A mock recall tests whether your recall process works before a real recall forces the answer. Most companies that run them find gaps they didn't know were there: contact information that's out of date, roles that aren't clear, data that takes too long to pull, notifications that go out but don't get acted on. Finding those gaps in a simulation is vital to being able to execute during a real recall.

This guide walks through how to run a mock recall that effectively tests your recall process — not just product lookup, but coordination, communication, and decision-making.

What Is a Mock Recall?

A mock recall is a test of your product recall process. Done right, it simulates what a real recall looks like and evaluates your ability to trace affected product, execute decisions, communicate with stakeholders, and document actions.

Manufacturers run mock recalls to:

• Practice decision-making based on available information
• Clarify roles and responsibilities
• Validate data systems and traceability
• Identify gaps in communication or execution
• Fulfill regulatory and customer requirements
• Reduce risk by improving response time and accuracy

If your mock recall stops after finding a lot number, quantity, and location, you're missing an opportunity to practice the parts of a recall that make a difference during the real event.

How to Do a Mock Recall: A Step-by-Step Approach

1. Set a Realistic Scenario

Start by selecting a product and creating a plausible reason for the recall. It might be a labeling error, allergen contamination, temperature abuse, a recent supply chain risk, or a supplier quality issue. The scenario should be specific enough to test your traceability and communication, but not so complex it becomes unmanageable.

Example: "A consumer reports an undeclared allergen in Product X, produced on March 7 with Lot code #301. QA suspects a label mix-up during second shift."

2. Notify the Team Like It's Real

No email with "Mock Recall" in the subject line. Simulate how your team would find out: a phone call from QA, a flagged report from customer service, a compliance alert from a retailer.

Once the issue is raised, prompt the recall team to make the same decisions they would in a real scenario: Does this trigger the threshold to assemble the full team? Should you begin drafting notifications? The goal is to test both speed and the team’s ability to think under pressure.

3. Identify the Scope and Draft the Communication

Based on the data, define the boundaries of the recall. What lots are affected? Are additional SKUs at risk? What process steps, records, or documentation define the scope?

Then create your internal messaging and external notifications. Tailor them for different audiences:

• Trading partners: what product to pull, from where, and how to confirm action
• Consumers: what to do if they've purchased the product
• Regulators: what happened, what action you're taking, and when
• Internal teams: clear updates so everyone stays aligned on progress and next steps

Use your templates, but test whether they match the situation and produce the outcome you need.

4. Trace the Product Through Your System

Use your current data systems — SAP, ERP, spreadsheets, whatever is already in place — to locate the affected product by lot, batch, or production run. Identify where it went: which customers, distributors, retailers, off-site storage locations. Pull the shipping logs, lot codes, and customer contact information. If this takes more than 60 minutes, you've found your first improvement area.

5. Notify Select Internal and External Customers

A recall simulation has to include at least some external trading partners to give you visibility into how a real recall would play out. Is your contact information current? Does your message result in action or confusion? Does manual notification slow the process, generate errors, or reduce overall effectiveness?

6. Track the Recall Process

Simulate product recovery and verification. How many units were located? How did you confirm they were pulled? How do you know the message was received?

Use your tracking system or dashboard to log actions. If you don't have one, this is a good time to evaluate recall software.

7. Review Roles and Team Response

Did your recall team know what to do? Who made the decision to recall? Who gathered the product data? Who notified partners? Who communicated with legal, media, and regulators?

If you had to stop and ask those questions, the plan needs more clarity. Include a responsibility checklist and test every person's role.

8. Document the Mock Recall

Record what happened: timeline, decisions made, who did what, and what was recovered. Good documentation is important for compliance, but it’s also how you evaluate and improve.

Include:

• Recall scenario and scope
• Time to locate product
• Communication materials
• Contact logs
• Stakeholder response
• System or process gaps

9. Conduct a Post-Mortem

Hold a debrief with your recall team. What worked? What slowed you down? Were there miscommunications? Did you need information that wasn't easily accessible?

Be direct. Use what you learned to revise your recall plan. Update team roles, communication templates, escalation steps, and data procedures. 

A Real Recall Is No Time for a Rehearsal

You don't want your first real recall to also be the first time your team tests the process. Mock recall simulations expose blind spots and build confidence, so your team doesn’t hesitate when the real thing happens.

Download the Recall InfoLink 9-Step Recall Action Plan to get started, or schedule a consultation with our team to walk through your current plan and build a stronger one.