How is the prevalence of x-ray mandates changing the food manufacturing industry? Suppliers have a lengthy checklist of steps to take to ensure food safety compliance, and for some, x-ray inspections might seem like just another box to check. However, these systems are more than just a formality; they’re fundamentally changing the way we define food safety.
Learn more about the benefits of foreign material detection in your production line, how your facility can comply with USDA regulations, and how to find x-ray equipment that suits your needs.
How Mandates From Major Retailers Are Driving Industry Changes
While there are several advantages to installing food x-ray equipment and metal detection systems, some suppliers don’t have a choice in the matter. Several large retailers are now requiring x-ray inspections if suppliers wish to put their products on the shelves.
Leading the charge is Costco. The wholesale chain, which has hundreds of locations across the U.S., now requires all stocked food products to be screened with a food x-ray detection device. Though there are exceptions to this rule for x-ray incompatible products, even those products must still be scanned by a food metal detector. Suppliers who aren’t compliant with this rule will automatically fail their Costco anniversary audit.
Rather than an isolated case, Costco’s actions should be seen as a bellwether, indicating the direction that other major retailers are likely to move in the future. Chains like Sam’s Club, Walmart, Kroger, and Target already have strict food safety guidelines in place which are likely to continue to change as the technology evolves.
And it’s not enough to simply buy the machines and turn them on. These new rules often come with increased training & certification requirements for manufacturers. Your staff must be actively performing inspections and quality-testing your products to ensure nothing harmful makes it through to store shelves.
The Evolution of Food Safety Standards and Regulatory Measures
The Food Safety Modernization Act aims to decrease the number of foodborne illness cases across the nation. First introduced in 2011, the legislation has since undergone various updates for suppliers to adapt to. A 2024 update emphasizes the importance of identifying physical hazards, highlighting the need for cutting-edge inspection equipment.
The Food and Drug Administration is also cracking down on production practices. To prevent product contamination and subsequent recalls, the FDA enforces the equipment validation process.
Contaminant Risks Go Beyond Metal Detection
When you rely on metal detectors to check your products, there are only so many objects that they can identify. What happens if a shard of glass ends up inside a package? Chances are, it will go undetected until it ends up in a consumer’s meal.
Today’s advanced x-ray systems can identify:
- Stones
- Glass
- Bones
- Rubber
- Dense plastics
According to Food Safety Net Services, 4.1% of all food recalls in 2024 were due to foreign objects, and an additional 3% cited a lack of inspection. Depending solely on metal detectors could make products vulnerable to a recall if the system can’t identify a non-magnetic foreign object, such as a shard of glass.
Food Manufacturing reports that more than 477,000 pounds of food were recalled in 2022 due to “extraneous materials.” Having an adequate x-ray machine to check for foreign objects before products leave the site prevents the hassle and safety concerns of a recall.
Cost Analysis and Investment Requirements
The prevalence of x-ray mandates often leaves suppliers with no choice but to install new systems in their plants. What does this mean for your facility’s finances?
The cost of food x-ray systems varies significantly. Standard models that handle a moderate volume can run anywhere from $60,000 to $120,000. On the other hand, your initial investment could cost as much as $500,000 if you prefer a machine with advanced automation technology or artificial intelligence.
You’ll also have to set aside funds for:
- Performing system maintenance
- Training your staff
- Increased energy consumption
Implementing and maintaining this technology could cause some financial challenges, especially for smaller processors. Review your plant’s finances and budget accordingly.
ROI and Business Benefits of X-Ray Inspection Systems
There’s no doubt that adding a food x-ray machine to your facility is a major investment. But is it worthwhile?
The rise of x-ray mandates goes a long way to explaining why so many manufacturers are adding this equipment to their production lines. However, that’s not the only reason suppliers are choosing to step up their inspection game. Some of the biggest benefits of installing an inspection system include:
- Recall prevention: Recalls not only lead to wasted product but can also tarnish a brand’s reputation. High-quality inspection systems protect businesses from these costly and high-profile failures.
- Improved operational efficiency: Real-time imaging allows for quick location and identification of contaminants, eliminating time and guesswork.
- Multi-functional capabilities: In addition to detecting contaminants, many systems can also perform weight checks and test a package’s seal. This type of investment can reduce the need for separate, costly equipment.
While the cost of a food x-ray system can be intimidating, the reality is that it’s far less costly than the damage that a single major recall can do to your brand. And when factoring in the savings of time and efficiency that modern x-rays offer, it’s a no-brainer.
How Modern Food X-Rays Make Implementation Even Easier
Deciding to purchase the equipment is one thing, but successfully integrating it into your production line is another. Thankfully, today’s technology makes the process a breeze.
With automatic detection/rejection and detailed data logs, you won’t need a full-time employee to monitor the machine. Dual-energy detection helps you catch even the most tricky contaminants that most older food x-ray systems miss. And modern Windows-based operating systems allow for real-time product imaging, letting your workers identify problems at a glance.
This is also why a good food x-ray won’t just be shipped to you sight unseen. It will come with training and support to ensure your staff is properly trained in its use, as well as annual testing and certifications.
Implementation Strategy and Preparation Steps
Whether you’re working to get compliant with x-ray mandates or looking ahead to future-proof your production line, it’s important to make a plan. Incorporating this technology into your facility could be a long and complicated process if you don’t know where to start. The right provider will be able to walk you through the process step by step.
Prioritize the following:
- Thorough assessment: Determine whether your current detection capabilities meet certain retailer requirements. Keep up with new industry regulations to determine if your plant will soon need new technology.
- Strategic product selection: Once you evaluate your detection needs, research available equipment. Select a machine that can meet your demands, such as one that processes powdered or solid food products.
- Timeline planning: If your plant has an audit scheduled and there’s a mandate in place, act quickly to avoid an automatic failure. Audit timelines often dictate when manufacturers have to install new detection machines.
- Training programs: For operational safety and compliance, train your staff properly. Installers like TDI Packsys assist with training and certification programs so your employees can operate the machine safely and with confidence.
Questions Food Manufacturers Should Ask About Installing X-Ray Systems
If you’re still on the fence about installing an advanced inspection system, make sure you ask the following questions:
- Are we compliant with current retailer requirements?
- What will non-compliance cost us in lost business opportunities?
- How do we calculate ROI on an x-ray equipment investment?
- Which x-ray technology best fits our product types and production volume?
- What are the long-term regulatory trends we need to prepare for?
Only you know the answers for your facility. Once you figure out what you need, it’s time to start researching equipment and installers.
The growing prevalence of x-ray mandates could make this the right time to embrace new technology. To find the ideal equipment for your facility, get in touch with the team at TDI Packsys. We will guide you through the process of selecting the right metal detectors, x-ray equipment, automated packaging systems, and more.
Submit our online form or call (877) 834-6750 to connect with a specialist.
