In the food and drink industry, maintaining robust packaging standards is absolutely essential and yet, things still go wrong with surprising frequency.
The vast majority of incidents on the UK market involve incorrect allergen labelling in a product’s ingredient description.
Often, the allergen isn’t emphasised in bold, as is required by law, or is missed out entirely. In some cases, products are labelled correctly, but in a foreign language.
Such mislabelling can have severe — even life-threatening — consequences for those with allergies.
Financially, too, robust and secure packaging is vital for any food and drink business, helping to preserve a product’s flavour, freshness and quality during manufacturing, shipping and in-store display.
So, given how pivotal good packaging is to the entire food and drink supply chain, why do things still go wrong at the highest levels – and how do manufacturers mitigate these risks?
Good labelling saves lives
In the grand scheme of things, labelling errors are quite rare – but they are far and away the leading cause of food and drink recalls on the British market.
To avoid the the aforementioned issues that can arise as a result of labelling errors, manufacturers must ensure that the labelling process goes through a series of failsafe checks before goods are sent out to retailers.
Naturally, most producers will already be operating this way – but the non-negligible number of recalls due to incorrect labelling illustrates that many firms simply aren’t up to speed.
“We always advise our clients: safe, legal and scalable product developments make for commercial growth,” Ruth Dolby, director at Food Science Fusion told Food Manufacture.
“Missing any one of those steps can result in unwarranted costs, both financially and reputationally, that will create damaging ripple effects and, in some cases, have been known to close businesses."
“Product recalls and notifications from Trading Standards cost companies more than just immediate cashflow losses and operational disruption. To mitigate this, good producers now use multiple verification checks, including artwork approval systems and production line inspections, because packaging is not just about branding; it is a critical part of consumer protection and food safety compliance.”
“It is absolutely critical,” added Mark Riley, head of regulatory, Europe and Africa at NSF.
“Labels are not just marketing tools; they are a primary food safety control. For consumers with allergies, a missing or poorly emphasised allergen can cause serious illness or even fatal reactions. Food recalls linked to labelling errors in the UK, particularly undeclared or incorrectly declared allergens, remain a continuing issue, with 89 allergen alerts issued in 2025.”
He continued: “Businesses should treat label approval with the same rigour as any HACCP control: checking artwork, recipes, supplier changes, translations and print runs before product release.”
Quality control is king
Not all recalls are linked to poor labelling, however – and although even rarer than allergen alerts, packaging defects do still occur.
Not only are these embarrassing for manufacturers, they can pose genuine risks to consumers and, once again, can be immensely damaging for brand reputation.
Choosing the right materials for the job at hand is perhaps the most important aspect of packaging design.
As seen recently, a drinks brand owned by England rugby star Johnny Wilkinson was forced to recall one of its kombucha products because of bursting bottle caps.
The materials used for the recalled batch of Wilkinson’s One Living drinks simply couldn’t handle the kombucha’s fermentation process. And while this was an error on the drinks side, it raises the question of whether more robust bottle materials might have withstood the pressure.
The issue of structural integrity is a recurring theme – with Dalston’s also forced to recall some of its products after cans containing its Pineapple Soda were found to break apart, exposing sharp edges. In this regard, this is clearly an issue of quality.
In both cases, the fault may lie primarily with the packaging manufacturers, but more rigorous checks by brands may have nipped issues in the bud.
“Packaging integrity is critical to food safety, quality and shelf life,” explained Sion Titley, solutions specialist at Bizerba.
“Defects can occur due to issues such as poor sealing, damaged materials, equipment wear or contamination during production. Even small faults can allow air or bacteria to enter the package, increasing the risk of spoilage and recalls.
“Manufacturers can reduce these risks through stringent quality controls and automated inspection technologies that check seal integrity, fill levels and packaging consistency in real time. Early detection helps prevent defective products from reaching consumers and protects both brand reputation and product quality.”
This need for manufacturers to conduct rigorous checks and testing is echoed by Dolby: “Manufacturers should carry out extensive testing on seals, durability, and barrier performance to ensure packaging remains effective under different conditions, including logistics.
“However, defects can still occur due to machinery faults, damaged materials, supplier quality issues, errors during high-speed production or issues with handling during transportation. In many cases, recalls happen because compromised packaging can affect product safety or shelf life.”
Intelligent leak detection transforms food packaging safety and efficiency
Food manufacturers are increasingly adopting automated leak detection systems to improve product quality, reduce waste, and meet stricter food safety requirements. Traditional methods, such as random sampling and destructive testing, can miss packaging defects, allowing leaks to compromise freshness and shelf life. Bizerba’s LeakSecure reflects a growing industry shift toward 100% in-line inspection, enabling every package to be checked in real time without slowing production.
Designed for Modified Atmosphere Packaging (MAP) applications, LeakSecure uses controlled pressure and advanced CO₂ sensors to identify leaks, weak seals, and micro-perforations that are becoming more common as packaging materials become lighter and more sustainable. The system also helps manufacturers identify recurring process issues and improve packaging performance.
By integrating leak detection with visual seal and label inspection, Bizerba’s LeakSecure supports comprehensive quality control within a compact footprint. Automated monitoring, rejection, and reporting enhance traceability, reduce operational costs, and simplify adoption across existing production lines.
Click here for more information about Bizerba.
The impact of inflation
We have seen how vital correct labelling and packaging integrity can be in maintaining a product’s quality, but another increasingly important area is the role of packaging in extending shelf life.
Naturally, losing stock because of poor packaging quality would be a nightmare for any manufacturer, but as food and drink inflation continues to rise, shelf life is becoming increasingly important.
With stock increasingly at a premium amid global supply chain instability, using the latest developments in packaging technology to extend freshness will only grow in importance – both economically and in terms of sustainability, helping to reduce food waste.
“Packaging innovation is becoming increasingly important as consumers look for ways to reduce food waste and make products last longer at home,” said Dolby.
“According to the FAO, roughly one-third of food produced globally is lost or wasted, which has driven increased focus on shelf-life innovation. Many packaging companies are developing high-barrier materials and modified atmosphere packaging technologies that help slow spoilage by reducing exposure to oxygen and moisture.
“Resealable packaging is also growing in popularity because it helps maintain freshness after opening. There is also increased investment in so-called ‘active packaging’, which can include oxygen absorbers or antimicrobial technologies designed to extend shelf life further.”
Spotlighting the financial benefits of more advanced packaging, Dolby continued: “With food prices continuing to rise, packaging is now seen as far more than just product presentation. It is an important tool in preserving food quality, improving convenience, and helping consumers reduce waste.”
In an increasingly unstable economic landscape, this highlights the vital importance of advances in packaging technology.
Despite all the recalls we see across the industry, the UK F&B sector has done an incredible job of ensuring the food and drink we consume is safe and of high quality. While innovations such as vacuum packs have given way to long shelf and alternative materials continue to improve.
Sustainability is the next frontier and manufacturers have already begun to adapt; but more will be asked of them over the coming years as calls to cut food, packaging waste and pollution grow louder.
