Costco Recalls 148,000 Pounds of Frozen Chicken Patties Due to Plastic Contamination

Costco's Recall of Frozen Chicken Patties Due to Plastic Contamination

In August 2022, Foster Farms issued a recall for approximately 148,000 pounds of frozen chicken patties sold at Costco stores. The recall was initiated after consumers complained of finding pieces of plastic embedded in the chicken patties. Food safety risks from contamination as well as the substantial amount of product affected make this a concerning recall for shoppers. Below well cover key details about the recalled frozen chicken patties from Costco and what consumers need to know.

What Products Were Recalled?

The recalled chicken patties were branded Kirkland Signature, Costco's exclusive in-house brand. The following frozen chicken patty products sold at Costco were included in the recall:

• Kirkland Signature Chicken Patties Stuffed with Cheese & Chicken Filet
• Kirkland Signature Chicken Patties Chicken Parmesan
• Kirkland Signature Chicken Patties Chicken & Spinach Artichoke

All recalled items have best by dates of 02/13/2023 to 03/13/2023. Products subject to recall were shipped to Costco distribution centers in Arizona, California, Colorado, Utah and Washington. From there, the frozen chicken patties made their way to Costco retail warehouse locations.

Why Were the Chicken Patties Recalled?

The reason for Costco's chicken patty recall was the potential presence of hard, sharp plastic pieces embedded in the chicken. Several consumer complaints alerted Foster Farms that their patties may have become contaminated with plastic material during the manufacturing process.

Upon investigation, the source was traced to a plastic conveyor belting fragment that broke off during production. The plastic fragments could be embedded in any of the recalled chicken patty varieties. If consumed, these plastic pieces pose a serious choking hazard or damage hazard to the mouth and digestive tract.

Out of an abundance of caution for consumer safety, Foster Farms issued an immediate recall on all affected chicken patties produced within the given date ranges. As of the initial recall date, there were no confirmed adverse events or injuries reported. However, the hard plastic pieces still present an injury risk if consumed.

How Did the Plastic Contamination Occur?

Foster Farms stated that the source of the plastic contamination was traced to a faulty conveyor belt system within their production facility. During patty production, a plastic fragment from a belt on the system dislodged and fell into the meat. Workers were unable to detect or remove the plastic pieces before the patties were processed and frozen.

The discovery highlights how easily manufacturing contaminants can evade detection. Foster Farms has not clarified what caused the belt to crack in the first place or whether adequate inspection protocols were in place. However, they have stated that the facility is working to upgrade equipment and improve monitoring for foreign object contamination.

All of the recalled frozen chicken patties were produced at the Foster Farms facility located in Kelso, Washington. After the problem was discovered, distribution of all chicken patty products from this facility was halted until investigations concluded and corrections could be made.

What Are the Dangers of Plastic in Food?

Why is plastic considered hazardous when ingested? The FDA warns that contamination from plastic materials commonly used in machinery can pose multiple risks:

• Choking: Hard, sharp plastic pieces can obstruct the throat, especially in children and elderly.
• Damage: Plastic fragments may lacerate or puncture tissues in the mouth, esophagus or digestive tract if swallowed.
• Toxins: Heating and ingesting plastics may release toxic chemicals linked to cancer, hormonal changes, and developmental issues.

While not all plastics contain toxic additives, these risks make it crucial to prevent inadvertent plastic contamination during food production. Prompt recalls help get affected products out of consumer homes before an injury occurs.

What Should Consumers Do?

If you purchased any of the recalled frozen Kirkland Signature chicken patties with best by dates between 02/13/2023 and 03/13/2023, take the following steps:

1. Discard the product. Even if patties have been cooked, they may still contain plastic fragments that present a hazard. Play it safe and throw away recalled patties.
2. Return unopened product to Costco for a refund. Bring the intact chicken patties back to the Costco warehouse where you purchased them. Unopened items are eligible for a full refund.
3. examine opened packages thoroughly. Check patties for any shards of hard plastic before consuming just to be safe.
4. Report injuries/illness If you ate the recalled patties and suffered any injury or illness, report it promptly to a medical professional and the Costco recall team.

Costco has removed all impacted chicken patty inventory from stores. However, consumers may still have the recalled items in their freezers at home. Check your freezer and discard any chicken patties matching the product numbers and best by date codes listed in the recall notice. Sign up for recall alerts at costco.com to stay up to date.

Costcos Recall History

Costco has built a reputation for selling quality products at a great value. However, with hundreds of millions of members and warehouses worldwide, having an occasional recall is an unfortunate inevitability. Here are a few of the major food and product recalls Costco has issued over the past decade:

Frozen Berries

Frozen triple berry blends sold under the Kirkland Signature brand were linked to a hepatitis A outbreak in 2016 impacting 13 states. The recalled frozen berries were sourced from an Egyptian company lacking adequate sanitation and worker hygiene practices.

Chicken Salad

Also in 2016, approximately 180,000 pounds of rotisserie chicken salad made and sold in Costco stores across the western U.S. was recalled after Listeria contamination was discovered at the suppliers facility.

Frozen Spinach

Organic frozen spinach packets sold at Costco and other major retailers were recalled in 2022 after testing revealed potential Listeria monocytogenes contamination. The recall impacted nearly 175,000 cases of product.

Alcohol Hand Sanitizers

During the peak of COVID-19 pandemic demand, several brands of alcohol-based hand sanitizers sold at Costco were found to contain unsafe levels of methanol and were promptly removed from store shelves.

Beef Products

Raw ground beef products processed by a Canadian plant were recalled from Costco stores in eight states in 2014 after random samples tested positive for E. coli contamination.

Costco maintains dedicated teams to monitor for supplier problems and rapidly respond should recalls become necessary. Still, with so much volume it's impossible to prevent every single recall. Members can sign up for email and text alerts about latest recalls at the Costco website.

Costco Chicken Supplier Foster Farms

As the producer of Costcos exclusive Kirkland Signature chicken patties, Foster Farms is responsible for the recall and potential plastic contamination. Heres some background on supplier Foster Farms:

• Headquartered in Livingston, California
• Privately owned poultry company since 1939
• Processes over 13 million birds per week
• Operates multiple facilities in California, Oregon, Washington, Louisiana and Alabama
• Employs over 12,000 people nationwide
• Produces retail branded chicken and turkey products along with private label products
• Kirkland Signature supplier since early 2000s

In addition to the Costco recall, Foster Farms has initiated other recent recalls include cooked chicken patties and nuggets for misbranding and undeclared allergens. They also were linked to a widespread salmonella outbreak in chicken during 2013-2014.

Foster Farms specializes in poultry as their sole protein focus. They emphasize minimizing antibiotics in raising chickens. Their facilities process fresh and frozen whole chickens, chicken parts, fully cooked products, breaded items, organic poultry, ground and shaped uncooked patties, burritos, bowls, and other prepared foods.

The company promises robust food safety controls although this latest recall indicates potential weaknesses in manufacturing plastic containment protocols. Still, Foster Farms remains dedicated to upholding rigorous quality standards and rectifying the machinery malfunction that caused this substantial recall.

Costco Chicken Products

Frozen chicken patties are just one of many different poultry products sold at Costco both in-store and online. Heres an overview of the retail giants chicken offerings:

Rotisserie Chicken

The $4.99 rotisserie chicken deal in Costco deli sections is arguably their most iconic chicken item. Shoppers can grab a fully cooked original or lemon pepper rotisserie chicken daily.

Whole Fryer Chicken

Prepackaged, raw whole chickens are available chilled in fresh meat coolers or frozen. Kirkland and Foster Farms are typical brands along with organic and air-chilled options.

Chicken Breasts

Boneless, skinless chicken breasts come individually sealed or in multi-pack pouches, sold fresh and frozen. Both conventional and organic chicken breast is offered.

Chicken Thighs and Legs

Value packs of bone-in, bone-out, skin-on and skinless chicken legs and thighs offer budget friendly chicken. Value pack chicken leg quarters are also available.

Ground Chicken

Typically sold in one or two pound chubs, Costco ground chicken makes a handy staple for versatile meals. Occasionally, Italian seasoned ground chicken appears as well.

Prepared Chicken Items

Fully cooked chicken patties, tenders, wings, nuggets, sausage links, balls, potstickers, Alfredo bowls, enchiladas, salads, wraps, and more can be found in prepared deli sections. These items require just heating at home for quick meals.

Costcos wide selection provides members chicken essentials from raw meat to heat and eat. Look for Kirkland Signature branding on many poultry products as well as third-party brands occasionally. Be diligent about checking any recalls that could affect the chicken in your fridge or freezer.

Costco Membership Basics

To shop at Costco warehouses and on costco.com, you must be a member. Heres what to know about Costco membership:

• Gold Star - $60 annual fee, access for one household/two cardholders
• Executive - $120 annual fee, access for one household/two cardholders plus added benefits
• Add-ons - Additional household members, upgraded business services
• Credit card - Costco Anywhere Visa Card by Citi provides rewards on purchases
• Renewal - Memberships auto-renew each year on join date
• Downgrade/cancel - Contact member services to downgrade or close membership

Costco memberships offer low warehouse prices on groceries, household essentials, clothing, appliances, outdoor items, office supplies, and more. Special benefits include pharmacy services, discounted gas, free samples, and no sales tax on most items in five states.

If you plan to buy groceries like chicken patties at Costco, the savings from a basic membership can quickly pay for itself. Review your monthly Costco hauls to see if one of their membership plans could fit your shopping needs and reduce your grocery costs.

Safety First at Costco

Costco makes every effort to provide high-quality products priced below traditional grocery stores. However, periodic recalls are inevitable when working with the massive scale of food production required to supply hundreds of warehouse stores.

The plastic contamination in frozen chicken patties represents a concerning oversight by supplier Foster Farms. But Costcos prompt recall notification and immediate action upholds their commitment to prioritizing consumer safety above profits.

Members can continue to trust Costcos dedication to quality while also taking sensible precautions. Review recall alerts, inspect products at home, and report any concerning symptoms or discoveries. By working together, suppliers, retailers and consumers can minimize health risks and keep improving product safety across the food industry.

Disclaimer: This article is for informational purposes only and does not constitute medical advice. Always consult with a healthcare professional before starting any new treatment regimen.