in the U.S., undeclared allergens accounted for more than a third of all food recalls at 34.1%, highlighting the scale of the issue and the need for more robust prevention methods.² Common triggers include recipe changes, cross-contamination and mislabeling, often the result of manual checks that leave too much room for human error. In response, the Food Allergen Labelling and Consumer Protection Act (FALCPA) requires manufacturers to clearly declare the presence of the top eight allergens on packaging, making label accuracy essential.

Modern metal detection and X-ray inspection systems, optimized for high sensitivity, can detect contaminants reliably and combat this worrying trend. Image courtesy of METTLER TOLEDO.

Physical Contaminants

Incidents involving foreign materials, such as metal and glass, highlight vulnerabilities in production processes. These often result from outdated or improperly positioned contamination detection systems at Critical Control Points (CCPs). Foreign material was responsible for 12 food recalls in 2024, a figure that reflects persistent contamination risks even as digital tools advance.³

Modern metal detection and X-ray inspection systems, optimized for high sensitivity, can detect contaminants reliably and combat this worrying trend. Regular testing and maintenance of these systems are essential to be sure of optimal performance and consumer trust.

Bacterial Threats

Pathogens like bacteria are another significant contributor to recalls. Maintaining stringent hygiene standards in production environments, especially in hot, harsh or wet conditions, is critical. Investing in washdown-capable equipment, such as metal detectors that have an IP69 rating and can withstand rigorous cleaning processes, can prevent machinery from contamination. Manufacturers are encouraged to implement thorough cleaning programs and invest in equipment designed with hygienic features to minimize risks.

Expiration Date Errors

Mistakes in labeling of expiration dates can lead to serious consequences for manufacturers and consumers. These errors often arise from manual processes but can be mitigated with vision inspection systems that automatically verify label content. By integrating this technology, manufacturers can prevent costly recalls and maintain consumer confidence.

Packaging Defects

Packaging issues, such as damaged seals or compromised materials, present a risk of product contamination or spoilage. X-ray technology offers a comprehensive solution by not only detecting a wide range of foreign body contaminants, but also conducting multiple quality checks on the packaging itself. This dual capability allows manufacturers to identify and address defects early in the production process so that only safe, high-quality products reach consumers. By adopting these solutions, manufacturers can be sure that products meet safety and quality standards before reaching store shelves.

Complex Products, Complex Risks

As food production becomes increasingly sophisticated, so do the risks. Ultra-processed foods, with their multifaceted supply chains and intricate handling, introduce multiple points of failure along the CCPs. Whether it’s contamination, labeling errors or packaging failures, complex foods require extra vigilance from manufacturers.

Embracing Advanced Technologies

Despite the challenges, there is a silver lining. The industry is seeing a growing adoption of cutting-edge product inspection technologies. Solutions like metal detectors, X-ray systems and vision inspection equipment are being installed at key production stages. These tools not only reduce recall risks but also strengthen relationships with consumers and retailers, fostering greater confidence in the safety of food products. This investment is particularly vital at a time when public trust in food safety enforcement is wavering, with more than 40% of Americans now reporting little or no confidence in food regulation, according to recent surveys.⁴

Labeling errors often arise from manual processes, but can be mitigated with vision inspection systems that automatically verify label content. © Christian – stock.adobe.com

As the food manufacturing sector adapts to these challenges, the path forward lies in proactive measures, continuous improvement and the integration of advanced technologies. By addressing the root causes of recalls, manufacturers can enhance safety standards and gain and uphold the trust of their consumers.

About the Author

Sarrina Crowley is Mettler-Toledo’s Marketing Communications Manager. Proven product inspection solutions from METTLER TOLEDO help you inspect every product with confidence to support manufacturing quality across food, pharmaceutical and other industries. Their advanced inline inspection systems help you meet safety and quality standards, so you can protect your brand, profits, and productivity, and comply easily with industry requirements. Visit www.mt.com/pi

References

1. https://www.fsis.usda.gov/food-safety/recalls-public-health-alerts/annual-recall-summaries/summary-recall-and-pha-cases-0 
2. https://fsns.com/food-recalls-in-2024-revealing-the-statistics/
3. https://fsns.com/food-recalls-in-2024-revealing-the-statistics/
4. https://www.foodsafetynews.com/2025/01/were-recalls-really-up-in-2024/