Metal Detection Test Standards
Make Sure You Meet Metal Detection Test Standards
April 5, 2018
Metal Detector
Why Use a Metal Detector and Its Test Pieces In The Food Industry?
April 5, 2018
Metal Detection Test Standards
Make Sure You Meet Metal Detection Test Standards
April 5, 2018
Metal Detector
Why Use a Metal Detector and Its Test Pieces In The Food Industry?
April 5, 2018
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Metal Detector Test Standards

Metal Detector Certified Test Pieces Can Make A Real Difference

In the world of metal detectors, standards are quite high and with good reason. Using certified test pieces on a regular basis can make a huge difference.  That’s true for your business and for the protection and safety of consumers.

There is almost no avoiding contamination entirely, as all metal machinery and equipment is subject to natural wear and tear. But your should ensure that you have a good quality metal detection system in place.  And you should be testing it on a regular basis.  It’s a straightforward strategy to stay on top of this process and ensure your products are the best quality possible.

Not surprisingly, many industries, including pharmaceuticals and textiles, employ metal detection.  But the food industry has the most vital need for promoting safety. That’s why quality metal detectors are key to meeting the increasing safety standards in the food industry. It’s also why it is so important to employ high quality, properly certified test pieces on a regular basis. Making sure that your products are safe is great for consumers.  But it’s also good for your business, so there’s every reason to follow these safety guidelines.

Metal Detectors

There are several types of metal detectors currently in use today.  But they are very different form the detector wands you might see in an airport or night club. While wands are common in  personal security, detectors in the food industry must locate metal sometimes as small as 0.5mm. That’s a standard no airport detector will ever locate!

In general, the first line of defense in the food industry is an inline detector.  This can be incorporated directly into the production line, usually at the very end, after the products have been packaged. This way each piece passes through the detector and is scanned for the presence of even the smallest possible particle. If a contaminant is detected, the product is automatically rejected so there is no danger of it reaching the public.

Certified Test Pieces

Once you consider the importance of metal detectors, it’s easy to see how test pieces are equally important.  To be sure your metal detector is working properly, it’s necessary to use certified test pieces on a regular basis. These are small plastic devices that contain particles of ferrous, non-ferrous and stainless steel metals. The test pieces come in a variety of shapes and sizes.  This helps make certain no matter what your metal detector or product, it meets the most stringent food industry standards.

Testing should be done on a regular basis according to a well-designed HACCP plan.  This will most likely involve testing at the beginning of each shift and between each change of product. Each test should be carefully observed and documented so that any problems with contamination can be immediately and properly addressed.

The use of metal detector certified test pieces is really quite simple. The test pieces are put together into a sample pack that is identical to the product being manufactured. When testing is done, you should use ferrous, non-ferrous and stainless steel 316 test pieces to test. The packs should be passed through the detector 3x.  Once at each position: leading, middle and trailing (last ) edge. If the detector is functioning properly, the metal in the test piece should be detected, and the pack automatically rejected.

Standards for Testing

This level of testing should meet the increasingly stringent food industry standards outlined by the BRC (British Resource Consortium) and the GFSI (Global Food Safety Initiative) as well as a company’s well-defined HAACP plan and ensure that your product is free from contaminants.

To accomplish this, it means using the best quality test pieces, designed specifically for your particular equipment and certified to meet industry standards. Since they are such an integral part of quality control for your business, you can’t afford to skimp where your metal detector test pieces are concerned. That’s why you need a name you can rely on to provide you with top of the line ferrous and non-ferrous pieces.

Since 1998, Regal Packaging Services has been that name for many in the textile, pharmaceutical and food industries. When it comes to metal detector certified test pieces, nobody measures up to Regal. We’ll custom design test pieces to fit your needs and provide free certification with each piece we produce so that you can breathe easier knowing your business is in good hands.

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10 Comments

  1. Abdul Karim says:
    February 1, 2023 at 4:04 am

    We want to buy standard test specimen for our metal detector in Fe, Non Fe and SS.

    Reply
    • brian says:
      February 1, 2023 at 6:55 am

      Abdul,
      You’ve come to the right place. Do you know what size metals you need.
      Are you just starting with a new metal detector or do you have standards that you are currently using?
      If you are note sure, email us at testrods@testrods.com and we can provide you with an “Expect Sensitivity Table” that will give you a starting place.
      We offer a full range of test pieces that will meet the needs of your application whether you’re using a conveyor, gravity fed or even a pipeline system.
      Call us at 866-977-8663 or email testrods@testrods.com and we can talk through your application needs.

      Reply
  2. Russell W Benjamin says:
    February 9, 2023 at 3:59 pm

    Is there a standard for placement of test wands when testing with product top of product, bottom of product or in product

    Reply
    • brian says:
      February 10, 2023 at 7:14 am

      Russell, the standard placement is actually determined by you and whatever you have determined are your standard operating procedures and written into your HACCP Plan. But there is definitely a best practice, and that is to place the test pieces as near the center of the aperture as possible, which often means placing it in the product. The middle of the aperture is the least sensitive place in the magnetic field of the detector. So if you can detect the metal (contaminant) there, you should be able to detect it anywhere else inn the aperture. Conversely, if you place the test piece near the wall of the aperture and use that for testing, you may be missing a contaminant anywhere closer to the center. Depending on your application, the center of the aperture may not be possible or practical, so you may want to choose a smaller size metal than what you would use in the center. For instance, if your standard for detection is 3.0mm Ferrous in the center, you may want to choose 2.5mm for testing closer to the wall because the detector is more sensitive there. I hope that helps. You can always email us directly at testrods@testrods.com or call me at 866-977-8663 or Justin at 866-691-8560. If needed, we can put you in touch with one of our techs who have a great deal more experience in the field and may understand the specifics of your application a little better. I will email you a copy of our “Expect Sensitivity Chart” which may be helpful as well.

      Reply
  3. Ray Lundy says:
    March 27, 2023 at 12:02 am

    Is there a standard for non-ferrous? Seems to me it could be made of Cu or AL or brass or bronze. These are all different. I know you should test for what is in your processing line but I ask – is there a standard metal that your non-ferrous should be composed of? Thx

    Reply
    • brian says:
      April 4, 2023 at 11:05 am

      Ray, sorry taking so long to respond. I’ve been out of the office for almost 2 weeks, so I appreciate your patience.
      The standard in the food industry for non-ferrous is brass.
      We also offer aluminum, but it typically is recommended only for x-ray applications.
      Brass is actually an alloy of copper and zinc.
      The brass we use has:
      Copper -68.5-71.5%
      Lead- 0.7% Max
      Iron – 0.5% Max
      Zinc – Balance
      and has a density of 8.48 g/cm3
      I hope that helps. Let us know if you have other questions.

      Reply
  4. Ben says:
    March 4, 2024 at 12:41 pm

    Do the test pieces have an expiration date and do they all come with a certificate?

    Reply
    • brian says:
      March 4, 2024 at 12:53 pm

      Ben, that’s a great question. We specify on our certificates that: “The metal detector signal and x-ray attenuation produced from these products does not deteriorate over time and our certificates do not expire.” As long as the contaminant is safely encased, there is no concern for a change in the effect the test piece will have on a metal detection or x-ray inspection system. There are companies that put expiry dates on their certificates as a means of getting to purchase new ones. All our test pieces come with free certificates and never expire. You just need to ask for them or download them from our website once you have an account here. We don’t send them out automatically with every order. We appreciate Marathon Cheese as a customer!

      Reply
  5. Ray Lundy says:
    April 5, 2024 at 10:33 pm

    Thanks for previous answer.

    Does anyone sell a test piece that is rod shaped not a sphere? We have been requested to use a 2mm by 0.5 mm test piece and its seems all are spherical in shape. This is due to a thin wire getting through a detector that was tested with a spherical test piece. Thanks

    Reply
    • brian says:
      April 8, 2024 at 8:41 am

      Ray, we don’t carry any test pieces with wire inside because we have never found a source. And finding a certified source would be even more difficult. The best we could offer is to have you send us wire samples that we could safely encase in a rod or card. The test pieces would be food safe, but the wire uncertified. Finding wire with a metal detector will always be subject to orientation.
      See
      https://www.testrods.com/orientation-and-metal-detection-are-key-to-success/
      for more information.

      Reply

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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.