Metal Detection Testing
Tips for Metal Detection Testing
June 27, 2019
metal detector verification
Guide To Metal Detector Verification
July 4, 2019
Metal Detection Testing
Tips for Metal Detection Testing
June 27, 2019
metal detector verification
Guide To Metal Detector Verification
July 4, 2019
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Detector Audit

Pass Your Metal Detector Audit

Operating SensitivityHow to Pass a Detector Audit

In the food industry, a detector audit is a necessary part of the standard operation procedures.  Regal Packaging can help. Stringent food safety guidelines (USDA, FDA, GFSI and FSMA) require the use of metal detectors.  This prevents costly recalls and protect consumers. By following these guidelines companies can help save themselves time, money and bad publicity.

No matter how careful a company is, there can still be problems if their detection system breaks down.  Both the machinery used in production and the detectors themselves can break down over time.  This opens the door to potential contamination.  So it is crucial to have regular audits.  This ensures that metal detectors continue to function properly and that provide certification for the governing bodies as well as the consumer.

Figuring out how to ensure that equipment passes a detector audit is something all food manufacturers need to focus on.  The more you maintain the safety of your products, the better off both you and your customers will be.  That means running tests and making sure that your detectors are picking up on potential contaminants and automatically rejecting them.

The Audit

During a metal detector audit, a product sample containing certified test pieces must pass through the detector without a reject.  This usually means a successful run multiple times.  If the detector is working properly it will identify the test piece and automatically reject the test pack each time. The auditor is not only checking the detector but also it’s interaction with the reject mechanism.  A detector may recognize the metal, but it has to be rejected.  Otherwise, the problem may go down the line while you think everything is safe.  Not only does the reject mechanism need to engage, but it has to remove the right box (bag or other container) at the right time.  If the timing is off, the system may be rejecting good product while leaving contaminant on the production line.

On a regular basis,  you need to calibrate your detector to the product and environment.  That means passing product you know is uncontaminated through the detector at the best sensitivity without the detector rejecting the product.  Once that’s set, you can determine the lowest possible sizes of contaminant that will be detected in your product.  Those values, ferrous, non-ferrous and stainless steel 316, should be written into your Hazard Analysis and Critical Control Points (HACCP) plan and those sizes available for regular testing.

According to HACCP principles, detectors should be positioned at various points throughout the production line.  This ensures that contaminants are found and isolated as early as possible.  Typically, your program(s) will include an audit by a 3rd Party Inspector.  Our inspection experts (DetectorAudits.com)can meet that need if you’re in Illinois, Wisconsin, Iowa or Indiana.

Test Pieces

Using test pieces of different metals and in various sizes (and/or shapes) makes for a thorough and complete detector audit.  That way you can be sure that your detector is working to identify any possible contaminant. The better the quality of the test pieces you use, the more certain you can be of obtaining valid results.  And you should be prepared when an auditor asks to see the certification paperwork on your test pieces.

Testing should be done on all types of metal detectors: conveyor, gravity fed or pipeline as well as x-ray systems.  The type of detector will dictate how an audit is performed. For conveyor fed systems, a test piece is placed inside the product, which is then inserted into the production line.  For gravity fed or pipeline systems, a test piece is inserted directly into the flow of loose product.

Passing the Audit

In order to pass a detector audit, you need to make sure that your equipment is regularly maintained.  In addition, the test pieces you use must be the highest, certified quality to ensure accurate results.  Regal offers only the best test pieces, designed to meet the exact specifications of your equipment and with individual certification. We give you the tools to be prepared for an audit.  In addition, if you run into a certification problem in the middle of an audit, we make it simple to download certificates.  You can also shoot us a quick email at testrods@testrods.com or call our number – 866-691-8560.

You can’t afford even one contaminated product reaching your customers, so you need to make sure that you follow all food safety guidelines including performing regular detector audits.  With quality test pieces from Regal Packaging, you’ll be able to pass every audit and provide your customers with products they can trust. If you’re company is in Illinois, Wisconsin, Indiana or Iowa and you need a metal detector audit, reach out to us at DetectorAudits.com.

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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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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 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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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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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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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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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 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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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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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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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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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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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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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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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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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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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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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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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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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.