Food Grade Metal Detectors

Pointers on Choosing Metal Detection Systems

June 1, 2026
Food Grade Metal Detectors

Pointers on Choosing Metal Detection Systems

June 1, 2026
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HACCP Plan

HACCP PlanHow in the World Do You Write a HACCP Plan?

Writing a HACCP plan is a daunting task. If you’ve never seen one, or your company has never created this kind of document, it may seem like an overwhelming job. The FDA, USDA, and FAO, among many others, all offer helpful information and guidelines for putting together the necessary records that will demonstrate your Standard Operating Procedures (SOP), Prerequisite Programme (PRP), Critical Control Points (CCP), Quality Control Points (QCP) and other details. It’s pretty easy to get lost in the sea of acronyms. The FSIS provides a copious list that, even to the knowledgeable food industry expert, can appear overpowering.

Here are a few of the things a HACCP Plan includes:

  • HACCP Team Identification: a list of all personnel involved in and/or responsible for developing, implementing, maintaining and documenting the plan.
  • Process Flow Diagram: A diagram covering the full process, including a step-by-step outline from the intake of raw materials to final delivery, with all identified CCPs.
  • Product Description & Intended Use: specific and comprehensive data/information about the food, its ingredients, processing methods, method and type packaging, storage details, safe shelf-life, and expected consumers.
  • Hazard Analysis: Recognition of possible and probable organic, chemical, or physical risks at each step of production.
  • Monitoring Procedures: Planned oversite and measurements to guarantee CCPs are within required limits, including rate for testing and responsible parties.
  • Critical Control Points (CCPs): Classification of specific places, steps, or process points where control can be implemented to minimize and/or prevent, remove, or reduce a vulnerability to an better-than-reasonable level.
  • Critical Limits: Max and minimum values (e.g., temperatures, humidity, condensation) that must be achieved to ensure the CCP is controlled.
  • Corrective Actions: Detailed actions to be carried out when monitoring warns of a deviance from a critical limit, safeguarding unsafe product from being introduce to the marketplace.
  • Verification Procedures: Actions, e.g. recorded evaluations and machine calibrations, to confirm the HACCP methods are employed effectually.
  • Record-Keeping & Documentation: Thorough documentation of the threat analysis, the plan itself, monitoring logs, remedial actions, and audit results.

Since we (Regal Packaging Services) don’t manufacture, process or package any food products, we’re not required to have a HACCP plan, however, we go through a very similar process with our ISO certification.

Testrods.com, as a division of Regal Packaging Services has held ISO Certification since November of 2018. ISO stands for the “International Organization for Standardization and is an international standard development organization composed of representatives from the national standards organizations of member countries. [It] was founded on 23 February 1947, and … has published over 24,500 international standards covering almost all aspects of technology and manufacturing.”1

There are a wide variety of reasons ISO Certification is important. But what it really means to you, as a Testrods customer, is that we’ve taken the time to make sure our manufacturing and sales practices are trustworthy.  It means we’re held accountable for the way things work both in our manufacturing, sales, and customer service. We test and retest products.  When we send an order out, we know it meets the standards necessary for your success as it relates to food safety. And we acquire our materials from the right sources so we know they can be trusted on your behalf.

To ensure this is always true, there are 3 parts of our process that are crucial to keep our products safe for use in the marketplace:

Customer focus:

We have a written procedure for how we handle incoming orders, whether by phone, email or our website. Every order is handled using the same steps and is documented in the same manner. No customer’s order will be lost in a chaos of paperwork, regardless of its timing or arrival. That’s not to say that mistakes aren’t made, but they represent less than 2% of our volume. Less than 0.35% represent a issue with the manufactured product. And when an error does occur, we are quick to resolve the issue with 24-48 hours.

Process approach:

As an organization we understand that a desired result is achieved more efficiently when activities and related resources are managed as a process or series of interconnected activities.  Our methods and procedures are designed to ensure that we send out consistent, quality, certified products.  Every step of the manufacturing chain is well thought out and well supported.  A series of checks and balances means we’re able to keep defective products off the shelf and out of the marketplace.

Improvement:

We had to achieving continual improvement across all aspects of our quality management system; it is one of our main annual objectives. We never assume that because we have been doing something a certain way that it cannot or does not need to be changed to produce a better result. We approach every day with an attitude that asks, “Can I do this better?”  We are not afraid to find new suppliers or investigate new ways to make custom products to meet the needs of your specific application.

Evidence-based decision making:

As an organization we have committed to only make decisions relating to our QMS following an analysis of relevant data and information.  We also never assume that what we “think” is happening is really occurring without checking the data to verify the accuracy of our thinking.  We work to resolve anything that may appear puzzling on the surface before we make any change to a process or a material.

In the end analysis, we want to be absolutely certain we can say with confidence that what we deliver to you is exactly as good as we claim it is.  When you’re using our products to test your equipment, you can be absolutely confident they are doing what they should.

As stated on our certificates, “Regal Packaging Services Inc., as a supplier of set products, testifies that the balls used are certified as being accurate in size and type (Grade 200 or better) and are traceable to the NIST standard applicable for this industry. Each lot is verified to produce an appropriate metal detector signal proportional to the metal sphere size/type and detector phase settings. Each lot is also verified to attenuate the appropriate x-ray, proportional to the density of the metal sphere size/type and x-ray detector settings. The metal detector signal and x-ray attenuation produced from these products does not deteriorate over time and our certificates do not expire. All items are approved for food contact in accordance with the FDA, Title 21 CFR 177.2470 and 177.1630.”

Find out what makes us different when you order here on our website, or call us at 866-691-8560 or email testrods@testrods.com.

 

 

  1. https://en.wikipedia.org/wiki/International_Organization_for_Standardization

 

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Floatable Thermoform Test Cards

Some applications involve large tubs, vats, or some other type of product travel where it would be nice to have a test piece that floats. Once again, our thermoform cards provide the simplest solution. We simply insert some type of structure that forces the thermoform card to retain air, which, of course, is what makes it float. We have also manufactured floating rods, which are more difficult because there is less space to close in enough air to make the rod float but is doable.

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Chip Clip

We took an ordinary plastic “chip clip” as defined by the customer and embedded the contaminant into the clip. The clip can be attached to the product on the line without damaging or opening the product for testing purposes.

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Bone Simulate

Bone is a difficult contaminant to find because it can vary widely based on the size, age, and calcium content (as well as feed used) of the animal. After working with several customers, Regal Packaging Services offers Pork, Beef and Chicken Bone Simulate. We have a small range of sizes at a variety of depths to simulate whatever you might expect to find in the product. Our recommendation (assuming your x-ray has visual display) is always to start with a multi-card. Using a multi-card gives you an easy way to test several sizes and depths to determine what matches the bone you’re using. Once you’ve made a comparison, testing the card against the bone you’re looking for, you can purchase a card with a single contaminant for regular testing.

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10mmd x 25mml Pill

This small pill shaped test piece is used in a system with a vacuum tube that shoots the test piece through the aperture and returns it to the “home” base. Your system may never be like it, but the point is that we can make a customized solution no matter how unusual or impossible it might seem.

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Thermoform Multi-Cards

As you may have seen in some of the other thermoform card descriptions, we can put nearly as many seeds as you can imagine on a single card. Pictured here you will find a wide variety of configurations and contaminants. Just let us know your specs: size of the card (up to 8” x 8”) along with size and type contaminant(s) and we’ll get you a quote as quickly as possible. Working with a multi-card is especially helpful when you are looking for multiple types of contaminants or when you want to determine what size of the same contaminant you are able to detect. In that event, once the size is chosen, you can order individual card(s) for regular, standard inspection and detection.

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48inch Testrod

There are a wide range of applications that require a test piece much longer than our standard 5” or 6” Testrods. We can make up to 3/8” x 34” or 1/2” x 34” rigid test pieces which can then be extended well beyond that length with a “handle” made of acetal cylinder larger than the 3/8” or 1/2” extension. In the photos, we used a 1” x 24” cylinder handle with a 3/8” x 24” inch extension.

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12x0.375 with Pointed End Test Pieces

Test pieces can be made in a variety of sizes and given a pointed end in applications that require the contaminant (metal) to be inserted into a food package such as sugar or some other soft packaged food product. This allows the metal to reach the center of the aperture.

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Double End Whips

Double-End Test Whips are also available, with metal in both ends. One consideration is to make certain that the whip is long enough to keep the metal on the non-testing side of the whip outside the metal free zone of your detector. If you insert, for instance one end of a whip with 2.0mm and 3.0mm Ferrous, you need to make certain that the 2.0mm metal doesn’t affect the detection of the 3.0mm metal (and vice versa). If the 3.0mm metal is inside the metal free zone, then the detector will be reacting to the 2.0 as well as the 3.0 as if they were combined.

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Laminate Multi-NonFerrous Card

Multi-seed laminate test cards are designed for seeds 4.0mm or less. Multi-cards are useful in x-ray inspection to determine what sizes and types of contaminants your system can achieve. They can be especially useful in temperate environments and applications. If your application is rugged or wet, or your standards are larger, we recommend our thermoform multi-cards.

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Package Simulate - Top View

We can simulate a variety of packaging in an application where you need the test piece to mimic what is traveling down the production line. In this case, we manufactured a clear “package” with the seed inside. With this method, the customer is able to reject the container appropriately, and, in the event the package is not rejected, it is easily seen by the line worker for manual removal.

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Candy Bar Simulate

There are two types of “candy bars” pictured here – one similar to a flat candy bar and the other in a custom, near perfect copy of a candy bar. Since we’re now able to produce many variations using colored material, the copy was made in red (Fe), green (NFe) and blue (SS 316). We have the equipment to accomplish nearly anything you can imagine, and these kinds of designs are proof positive.

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Nugget Test Piece

Need a test piece that looks and handles like chicken nugget? We can do it. Interestingly enough, in this situation, our first version for the customer left too much “void” in the hole where the metal was placed. Given the sensitivity the customer system was using, the void had the effect of causing false positives. We were able to minimize that hole and supply the test piece with almost no void. It’s an example of how we can work with you before, during and after manufacturing to ensure all the specifications were met.

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Mini Acetal Card

Our standard acetal card is 2 1/4"x3 3/8,” but if needed, we can cut that size down to as small as 1 1/4” x 1 1/4” (with limited engraving). If a larger card or a card with multiple seeds is needed, see our Custom Shape-Size Blocks and Tablets.

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Burger Simulate with Blue Contaminant

This distinctive test piece was created to mimic an actual hamburger patty. The customer supplied photos of the raw product, which we were able to reproduce and then we placed blue glove contaminant. Using this configuration, the customer was able to determine what size piece the vision scanning system could detect with the raw burger as the background. Had they simply used a blank card with the glove, the system could easily have achieved contaminant rejection, but they needed to be sure the system could “see” the blue against the product itself.

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Ceramic - 100 seed Card

A card with 100 seeds in a 10x10 configuration is used to place beneath whole chickens on a production line. This gives the x-ray system operator the ability not just to see IF the equipment can detect the metal in the card, but also WHERE the equipment can detect it. If there is a problem, the operator (or company) can make any changes necessary to achieve the end goal – safe chicken in this case. This card really highlights another valuable facet of our thermoform cards.

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Sugar Block Ferrous Top

In this scenario, a company processing sugar needed to have a “bag” simulated with the same weight in order to accurately fall through the reject mechanism. A lighter test piece had the risk of passing over the reject mechanism.

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1/2" Cubes

Our standard cubes are 1” and 1.5,” but we can also manufacture other sizes if needed. The cubes shown here are 1/2" in dimensions. Cubes can be helpful in applications where a ball or cylinder may bounce or roll away during testing, making their retrieval difficult, or, in some cases, present a hazard to the product or production equipment.

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Testrods with Stop Side

This is a test piece that is dropped into a bottle. It’s designed so that the metal appears in the center of the aperture when testing the metal detector. In addition, the round stop makes the test piece easily removable after testing.

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Hexagons

Hexagonal Shaped test pieces can be very useful in places where a cylinder or ball might roll or bounce around a production floor whether dropped by a line worker or ejection from a reject mechanism. Hexagons are similar in weight to the 1inch cylinders without having the smooth, rounded cylinder edge.

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Ultra Thin Rod

Our customer in this plant needed a test piece with a thickness less than 5.0mm. Because we have the capacity to customize sizes and shapes, we were able to mill down a product that met their specifications. That’s always our goal, meeting the specs you need for your product, testing environment and contaminants.

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Thermoform 25mm Ball-Side

There are some applications (e.g., metal detection in lumber) that require large seeds. We could put the seed (ball/contaminant) in a large rod or block, but the thermoform card presents a simple, durable, and lightweight solution. The capacity for manufacturing using our thermoform (PETG) system makes it possible to encapsulate nearly anything you can imagine.

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Blocks with Bevelled Edge

We can custom cut nearly any shape needed to fit your application. At times, you may want the test piece to look like your product in its raw form or after packaging. In many instances, we can supply the standard colors for ferrous (red), non-ferrous (green) or stainless steel 316 (blue) used in food and other industries. If your project is larger than 1” in thickness, we can always manufacture in white and color the letters.

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Small Card

This flat tablet or card with multiple seeds and a diagonal configuration is used for x-ray inspection. The various contaminants are different densities and represent the type contaminants that might appear in the end product. We can manufacture a broad array of sizes and thicknesses with as many contaminants as needed for testing your x-ray inspection equipment.

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3in x 1in Puck

Sometimes a cylinder or “puck” is needed to mimic product shape moving down the line. We’re not limited to any particular shape. Pucks can range from 3/4" all the way up to 8.” So, if you’re running hamburgers or some other puck shaped product, this may be the solution you need.

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Acetal Cards-Custom Engraving

In applications where the test piece needs to be identified for use on a particular production line or have some other type note regarding its use or placement, we can easily accommodate a wide range of types as specified by our customers.

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Round Laminate Cards

There may be a reason your application requires a different shape laminate card. We can manufacture a number of shapes like the circular one shown here, but particularly in square and rectangular sizes smaller than 2.5” x 4.25.” We can also manufacture larger sizes as well, if needed.

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5ft Rods with 12inch Whip End

In this example, the Testrods team manufactured a 5-foot test piece with a “whip” end for use in an overhead application. With the flexible end, our customer found the test piece well suited for a difficult-to-reach spot on the production line. Test pieces like this can be made in a variety of lengths with the whip being as short or long as needed.

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0.5in x 34in Testrods with 0.25in Hole on End

There are a wide range of applications that require a test piece much longer than our standard 5” or 6” Testrods. We can make up to 3/8” x 34” or 1/2” x 34” rigid test pieces which can then be extended well beyond that length with a “handle” made of acetal cylinder larger than the 3/8” or 1/2” extension. In the photos, the customer also needed the hole opposite the metal end for use in hanging the test pieces in convenient location for regular testing.

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1.5inch Blocks-Front

Pictured here are white blocks 1.5” L x 1.5” W x 7/8” T. We have the capacity now to offer this item in colors appropriate to the type metal (Fe-Red, NFe-Green, and SS316-Blue). You can select nearly any variation in dimensions, though there are limitations to the colored material. The colorant used for lettering on white test pieces is not guaranteed to last over the life of the test piece, however, it is food safe and does not present a problem on a food production line. We make it standard practice now to color the dot (where the metal is and not shown here), and the colored dot is guaranteed to last.

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Hollow Box showing opening

This hollow box represents or mimics the shape of a product box. The customer was normally emptying the contents and inserting a test piece for passing through the metal detector. The box, would, of course, wear down and tear after numerous uses. By creating the box using acetal (plastic), both of these issues were resolved. These kinds of product simulates can be created for whatever your application may require.

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1.5 Inch Cylinders

Standard cylinders are 1” in diameter, 1” in length, but we have the capacity to manufacture 1.5” x 1.5”, 2” x 2” or a variety of other sizes such as 1.5” D x 2” L. On occasion, we have made the 1” D cylinder in longer lengths as well.

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Ice Cream Bars

This was a very unique product simulate both in design and metal placement. The “ice cream bar” had 3 locations for each type metal (ferrous, non-ferrous, and stainless steel 316), the leading, middle, and trailing edges. A difficult testing process was made simple, which is always one part of the goal.

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Acetal Card with 3/8ths inch hole

One (or more) holes can be positioned on Acetal Cards so that a metal free lanyard or other type retrieval or hanging attachment needs to be added. The hole can also be used for hanging the test piece on a hook of its own.

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Puck 3in x 1in

Sometimes a cylinder or “puck” is needed to mimic a product shape moving down the line. We’re not limited to any particular shape. Pucks can range from 3/4" all the way up to 8.” So, if you’re running hamburgers or some other puck shaped product, this may be the solution you need.

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Cylinder with flat sides

In this instance, the customer wanted a 2” x 2” Cylinder with flat sides, which, of course, means it’s not really a cylinder. But by cutting the sides, it means the test piece can be used as if it were a cylinder without the nuisance or danger of it rolling along the ground if dropped by hand or along the production line. These kinds of shapes can be designed and manufactured as needed for whatever your application may require.

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Puck w-Tray and Thermoform Card

As referenced in our “3" x 1" Puck Test Pieces” listing, we can not only make the puck shaped test piece with a “tray” for placing (in this case) a multi-card. Should different standards be needed for another (or a new) product, the test piece in the tray can easily be swapped out for varied sizes or other contaminants.

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We now carry our 5” Testrods in construction orange, high vis green and dark purple. So, if you’re looking for something that will stand out against your product, consider one of these 3 new colors! Only available by custom order (email testrods@testrods.com or call 866-691-8560). Not available here on the website.

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We now carry our 6” Testrods in construction orange, high vis green and dark purple. So, if you’re looking for something that will stand out against your product, consider one of these 3 new colors! Only available by custom order (email testrods@testrods.com or call 866-691-8560). Not available here on the website.

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We now carry our 1” Test Balls in construction orange, high vis green and dark purple. So, if you’re looking for something that will stand out against your product, consider one of these 3 new colors! Only available by custom order (email testrods@testrods.com or call 866-691-8560). Not available here on the website.

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Thermoform Orange & Blue Glove Material

Thermoform cards are useful not only in x-ray and metal detection, but also when working with vision systems. In this instance, the customer wanted a card with two distinct colors of latex gloves. This would allow them to determine if the system could capture/reject any product with all or just part of a torn glove. All kinds of material can be put in a card like this. All you need to do it is send us the material you need to capture and we’ll put it in a card for you!

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NFE Cookie

Though this test piece doesn’t look like a cookie, it does match the outer shape and size of the customer’s product. In addition, the weight of this test piece needed to match the average weight of a cookie at 43 grams. We were able to remove material and accomplish each part of the challenge.

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High Vis Orange Test Cards

High Vis Laminate Test Cards are useful in an environment where the standard color might be difficult to see and capture in a product of similar color. High Vis cards can be made in red, green, blue, neon: yellow, pink, green or orange.

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Miniature Bottle Stop

This test piece was designed for a pharmaceutical application. It could be placed in the top of a small bottle and easily removed as needed after testing. This eliminated the need to drop a testing seed into the bottle and then attempt to recover it after testing. And because the test piece was made using our standard acetal (plastic), it could be used nearly an unlimited number of times.

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Rod Ultra-thin Length Bottom

Our customer in this plant needed a test piece with a thickness less than 5.0mm. Because we have the capacity to customize sizes and shapes, we were able to mill down a product that met their specifications. That’s always our goal, meeting the specs you need for your product, testing environment and contaminants.