Berry unfortunate

Food recalls rose by 10% in 2024, with 127 cases reported — one of the highest on record — according to data from the Food Standards Agency (FSA). The increase reflects advancements in detection technology and reporting systems, but also underscores the growing complexity of food production and supply chains.

Top causes of recalls in 2024

• The FSA’s “Allergy and Food Alert” system identifies the most common causes of recalls as:
• Undeclared Allergens (53 cases): Labelling omissions due to recipe changes or cross-contamination.
• Physical Contamination (25 cases): Foreign materials such as metal or glass entering food during processing.
• Pathogen Contamination (23 cases): Bacterial contamination from inadequate hygiene or storage.
• Incorrect Use-By Dates (9 cases): Errors in labelling or coding.
• Additional issues include cross-contamination, supply chain counterfeits, and defective packaging.

Industry insights on rising recalls

OAL, a leading provider of food automation solutions, convened experts to explore the drivers behind the increase.

Jake Norman, managing director at OAL, explains: “The rise in recalls highlights both improved detection capabilities and the challenges of managing increasingly complex supply chains. Manual processes and disconnected systems leave gaps where errors can occur.

“The financial impact of a recall extends far beyond fines. Costs related to production, recovery, and disposal are significant, making it essential for manufacturers to take a proactive approach.”

Solutions to reduce recall risks

OAL is helping food manufacturers address these challenges through automation and integration. Their solutions focus on reducing human error, improving traceability, and ensuring compliance with food safety standards.

“By automating critical processes like label and date code verification, we help businesses eliminate manual errors and achieve greater efficiency,” says Faye Louch. “Our systems also provide real-time updates, ensuring all factory systems operate from a single source of truth.”

Leena Malde, executive chair of Wealmoor, shared her experience with OAL’s 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.”

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 by verifying every label with cameras.

The role of AI in food safety

AI technology is emerging as a game-changer in food safety. OAL’s AI-driven solutions integrate with ERP systems to streamline processes, minimise errors, and improve traceability. Powerful AI cameras can complete complex checks like seal and product integrity. It’s imperative the data driving these systems is accurate and up to date.

However, as Nic Sharman cautions, “Technology must be supported by a culture of accountability. Robust systems and ongoing maintenance are key to long-term success. Its imperative teams create a culture that maintains these systems and doesn’t switch them off!”