The bakery and snacks sectors are currently facing a pivotal moment in food safety. A recent report by Sedgwick Brand Protection, titled Product Safety and Recall State of the Nation 2025 (US edition), reveals a slight decrease in the total number of food recalls, falling from 506 in 2023 to 495 in 2024. However, this overall decline is accompanied by a dramatic increase in the scale of these recalls. “Although the total number of recalls has seen a slight reduction, the number of impacted units has soared,” stated Mark Billingham, recall advisor for International Markets. “There’s been a staggering increase of 357.6% in recalled units, escalating from 4.62 million in the third quarter to 21.15 million in the fourth quarter. Large-scale recalls, such as the 9.91 million units of frozen waffles, pancakes, and cakes due to Listeria concerns, have played a significant role in this trend.”

These figures highlight the imperative need for stringent quality control and proactive recall preparedness within the food industry.

The Numbers

From 2020 to 2023, the total number of food recalls issued by the USDA and FDA increased by over 20%, from 454 to 547. However, in 2024, the total number of recalls experienced a slight decline to 495, down from 506 the previous year. “Despite the minor decrease in total recalls, the volume of impacted units remains a significant concern,” remarked Rachel Quinn, Sedgwick’s senior account manager. “The fourth quarter of 2024 recorded one of the highest recall volumes in recent history, with the bakery and snacks sectors being notably affected.”

The primary causes of recalls in the bakery and snacks sectors for 2024 have remained consistent with previous years, with undeclared allergens being the most prevalent issue. In Q4 alone, this accounted for 54 recall events, with wheat and milk being the most frequently cited allergens. “The inclusion of sesame, recently designated as a major allergen, was linked to 1.08 million recalled units of bread,” Quinn added. “This indicates heightened vigilance concerning allergen labeling and compliance, while also underscoring ongoing challenges within the sector.”

Bacterial contamination was identified as the second most common cause of recalls, impacting 16.37 million units in Q4. However, there are indications that stricter monitoring and compliance efforts have alleviated some risks. Foreign material contamination, including plastic, metal, and glass, continues to pose a serious threat, though the frequency of such recalls has not changed significantly.

Recently, Birds Eye in the UK had to recall Goodfella’s Stonebaked Thin Garlic Bread due to undeclared milk, posing risks for those with milk allergies or lactose intolerance. Conversely, in Australia, a major bakery brand recalled batches of croissants in September 2024 due to the presence of metal fragments. Canada also witnessed multiple recalls of granola bars and snack mixes from brands like MadeGood and Quaker due to Salmonella contamination stemming from nut-based ingredients in the latter half of 2024.

The scale and severity of these recalls highlight the necessity for manufacturers globally to remain vigilant and proactive in mitigating contamination risks. “Consumers today are more informed about food safety issues, and regulatory scrutiny is intensifying across the board,” Buckingham cautioned. “Neglecting to implement stringent quality control measures can lead to catastrophic financial and reputational consequences.”

High-Profile Recalls

In January 2025, FGF Brands, a supplier for major chains such as Dunkin’ Donuts, voluntarily recalled over two million doughnuts and pastries due to potential Listeria monocytogenes contamination. The recall affected 60 different products distributed across the United States and Canada. Although no contamination was found in the final products, the company opted for this precautionary action following non-product-related findings at one of its facilities.

In December 2024, Lay’s potato chips were recalled due to undeclared milk, raising alarm over allergen mislabeling, which remains the leading cause of food recalls. Earlier that same year, General Mills faced a significant recall of Gold Medal flour due to Salmonella contamination, marking one of the largest flour recalls in history and echoing previous incidents linked to bacterial risks within the flour sector.

The infant food sector also faced challenges, particularly when WanaBana recalled its lead-contaminated cinnamon applesauce pouches in 2023. Unlike most food recalls that arise from accidental contamination, this incident stemmed from deliberate economic fraud, where lead was added to increase weight and allow the seller to charge a premium price. This scandal prompted extensive regulatory scrutiny and reignited discussions regarding the need for enhanced food fraud detection measures.

Another significant recall occurred in late 2024, involving granola bars and cereal mixes from brands such as Quaker and Nature Valley contaminated with Salmonella. This recall affected numerous brands across North America, leading to a widespread reassessment of safety protocols for nut- and grain-based products. Additionally, Hostess had to recall several million units of snack cakes due to Listeria concerns, further emphasizing the ongoing risks in ready-to-eat bakery goods.

The Costly Consequences

The repercussions of product recalls can be devastating for manufacturers, leading to significant financial losses, reputational harm, and potential legal ramifications. Immediate costs include product retrieval, disposal, and replacement, as well as potential regulatory fines and legal fees. Furthermore, indirect costs such as lost sales and deteriorating consumer trust can persist long after the recall is resolved.

Negative media coverage exacerbates these challenges, complicating recovery efforts for brands following food safety incidents. Even in cases where a company voluntarily issues a recall, such as FGF Brands’ doughnuts, public perception of the brand’s reliability can suffer severely.

The legal and regulatory consequences of recalls are equally severe. In 2024, the US Department of Justice (DOJ) intensified its crackdown on food safety violations, imposing heavy fines and even criminal charges in select instances. Several food manufacturers faced charges for failing to report safety concerns, signaling to the industry that noncompliance will have serious repercussions. In the UK, the Food Standards Agency (FSA) increased inspections and enforcement actions, while the European Food Safety Authority (EFSA) established stricter regulations regarding cross-border food safety violations.

To avert recalls, manufacturers in the bakery and snack sectors must establish robust food safety protocols. “It’s crucial for manufacturers to remain alert to regulatory changes and implement rigorous safety measures,” advised Quinn. “Enhancing allergen management, improving sanitation protocols, and conducting regular microbial testing can significantly mitigate risks.”

Additionally, supply chain transparency plays an essential role in preventing recalls. Implementing thorough third-party audits and supplier verification programs ensures that ingredients meet safety standards before they are integrated into the production process. The adoption of AI-based detection systems and blockchain-enabled traceability solutions is gaining traction, enabling companies to identify potential risks before they escalate into significant recalls.

The magnitude and severity of recent recalls serve as a stark reminder for food manufacturers worldwide to remain vigilant and proactive in addressing contamination risks.

“Companies that disregard food safety are jeopardizing their reputation, financial stability, and may face legal consequences,” Buckingham warned. “Now, more than ever, prioritizing food safety is essential.”