Product Recalls Dip Slightly But Remain Historically High: Sedgwick

Product recalls across five major industries saw a slight dip in 2024, yet the total number of events marked the second-highest annual figure in six years, according to the Sedgwick State of the Nation 2025 Product Safety and Recall Index.
Across five major industries, there were 3,232 recalls, representing a 2.1% decrease from the 3,301 events recorded in 2023, which was the highest total in recent years. The total volume of recalled units fell by 10.3%, from 759.36 million in 2023 to 680.87 million in 2024, marking the lowest annual total since 2015, according to the index.
Notable Sector Performance and Challenges
The product recall landscape across major industries reveals persistent challenges and emerging trends that are shaping the safety and quality control measures in various sectors.
Automotive: The automotive industry showed signs of improvement, albeit with mixed results, Sedgwick found. The number of units affected by recalls decreased to 31.98 million in 2024 from 38.43 million in 2023. However, the industry still maintained a high number of recall events, with 988 recorded in 2024 – the third-highest total in a decade for this sector – up from 916 in 2023. Electrical systems was the leading cause of automotive recalls in 2024, accounting for 194 events, which was the highest for this category in five years.
Consumer products: The consumer products sector experienced a significant impact in 2024, with 80.9 million units affected by 299 recalls. While down from 2023’s 135.2 million units recalls in 322 events, the 2024 volume of units affected still marks the second-highest total in seven years, highlighting the ongoing challenges faced by manufacturers in this industry. Fire risk was the leading cause of consumer product recalls in 2024, Sedgwick reported, accounting for 65 events.
Children’s products also saw a substantial impact, with 2.35 million units recalled. A single recall involving children’s swings accounted for the majority of this volume, the report noted. Electronics rounded out the top three consumer product categories by unit volume, with 1.52 million items recalled. Space heaters and power banks were the main culprits in this category, accounting for 1.05 million of the recalled units, Sedgwick reported.
Food and drink: The food industry experienced its own set of challenges in 2024. While U.S. Food and Drug Administration food recalls for the full year were down 2.2% to 495 and total units impacted by food recalls dropped 66.9% to 66.2 million, the fourth quarter told a different story. FDA food recalls saw an 18.9% increase in Q4 compared to the previous quarter, totaling 132 events. Similarly, total impacted units skyrocketed by 357.6% in Q4, reaching 21.15 million units, according to Sedgwick.
This increase was largely driven by several high-impact recalls, with five separate events each affecting more than 1 million units. Among these, a single recall of frozen breakfast products, including waffles, pancakes, and cakes, accounted for 9.91 million units.
Pharmaceutical: In contrast to other high-impact sectors, pharmaceuticals experienced a decline in recall activity. In addition to the sector’s lowest unit recall in over a decade, the total number of recalls decreased by 31%, dropping to 356 in 2024 from 517 in 2023.
Medical devices: The year saw a substantial increase in medical device recall activity, according to the index. The sector recorded a 8.6% rise in recalls to 1,059 events, up from 975 the previous year, with 440.41 million units recalled in 2024, up from 283.44 million in 2023.
Access the full index on the Sedgwick website. &