Despite new regulations, food safety programs, and third-party audits, food and beverage recalls are expected to reach a five-year high. This raises a crucial question: Why are we witnessing such a significant rise in food safety and quality issues? What underlying factors are contributing to this trend?

Drawing on 30 years of experience in operations and quality management—combined with insights gained from handling numerous recalls, market withdrawals, and investigations—the author has identified a list of precursors that, if identified and addressed, could close critical gaps and help organizations prevent costly recalls.

Precursor 1: Leadership

Leadership is not just the cornerstone of an organization's success, but also the key to preventing some of the greatest challenges. It all starts at the top—with the Board of Directors, the CEO, and the executive team, who are responsible for setting the vision, aligning strategies, and allocating the resources and capital needed to drive the company's mission. When leadership places equal emphasis on critical areas such as food safety, quality, sanitation, and maintenance, the results can be transformative.

One of the biggest challenges occurs when leadership prioritizes output at the expense of these foundational elements. In many cases, organizations may achieve short-term gains in productivity, but they also introduce hidden risks that can lead to operational vulnerabilities. These can manifest as product failures, recalls, or compliance issues that erode trust and impact the bottom line. On the other hand, I have also seen leadership teams adopt an overly conservative approach, where excessive caution hinders innovation and progress. In both scenarios, the absence of balance between growth and operational integrity often results in setbacks.

To succeed, companies must take a balanced, strategic approach that values both operational efficiency and the pillars of food safety and quality. Strong leadership ensures these principles are not just side concerns, but integral to the overall business strategy. This means investing in systems, training, and resources that drive both high performance and adherence to essential food safety and quality standards. Leaders who actively engage with their teams, ask the right questions, and maintain clear priorities inspire a culture of accountability and continuous improvement.

When leadership aligns food safety, quality, and operations, the entire organization benefits. Risks are minimized, consumer trust is protected, and operational efficiency improves—ultimately enhancing the company's brand reputation and market position.

Effective leadership is about more than just driving output; it is about aligning strategy with core operational values like food safety and quality. Companies that strike this balance outperform competitors, reduce risk, and build stronger brands that stand the test of time.

Precursor 2: Culture

A company's culture can be both its greatest strength and its biggest challenge, especially in the food and beverage industry, where operational risks are high. Unfortunately, when leadership falls short of developing a strong culture in certain key areas, it can lead to costly failures. One of the most common pitfalls is the lack of engagement from leadership. When CEOs and department heads are not visible on the manufacturing floor, it sends a message of disconnect, creating a culture where missed opportunities and unresolved issues thrive. Even worse, when employee concerns are met with negative reactions or suppression, it discourages openness and stifles innovation. Leaders who push their own agenda rather than focusing on the organization's core values can ultimately set the company on a path toward failure.

Another significant challenge is having a culture that lacks discipline and allows for the inconsistent execution of policies and procedures. While most policies are designed to ensure operational and food safety efficiency, the failure to consistently follow them is a recipe for disaster. Complex or overly long procedures can contribute to poor execution, but the allowance of change without a solid change management process is worse. Without a system to track and manage procedural changes, businesses risk compounding problems or creating new ones without realizing it.

To succeed, companies must start with visible and engaged leadership, beginning at the CEO level. When executives actively engage with employees on the manufacturing floor, they not only build stronger relationships but also gain crucial insights into what's working and what needs attention. Open dialogue allows employees to express concerns, share successes, and feel empowered to contribute to the company's mission. A CEO who leads by example, emphasizing the importance of food safety, quality, and compliance, fosters a culture where these values are non-negotiable.

“A strong company culture, driven by visible leadership and adherence to core values, is essential for minimizing risks and fostering excellence in the food and beverage industry.”

Moreover, success requires discipline in following policies and procedures, promoting interdepartmental collaboration, and creating an environment of psychological safety where employees feel comfortable escalating issues. Companies that encourage continuous improvement and allow for constructive feedback are better positioned for long-term success.

A strong company culture, driven by visible leadership and adherence to core values, is essential for minimizing risks and fostering excellence in the food and beverage industry. When leaders actively engage, support employee contributions, and maintain a focus on food safety and quality, companies unlock the potential for continuous improvement and innovation.

Precursor 3: Infrastructure and Equipment

Infrastructure and equipment are the backbone of any food and beverage manufacturing operation, but when the health of these components is not rigorously monitored, it becomes a significant source of risk, especially for recalls. The facility's infrastructure—such as roofs, floors, drains, walls, ceilings, lighting, and essential utilities—are critical components to be inspected. Without proper monitoring and maintenance, these elements can deteriorate without immediate signs, leading to future failures, costly downtime, and potential regulatory non-compliance.

An equally important challenge lies in the health of production equipment. While following OEM-recommended maintenance is essential, companies sometimes reduce maintenance activities or use non-OEM parts to save on costs. Although these cost-saving measures might seem effective in the short term, they can significantly increase the risk of breakdowns, inefficiencies, and contamination and shorten the life of the equipment. In the long run, this approach may jeopardize not only production but also food safety and quality standards, leading to significant consequences.

For companies to mitigate these risks and ensure long-term success, ongoing, detailed assessments of equipment health must be prioritized. Leveraging technology, such as sensors and predictive analytics, can provide real-time insights into equipment performance, detecting early signs of wear and allowing proactive measures to be taken before failures occur. This approach goes beyond simple maintenance; it involves data-driven, predictive diagnostics that enable corrective actions well in advance of potential breakdowns.

Ensuring that all components are carefully monitored and maintained is key to a seamless, risk-reduced operation. Cross-functional collaboration among operations, maintenance, and quality assurance teams is essential to develop an integrated approach to equipment health. Additionally, empowering employees through ongoing training ensures they can identify issues early, further reducing risk.

When companies invest in the health of their infrastructure and equipment, they not only protect the integrity of their manufacturing processes but also foster a culture of employee and food safety, quality, and sustainability. A proactive approach to equipment health reduces operational risks, boosts efficiency, aligns with regulatory requirements, and strengthens the organization's commitment to long-term excellence.

Precursor 4: Sanitation

Sanitation is sometimes overlooked or under-prioritized in manufacturing operations, yet it is critical to ensuring food safety and quality. In my experience, sanitation practices vary widely—some companies have highly organized and consistently executed sanitation programs, while others rely on skeleton crews or even temporary labor. When sanitation is not treated as a cornerstone of operations, it can be the precursor for major failures, extended downtime, and a dramatically higher risk of recalls.

The challenges begin when sanitation is viewed as secondary. When companies downplay its importance, discipline erodes—corners are cut, shortcuts become routine, and the master sanitation schedule begins to slip. Over time, this neglect compounds: sanitation cycles are reduced or skipped altogether, and the percentage of completion on the sanitation schedule drops. Eventually, the cracks show, finished product quality deteriorates, and in the worst-case scenario, issues are discovered only after the product has shipped, triggering costly and reputation-damaging recalls.

Successful companies recognize that sanitation is not an afterthought but a foundational element of manufacturing. They actively collaborate with cleaning chemical suppliers and maintain a robust sanitation program that complements their operational and quality initiatives. This disciplined approach not only reduces consumer safety risks but also leads to increased product quality, minimized downtime, and greater production efficiency. Companies that prioritize sanitation also benefit from fewer product failures, better yields, and overall improved performance.

Sanitation is more than just a cleaning process—it is a critical component of operational success. Companies that treat sanitation with the same importance as production and quality see fewer failures, reduced downtime, and greater efficiency, positioning themselves for long-term success and improved product yields.

“When maintenance is neglected or deviates from the manufacturer's recommended frequencies and materials, it becomes a major contributor to recalls and operational failures.”

Precursor 5: Maintenance

Maintenance, whether reactive or preventive, is a critical factor in the success of any manufacturing operation. When maintenance is neglected or deviates from the manufacturer's recommended frequencies and materials, it becomes a major contributor to recalls and operational failures.

Unfortunately, some companies reduce or modify maintenance schedules without fully understanding the risks, leading to costly breakdowns, extended downtime, and even the possibility of product recalls.

Beyond simply following the manufacturer's recommendations, companies must consider the specific conditions of their operations. Factors such as extended production runs, changes in cleaning and sanitizing protocols, and excessive use of equipment can cause accelerated wear and tear. These variables necessitate adjustments to maintenance schedules to prevent premature equipment failure. Ignoring these factors can significantly increase the risk of unscheduled stoppages and safety hazards.

Another challenge lies in the skill level of the maintenance team. High employee turnover, a common issue in many industries, creates knowledge gaps that can lead to improper maintenance procedures. When teams rely on junior or less experienced staff without adequate training, mistakes are more likely. The use of incorrect components or improper maintenance techniques not only accelerates equipment wear but can also result in premature failures, which, in turn, introduce a cascade of problems, from operational inefficiencies to compromised product safety.

For companies to achieve success, they must implement comprehensive preventive maintenance programs that adhere to OEM guidelines while also considering the specific demands of their production environment. This includes using proper components and consumables and ensuring ongoing training for maintenance staff to bridge any knowledge gaps. Furthermore, companies should regularly reassess how operational factors, such as production cycles and sanitation practices, impact the wear and tear of their equipment. By taking these preventive measures, companies can reduce mechanical failures, minimize downtime, and protect both their products and consumers.

A well-executed preventive maintenance strategy is vital to minimizing equipment failures and safeguarding product integrity. Companies that prioritize proper maintenance schedules, high-quality components, and continuous training prepare themselves for fewer disruptions, better efficiency, and stronger consumer safety.

Takeaway

Effectively managing critical precursors such as leadership, company culture, infrastructure, sanitation, and maintenance is vital to minimizing risks and preventing costly failures. Companies that foster a strong culture of innovation, continuous improvement, and accountability can turn these challenges into competitive advantages. With strong leadership that prioritizes collaboration, strategic partnerships, and robust processes, businesses can reduce risks while enhancing operational efficiency, food safety, and quality. Organizations that embrace a leadership-driven, culture-focused approach are well-positioned for sustained growth and long-term success.

Part 2 of this article series, to be published in the February/ March 2025 issue, will examine additional precursors to failure and share guidance for failure prevention to avoid costly recalls, damage to brand reputation, and the possibility of consumer harm.

References

1. Weinroth, M.D., A.D. Belk, and K.E. Belk. "History, development, and current status of food safety systems worldwide." Animal Frontiers 8, no. 4 (August 2018): 9–15. https://doi.org/10.1093/af/vfy016.
2. Encyclopedia.com. "Nicolas Appert." May 21, 2018. https://www.encyclopedia.com/people/food-and-drink/food-and-cooking-biographies/nicolas-appert.
3. Encyclopedia Britannica. "Pasteurization, heat-treatment process." 2024. https://www.britannica.com/technology/pasteurization.
4. Amiri, F. Food Safety & Quality Assurance: A Survey of Food Laws & Regulations. Seattle, Washington: Kindle Books. 2023. https://www.amazon.com/dp/B0C2WDHFWG.
5. World Health Organization. "WHO Estimates of the Global Burden of Foodborne Diseases." 2015. https://iris.who.int/bitstream/handle/10665/199350/9789241565165_eng.pdf.