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The People Behind the Metrics of Quality ControlThe People Behind the Metrics of Quality Control

My first foray into the metrics of quality control and food safety was during a time when I was unemployed for three years.  A friend recommended me to a company that did x-ray inspection for other food plants.  The product being inspected was on hold because the customer either had a problem with their inspection systems or it needed to be retested for suspected contaminant.

This company employed people who were either out of work or at some other stage of life where they needed or wanted additional income.  However, the employee selection always reflected a strong work ethic and a willingness to maintain high standards of quality control.

The packaged food was placed on a conveyor, passed through a medical grade x-ray machine, was viewed on a screen (in a booth) by the quality control worker, rejected as needed and then replaced in its larger box and onto a pallet.  It was the job of the viewer to assess the image on the screen and determine whether there was a contaminant.

The metrics of quality control were safeguarded carefully by collecting (rejecting) the product before and after the item with suspected contaminant.  These items would later be rescanned to determine, in a second pass, if an impurity was still detected.  It was the watchful eye of a trained technician that captured contaminated product in order to keep it out of the marketplace.

Another way to manage the metrics of quality control was to run the line a great deal slower than you would find on an industrialized line with an automatic x-ray system.  Given that the product was on hold, this was a necessity, and even preferred.  In addition, a “test” package was sent through the x-ray to make sure the operator was capable of rejecting what the expected contaminant looked like.  For instance, if the suspected pollutant was a 1.0mm Stainless Steel 316 object, then that same size (or smaller) would be used for testing.  If the operator missed the test, then all product since the last test would be reinspected, just as it should be in a food plant.

Three years later, I began working as the Sales and Quality Manager for Regal Packaging Services.  I discovered that my time “in the booth” was extremely helpful in understanding what companies were expecting to accomplish when in quality control testing both in x-ray inspection and in metal detection.  I already understood the metrics of quality control.  I recognized how critical it is to manage a production line right down to the lowest or smallest part of the process.

Along with our sales and service team, we bring nearly 100 years of experience to the job, so we can offer expertise that other companies who are in the business of selling “metal detectable products” just can’t offer.

In addition, we have worked to maintain ISO 9001:2015 certification, demonstrating our commitment to excellence in product quality and cutting-edge innovation in the industry.  We are consistent, dependable, and focused on our part in setting a high level of metrics for quality control in the food safety chain.  Ten years into the job, I realize I couldn’t have imagined having an influence of any kind in the food industry.

As we have worked with our customers, we’ve gone from offering four types of certified contaminants to seventeen, including what we believe is the best bone simulate available on the market.  As a result, over those same ten years, we have tripled our revenue.  We know that is a direct result of hiring the right people and training them appropriately.

At every level, we want our employees to be ahead of the industry, responding to customers’ inquiries about how to successfully meet the needs of their application.  At times, we put them in touch with our metal detectors salespeople, technicians and auditors who provide guidance based on decades of field experience.  Those same people bring back their experience to the Testrods team to help us navigate the ins and outs of a wide variety of metal detection and x-ray inspection challenges.  We’ve also been known to visit assorted plants to see what they are doing first-hand.

In fact, our first venture into bone simulate products came as the result of a visit to a nearby, nationally known meat processing and packing company.  We were able to provide them with a multi-card containing an array of sizes and thicknesses of contaminant which they could view and compare with the typical bone they were expecting to find at the end of the production line.

Most companies selling metal detection and x-ray inspection verification test pieces are also selling a host of other products.  They leave the details up to their providers and essentially serve as a middleman in the food safety picture.  That’s not to disparage any of their products or services.  They just don’t have the time or resources for their staff to be experts in the industry.  At Testrods.com we’re passionate about providing the right tools for the food industry.

In the end analysis, keeping food safe is more than just machines, tools, processes, procedures, or systems.  It is about the people who manage these things, people who care about the quality of their work and how it impacts their own families and friends.  So, when you get right down to it, you have to ask yourself, “Am I the right kind of person to fit into the metrics of quality control?”  Call us at 866-691-8560 or email testrods@testrods.com.

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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.