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, a total of 3,295 recalls were recorded across the five industries analyzed, 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.
Defective automotive units fell to an 11-year low.
Sedgwick’s quarterly Product Safety and Recall Index report provides in-depth analysis of recall activity across the automotive, consumer products, food and drink, pharmaceutical, and medical device sectors. This special State of the Nation edition offers a comprehensive year-in-review analysis of 2025 recall data and product safety trends, as well as a deeper dive into fourth quarter developments and data.
For the full year, the consumer products, food and drink, 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 addition to recall data and analysis, the State of the Nation Product Safety and Recall Index report delivers essential insights into the regulatory developments that shaped 2025 and perspectives on what product safety stakeholders should anticipate for 2026. 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 U.S. 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.
“Despite shifting priorities and policy changes, product safety remains at the core of U.S. regulatory activities,” said Chris Harvey, Senior Vice President 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.”
