Mock recalls: Why every organization needs to practice for the unexpected

Imagine your office never practiced fire drills. In an emergency, people wouldn’t know what to do and could get hurt. The same principle applies to product recalls: If your team has never tested the process, a real recall could quickly spiral out of control, leading to costly mistakes and reputational damage. That’s where mock recalls come in — a proactive exercise that prepares organizations to respond swiftly and effectively when the stakes are highest.

What is a mock recall?

A mock recall is a simulated exercise that allows a company to test its recall procedures, familiarize the team with the process and identify gaps or deficiencies before a real recall occurs. It’s much more than a simple traceability or shipment history exercise. A robust mock recall should mirror a real-life scenario, ideally a worst-case situation such as a Class I food recall (for example, undeclared allergen) or a medical device recall with potential for serious injury. The goal is to walk through every step — from the decision to recall, through stakeholder communication, regulatory reporting and remedy implementation.

Why are mock recalls important?

Mock recalls are essential for several reasons:

• Team familiarity: Staff turnover is common, and team members who handle recalls may change frequently. Mock recalls ensure everyone knows their role and is comfortable with the process.
• Process validation: Over time, procedures can become outdated, especially if a company hasn’t had a recall in years. Mock recalls help organizations update their recall plans and ensure they’re fit for current conditions.
• Gap identification: By simulating a recall, companies can spot weaknesses —whether in communication, documentation, regulatory reporting, or remedy logistics — and fix them before a real event.
• Regulatory and legal readiness: Mock recalls help organizations understand their regulatory obligations and potential liability issues, ensuring legal and communications teams are aligned.
• Insurance utilization: Many recall or contamination insurance policies allow a percentage of the premium to be used for mock recalls or recall plan development, yet few companies capitalize on this “free money.”

It’s best practice to conduct a mock recall every 12 to 18 months, especially for companies that haven’t had a recent recall. For organizations with frequent recalls, the exercise may be less critical, but for others — especially those in consumer products, medical devices or food — it’s a vital part of risk management.

Best practices for mock recalls

1. Create a realistic scenario: Use a worst-case scenario relevant to your industry. For global companies, include international scope to test cross-border processes.
2. Use a fake product name: Avoid confusion in the marketplace by simulating the recall with a fictitious product, but real batch numbers.
3. Test the full process: Go beyond traceability. Walk through the entire recall plan, from strategy development to implementation, including stakeholder identification and remedy logistics.
4. Engage the right team: Assemble your recall or “SWAT” team as you would in a real event. Include regulatory, legal, communications, and operational experts.
5. Practice communication: Develop recall letters, press releases, FAQs for call centers and internal communications. Test your ability to report to regulatory bodies like the FDA or CPSC.
6. Consider remedies: Decide whether the recall involves repair, refund or replacement, and how you’ll manage logistics for stakeholders like distributors, hospitals or consumers.
7. Try an unplanned mock: While most companies tend to want to schedule mock recalls in advance, an unannounced exercise can reveal real-world gaps and test your team’s readiness under pressure.
8. Legal review: Involve legal counsel to assess liability, regulatory compliance and the wording of communications.
9. Leverage insurance: Explore how your recall insurance policy can support mock recall exercises and plan development.
10. Conduct a look-back session: After the mock recall, hold a debrief to summarize what worked, what didn’t, and what needs improvement.

There’s a helpful acronym for recall strategy that helps to keep it all top-of-mind: SCARE —Scope, Communication, Action, Remedy, End. This framework ensures every aspect of the recall is considered, from the initial scope to closing out the event.

Conclusion

Mock recalls are a critical tool for organizational preparedness. By practicing for the unexpected, companies can protect their customers, brand, and bottom line. Don’t wait for a crisis — schedule your next mock recall and ensure your team is ready to respond when it matters most.