Food inspection is nothing new, but the technology behind it continues to advance every day. Where once food processors relied on simple weight testing or visual inspection, they now use metal detectors and x-ray inspection systems.
Having a proper food inspection system in place isn’t just a good idea, it’s a requirement for getting your products stocked on many major retailers’ shelves. But even if you know it’s the right step for your business, taking that step can seem daunting.
That’s where we come in. Let this guide walk you through the steps of evaluating, purchasing, and integrating your new food inspection equipment into your line. As a leading provider of food inspection systems of all kinds, we’ve helped manufacturers of all sizes modernize their production lines.
Pre-Installation Tips for Food Manufacturers
The process of buying your food inspection system doesn’t begin when you click “Add to Cart,” and it doesn’t end at delivery. Much like any investment you make into your business, it requires careful consideration.
Know Your Goals
In an industry as highly regulated as food production, you have to align your goals with compliance standards. Ask yourself one simple question: Why does the plant need an inspection system?
Your answer might have to do with updates to the Food Safety Modernization Act or mandates put in place by major retailers. If so, their requirements will be guiding your decision-making. On the other hand, maybe your brand has been hurt from recalls in the past, in which case the nature of the contaminant would dictate what sort of inspection system you need.
It’s equally important to look ahead into the future. Even if there hasn’t been an incident in your line yet, consider what might happen. If your facility works with glass bottles, for example, you’d need a system which can detect non-metallic contaminants if one of those bottles breaks. Are you a high-volume manufacturer? You might need to invest into automatic sorting/rejection systems to ensure the inspection process doesn’t slow down your line.
Choose the Right System
Any guide to introducing new food inspection systems will urge you to take your time selecting your equipment. After all, this decision could potentially improve your operations or present you with more challenges.
Are you thinking of installing a dual-energy x-ray inspection system or an advanced metal detector? What types of features does each system need to help you meet your goals? Does the equipment meet government rules put forth by the FDA and USDA?
Dig deeper into available metal detector and x-ray capabilities. A standard model could meet current requirements, but more innovative solutions could help put your brand above the competition in terms of food safety.
Don’t just research the products themselves. Talk to different suppliers and see if they offer support, manuals, and training. It might be in your best interest to work with a supplier who not only installs new equipment but also trains your staff and is available for technical support.
Prepare Your Space
Finding the ideal machine is just one piece of the pre-installation puzzle. You’ll have to turn your attention to the space. Your priorities include:
- Checking the infrastructure: Ensure that there’s enough room for a new machine and that it can hook up to nearby electrical outlets.
- Clearing the area: Prepare the facility by cleaning the space where your new system will go.
- Making any necessary adjustments: If you plan to integrate a new x-ray machine or metal detector into your current setup, you may have to make some minor adjustments.
Key Components of a Successful Installation
What comes next in our guide to introducing new food inspection systems? With preparation complete, it’s time to install the technology inside your facility. This process can have its challenges, but the tips below can help you avoid unwanted setbacks or delays.
Set Up the System
Inspection systems can help improve your operations. However, some downtime and interruptions are inevitable while installing them. See if your supplier is willing to perform the installation in stages to minimize business disruptions.
Calibrate the equipment immediately to ensure that it works properly. If you wait to calibrate it, you may run into performance issues that slow down your operations.
Organize Owner’s Manuals and Instructions
Your system will likely come with one or more self-inspection guides. Look through the documents and keep them in a safe place if you ever need to access them. It’s wise to create digital files as well for easy access.
Assemble Data Connections
The next step in the installation process is to connect your machine to existing computers. Make sure you only provide select users with access. Trained staff should be the only ones allowed into the system.
How To Properly Use and Improve Your Equipment After Installation
This guide to introducing new food inspection systems doesn’t stop once the technology is set up. It’s now time to start using it and reaping the benefits of accurate contaminant detection. Check out the ways your plant can make this phase of the process a success.
Make Sense of the Results and Daily Operations
The staff who will be operating the machine have to know its basic functions. Your first step is to teach them how to start and stop the system, as well as how to react to potential problems.
Reviewing results can be a challenge at first. Dedicate ample time to teach employees how to read the results and understand them. Completing these steps can ensure that your company begins accurately detecting contaminants from day one.
Review Data and Report Problems
You’ll have to compile reports of everything the system finds, including contaminants like:
- Glass
- Stones
- Metals
- Bones
- Dense plastics
Take note of anything that triggers the rejection system using a simple, easy-to-read template. Perform a risk-based assessment if you identify any patterns in your reporting. This helps your facility stick to the highest quality standards.
Prioritize Machine Maintenance
Cutting-edge food inspection gear is no small investment. Make sure you get the most out of yours by performing routine maintenance. Experts recommend:
- Frequently cleaning the equipment
- Scheduling regular checks
- Keeping spare parts handy as a precaution
Do you know who to call if something goes wrong? Reach out to your supplier if you need any technical support or repairs.
Establish Training Protocols and Standard Operating Procedures
You may think that the only people who need training are the ones who’ll operate the machine daily. While they certainly require and benefit from robust training, other staff members should learn various protocols. Your business’s guide to introducing new food inspection systems should pertain to the following workers:
- Operators: Those who oversee these machines every day should understand the complexities of using them.
- Technicians: Some team members should have the role of fixing or adjusting the gear if it malfunctions or needs calibrating.
- Managers: Supervisors are in charge of checking reports and taking action if problems arise.
Integrating new technology into your facility could pose certain safety risks. Update your company’s rules and safety plans as necessary.
Streamline Your Operations With These Tips
After the initial transition, everyone in your facility should be used to having an inspection system on the production line. This doesn’t mean there isn’t room for improvement. Check out some simple ways that you can maintain a productive workflow.
Monitor the System’s Performance
Ensure you’re always adhering to food safety regulations set forth by government agencies. Regularly monitor the machine for any mistakes and track its uptime. If your gear consistently processes packages but sees an increase in false rejections, it may be time to recalibrate it or consult a technician.
Welcome Feedback and Suggestions
Your operations can’t improve if you don’t know where to begin. That’s why it’s important to encourage team members to provide both positive and constructive feedback. Consider scheduling regular meetings to discuss how the system is working.
Team discussions could uncover potential issues with the equipment that business leaders aren’t privy to. They also allow people to come together and brainstorm solutions for continued success. In some cases, manufacturers may ask vendors for feedback about their products and distribution services.
Build a Good Team Culture
Your staff may hit a few bumps in the road. After all, the food production industry faces constant scrutiny and is subject to frequent regulatory updates. To prevent safety and productivity issues, try to cultivate a positive workplace culture.
Reward staff members who play a crucial role in keeping things running smoothly. If an employee causes a delay or makes a careless mistake, encourage them to take ownership of their actions. This type of culture can motivate workers to be at their best and minimize errors.
Remain Compliant With All Food Safety Regulations
Once you go through all of the steps above, there’s still one essential task left. Keep your facility compliant with various food safety laws. Not only does this ensure consumers receive safe, uncontaminated products, but it also protects your business from harsh legal penalties.
How can you stay on top of compliance issues? Experts recommend the following tips:
- Keep clear records that show you’re adhering to all regulations.
- Store your data in a way that meets legal requirements, as outlined by the FDA and FSIS (including the electronic records provision).
- Practice for site inspections or audits using regulatory requirements and agency guidance, such as the FDA’s Draft Guidance for Industry: Hazard Analysis and Risk-Based Preventive Controls for Human Food and FSIS Guideline for Industry Response to Customer Complaints (including foreign materials) and the Federal Register notice announcing it.
Do you still have unanswered questions after reading this guide to introducing new food inspection systems? Our team at TDI Packsys can help. We’re a leading supplier of food safety systems and are happy to assist you in your search for x-ray, color sorting, or metal detection equipment.
Submit our online form or call (877) 834-6750 to learn more.
