Calibration and Verification
Calibration and Verification
March 10, 2021
metal detection or x-ray inspection
Metal Detection or X-Ray Inspection?
July 24, 2021
Calibration and Verification
Calibration and Verification
March 10, 2021
metal detection or x-ray inspection
Metal Detection or X-Ray Inspection?
July 24, 2021
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Culture of Food Safety

A culture of food safety requires the right people

A Culture of Food Safety with the Right People

There are a lot of factors that go in to making the food we eat safe for consumption.  There are things like: manufacturing equipment (incl. metal detectors and/or x-ray inspection systems), supply side control, ingredient management, testing equipment and packaging materia. And the list just goes on.  The processes need to be well defined and the methods well documented.  In addition, HACCP plans must be discussed, lab testing procedures outlined and final checkpoints determined.  In essence, you need to create a culture of food safety with the right people,

Guaranteeing that food coming out of your facility will be safe means having the right people oversee the whole process.  From the top down, there has to be a culture of quality assurance and safety.   In a purely practical world, this commitment first has to be demonstrated by managers and leaders. And it must be done on a consistent, daily basis.  The company vision, values, systems, language, beliefs, and habits must reflect it.  Keep in mind that all the best processes, procedures and equipment mean nothing if the right people aren’t in place.  And it’s not just knowledge or education that will make the difference.  Your plant might be full of PHDs and still fail to protect the final product in the marketplace.

The Right PeoplePEOPLE ARE THE PRIORITY

You need people who think about the customer at the end of the food chain.  They should treat the product as if it were their own families at the dining room table.  They must be the kind of people who will ensure there is quality control in the marketplace.  That means having a hiring process that seeks out more than knowledgeable or even experienced employees is crucial. It’s probably more important to hire and train the right kind of person.  A staff that understands the ins and outs of the food industry may be secondary.  Training will require time and effort.  Imagine your wife or your children eating your product knowing they might be at risk.

So on your list of employee requirements, consider carefully how much weight you place on each of the qualities needed for the job.  You might have to develop a training curriculum.  Maybe you will set aside days for educating employees.   You want trust sure about your people have everything to make your product trustworthy.  Digging into a potential employee’s references and asking the right questions may have a huge impact on what you bring to the marketplace.  You might ask, “Tell me about a time when you successfully led a project from start to finish,.” Better yet, you could ask, “Tell me about the people you worked with on a project, how you treated them throughout the process and the quality of the end product or goal.”

THEN DOES EDUCATION REALLY COUNT?

Of course, it’s not an either/or question.  It’s a both/and.  In a best case scenario, you get employees with the right knowledge base and education who really care about the quality of the product.  You want people who are proud of what they do.  Wouldn’t it be great to have a crew that can defend your product without having to being defensive?  And how nice would it be to fall asleep at night knowing your team has done the best job possible to protect every consumer who buys your product?  A culture of food safety isn’t just what appears in your employee handbook, it’s what goes out the door with every product you sell.

At Testrods.com, we know we’re only 1 small link in the food safety chain, providing you with the necessary test pieces and certificates to ensure your metal detectors and x-ray inspection systems are working.  But even here, we understand the value of a culture of safety.  We want to know, as much as you do, that what we buy off the shelf we can feed to our families.  In fact, for us, it’s what drives customer service.

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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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.