Food recalls have increased over 20%. What is your business doing about it?

Food safety doesn’t take time off. 

In December 2024, as consumers across the country gathered for holidays with loved ones, news of over two dozen food recalls led to a flurry of flustered people who were trying to figure out the right grocery list and change their menus. Unfortunately, it also sent dozens of people to the hospital.

It’s no wonder that consumer trust in food safety is at an all-time low. That’s not hyperbole—it’s data from the 2024 IFIC Food & Health Survey. Confidence in food safety has dipped to 62%, down 8% from the previous year, and findings show nearly one-third of consumers (32%) are extremely concerned about foodborne illnesses like E. coli.

At the same time, a recent Gallup poll shows that only 39% of Americans trust the government to ensure food safety—a sentiment down from 47% in 2019.

For food industry businesses, these numbers directly affect their brand reputation, consumer relationships, and bottom line.

The business cost of food recalls

Food recalls are among the most disruptive and costly events for a food company. 

The average direct cost is $10 million, reflecting expenses related to logistics, legal fees, and public relations efforts. 

The immediate financial burden is only part of the story. A 2022 NielsenIQ survey revealed that 68% of consumers would stop buying from a brand after a food safety incident. Nearly half would share their negative experiences with others.

Depending on the severity of the recall, it can take 1–4 years for sales and consumer trust to return to pre-recall levels, as seen in cases like the 2009 peanut recall, which led to nearly $1 billion in lost peanut sales over several months.

Food recalls: New regulations, new challenges, and new opportunities

Food recalls are multifactorial—numerous elements contribute to their occurrence. Yet, with foodborne illnesses sickening 48 million people each year in the U.S., aggressive measures to curb them are imperative. 

At the beginning of 2025, dozens of new regulations at the state level were implemented, all to address food safety issues. Similarly, new federal legislation was proposed to protect consumers against salmonella and other contaminants. This includes:

• Food Safety Modernization Act (FSMA) Section 204 (enacted): This new rule mandates that businesses dealing with high-risk foods establish measures to create comprehensive food traceability plans and log tracking events and key data elements. 

Read the guide to how FSMA 204 will affect you.

• Salmonella Framework for Raw Poultry Products (proposed): The Food Safety and Inspection Service's proposal would establish product standards to prevent raw poultry products containing specified levels or strains of Salmonella from entering the market.
  
   
• Keep Food Containers Safe From PFAS (proposed): Recently reintroduced legislation designed to prevent the use of PFAS in food containers. Found in greaseproof, waterproof, and nonstick products, PFAS can contaminate food and lead to serious health complications. 

These regulations are necessary to prevent food safety issues, but compliance can require hefty organizational effort. Moreover, change is difficult when businesses are already busy dealing with supply chain disruptions, labor shortages, and inflationary pressures.

So, when a single solution can address multiple issues, it’s important to give it fair consideration. 

The role of packaging in food safety and recalls

Packaging plays a much bigger role in food safety than many realize. In an industry where cardboard boxes are still the go-to solution, the juxtaposition of high food recall rates and emerging regulations emphasizes the need for a better packaging product. 

When it comes to recalls, there are two main issues with cardboard packaging: construction and traceability.

Construction

As a paper product, corrugated boxes are highly susceptible to moisture absorption, especially for fresh produce and meats, even when the boxes are waxed. Moreover, because they are poorly ventilated, they don’t cool products (such as eggs or leafy greens) quickly. 

This creates an environment conducive to bacterial growth and increases the risk of contamination. The greater the risk of contamination, the greater the chance of recalls. 

Traceability

Preventing situations where a recall might be needed is one thing. Still, once a recall has occurred, businesses must respond quickly to mitigate safety risks. 

Single-use packaging complicates this process. Unlike reusable packaging solutions, traditional corrugated boxes lack built-in traceability features, making it difficult to identify and isolate contaminated products.

This can lead to broader, more costly recalls as companies err on the side of caution and destroy thousands of dollars worth of product to try to avoid outbreaks. 

How packaging bridges recalls and loss prevention

Dealing with a food recall costs a lot, and a fair share of it goes into crisis response support. 

Yet what if those funds were put towards earlier mitigation? 

The financial benefits of investing in modern packaging solutions are substantial. For example, improved traceability can cut recall costs by up to 80%, potentially saving tens of millions of dollars for a single avoided widespread recall.

Minimize contamination risks and product loss

Packaging solutions like reusable plastic containers (RPCs) prevent and reduce food safety risks and reputational damage. Unlike corrugated, the non-porous construction minimizes exposure to bacteria, moisture, and environmental contaminants. 

This is particularly important in the produce, meat, and seafood sectors, which have higher contamination risks and increased regulatory oversight.

RPCs are also a cost saver: Designed to be sturdier, RPCs protect the food better than corrugated boxes. In turn, businesses see a positive impact in rejections; improving their bottom line. 

Get ahead of the recall curve with traceability

Speed is one of the most critical elements in recall management—every hour counts. But taking advantage of time requires traceable packaging solutions so batches can be quickly isolated and costly recalls avoided. 

Both active and passive traceability play a part:

• Active tracking (e.g., IoT sensors) traces food in real-time through the supply chain. This kind of traceability increases asset visibility at all times, helping businesses see location, environment, temperature, and more, which expedites recalls and minimizes loss. 
• Passive tracking (e.g., RFID sensors) provides historical data on products, which proves vital in tracking product origin, manufacturing details, and batch performance over time​.

Packaging can be a strategic advantage

By improving safety measures and responsiveness through packaging choices, companies strengthen their reputations for reliability and care. When consumers are confident in the safety and quality of a brand's products, they're more likely to stay loyal to that brand—even when the market is volatile. 

Packaging choices like RPCs also build better partner relationships. Just like consumers, when partners trust your commitment to reducing risks, preventing losses, and upholding compliance requirements, you position yourself as a preferred partner

Proactive measures: The key to reducing food recalls

At Tosca, we help businesses meet today’s food safety challenges with innovative packaging systems and traceability solutions. Our reusable containers are designed to be traceable, safer, reduce costs, and improve operational efficiency. By taking measurable steps now, you can protect your supply chain and create a safer, more trusted brand.

Visit toscaltd.com to learn how Tosca can help your business take action on food safety.