In April 2025, Hearthside Food Solutions, LLC, a food manufacturer based in Salt Lake City, Utah, issued a significant recall of nearly 500,000 pounds of ready-to-eat (RTE) breakfast sandwiches due to misbranding and the presence of an undeclared allergen; sesame.
The recall affects frozen sausage and bacon breakfast sandwiches distributed to Army & Air Force Exchange Services (AAFES) locations nationwide. This issue was identified when the company realized that sesame flour, used in the French toast component of the sandwiches, was not listed on the product labels. While no adverse reactions have been reported so far, the recall underscores the critical importance of accurate food labeling and allergen disclosure in ensuring consumer safety.
Recall Details
Hearthside Food Solutions, LLC is a prominent food manufacturing company based in Salt Lake City, Utah. The company specializes in producing ready-to-eat (RTE) food products, including breakfast sandwiches, snacks, and other convenience foods. Known for its partnerships with retailers and military exchange services, Hearthside has built a reputation as a reliable supplier of frozen meals designed for quick preparation and consumption.
Description of Affected Products
The recall involves two specific types of frozen breakfast sandwiches that feature French toast as a key component. Both products are branded under the “LETTIERI’S FOOD TO GO” label and were distributed to Army & Air Force Exchange Services (AAFES) locations nationwide. Below is a detailed description of the affected items:
Sausage, Egg & Cheese Sandwiches
- Weight: 8.35 ounces each
- Packaging: Individually film-wrapped
- Product Name: LETTIERI’S FOOD TO GO Sausage, Egg & Cheese FRENCH TOAST BREAKFAST SANDWICH
- Lot Codes: Beginning with the numbers 23, 24, and 25, up to 2508451
- Key Issue: The French toast component contains sesame flour, which is not declared on the product label.
Bacon, Egg & Cheese Sandwiches
- Weight: 7.3 ounces each
- Packaging: Individually film-wrapped
- Product Name: LETTIERI’S FOOD TO GO Bacon, Egg & Cheese FRENCH TOAST BREAKFAST SANDWICHLot Codes: Beginning with the numbers 23, 24, and 25, up to 2508451
- Key Issue: Similar to the sausage variant, these sandwiches also contain sesame flour in the French toast but fail to list sesame as an ingredient on the label.
Both products bear the establishment number “EST. V4907” inside the USDA mark of inspection, which helps identify them as part of the recall.
Scope of Recall: Quantity Recalled (489,887 Pounds)
The scale of this recall is significant, involving approximately 489,887 pounds of ready-to-eat breakfast sandwiches. This massive quantity underscores the widespread distribution of the affected products and highlights the potential impact on consumers across the country.
Given the sandwiches’ long shelf life of 12 months, many of these items may still be stored in freezers or refrigerators, posing an ongoing risk to individuals with sesame allergies.
Production Dates (April 1, 2023 – March 25, 2025)
The recalled sandwiches were produced over a nearly two-year period, spanning from April 1, 2023, to March 25, 2025 . This extended timeframe means that the mislabeling issue persisted for a considerable duration before being identified. It also increases the likelihood that a large number of affected products have already been purchased and consumed by unsuspecting customers.
Distribution Details (AAFES Locations Nationwide)
The sandwiches were exclusively distributed to Army & Air Force Exchange Services (AAFES) locations nationwide. AAFES operates retail stores and facilities on military bases, providing goods and services to service members, their families, and authorized personnel.
The Allergen Issue
Sesame allergies, though less common than other food allergies, can be just as severe and potentially life-threatening for those affected. Sesame is now recognized as one of the nine major allergens in the United States, alongside milk, eggs, fish, crustacean shellfish, tree nuts, peanuts, wheat, and soybeans.
For individuals with a sesame allergy, even trace amounts of sesame or its derivatives (such as sesame flour)can trigger adverse reactions. Symptoms of an allergic reaction may include skin rashes, hives, swelling, nausea, vomiting, diarrhea, abdominal pain, and respiratory issues like difficulty breathing.
In severe cases, exposure to sesame can lead to anaphylaxis, a life-threatening condition characterized by throat swelling, low blood pressure, trouble breathing, and unconsciousness.
If you’re a sandwich lover, especially one who values both convenience and safety, investing in a grilled cheese sandwich maker could be a game-changer for you. Not only does it allow you to enjoy delicious, freshly made sandwiches at home, but it also gives you full control over the ingredients,
Regulatory Requirements for Allergen Labeling
Under the Food Allergy Safety, Treatment, Education, and Research (FASTER) Act, which took effect on January 1, 2023, sesame was officially added to the list of major allergens that must be declared on food labels.
This legislation mandates that food manufacturers clearly identify sesame as an ingredient if it is present in any form within their products. The FASTER Act aligns with broader efforts by the U.S. Department of Agriculture (USDA) and the Food and Drug Administration (FDA) to enhance food safety and protect consumers with food allergies.
Failure to comply with allergen labeling requirements not only violates federal regulations but also undermines consumer trust and endangers public health.
In this case, the omission of sesame flour from the ingredient list of the French toast component in Hearthside Food Solutions’ breakfast sandwiches constitutes a violation of the FASTER Act and underscores the need for stricter adherence to labeling protocols.
Discovery of the Problem
The root cause of the recall was traced back to the French toast used in the breakfast sandwiches. While sesame flour was intentionally included as an ingredient in the French toast, it was inadvertently omitted from the product’s ingredient list. This misbranding error meant that consumers purchasing the sandwiches were unaware of the presence of sesame, leaving allergic individuals at risk of accidental exposure.
The use of sesame flour in food production is not uncommon, as it is often valued for its nutty flavor and nutritional benefits. However, its inclusion must always be accompanied by clear disclosure on the label to ensure compliance with allergen regulations. The oversight in this instance highlights the complexities of food manufacturing and the importance of cross-checking ingredient lists at every stage of production.
Guidance for Concerned Consumers
If you suspect you may have consumed one of the recalled sandwiches and experience any unusual symptoms, seek medical attention immediately. Even mild symptoms should not be ignored, as they could escalate quickly. For those who are unsure whether they have a sesame allergy but are concerned about possible exposure, consult a healthcare provider for personalized advice.
Additionally, consumers should stay informed about food recalls by regularly checking updates from reliable sources such as the USDA’s Food Safety and Inspection Service (FSIS) website or signing up for recall alerts. Being proactive about food safety can help prevent accidental exposure to allergens and ensure peace of mind.
Disposal and Return Instructions
If you discover that you have purchased any of the recalled breakfast sandwiches, do not consume them under any circumstances. The USDA advises consumers to safely dispose of the products to prevent accidental ingestion. To properly discard the items:
- Wrap the product securely: Place the sandwiches in a plastic bag or container to prevent leaks or contamination.
- Label the package: Clearly mark the bag or container as “Recalled Product – Do Not Consume” to alert others who might handle the trash.
- Dispose of it responsibly: Throw the wrapped package in your household garbage bin, ensuring it is inaccessible to children, pets, or scavengers.
- For environmentally conscious consumers, composting or recycling the packaging separately (if applicable) may be considered, but the food itself must always be discarded in accordance with local waste management guidelines.
Return Policies at AAFES Locations
Alternatively, consumers who purchased the affected sandwiches from Army & Air Force Exchange Services (AAFES) locations can return them for a refund or exchange. AAFES has committed to supporting the recall by accepting returned products without requiring a receipt. To facilitate the process:
- Bring the product to the store: Take the recalled sandwiches to your nearest AAFES location. Ensure they are still in their original packaging to verify the lot codes and confirm eligibility for the recall.
- Speak with customer service: Inform the staff about the recall and request assistance with processing your return. They will guide you through the refund or replacement procedure.
- Ask questions if needed: If you’re unsure whether a specific product is part of the recall, don’t hesitate to ask AAFES personnel or contact Hearthside Food Solutions directly for clarification.
Company Response and Contact Information
In response to the discovery of sesame flour in the French toast component of their breakfast sandwiches, Hearthside Food Solutions, LLC acted swiftly to address the issue. The company voluntarily notified the USDA’s Food Safety and Inspection Service (FSIS) about the misbranding error, demonstrating a commitment to transparency and consumer safety.
By initiating the recall of approximately 489,887 pounds of ready-to-eat sausage and bacon breakfast sandwiches, Hearthside aims to mitigate any potential risks to consumers with sesame allergies.
Contact Information for Inquiries
For consumers or stakeholders seeking more information about the recall, several resources are available:
Roger Harris, Chief Legal Officer
Hearthside Food Solutions has designated Roger Harris, the company’s Chief Legal Officer, as the primary point of contact for inquiries related to the recall. Consumers can reach him directly at 630-967-3600 for clarification on the recall process, product details, or reimbursement policies.
USDA Meat and Poultry Hotline
The USDA’s Food Safety and Inspection Service (FSIS) provides additional support through its toll-free hotline. Consumers with food safety questions or concerns can call the USDA Meat and Poultry Hotline at 888-MPHotline (888-674-6854).
The hotline is staffed by experts who can offer guidance on handling, storage, and disposal of recalled products. Alternatively, individuals can send an email to [email protected] for written assistance.
Online Complaint System
For those who need to report a problem with a meat, poultry, or egg product, the FSIS offers a convenient online Electronic Consumer Complaint Monitoring System. This system is accessible 24 hours a day at https://foodcomplaint.fsis.usda.gov/eCCF/ , allowing consumers to file complaints and provide feedback electronically.
Conclusion
The recall of nearly 500,000 pounds of breakfast sandwiches by Hearthside Food Solutions, LLC highlights the critical importance of accurate food labeling and allergen disclosure. The undeclared presence of sesame flour in the French toast component poses a potential risk to individuals with sesame allergies, even though no adverse reactions have been reported.
Consumers are urged to dispose of or return the affected products, which were distributed nationwide to Army & Air Force Exchange Services (AAFES) locations. This incident underscores the need for strict adherence to regulations like the FASTER Act and serves as a reminder of the shared responsibility between manufacturers, regulators, and consumers to ensure food safety and transparency.
