How does metal detection help to keep food packaging industries compliant and products safe?

Productivity and Compliance in Vertical Packaging

Inspecting free-falling, dry product applications can be a challenge for food manufacturers who want to increase productivity, improve product quality and ultimately protect their brand reputation. Explore how METTLER TOLEDO Safeline's innovative Reduced Test Mode, ATS - Automatic Test System, Emulation and eDrive™ features optimize testing procedures, improve product and process quality and enhance worker safety, to enhance overall brand protection.

Metal contaminants can enter food products at any stage in production, from the arrival of raw ingredients to the packaging stage. This contamination can come from various sources and can pose a serious health risk to consumers and a threat to the manufacturers brand reputation. Using industrial metal detection systems in food packaging lines and industrial metal detection systems for food processing lines before packaging starts can help to identify and remove metal contaminants from food products throughout the manufacturing and packaging process. This helps to keep manufacturers in the food industry compliant with food safety regulations while at the same time protecting the customer and the reputation of the brand.

Why is food safety so important?

Food safety is a top priority in the food and beverage industry to make sure that the food products produced and consumed are free from harmful contaminants that could cause illness or injury. The food industry is responsible for producing and supplying safe food to consumers. Food safety practices, such as installing a metal detection system on the production line, can help to maintain consumer trust and confidence in the food supply chain, while giving food brands with proven safety records a competitive edge and access to global markets.

What is the typical setup and management of a metal detection system?

  1. Equipment Installation: Metal detection equipment (such as a metal detector head with conveyor system) is installed at pre-defined Critical Control Points (CCPs) throughout various areas of the food production process. This can be at the beginning of the line to monitor incoming raw materials, in the middle of processing at points where metal contamination is most likely to occur, and at the end of the line before or after final packaging.
  2. Product Inspection: During production, food products are passed through the metal detection equipment to check for any metal contaminants. The metal detector head generates a magnetic field that detects for the presence of metal particles in the product.
  3. Calibration and Validation: Metal detection and inspection equipment must be calibrated and validated regularly to check that it is functioning as expected and accurately detecting metal contaminants, i.e., daily performance monitoring and periodic performance verification. This process involves testing the equipment by running metal detector test samples of different sizes and types through the equipment to confirm that it is working properly, as well as covering other compliance checks.
  4. Documentation and Record-Keeping: Food manufacturers are required to maintain detailed records of their metal detection activities, including testing results, due-diligence checks, and any corrective actions taken in response to identified issues. These records are used to demonstrate compliance with regulatory standards and to identify areas for improvement in the metal detection process. Using a reliable Quality Management System (QMS) software helps to reduce the time and effort needed for proper documentation.

Is it safe to use a metal detector on food? Will it affect the quality or taste of the food products?

Metal detection systems are designed to support food safety without compromising the quality or taste of the food products. Our technology allows for precise detection of metal contaminants while preserving the integrity and nutritional value of the food. Thus, consumers can enjoy safe and high-quality food without any negative impact on taste or dietary composition.

Smart Metal Detection Solutions

Safeline Metal Detection systems from METTLER TOLEDO can safely detect and reject metal contamination from production lines to help manufacturers achieve compliance, minimize risk of product recalls and reduce production downtime.

What other entities are involved in food safety compliance topics?

  • European Food Safety Authority (EFSA): The EFSA is the agency of the European Union that provides independent scientific advice and communicates on risks associated with the food chain. Its goal is to ensure a high level of food safety across the EU.
  • Codex Alimentarius Commission: The Codex Alimentarius Commission is a joint initiative of the World Health Organization (WHO) and the Food and Agriculture Organization of the United Nations (FAO). It develops international food standards, guidelines, and codes of practice to protect the health of consumers and ensure fair practices in the food trade.
  • Hazard Analysis and Critical Control Points (HACCP): HACCP is a food safety management system that is recognized worldwide. It is a preventative approach to food safety that identifies and evaluates potential hazards in the food production process and establishes critical control points to prevent or reduce those hazards.
  • Global Food Safety Initiative (GFSI): The GFSI is a collaboration of some of the world's leading food safety experts, retailers, manufacturers, and other stakeholders. Its goal is to improve food safety by establishing a benchmarking system that recognizes and certifies food safety management systems around the world.
  • Compliance officers: Compliance officers are professionals responsible for ensuring that organizations comply with relevant local regulations and laws. In the food industry, compliance officers may work for regulatory agencies, food manufacturers, or other organizations involved in the food supply chain. They are responsible for ensuring that organizations meet all applicable food safety and regulatory requirements.

What software is available to help meet compliance goals, improve performance checks, and facilitate due diligence?

Boost your productivity with METTLER TOLEDO smart ProdX software

Boost your productivity with our ProdX software, which simplifies quality management processes allowing you to focus on what really matters - producing high-quality goods.

METTLER TOLEDO offers many solutions to help your food processing facility run smoothly and compliantly.

ProdX Quality Management Software helps manufacturers automate and optimize their production processes for consistent product quality while reducing the risk of recalls and regulatory compliance issues. 

The Automatic Test System (ATS) is designed to improve the reliability and consistency of performance testing in your metal detector. It can be controlled through the HMI or a Control Unit and optimizes testing for various metal types. With the ATS, it's possible to complete up to four tests for FE, Non-Fe, SS, and AL in under 60 seconds. This system also enhances worker safety by reducing the need for workers to climb ladders or work at heights during testing.

Reduced Test (RT) Mode reduces the frequency of metal detector testing by tracking and identifying any issues that may affect performance during production. This intelligent software is designed to continuously monitor the metal detector's performance and alert users of any changes that could cause it to operate out of specification, while also reducing the frequency of testing and the time required to carry out tests in VFFS and free-fall applications.

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