E.A. Sween Recalls Deli Express BBQ Pulled Pork Sandwiches Over Plastic Pieces

EDEN PRAIRIE, Minn. (December 15, 2025) — The U.S. Department of Agriculture’s Food Safety and Inspection Service (FSIS) has announced that E.A. Sween Company is voluntarily recalling approximately 127,887 pounds of its Deli Express BBQ Pulled Pork Sandwiches due to contamination with extraneous materials, specifically pieces of plastic. According to regulators, the plastic fragments were introduced during the production process, posing a potential choking hazard or risk of dental injury to consumers. The agency confirmed that the problem was discovered after the company received multiple consumer complaints regarding plastic found inside the sandwiches.

Deli Express Recall: Quick Summary

E.A. Sween Company has issued a massive recall for more than 63 tons of its popular Deli Express BBQ Pulled Pork Sandwiches. The recall was initiated after it was determined that plastic from the gallon-sized barbecue sauce bottles used in production had made its way into the final product. The affected sandwiches were produced between January and October 2025 and were shipped to retail locations nationwide, including convenience stores, mass merchandisers, and the Department of Defense. Consumers are urged to check their freezers immediately, as these items have a long shelf life and may still be in storage.

What Happened?

The FSIS said E.A. Sween Company initiated the recall after receiving multiple complaints from consumers who found hard plastic pieces embedded in the pulled pork sandwiches. The company told regulators that an internal investigation determined the plastic originated from the containers used to hold the barbecue sauce during the manufacturing process. The recall covers a significant production window, affecting items made as early as January 13, 2025, through October 15, 2025.

In its recall alert, the FSIS stated it is “concerned that some product may be in consumers’ refrigerators or freezers” due to the product’s shelf stability when frozen. The agency confirmed that there have been no confirmed reports of injury or adverse reactions due to consumption of these products, but the risk of choking or mouth injury remains.

Affected Products

Brand	Product	Size	Est. Number	Production Dates	Issue
Deli Express	BBQ Pulled Pork on a Sesame Bun	5.5 oz.	EST. 2451	Jan. 13, 2025 – Oct. 15, 2025	Plastic Pieces

What Caused the Issue?

According to the recall notice, the contamination was caused by the degradation or breakage of the gallon-sized plastic bottles used to dispense barbecue sauce during the sandwich assembly process. Foreign material contamination like this is a “Class I” recall situation, meaning there is a reasonable probability that the use of the product will cause serious, adverse health consequences.

Company officials said in the statement that they have identified the source and corrected the issue to prevent recurrence. The primary health risk is physical injury to the mouth, teeth, or throat, as well as potential choking if the plastic pieces are large enough. The agency confirmed that anyone concerned about an injury or illness should contact a healthcare provider.

Questions You Might Have

1. What specific sandwich is recalled?The Deli Express BBQ Pulled Pork on a sesame bun, 5.5 oz package.
2. How much product is affected?Approximately 127,887 pounds, or over 63 tons, of sandwiches are included.
3. What dates should I look for?The recall covers sandwiches produced between January 13, 2025, and October 15, 2025.
4. Where do I find the establishment number?Look for EST. 2451 printed inside the USDA mark of inspection on the label.
5. What kind of plastic was found?The plastic pieces came from the barbecue sauce bottles used in production.
6. Has anyone been hurt?No confirmed reports of injury or illness have been linked to this recall so far.
7. Where were the sandwiches sold?They were shipped to retail locations nationwide and to the Department of Defense.
8. Can I heat the sandwich to melt the plastic?No, cooking will not remove the physical hazard and may make it harder to detect.
9. What should I do if I have one?Throw it away immediately or return it to the store where you bought it.
10. Who can I contact for a refund?You can contact the E.A. Sween Company Customer Service Hotline (typically 1-800-328-8184) for assistance.

Here’s What You Should Do

• Inspect your freezer: Look for “Deli Express BBQ Pulled Pork” sandwiches in 5.5 oz paper wraps.
• Check the Est. Number: Verify if EST. 2451 is printed on the package.
• Do not eat: If you find the recalled product, do not consume it.
• Discard or Return: Throw the sandwich in the trash or return it to the retailer for a full refund.

Behind the Brand

E.A. Sween Company, headquartered in Eden Prairie, Minnesota, is a major supplier of ready-to-eat sandwiches for the convenience store industry. The company produces millions of sandwiches annually under the Deli Express brand. This massive recall highlights the challenges large-scale manufacturers face when a single component of the production line—in this case, a sauce bottle—fails, potentially contaminating months of production.

Other Relevant Recalls

This recall follows a series of recent “foreign material” contamination events tracked by Source86. Danone U.S. recently recalled its So Delicious Frozen Dessert after discovering stones in the cashew ingredients. Similarly, Valley Fine Foods recalled its Chile Verde Egg Bites due to the potential presence of hard objects.

In a related incident involving foreign material in the pet food sector, Fromm Family Foods recalled its BeefiBowls due to potential plastic contamination. The recall, announced in early December 2025, affects 300 cases of Bonnihill Farms BeefiBowls Beef Recipe frozen dog food distributed across 14 states, including Texas and Wisconsin. Much like the Deli Express situation, this alert was triggered by consumer complaints of plastic pieces in the product, highlighting the universal challenge of preventing physical contaminants in processed food supply chains.

Eran Mizrahi, CEO of Source86, said that while the E.A. Sween recall highlights a single production error, it also underscores a broader truth in the food industry:

“Food safety isn’t just about compliance; it’s about trust. Every recall reminds us how vital it is to maintain transparency, rigorous checks, and supplier accountability.”

Ensuring Safe Eats

The discovery of plastic in over 60 tons of product serves as a critical reminder of the importance of physical contaminant detection in food manufacturing. While metal detectors and X-ray machines are common, plastic can sometimes be difficult to detect if it lacks density. Consumers rely on manufacturers to monitor the integrity of their equipment constantly. If you purchase ready-to-eat sandwiches, checking recall alerts is a simple way to ensure your quick meal is safe.

At Source86, we help food brands manage ingredient sourcing, FSQA oversight, and private label production with transparency and precision, ensuring that when recalls happen, supply chains are prepared to respond quickly. Contact Us!