Let’s put ourselves in the position of a production line operator who must test metal detectors used in free-fall applications; they are likely to face several daily challenges. Firstly, interrupting production multiple times per shift to verify the metal detector continues to work as it should. Secondly, manually recording test results and filing them correctly. Thirdly, climbing ladders and stretching across equipment, which can put their safety at risk. Switching from manual testing processes to automatic ones can overcome these challenges and deliver tangible benefits.
Automatic Test System (ATS) from METTLER TOLEDO is a value-added accessory that can be supplied at the point of sale, or retro-fitted to compatible metal detectors used to inspect free-falling product in vertical packaging or gravity-fed applications. Throat metal detectors are typically used to inspect products such as crisps, sweets, nuts and cereals in Vertical Form, Fill & Seal (VFFS) processes. Gravity Fall metal detection systems are most often used to inspect bulk granular and powdered products prior to the packaging stage such as infant formula, sugar, flour, nutraceuticals, and fertilizers.
Automatic Test System from METTLER TOLEDO has enabled Italian savory snack retailer, PATA S.p.A., to enhance the accuracy and efficiency of its quality control processes, reducing the risk of contamination and offering high standards of product safety and integrity. Seamless integration with existing production systems empowers real-time monitoring and data analysis, driving informed decision-making and continuous process improvement.
Read the full case study below to learn how PATA successfully used Automatic Test System with their metal detectors.
With ATS, the test samples sit inside the metal detector’s aperture and the pneumatic control transports each test sample in turn to a defined position above the principal sensing coils within the metal detector. The test sample is then released, simulating the presence of a contaminant in free-fall under gravity.
This replaces the traditional method of manual testing where your operators would likely have had to work at height, randomly introducing samples to conduct routine metal detector performance tests. Now, a software algorithm within the ATS correlates sensitivity readings from the position of the ATS to the center, offering precise detection and confirming centerline (worst case) sensitivity.
Conventional performance testing can be almost impossible to consistently test the center of the aperture – the weakest point of detection (confirming worst-case performance of the metal detector). ATS uses ferrous, non-ferrous and stainless-steel test pieces (aluminum option also available) and a second detection threshold to confirm centerline sensitivity and improve testing accuracy.
Due to its accurate centerline testing, ATS is acknowledged as a best practice for achieving compliance with stringent quality standards. It aligns with the Global Food Safety Initiative (GFSI) guidelines, providing a reliable method for meeting regulatory requirements and maintaining food safety standards. Plus, a high street retailer is now citing it in their code of practice.
ATS virtually eliminates the need for manual intervention and associated production line stoppages, seamlessly integrating testing processes into ongoing production to maximize output. Unlike manual testing which typically requires two operators to complete the routine performance tests, ATS requires only one operator to run the end-to-end process.
By streamlining testing procedures and reducing testing times to under 40 seconds, ATS can deliver substantial savings in both time and resources, enhancing operational efficiency.
ATS adopts a non-invasive testing approach, minimizing the risk of cross-contamination inherent in manual methods, upholding stringent food safety standards.
ATS virtually eliminates the need to work at height to complete performance tests of vertical packaging applications and removes the need to reach across production equipment to insert test samples into the product flow.
Moving away from having to ask your operators to work at height to routinely conduct performance monitoring tests instantly improves operator worker safety.
Reduce the risk of errors or lost documentation from manual record-keeping by incorporating quality inspection data management software such as ProdX.
ProdX allows you to automate reporting and manage data, helping you to enhance efficiency and sustainability while meeting the demands of modern manufacturing practices. Electronic records can also help facilitate compliance with evolving industry standards and regulatory requirements and provide the necessary information in the event of a product recall or audit.
Investing in an approved metal detection Automatic Test System is essential if you want to make sure your equipment is working correctly, every time. Automatic Test Systems help you meet compliance needs, while increasing productivity and improving product quality.
Automatic Test System (ATS) from METTLER TOLEDO can help ease the burden of testing Throat and Gravity Fall metal detection systems. It is designed to improve the accuracy of performance monitoring tests and reduce the time it takes to carry them out.
Download our “5 Reasons to Invest in Automatic Test System” application note to discover how an Automatic Test System can deliver significant quality and productivity benefits to your business.
