Flow wraps are a popular choice for packaging in the food industry. They secure product freshness and integrity and offer strong barrier properties and longer shelf-life. These qualities are important for maintaining product quality in supply chains, especially with the growing eCommerce demand.
Flow wrap production lines usually operate at high speeds, making it challenging to check product quality and safety. Rising costs of raw materials and energy add to food manufacturers' concerns. This article explores how the right product inspection equipment can control costs, even in unique flow wrapping applications.
There are three main stages for quality checks along a flow wrap line:
Different technologies can be installed at each point to check for physical contaminants, correct weight and fill level, and quality and labeling defects. Each inspection system plays a part in helping food manufacturers combat rising costs.
A great place to do this is before primary packaging, which is before a product is placed in its individual wrapper. Metal detection systems are often used at this point. They can reliably detect all types of metallic contaminants in food that occurs from contaminated raw materials, accidental introduction by employees (e.g., personal effects), accidental introduction during maintenance near the production lines, and equipment malfunction or breakage throughout the manufacturing and packaging process. If used before primary packaging, whether in horizontal or vertical lines, contaminated products are rejected before more value is added through packaging. This helps to minimize waste and reduce costs.
While metal detection is ideal before primary packaging, x-ray inspection is typically installed just after the flow wrapping machine packs the individual products. X-ray inspection systems can also perform quality checks, such as detecting missing or damaged items. At this stage, production speed is high, and any stoppages can result in costly downtime. X-ray excels here to help food manufacturers seeking efficient ways to maintain productivity. X-ray inspection detects multiple physical contaminants such as stone, calcified bone, and glass fragments, and it also performs integrity checks such as identifying missing or malformed products. It helps prevent substandard products from leaving the factory and potentially triggering a product recall.
Another way to prevent product recalls and reduce waste at this stage is through vision inspection. Precision cameras are used to check for label defects or missing information, helping manufacturers identify substandard packaging before it moves further along the production line. Vision inspection systems also save costs by eliminating the need for manual spot checks, which can often miss labeling issues.
Dynamic checkweighers can also be installed after the flow wrapper. They accurately weigh each wrapped product at high speeds, verifying each product complies with weights and measures regulations. Expensive product giveaway is avoided as overweight products are detected immediately and can be placed back into production for re-work. Dynamic checkweighers eliminate the need for time-consuming manual spot checks and support requirements, all helping manufacturers boost productivity and save costs.
This is the final opportunity for a food manufacturer to check product quality and safety and avoid potential recalls. An ideal solution here is a machine that combines checkweighing and label inspection. Checkweighers offer exceptional accuracy, helping products comply with local and international weights and measurements regulations. Vision inspection cameras verify that all information on a food label is correct, including vital allergen and expiration date details. Errors or missing data on labels can lead to costly product recalls, so investing in this technology can save significant expenses.
The combined power of these technologies also offers other cost savings. A combination machine saves factory floor space as it is more compact than two separate machines. It also reduces maintenance costs since only one engineer is needed to service the entire system. At this stage, a combination solution is an excellent choice for both space and cost savings.
Another way to combat rising costs in flow wrapping applications, alongside product inspection equipment, is software. ProdX™ is our innovative quality inspection data management software that works in tandem with our inspection devices, allowing food manufacturers to collect and safely store production data. Automated reporting capabilities saves time and labor costs. Preparing for food safety audits is easier with ProdX™ because all production data is readily available. Additionally, data analysis can help optimize production processes for further efficiency savings. Software like ProdX™ helps reduce costs and takes food safety to the next level.
In today’s uncertain economic climate, food manufacturers must do everything they can to keep costs under control. Product inspection solutions, software, and services from an experienced provider like METTLER TOLEDO can help combat rising costs in flow wrap applications and beyond. To learn more about this topic, watch our on-demand flow wrap packaging inspection webinar.
Miriam Krechlok, Segment Marketing Manager, METTLER TOLEDO Product Inspection
Miriam provides expertise and insights for business development and segmented marketing activities in food and pharmaceutical segments. With experience in corporate identity and marketing in the food, cosmetic, and pharma industries, she has a wealth of experience to deliver great insights into these key segments. Based in Germany, her previous role at METTLER TOLEDO was Head of Marketing for the DACH region.
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