Product Recalls: The Curse of the Manufacturer

Product recalls in the UK food and drink industry remain a significant challenge, with the latest RQA (Research Quality Association) Group report highlighting a concerning increase in the number of products recalled per event. While the number of UK Food Standards Agency (FSA) alerts in 2024 remained relatively low, the volume of products affected per alert has risen to 2.5 times higher than in 2023.

Allergen Control: One of the Leading Causes of Recalls

Allergen mislabelling remains the top reason for product recalls. While the percentage of ‘Never Event’ recalls—those deemed entirely preventable—has decreased to 27% in 2024, these incidents continue to pose a serious threat to consumers. Historically, ‘Never Event’ mislabelling alerts accounted for over 40% to 50% of recalls, meaning progress is being made, but challenges remain. A ‘Never Event’ recall is defined by RQA as a recall that can cause serious harm and should be easily prevented. E.g. Wrong label on pack or product put in wrong packaging with allergen safety implications.

Recent incidents underscore the ongoing risk. Birds Eye Ltd. recalled Goodfella’s Stonebaked Thin Garlic Bread because it contained cheese, an undeclared allergen posing a health risk to those with a dairy intolerance or allergy. This case, as with others, highlights the critical need for stringent allergen control measures throughout the supply chain.

Microbiological Contamination: A Rising Threat

The RQA report also revealed an 80% increase in recall events caused by microbiological contamination, with Listeria and Salmonella leading the list of concerns. Despite this surge, the total number of products recalled due to contamination is 426 fewer than last year, suggesting more successfully targeted recall efforts.

Listeria monocytogenes contamination remains a major concern, particularly for vulnerable populations, including the elderly, pregnant women, and those with weakened immune systems. Lidl Northern Ireland recently recalled a batch of Deluxe Sriracha Cheddar Cheese Wedge after Listeria was detected. This bacterium can cause flu-like symptoms and, in severe cases, lead to life-threatening complications such as meningitis.

Salmonella-related recalls also continue to impact the industry, particularly in high-risk food categories like meat and ready-to-eat products. Contaminated foods can lead to severe gastrointestinal illness, prompting swift action from manufacturers and retailers to prevent outbreaks.

Foreign Bodies and Fraudulent Lab Results

Foreign body contamination, particularly involving metal fragments, is another leading cause of recalls, tied in third place with non-allergen-related labelling errors. The presence of metal fragments in food poses a serious risk of injury, making it a key focus area for quality control teams.

Additionally, food fraud remains a pressing issue, with the UK’s National Food Crime Unit (NFCU) issuing an amber food crime alert regarding document fraud in laboratory results. Fraudulent lab reports undermine food safety assessments, legislative compliance, and supplier approval processes. This alarming trend highlights the need for robust traceability and verification systems to ensure consumer safety and maintain trust in food products.

Preventing Recalls: The Role of Technology and HACCP

To mitigate these risks, food manufacturers must implement rigorous quality control measures, including Hazard Analysis and Critical Control Points (HACCP) strategies, which help identify potential contamination risks at every stage of production. Effective traceability systems and accurate labelling solutions are also essential in preventing mislabelling errors and ensuring that recalled products can be efficiently removed from circulation.

Harford Control: Ensuring Accuracy and Traceability

Harford Control provides Autocoding Solutions to ensure accurate labelling, ensuring that the right information appears on the right label and that the correct label is applied to the right packaging. The solution plays a crucial role in preventing Never Event recalls, minimising the risk of allergen mislabelling and enhancing overall food safety compliance.

Additionally, Harford’s Laboratory Information Management System (LIMS) enables manufacturers to track and trace approved materials while monitoring non-compliant products. By providing full traceability of ingredients and finished goods, LIMS strengthens laboratory quality control and ensures compliance with stringent food safety regulations. It also facilitates efficient recall management when necessary.

Harford Autocoding and LIMS Solutions can be integrated seamlessly. Any batches from the shop floor will automatically initiate certain actions based on predefined risks, thereby protecting the consumer.

Smart Solutions to Prevent Recalls

Product recalls are avoidable, through diligent attention to detail, and risks, at each stage of food and drink manufacturing, thereby ensuring that the customer obtains only the food, plus allergens, as stated on the packaging. Mix ups or misunderstandings may still occur at the retail or fast-food outlet, which can be reduced, if not eliminated, through better training, supervision and communication. In time, the consumer will also become better informed.

To this end, the Natasha Foundation (set up in memory of Natasha Ednan-Laperouse, whose life was tragically cut short through eating an apparently allergen-free bread roll that contained sesame seed extract, purchased on confident assurances of safety from Pret a Manger) are doing brilliant work to raise awareness of allergen risks and only last week introducing a training programme for schools called ‘Allergy School’.  In the UK alone, there are on average two children per class suffering from allergies.

As recalls continue to evolve in complexity, leveraging advanced solutions such as Autocoding and LIMS to minimise risk, is key to protecting consumers, ensuring regulatory compliance and maintaining brand integrity. When you are ready to learn more about available protection, please get in touch with our specialists at info@harfordcontrol.com or call us on +44 (0)1225 764461.