Why were food recalls on the rise in 2024?
2024 saw a notable rise in food recalls, with 127 reported cases—a 10% increase compared to the previous year. While this reflects improvements in detection and reporting systems, it also highlights the growing complexities of today’s food production and supply chains.
What were the key causes, and how can businesses reduce their risk? To explore these questions, we spoke with industry experts, including Faye Louch (OAL), Nic Sharman (Food Safety Consultant) and Mark Spurdens (University of Lincoln.
What are the top reasons for food recalls in 2024?
According to data from the Food Standards Agency (FSA), here’s a breakdown of the most common reasons for recalls last year:
Undeclared Allergens: 53 cases
Mislabelling, recipe changes, or cross-contamination during production led to allergens like nuts, dairy, or gluten being omitted from product labels.
Physical Contamination (metal, stones, packaging, glass, etc.): 25 cases
Foreign materials entered food during processing due to equipment wear, handling issues, or insufficient quality checks.
Pathogen Contamination (Salmonella, E. coli, Listeria): 23 cases
Results from harmful bacteria like Salmonella, E. coli, or Listeria contaminating food. This can occur due to improper handling, poor hygiene, or inadequate cooking and storage conditions.
Incorrect Use-By Date Codes: 9 cases
Human error or equipment failure causes wrong or missing date codes, leading to confusion over product safety and shelf life.
Food Contamination (Allergy-related): 10 cases
Cross-contamination with allergens during production, such as shared equipment or improper cleaning, leads to allergen residues in products not meant to contain them.
Wrong Labels: 6 cases
Arises from errors in packaging design or printing, such as using the wrong label or failing to update the label after recipe adjustments.
Supply Chain Counterfeits: 2 cases
Fake or unauthorised products infiltrate the supply chain, often due to weak supplier vetting, fraudulent activities, or lack of traceability measures.
Burn Risks (exploding cans): 2 cases
Defective products can cause pressure build-up or overheating when heated.
Incorrect Ingredients: 1 case
Occurs when production line errors or supplier mistakes lead to the use of unintended or mislabelled ingredients, potentially altering the product's safety or compliance.
Based on data released by FSA for “Allergy Alert and Food Alert”
So why are recalls on the rise?
The rise in recalls reflects progress in detection technology, testing sensitivity, and consumer reporting. However, it also underscores the challenges manufacturers face in navigating increasingly complex processes and supply chains. Key contributing factors include:
Reliance on Manual Processes
Human error can occur at critical points, particularly when systems rely on standalone or paper-based methods that aren’t fully integrated.
Growing Supply Chain Complexity
With diverse ingredients sourced globally, risks increase. Managing these intricacies with manual systems for allergens or labelling is particularly challenging.
Cost Pressures and Risks
The financial impact of recalls continues to grow. As Faye Louch, OAL Connected Trainer, explains:
"If a product is recalled due to a labelling error, the costs extend far beyond the fine. You also need to account for production costs, labour, ingredients, distribution, recovery, and disposal. These can significantly impact a business's bottom line."
Example Recall: Undeclared Allergen Due to Labelling Error
When a new ingredient is added to a product, it’s critical that all teams involved—product development, production, and technical —are fully aligned.
Here’s how a simple oversight can lead to a recall:
A food manufacturer introduces a new ingredient, such as almond flour, to enhance a product’s flavour. The internal team responsible for recipe changes notifies the labelling team, who create an updated version of the product’s packaging.
However, there are now two versions of packaging artwork: one declaring almond flour and one without. Unfortunately, not all of the old packaging is disposed of, and an operator accidentally brings the outdated version to the production line.
The error goes unnoticed until the product has already been shipped to retailers. A consumer reports an issue, triggering a costly recall
OAL’s automated label and date code verification systems prevent issues like this by ensuring complete artwork version control. Using technologies like 2D barcodes, we track packaging changes and prevent the use of outdated materials on the production line, verifying every piece of packaging.
How to stop a recall.
At OAL, we understand the challenges technical managers face in maintaining compliance while improving operational efficiency. We’ve partnered with leading food manufacturers to implement robust systems that reduce reliance on manual processes, enhancing both safety and traceability. Our approach includes:
Automation and Integration
By automating label and date code verification, we eliminate many sources of human error. Integrated systems ensure consistency across production lines, improving compliance and reducing risk.
Proactive Support
Our team collaborates with you to design tailored solutions, providing ongoing training and audits to ensure compliance with BRC and other industry standards.
Improved Efficiency
Our systems don’t just protect against recalls—they also enhance operational effectiveness, helping you achieve greater accuracy and productivity.
Leena Malde, Executive Chair of Wealmoor, shared her experience with OAL systems:
““The introduction of automated systems from OAL has completely changed our operations. Since its installation, we’ve been able to streamline our processes and prevent errors before they caused further issues, protecting our reputation, enhancing trust and confidence. We’ve also seen the significant opportunity in increasing efficiency and operational effectiveness.””
Is AI the Future of Food Safety?
AI technology is playing an increasingly important role in food safety, but it’s most effective when supported by robust processes. For example, AI cameras can verify product labels, but the data driving these systems must be accurate and up-to-date.
““Technology is readily available to read and verify labels but it’s imperative teams create a culture that maintains these systems and doesn’t switch them off!””
Forward-thinking manufacturers like Worldwide Fruit are already integrating their ERP systems with OAL’s label and date code verification technology. This ensures that:
Real-Time Updates: Production changes are immediately applied across systems.
Error Reduction: Human intervention is minimized, ensuring accurate checks every time.
Improved Traceability: A single source of truth provides end-to-end visibility and accountability.
By digitalising manual processes, manufacturers gain not only safety and compliance but also valuable insights into production trends, downtime, and efficiency.
Looking Ahead: Protecting Your Business in 2025
Recalls remain a sensitive and challenging issue, but with the right systems in place, they can be significantly reduced—or even eliminated.
At OAL, we’re here to support your business every step of the way, from designing and implementing automated solutions to providing training and ongoing support.
For more details on automated label verification, contact us by clicking the button.
