With 2020 behind us, we can look back and assess the state of recalls for food and beverage. Due to the pandemic, the numbers deviate from prior years but still paint a clear picture of where the industry needs to focus moving forward.
The U.S. Food and Drug Administration (FDA) and the U.S. Department of Agriculture Food Safety and Inspection Service (USDA FSIS) confirmed a total of 363 issued recalls in 2020. While that’s on par with prior years, the distribution of recalls wasn’t. Starting with a moderate 141 recalls in the first quarter, the COVID-19 pandemic limited regulatory oversight activities at the start of the second quarter, when recalls fell 44% YOY to 79. As the year continued, quarterly recalls remained low with 52 in the 3rd quarter, before rising to 91 by the end of the year. Regulators attributed these fluctuations to an overall inability to deploy oversight, resulting in missed food safety issues.
Unfortunately, specific recall trends continue despite the pandemic. Read on for a breakdown of the top recall categories in 2020.
For the 16th straight quarter, undeclared allergens remained the top contributor to recalls in the food industry. Undeclared allergens accounted for nearly half, 48%, of all recalled food and beverages. Milk led the list with 83 recalls, followed by soy, (28) nuts (25), and eggs (15). Sulfates, wheat, and peanuts were also leading contributors.
A close second, and almost double last year’s rates, were 90 food products recalled due to contamination by foreign materials. Though regulators mandated only nine recalls in Q2 of last year, they affected 672,000 lbs., or 69%, of all USDA meat, leading to a short-term shortage and skyrocketing prices.
Listeria, Salmonella, and E. coli
Salmonella increased substantially and was the root cause of 69 recalls, the large majority relating to fruits or pet foods. Regulators recalled 47 food products because of listeria contamination – many linked to frozen produce, ready-to-consume deli products, and eggs.
The Silver Lining of 2020
After months of delays, 2020 saw two distinct events causing many in the industry to sit up and take notice.
First, the FDA delivered a cautionary tale to the industry in the second quarter when it brought federal charges against Blue Bell Creameries after 2015’s deadly listeria outbreak. According to regulators, the company failed to respond adequately to continued safety warnings and delayed recalls of contaminated products. This failure led to hundreds of millions of dollars in lost sales, legal fees, and massive damage to the company’s brand and reputation. This verdict sharpened the industry’s focus on recalls and reminded food manufacturers that they’re still accountable for recall activities and events.
Second, 2020 saw the FDA release its “New Era of Smarter Food Safety: Blueprint for the Future.” Though the outlined directions weren’t much different from what you’d expect from earlier years, 2020 seems to have driven an industry-wide resurgence in the importance of food safety culture. All along the supply chain, a revival of cleanliness emerged. The pandemic put health guidelines into an entirely different light for essential workers. In 2020, the industry shifted its primary focus to protecting its workforce through strengthened cleaning and sanitation processes. This renewed effort serves as a solid foundation for future food safety initiatives.
Reducing Recalls in 2021 and Beyond
The following approaches can help food companies reduce the chance of a recall:
1 - Correctly Label Allergens
If you make a product with an allergen, you need to make sure it’s declared accurately on the label. The No. 1 reason for the mislabeling of allergens is the wrong package or the incorrect label on a product. While there are various reasons why the wrong package or label is applied, the most common is that packages for similar products made with different allergens tend to look similar. Workers can easily grab the wrong packaging from inventory to support a production run. Though it’s a simple mistake, it can be extremely costly.
A few best practices to keep in mind for your allergen control programs include
Confirm the correct label is on the line at the beginning and end of the roll.
Create a transparency/acetate (i.e., transparent sheet of film) with the correct ingredient statement to confirm ingredient statements on the packaging for finished products and raw materials upon receipt.
When adding an allergen to a formula that didn’t previously contain it, the packaging or labels used for the old formula must be disposed of or otherwise made unusable.
2 - Environmental Pathogen Control
To help control pathogens, conduct environmental monitoring at a consistent frequency for food contact and non-food contact sites. Create a baseline to generate continued monitoring data of the facility environment. This baseline helps identify microbial growth areas, contributing to Listeria monocytogenes contamination in wet environments or Salmonella contamination in dry ones.
Additional best practices for a clean environment include:
Separate raw products from cooked/RTE (ready-to-eat) products
Control temperature and moisture levels
Implement pest controls
Choose equipment that can be easily cleaned
3 - Establish an Approved Supplier Program
For food manufacturers, the safety of finished goods depends not only upon the ingredients themselves but also the suppliers used throughout the food supply chain. Having a properly managed supplier program can help to ensure quality and safety measures. It also encourages great working relationships between manufacturers and suppliers, and who doesn't want that?
One key component of having an outstanding supplier program is the benefit of a well-built and well-maintained supplier approval process. Not to mention, supplier verification in the U.S. is a big part of the Preventative Controls required by the Food Safety Modernization Act (FSMA).
Your reputation is on the line should something fall through the cracks. Ensuring approved procedures and processes are followed any time a new ingredient or supplier is considered can significantly mitigate the risks involved.
The industry won’t eliminate recalls completely, but we can make a tremendous impact if every manufacturer does their part. Take the first step with TraceGains’ eBook, “9 Things Your Allergen Control Program is Missing,” here.