Did you know that over 600 food recalls occur in the US annually? This startling statistic, reported by Food Safety Magazine, highlights the importance of identifying metal and other dangerous objects in sensitive production environments. Manufacturers must implement the best practices for integrating metal detectors in production processes.
Learn how businesses can use this technology while adhering to HACCP compliance standards and other industry regulations, including FDA, USDA, and ISO 9000 requirements. This comprehensive guide dives deeper into the role of industrial metal detectors for quality assurance and tips for enhancing food safety.
Understanding Metal Detection Technology
The two main types of food metal detectors are balanced coil systems and magnetic field systems. With a balanced coil system, the technology uses one transmitter piece that emits a high-frequency field. Two receiving coils alert the connected control and signal processor if a metal particle enters the field, also known as the illuminating process.
Magnetic field systems feature a tunnel lined with coils and a strong magnetic field. When ferrous materials pass through the tunnel, the coils generate an electrical current that triggers the detection alarm. This technology is ideal for inspecting foil-packed items.
Despite the many advantages and capabilities of these systems, they also have some limitations. Small pieces of stainless steel or non-ferrous materials likely won’t trigger a magnetic field detector, while the size and shape of contaminants could bypass a coil-based system. This ultimately impacts the chance of a recall and subsequent product effect compensation amounts.
Tips To Follow When Planning for Integration
One of the best practices for integrating metal detectors in production is to plan ahead. Assess your production flow and figure out your space requirements. Before investing in food inspection technology, ensure your property has the proper infrastructure to power and clean these systems.
Your planning process should focus heavily on finding the right spot for new equipment. This involves evaluating your existing Hazard Analysis and Critical Control Points system to mark areas of concern. Identify critical control points along the assembly line and use them to determine where to place the detection system.
Use multiple checkpoints, particularly early and late-stage production detection. This way, any contaminants found at the beginning of the process can be removed easily. Another metal detector near the end of the line ensures quality and safety before you ship items to consumers.
Essential Equipment Selection Criteria
How do you choose an inspection system for your manufacturing plant? With so many cutting-edge products available, narrowing your options may seem difficult. However, you should select technology based on the business’s unique needs.
Figure out how well the machine will serve you in the following scenarios:
- Processing wet vs. dry products
- Detecting contaminants in unpackaged vs. packaged items
- Identifying problems as quickly as products move through your line
- Working in a building with a set temperature or humidity level
Researching these factors can help you find the right system for your building. In addition, you should consider the IP rating of machines and aim for a higher number for optimal protection. Don’t forget to look into a detector’s cleaning requirements before investing in new equipment.
Installation Best Practices
What are some of the best practices for integrating metal detectors in production plants? Experts recommend the following measures:
- Mount them properly: If you opt for a conveyor-mounted system, let a trusted professional install it for optimal stability.
- Integrate them with your food production management system: Given their essential role in quality assurance and overall product safety, your metal detectors should become a central part of your plant’s production management software.
- Utilize rejection systems: A metal detector can only benefit you if you have an effective rejection system in place. These allow you to investigate possible contaminants and remove them from the line.
- Consider electrical components: Bear in mind that your staff will have to clean and monitor these systems regularly. Think about nearby electrical components that may hinder these steps.
- Manage potential interference: Don’t install your metal detector or food X-ray system near items that could lead to false triggers.
How To Optimize Detection Sensitivity
Along with the aforementioned best practices for integrating metal detectors in production lines, food manufacturers need to strike a perfect balance between enhanced system sensitivity and false rejects. You don’t want to constantly deal with false alarms and reject logging because the detector is too sensitive. However, you also don’t want any harmful contaminants to bypass the machine and potentially impact consumers.
Calibrate your detector to get the most accurate results for certain products. Adjust the settings based on the following:
- Product type
- Item size
- Packaging
For example, a plant that processes trail mix in both foil wrappers and plastic containers will need to adjust its metal detector to avoid false rejections in the packaging. If a manufacturer ships both frozen meals and fresh produce, the calibration settings must adapt to each item.
Keep sensitivity controls in the hands of trained employees only, and have them document setting changes. Establish system validation protocols to verify contaminants within an hour of item rejection.
Perform routine testing to check the detector’s sensitivity and ensure it works properly. Send test packs containing ferrous and non-ferrous items through the conveyor to see if the machine rejects them. Don’t hesitate to recalibrate your system or contact the manufacturer after a failed test.
Implement Effective Rejection Systems
State-of-the-art industrial metal detectors, like TDI Packsys products, feature automatic rejections. When the machine identifies the slightest trace of metal within a product, it will drop that item into a reject bin for inspection. Other common rejection systems include:
- Stop-on-detect mechanisms: The inspection line comes to a halt when the machine flags a possible contaminant.
- Air blast systems: These machines send a quick blast of air toward the product to move it to the reject bin.
- Retractable conveyors: The conveyor will automatically retract, so flagged products can’t continue to move through the line.
- Pusher mechanisms: Potentially defective packages will be pushed to one side of the conveyor.
One of the best practices for integrating metal detectors in production lines is to perfect your rejection methods. The machine will streamline your quality assurance process with fail-safe operations and prompt timing. It’s vital that your staff contain the rejected items and inspect them to rule out dangers.
Focus on Maintenance and Performance Monitoring
Invest in consumer safety by regularly inspecting and testing your equipment. Train your staff on cleaning procedures and conduct performance verification tests. To optimize sensitivity, you should also set a metal detector calibration schedule and adjust this equipment when necessary.
Preventive maintenance ensures that the machine works properly so you can get the most out of your investment. More importantly, it promotes food safety so you can provide quality products to consumers.
Are you ready to implement these best practices for integrating metal detectors in production? Reach out to TDI Packsys to explore our cutting-edge technology. Request a quote online or call (877) 834-6750 to get started.
