In the world of cookware manufacturing, safety is non-negotiable. From non-stick coatings to heat resistance and handle design, every detail must meet strict standards. When these standards aren’t met, the consequences can be devastating—financially and reputationally. Here are five notable cookware recall cases that serve as cautionary tales for manufacturers and underline the vital importance of quality control.
1. SharkNinja Ninja Foodi Pressure Cooker Recall (2025)
Estimated cost: Potentially over $50 million
In May 2025, SharkNinja recalled approximately 1.85 million Ninja Foodi OP300 Series Multi-Function Pressure Cookers. The recall was prompted by reports that the cookers' lids could be opened while still pressurized, leading to hot contents escaping and causing burns. The U.S. Consumer Product Safety Commission (CPSC) received 106 reports of burn injuries, including over 50 cases of second- and third-degree burns. According to estimation, this recall could cost SharkNinja over $50 million.
How Product Inspection Might Have Prevented the Pressure Cooker Recall
On-site inspections of pressure cookers often include critical on-site tests to ensure safe usage. Real-life function testing—such as pressure safety test, full function test, and leaking test—can help detect issues early, like the risk of opening under pressure, and prevent further product recalls.
Key Takeaways:
- Test real-life usage to verify safety
- Detect critical risks before market release
- Prevent costly recalls through early intervention
2. Stanley Switchback and Trigger Action Mugs Recall (2025)
Estimated cost: Not disclosed
In early 2025, Stanley recalled over 2.6 million Switchback and Trigger Action stainless steel travel mugs worldwide. The recall was due to the mugs' lids detaching when exposed to heat and torque, leading to 38 reported burn injuries. The affected mugs, sold between June 2016 and December 2024, were available in various sizes and colors through retailers like Amazon and Walmart. Stanley is offering a free replacement lid that will work with the recalled products as remedies.
How Inspection Could Have Prevented the Travel Mug Recall
A thorough product inspection—particularly focusing on-site functional testing—could have helped identify such quality issues. On-site function testing—like heat exposure test and physical stress test—could help to revealed the lid detachment issue early. Detecting this defect during inspection would have allowed timely correction before reaching end consumers.
Key Takeaways:
- Test for heat and stress durability
- Simulate daily use to catch functional flaws
- Prevent safety hazards through early detection
3. Emba Cast Iron Cookware Recall (2025)
Estimated cost: Not disclosed
In March 2025, Emba Cookware issued an urgent recall for various cast iron cookware items sold since 2023. Testing by the UK's Office for Product Safety and Standards revealed that the cookware could release heavy metals during use, posing a serious health risk. The recall affected multiple products, including skillets and griddles, and customers were advised to stop using the items immediately and contact Emba for a full refund.
How Laboratory Testing Catches Toxic Content Risks in Cookware
Lab testing plays a vital role in detecting harmful substances like heavy metals before products reach consumers. Professional testing helps identify chemical migration risks early, ensuring safety and compliance.
Key Takeaways:
- Detect toxic materials before market release
- Simulate real-use to assess chemical safety
- Ensure compliance with health regulations through routine lab testing
4. GreenPan SimmerLite Dutch Ovens Recall (2020)
Estimated cost: Not disclosed
In July 2020, Cookware Company recalled approximately 11,160 GreenPan SimmerLite Dutch Ovens. The recall was issued because the lids could explode while the oven was in use, posing a significant risk of injury and burns. The firm has received four consumer reports of incidents, including one report of property damage, and no injuries have been reported.
How Product Inspection Could Have Prevented the Dutch Oven Recall
Comprehensive inspections—including key steps like pressure test, sealing test, and fatigue test—could have identified lid vulnerabilities in the Dutch ovens before shipment. Catching these risks early helps prevent safety issues and costly recalls.
Key Takeaways:
- Simulate cooking conditions to test durability
- Identify design flaws before full production
- Prevent product failure through early-stage checks
5. Instant Pot “Smart” Cooker Recall (2018)
Estimated cost: Estimated low millions
In 2018, Instant Brands recalled a batch of its Gem 65 8-in-1 multicookers due to overheating, which could cause the unit to melt and pose fire hazards. The problem was linked to a manufacturing defect affecting certain batch codes. Given about 104,000 units were impacted, the brand had to act quickly to maintain consumer trust in an intensely competitive market. This case underscores the importance of batch-level inspection and early problem detection in smart kitchen appliances.
How Inspection Can Prevent Overheating Issue in Cookware
Daily-use appliances like multicookers must be fail-safe. During-Production Inspection (DUPRO) helps catch issues—like faulty sensors, poor insulation, or unstable materials—early in the manufacturing process. This enables brands to take corrective actions while products are still on production lines and prevent costly re-dos before full assembly.
Key Takeaways:
- Inspect components during production stage
- Catch defects in semi-finished products early
- Reduce fire hazards and protect brand reputation
Safety is Fundamental to Cookware, Quality Control is Key to Safety
Each cookware recall case above reinforces a clear message: safety must be at the heart of every cookware product. From heat resistance to structural integrity and material safety, even the smallest flaw can pose serious risks in daily use. These examples highlight why thorough quality control solutions are essential—not just to ensure product quality, but to protect the health and safety of consumers in the environments where they cook, eat, and live.
Here’s how a robust quality control strategy can help avoid these costly mistakes:
- Product Inspection: Ensuring that finished products meet your provided product specifications and required safety standards.
- On-Site Testing: Simulating real-world usage helps identify durability issues and safety issues that can happen during day-to-day usage.
- Supplier Factory Audits: Many cookware products are manufactured by overseas suppliers. Regular audits and tighter oversight can ensure that the suppliers fully understand your quality standards and product requirements.
- Laboratory Testing: Laboratory testing plays a vital role in verifying cookware product safety, quality, and regulatory compliance. It evaluates key factors such as the composition of materials, durability of the coatings, heat tolerance, and risks of harmful substances leaking into food during usage.
At the end of the day, quality control is not just about checking boxes—it's about safeguarding your customers and protecting your brand. A small investment in quality control can prevent massive losses, both financial and reputational. As these five cases demonstrate, overlooking quality is a risk no manufacturer can afford.
Ready to strengthen your product quality and brand reputation? Don’t wait for a recall to protect your brand. Partner with quality control experts who understand the cookware industry and can help you implement end-to-end quality solutions—from factory audits to product testing and pre-shipment inspections.
