Food product recalls are a valuable measure to secure consumer safety, but they come at an enormous financial and reputational cost. Thankfully, technological advances are enabling new, effective ways to prevent and minimize food contamination in all its forms.
Fighting physical contamination and other major recall risks
25 Aug 2021
What causes food product recalls?
Food contamination risks exist across the value chain, many of them invisible to the human eye. Understanding the common causes of food recalls is the first step toward preventing an incident:
- Physical contaminants
Foreign materials such as metal, plastic, glass, bone fragments, pests, hair, and dirt were the leading cause of US food recalls in 2019, accounting for 34 recalls.
- Cross-contamination of allergens
Undeclared allergens came in a close second, accounting for 32 recalls. The most common culprits included milk, wheat, soy, and peanuts.
- Pathogens
E. coli, listeria, and salmonella led to 16 product recalls in 2019. Pathogens are particularly concerning because they can make anyone ill, not only people with food sensitivities.
Avoiding contamination and minimizing the impact of recalls
It’s no secret that food contamination risks are numerous and varied. Plus, every food processing line is unique, further complicating the risk management process.
Setting priorities and establishing clear protocols—including accountability and crisis response plans—is an effective way to control risks in the context of your operation.
Strategies to minimize food contamination risks
| Food contamination risk area | Possible mitigation strategies |
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Employees |
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Equipment |
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Procedures and systems |
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Facility management |
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Communication |
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Supplier and customer relationships |
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It’s almost impossible to eliminate all food contamination risks. However, being able to identify issues early can help ensure they’re contained in time to prevent a costly recall.
In the worst-case scenario of a suspected or confirmed contamination, manufacturers must be able to contain the issue quickly and demonstrate adherence to food safety standards and regulations.
The financial cost of product recalls
It is difficult to overstate the financial impact of food recalls. The direct costs average around 10 million US dollars, and in 23% of cases the cost exceeds 30 million US dollars. That’s just the beginning: These figures only account for direct costs such as assembling a crisis team, issuing recall notifications, and recovering products.
Reputational costs are harder to quantify but potentially even more devastating. When customers lose confidence in a brand, it can be a long, difficult, and expensive journey, often taking years to regain trust among customers and end consumers.
Marel helps food producers avoid and contain contamination
We work in close partnership with our customers to develop state-of-the-art solutions that help prevent food contamination.
A fine example is our industry-leading SensorX Magna meat inspection solution. SensorX Magna uses advanced X-ray inspection technology to detect and remove bone and metal while maximizing yield.
We also offer a range of advanced Innova Food Processing Software modules, such as Innova Traceability and Innova Quality Control. By providing full-line solutions and software, backed by a global network of service experts, we can help your business achieve outstanding levels of food safety.
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