Metal Detector Test
What to Look for in a Metal Detector Test
June 6, 2019
Best Practices for Metal Detection
Best Practices For Metal Detection In The Food Industry
June 17, 2019
Metal Detector Test
What to Look for in a Metal Detector Test
June 6, 2019
Best Practices for Metal Detection
Best Practices For Metal Detection In The Food Industry
June 17, 2019
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X-Ray Systems Test Pieces

Using X-Ray Systems Test Pieces is different from metal detection because it is based on density

X-Ray Systems Test Pieces

Using X-Ray Systems Test Pieces can be a vital part of any company’s safety procedures, especially in the food industry.  X-ray systems are much more expensive and require an understanding of a different technology.  X-ray inspection is based on density and allows you to test for a broader range of potential contaminants.  In turn, this offers a level of security beyond that of ordinary metal detectors.

Many companies employ a combination of both metal detectors and x-ray systems in order to cover all their bases.  Even one instance of contamination can cost a considerable amount of time and money as well as damage to a company’s image.  It makes a lot of sense to do everything possible to avoid it.

Metal detectors and x-ray systems are used in everything from pharmaceutical packaging to textile manufacturing.  But perhaps the most important application of these critical safety procedures is in the food industry.  Contamination of food products can be a major health concern.  It should be avoided at all costs, which is why the USDA and FDA have enacted strict safety guidelines. And it’s the reason you need metal detection and X-ray systems test pieces

Ensuring Safety

In order to ensure safety, it is necessary for companies to regularly test their products.  As always, this should happen at various points throughout the manufacturing and packaging process.  This means having a series of metal detectors and/or x-ray systems positioned at various points along the production line.  This provides certainty in detecting the presence of any contaminants before the product reaches consumers.

Unfortunately, with regular use, machinery can break down and when that happens, it can lead to dangerous results. X-ray systems test pieces and metal detection test pieces can be used to ensure that equipment is operating properly.

The process for testing equipment is pretty straightforward.  A sample of the product is created and a test piece inserted into the sample.  The test sample is then inserted into the production line and run through each machine.

If the machinery is working properly, it will detect the presence of the test piece and automatically reject it.  For compliance with all safety standards, testing should be done (at minimum) at the beginning and end of daily production.  Add to that every shift change and any time you change the production machinery settings or it’s down for repairs.

Accuracy

Because x-ray depends on density, this affects what type of contaminant standard is achievable.  In order to ensure the accuracy of testing, X-Ray systems test pieces systems should include a variety of contaminants.  This could be metals like aluminum, stainless steel 316, soda-lime glass, ceramic or rubber. Not all metals, such as copper or other contaminant possibilities, like stone, are available.  That’s because they are not available in certifiable standards. Stone, for instance, can have a broad range of densities depending on its source and type. But by employing a wide variety of test materials, you can get a more accurate reading of your x-ray system capabilities.  You will know, then, that it is operating properly to keep your products contaminant free.

Innovation – Research and Development

Bone, as well, can present a difficult challenge, because it depends on animal type, age, feed and calcification.   Regal Packaging has found a way to simulate bone using a material that can be set to the desired density.  Customers generally purchase a multi-card (with a variety of sizes) to determine what can be achieved.  Then they will purchase an individual card for daily, regular testing.

Aside from testing frequently and using the widest range of quality test pieces, it is also important to position the test pieces properly.  The goal is get the most accurate reading from your x-ray system.  Also, you’ll want to run multiple test samples at the beginning, center and end of a batch.  It’s the best way to determine that your x-ray system is working properly at every point along the process.

No matter how often you run tests and how accurately you position the test packs, your results can’t be guaranteed without the best quality X-ray systems test pieces.  Nobody understands this better than Regal Packaging Services, Inc.  We have the field experience to back up our innovations.  And it’s the reason we offer a full line of test pieces in a range of shapes and sizes. Research and development give Regal the ability to meet the challenges of any product type or detection system.

Customer Focused

We work closely with each customer to provide them with the pieces they need.  We fit their system and we certify each individual piece so you can be assured of their quality and durability.

Our pieces come in a variety of shapes, with standard metals ferrous, non-ferrous metals,  and stainless steel 316.  For x-ray systems, we also manufacture test pieces in aluminum, soda lime glass, ceramic (ZRO2 and AL203), acetal, teflon and rubber.

When it comes to your business, you can’t take safety lightly.  That means keeping your x-ray system working at its best with high-quality test pieces from Regal Packaging Services.

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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.