How food contamination & product recalls impact brands

No one plans for a food contamination event and product recalls!

Each January, food manufacturers around the world set ambitious goals for growth and success. They should also factor into their plans the need to avoid food contamination and product recalls. The damage caused by such events doesn’t just endanger the health of your consumers and impact your bottom line in the short term; it can irreparably harm your brand's reputation.

You’ve probably read about recent high-profile cases where foreign matter, namely fragments of metal, were discovered in frozen chicken nuggets, bagels and granola bars. We won’t name names - because these brands have suffered enough damage - instead, put yourself in their shoes. Imagine discovering that a customer has found a foreign object in your product. Now imagine the cascade of consequences: pulling products off shelves, issuing apologies, dealing with both financial and reputational fallout. And that’s if you’re fortunate enough to have caught it before anyone was harmed.

The reality is that no business is immune. But, by learning from these cases, you can take proactive steps to avoid a similar fate.

Why product recalls happen and the impact on brands

A product recall is up there in the list of a food manufacturer’s worst nightmares. They occur when food contamination - be that microbial, chemical or physical - compromises the safety of your products. While microbial contamination like Salmonella or E. coli often grabs headlines, foreign matter contamination can be just as serious - and we discussed the most common types of foreign matter contaminants in this article.

The sources of foreign matter contamination can include:

Broken equipment: fragments from tools or machinery falling into food during processing.

Human error: personal items, improperly handled equipment or PPE enter the production lines.

Packaging defects: pieces of packaging material mixing with food products.

As soon as a contaminant is discovered - or even suspected of being present - production has to stop. If the affected food is already out in the marketplace, there have to be product recalls.

The ripple effects of product recalls

A product recall doesn’t end with removing contaminated items from shelves. It triggers a chain reaction of negative consequences, including:

Erosion of consumer trust: once trust is broken, it’s hard to rebuild. Customers may switch to competitors permanently.

Operational disruption: recalls divert resources and cause delays in production and distribution.

Financial toll: from the recall process to potential legal fees and lost sales, the damage to your bottom line can be significant.

Regulatory consequences: recalls invite greater scrutiny, increasing the risk of fines and mandatory changes to processes.

These effects ripple through every aspect of your business, making prevention a crucial focus for food manufacturers.

How to prevent foreign matter contamination

The good news is that contamination risks can be significantly reduced with the right systems and practices. Here’s how you can protect your brand from the dangers of foreign matter contamination:

A) Implement robust training programs

Educate your team on food safety protocols, including proper handling of tools and PPE. Employees are your first line of defence against contamination.

B) Invest in detection systems

Metal Detectors and X-Ray systems are essential tools for identifying foreign matter in food products. Regularly maintained and calibrated, these devices can catch contaminants before they leave the facility.

C) Conduct regular maintenance

Inspect and repair equipment to prevent wear and tear or breakdowns which could introduce foreign matter into production lines. Preventative maintenance helps to significantly reduce risks.

D) Use detectable products

Integrate detectable tools and supplies into your operations to make the best use of your Metal Detectors and X-Ray systems. From pens and knives to tags and ties and beyond, Detectamet’s detectable products help you minimise the risk of foreign objects entering your workflow.

How Detectamet products help you prevent food contamination

Detectamet is the global leader in detectable products for food safety, offering solutions that integrate seamlessly into every stage of food production. Our range is designed to help you minimise food contamination risks and maintain compliance with industry standards like HACCP and BRCGS.

Made with our unique FDA and EU food contact approved polymer, our extensive range of detectable products includes:

PPE

Our award-winning Metal Detectable Nitrile Gloves and our detectable beard snoods, hairnets and facemasks are essential for protecting both employees and food products. Designed for safety and comfort, these detectable products ensure that even if a shred of PPE enters your food production pipeline, it can be quickly detected and removed.

Stationery and Tools

From our market-leading elephant pens to safety knives and from scoops to heavy-duty scissors, our detectable stationery and tools also feature our food-safe detectable polymer. They were designed to cater to the demands of our customers and, as such, they make good food hygiene as easy and convenient to achieve as possible.

Calibration Test Pieces

Detectamet’s wide range of calibration test pieces help keep your detection systems running at peak performance. By using test pieces regularly, you can help ensure accurate results and maintain compliance during audits.

Customisable Solutions

Every facility has unique needs, which is why Detectamet offers tailored solutions to meet them. Whether it’s our selection of sequentially numbered products for traceability, pad printing to comply with your branding and safety protocols or bespoke detectable products, we’re here to help.

Prevention is the best protection

By prioritising food safety and taking preventative measures, you are doing everything you can to protect your business and reputation from the dangers of foreign matter contamination and the damage wrought by product recalls.

At Detectamet, we believe that food safety doesn’t happen by accident. It’s the result of careful planning, robust systems and the right tools.

By investing in detectable products and aligning with global standards, you can safeguard your operations and provide peace of mind to your customers.

Ready to protect your brand in 2025?

Detectamet is committed to excellence because food safety doesn’t happen by accident - it happens with care, consistency and the right tools.

You can check out our world-leading range of Metal Detectable and X-Ray Visible food hygiene resources right here. And, if you have a specific, bespoke requirement, get in touch with us here.