We’ve often written about metal detection technologies used in food production facilities as part of food safety and quality product inspection programs. But we haven’t addressed what one should do after the metal contaminant is found and removed. That’s where portable XRF analysis technology can be utilized.
Industrial food metal detectors have been an important safety tool in the food industry. Metal detectors find small particles of ferrous, non-ferrous and stainless steel using coils wound on a non-metallic frame and connected to a high-frequency radio transmitter. When a particle of metal passes through the coils, the high frequency field is disturbed, changing the voltage by a few microvolts. The high frequency field is no longer balanced. The output is used to detect metal and then the contaminated product will be rejected from the production line.
These systems provide reliable, cost-effective protection from even the smallest metal contaminants found anywhere in a food-production process. It is not uncommon for pieces of mesh screen or broken-off parts from metal food processing equipment to find their way into packaged foods. Food metal detectors are one of the ways that food processors help ensure only metal-free food products are being shipped to consumers.
Metal Contaminant Sources
However, after a piece of metal is found, what does the operator do with it? Yes, it’s great that it has been found and removed from the food processing line so it doesn’t end up in a consumer’s hands. But there are many questions that still need to be answered:
- Where did the metal come from?
- Was the metal piece contained in the raw materials or part of the machines running in the facility?
- Is there a broken machine still running?
- Has a blade snapped so slicing is no longer working properly?
- Will there be additional metal pieces falling into food products that will need to be found by the product inspection equipment?
- Should the line be shut down?
- Should the whole facility be shut down?
- Will a recall have to be made?
In food processing plants where there are hundreds, maybe thousands of screws, rivets, screens, and other metal pieces, it is difficult to know the origin of the metal contaminant. Thus, it may not be possible to prevent further damage to machines or stop metal contaminants from entering the process.
XRF Technology Can Help Identify the Metal Contaminant
There is XRF technology available now that can be utilized as part of an investigation to help determine the contaminant source so appropriate corrective actions can be taken. Portable XRF analyzers, which are used to identify metals and alloys in manufacturing plants, can also be utilized in food processing facilities.
There is some preparation needed, though. First, the production line must be mapped. A spectral fingerprint library of potential contaminants must be created through XRF scans of parts and components throughout the line, using a portable XRF analyzer. This way, after a product is rejected by the product inspection equipment, the metal contaminant can be analyzed by the same portable XRF analyzer, right on the plant floor. The cause can be identified by comparing the contamination ‘fingerprints’ revealed through detection to the XRF analyzer’s library that has been created. If there is a match, plant personnel will know the source of the problem and can immediately mitigate any issues – whether it’s fixing the machine or replacing parts. If there is no match, then there is a probability that there were metal contaminants in the raw materials, so supplies should be thoroughly checked before entering the production process.
4-Steps to Enhancing Food Safety
Many food facilities are using this 4-pronged approach to foreign material contamination as part of a food safety and quality program:
- Inspect products or ingredients with Food Metal Detectors or X-Ray inspection systems
- Detect by using technology that will determine contaminant type and size
- Reject and remove product containing foreign body from the production line
- Identify utilizing XRF technology to help determine contaminant source in order to implement fast corrective actions
The quicker the problem source can be identified, the minimal amount of downtime the facility will face, and the better your brand and bottom line are protected.
Additional Resources
- eBook: A Practical Guide to Metal Detection and X-ray Inspection of Food
- eBook: XRF Technology for Non-Scientists
- Resources for Food Weighing and Inspection
Editor’s Note: This article was originally published in August 2019, but has been updated and broken links fixed.
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