Why are food manufacturers failing more at food safety?

Photo by Anna Shvets
No matter what industry you’re in, you’re going to want to do whatever you can to minimise the risk of getting into legal trouble, right? Well, even though that is common sense, there are more than enough businesses and industries that seem to constantly break compliance and wind up needing legal assistance. Actually, the food manufacturing industry is a great example.
So, the food manufacturing industry is hitting record profits globally, but with those financial highs, there’s a troubling undercurrent: food safety failures. Recent headlines have revealed serious contamination issues, from E.coli outbreaks to unsanitary factory conditions that no one expected (and even in the US, unlawful child labor in meat processing plants).
These failures not only threaten public health but also damage the reputation of companies that were once trusted. And yet, food manufacturers and processors continue to miss the mark in safeguarding the food supply chain. Why is this happening, and what needs to change?
As everyone knows, food safety should be a non-negotiable priority for any manufacturer, but too often, it seems to slip through the cracks—sometimes with dire consequences. So, let’s break down why food manufacturers need to step up their game and focus more on food safety and what’s really going wrong behind the scenes.
Understanding the growing crisis of contaminated food
There have been alarming trends in recent years, with the West making the most of the news, where food safety issues are surfacing more frequently. For example, in 2023, a Nestlé factory in France was linked to a tragic E. coli outbreak after contaminated frozen pizza caused several illnesses and even resulted in the deaths of two children.
But sadly, there’s been similar issues have occurred across major manufacturers, raising serious concerns about the quality control processes in place. And it’s not just bacteria — dead insects and unsanitary conditions in food factories are also being reported with shocking regularity.
Despite these safety failures, the food manufacturing industry continues to thrive financially. But while profits soar, so do the risks to public health. Overall, these manufacturers must shift their focus from purely profit-driven motives and reinvest in better safety practices to avoid scandals and prevent harm.
But why the safety failures in the first place?
The reality is that food manufacturers are so focused on maximising production that corners are cut when it comes to safety. What’s shocking is that despite these safety failures, the food manufacturing sector continues to see record profits (just like what’s been mentioned before). One might wonder: why isn’t the money being reinvested into better safety protocols?
High profits vs. low standards
So, it’s not that food manufacturers can’t afford to implement better safety measures—many simply don’t prioritise it. At the end of the day, these are businesses, but with profit margins being the ultimate goal, safety inspections and audits might feel like a hassle rather than a priority.
Unfortunately, this approach can backfire when contaminated products lead to expensive recalls and lawsuits. However, for some, especially the major companies such as Nestle, it’s nothing more than a drop in the bucket for them.
Why food manufacturers fail food safety audits
For many manufacturers, the dreaded food safety audit is a real pain point. Now, nearly all industries have some sort of compliance they need to adhere to, and that usually includes audits as well. These audits are designed to ensure that food manufacturers are adhering to strict safety regulations, but they can expose major gaps in operations.
When these audits fail, the consequences range from costly fines to facility shutdowns. So why do so many manufacturers struggle with food safety audits?
Lack of proper training
One of the most common reasons manufacturers fail food safety audits is the lack of training among staff. Thats almost always why most businesses fail some sort of audit, as employees just don’t get the training that they need. While sure, machinery and automation have improved production speeds, they can’t replace the human element needed for proper sanitation and safety oversight.
To be more specific about this, employees may not fully understand proper sanitation practices, leading to contamination risks that go unchecked. If they’re not trained on this, how are they going to know what’s right and wrong?
It’s obvious that training should be a priority, but many manufacturers cut corners, leaving their workforce ill-prepared to handle safety issues effectively. Generally speaking, workers need to be trained extensively in safe food handling practices, recognising contamination risks, and understanding how to maintain clean environments in food production.
Poor record keeping
Just about all industries do this, but accurate and consistent record-keeping is essential for passing audits, yet many companies fail to maintain the necessary documentation.
Yes, a lot of food manufacturing plants tend to fail this! So, this lack of organisation makes it difficult to track safety protocols and increases the likelihood of contamination going unnoticed. Without the proper records, manufacturers have no way to prove their compliance during audits.
Unsanitary conditions
Now, this one might just be the biggest of them all, and one of the main reasons (next to lack of training) on why food contamination is such an issue. So, unsanitary working environments, including unclean machinery and improper storage conditions, remain one of the biggest reasons for audit failures. Bacteria such as E.coli can thrive in unsanitary environments, leading to widespread contamination of food products.
Even with automation, human error or neglect can cause harmful bacteria or foreign objects to end up in food products, which can be disastrous for both the company and consumers. A great example of this would be a recent news story about the Ferrero factory in Belgium being investigated.
It was revealed that severe Salmonella contamination resulted from unsanitary conditions. This is exactly what leads to lawsuits, fines, and other serious consequences, such as the shutdown of entire plants.
Inconsistent compliance with safety standards
While this one might seem like low hanging fruit because it’s so similar to the one tied just right above, some food manufacturers and processors (major companies being a prime example) have this idea that they can take shortcuts, which immediately leads to constant inconsistent compliances being broken.
Now, there are different safety standards, both global safety standards and local/ regional based ones as well; for example, there’s the Global Food Safety Initiative, and there’s even certification food manufacturers can get for this (same for other organisations too), and there are plenty of outlines and guidelines to achieving the proper steps to achieving GFSI Supplier Compliance. In the first place, manufacturers and processors need to follow all of these factors.
Unfortunately, many fall short due to a lack of understanding, a lack of caring (usually due to shortcuts and maximizing profits), and inadequate systems in place from the start to track compliance.
But what’s the true cost of ignoring food safety?
This one was briefly mentioned earlier, but then food safety isn’t taken seriously, and the consequences extend beyond legal repercussions. You have to remember that foodborne illnesses are responsible for millions of cases of illness and even deaths each year.
Contaminated products can lead to costly recalls, lawsuits, and irreversible damage to a company’s reputation. For smaller food manufacturers, a major safety scandal can lead to bankruptcy.
Public health impact
The most obvious and devastating consequence of poor food safety practices is the impact on public health. Contaminated food can cause outbreaks of foodborne illnesses, affecting thousands of people. The most vulnerable, such as children, the elderly, and those with weakened immune systems, are often hit the hardest.
Financial repercussions
Recalls, legal fees, and settlements from lawsuits can cost food manufacturers millions of pounds. In some cases, these expenses are so high that they can drive a company out of business. But even more costly is the long-term damage to a brand’s reputation.
Once consumers lose trust in a company, it’s nearly impossible to win them back. Just like what was mentioned earlier, sometimes these fines won’t make a difference, with Unilever and Nestle being a great example consider how large they both are.
Can technology improve food safety standards?
Needless to say, there’s a lot of advancements in technology, there’s no excuse for poor food safety practices. Automation, artificial intelligence, and real-time monitoring systems can all be used to ensure food safety standards are met consistently. Especially when it comes to AI, since that alone is helping technology speed up fairly quickly.
Real-time data tracking
So, one of the key benefits of technology is the ability to track food safety practices in real-time. Manufacturers can use digital portals to collect and analyse data from every stage of production, ensuring that any potential contamination is caught and resolved immediately.
Predictive analytics
Another powerful tool is predictive analytics, which allows manufacturers to identify trends and potential risks before they become major issues. By analysing historical data and current conditions, companies can make informed decisions to prevent contamination and safety breaches before they occur.
But what needs to change?
It should be simple enough, right? In order to truly make a difference in food safety, food manufacturers need to prioritise training, sanitation, and record-keeping. They should implement regular safety audits and adopt technology that ensures constant compliance with safety standards. These businesses can still reach profits without having to make any shortcuts or sacrifices, so it really is just a choice of greed or not.