U.S. product recall activity increased in 2025, with both the frequency of recall events and volume of defective units rising year-over-year, according to Sedgwick's 2026 State of the Nation U.S. Product Safety and Recall Index report.
In fact, a total of 3,295 recalls were recorded across the automotive, consumer products, food and beverage, pharmaceutical, and medical device sectors, up slightly from 3,232 in 2024. For context, only three years in the past decade have recorded a higher number. The increase in defective units was more significant, rising 26% from 681 million in 2024 to 858 million units in 2025.
"Despite shifting priorities and policy changes, product safety remains at the core of U.S. regulatory activities," says Chris Harvey, SVP for Sedgwick. "Regulators across industries are looking to increase oversight, improve the effectiveness of product recalls, and expand post market responsibilities beyond just the manufacturer. By prioritizing both safety and compliance, organizations can protect consumers, uphold their reputations, and thrive amid ongoing change."
Key takeaways:
· For the full year, the consumer products, food and beverage, and pharmaceutical sectors all experienced higher recall volumes than in 2024. Notably, the consumer products industry recorded its highest annual total in over a decade. Both the medical device and automotive industries saw modest declines in recall activity of 8% and 6%, respectively.
· In terms of defective units, the pharmaceutical, food and beverage, and medical device sectors experienced year-over-year increases, while the consumer products and automotive industries saw declines. Defective automotive units fell to an 11-year low.
· There were considerable changes in 2025 as the Trump Administration established and advanced new regulatory priorities and shifted how policy changes are implemented. Both penalties—in the form of tariffs—and incentives were used to encourage companies to shift production facilities to the United States or increase existing operations.
· Conducting effective product recalls was also an important topic across several industries in 2025. Regulators reminded stakeholders of their responsibilities and issued heavy fines—and in one instance prison sentences—for delays in reporting product defects.
· Department secretaries made sweeping changes to long-standing policies around trade and health. That trend will likely continue in 2026. Key areas of focus include trade and tariffs, increasing domestic manufacturing across multiple industries, lowering the prices of pharmaceuticals, reducing regulations viewed as burdensome to business, and easing environmental restrictions.
