FOOD RECALLS: KEY CHALLENGES AND SOLUTIONS

Food recalls: Key challenges and solutions. 

By Mike Pipe, Head of Product Inspection, Mettler-Toledo Product Inspection.

In Britain, food recalls are no longer rare events, they are a persistent challenge that continue to test the UK’s food industry. The Food Standards Agency (FSA) recorded 1,837 food and feed safety incidents in the UK in 2023/24, which is a 10 percent drop from the previous year and the lowest total in six years1. While this marks an improvement, it still equates to an average of more than five safety alerts every day, underlining the continued scale of the challenge. These numbers also underscore common pitfalls in production and present opportunities for adopting advanced technologies to mitigate risks. So, how can manufacturers tackle the root causes before they turn into bigger issues?

Labelling Mishaps

In the UK, allergens accounted for 240 food safety incidents in 2023/24, making them the second most common hazard after pathogenic microorganisms2. Common triggers include recipe changes, cross-contamination and mislabelling, often the result of manual checks that leave too much room for human error. UK legislation requires that all 14 major allergens are clearly declared on packaging, making label accuracy a critical line of defence for consumers.

Physical Contaminants

Incidents involving foreign materials, such as metal and glass, highlight vulnerabilities in production processes. In the UK, contamination from foreign materials such as metal or glass continues to be a recognised risk in food production. In 2023/24, the FSA recorded 136 incidents in the hazard category “Poor or insufficient controls”, a classification that can include failures in contamination detection systems at Critical Control Points.3 These figures show that even with advances in detection technology, process weaknesses still leave openings for potentially harmful materials to enter the food supply.

Modern metal detection and x-ray inspection systems, optimised 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 to build consumer trust through consistently high quality products.

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 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 minimise risks.

Expiration Date Errors

Mistakes in labelling 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 simultaneously conducting multiple quality checks on the packaging itself. This dual capability allows manufacturers to identify and address defects so that only high-quality products reach consumers.

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 on a production line. Whether it’s contamination, labelling 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.

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.

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