Regal Packaging Services
About Regal Packaging Services
October 21, 2022
Cleaning Test Pieces
February 14, 2023
Regal Packaging Services
About Regal Packaging Services
October 21, 2022
Cleaning Test Pieces
February 14, 2023

What’s Really Being Certified?

There are several important and necessary components that need to be included in a Certificate or Compliance (or Conformity) that let you be confident about what’s really being certified.  In the food industry, there need to be specifics such as:

  • NIST standard met for contaminant size
  • A statement of FDA compliance as to food safety contact
  • The name of the Supplier
  • A statement of certification
  • Notes regarding grade of the contaminant and chemical analysis where available
  • Note as to the effect the contaminant should have on a metal detection or x-ray inspection system

#s 1 and 2 are particularly crucial to defining what’s really being certified because they have a direct effect on the outcome of any testing done for contaminant on a food production line.  If you know those two items, it should give you what you really need to know about what’s being certified.

Our certificate statement indicates (sample ferrous text):

Certified TestrodsRegal Packaging Services Inc., as a supplier of set products, testifies that the balls used are certified as being accurate in size and type (Grade 200 or better) and are traceable to the NIST standard (681/280800-11) applicable for this industry. Each lot is verified to produce an appropriate metal detector signal proportional to the metal sphere size/type and detector phase settings. Each lot is also verified to attenuate the appropriate x-ray, proportional to the density of the metal sphere size/type and x-ray detector settings. The metal detector signal and x-ray attenuation produced from these products does not deteriorate over time and our certificates do not expire. All items are approved for food contact in accordance with the FDA, Title 21 CFR 177.2470 and 177.1630.”

And at Testrods.com, we want you to know within the certificate document exactly what’s really being certified!  In fact, as of January 1, 2023, our certificates have all been updated to include wording that is a little more precise than what we used to say.  We’re always looking for ways to give you confidence in our products and how they can help keep your products contaminant free.

The Food and Drug Administration (FDA) has a very specific set of standards used to determine whether or not a material should be allowed to enter or contact the food being produced.  Distinctively, because we use polymers as the basis for manufacturing our products, we meet the specifications outlined in Title 21 CFR 177, which addresses the various types of plastic that are permitted to have contact with food and not be considered as contaminating the food.

And the National Institute of Standards and Technology (NIST) also has a set of guidelines which is used for certifying the size of contaminants we provide.   “The National Institute of Standards and Technology (NIST) was founded in 1901 and is now part of the U.S. Department of Commerce. NIST is one of the nation’s oldest physical science laboratories. Congress established the agency to remove a major challenge to U.S. industrial competitiveness at the time — a second-rate measurement infrastructure that lagged behind the capabilities of the United Kingdom, Germany and other economic rivals.”

Traceability, by definition, means that the measurement of any of our contaminants can be compared to or defined by a standards measurement set by the NIST.  Traceability, in and of itself, is “a property of a measurement, not of a device (instrument). You cannot have a thermometer which is ‘traceable to NIST’. You can have a calibrated thermometer whose indications are traceable to NIST, providing certain criteria have been met.”  As an example then, when we say you’re getting a 2.0mm Ferrous test piece, it means that it meets the requirements set by the NIST to verify that it is, indeed 2.0mm.   To put it simply, “Only measurement results are traceable.”

So when you read our certificates, you can trust the information we’re providing is as accurate as we can define.  It’s pretty straightforward, really.  We just want you to know what’s really being certified.

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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.

We can custom cut nearly any shape needed to fit your application. At times, you may want the test piece to look like your product in its raw form or after packaging. In many instances, we can supply the standard colors for ferrous (red), non-ferrous (green) or stainless steel 316 (blue) used in food and other industries. If your project is larger than 1” in thickness, we can always manufacture in white and color the letters.

This flat tablet or card with multiple seeds and a diagonal configuration is used for x-ray inspection. The various contaminants are different densities and represent the type contaminants that might appear in the end product. We can manufacture a broad array of sizes and thicknesses with as many contaminants as needed for testing your x-ray inspection equipment.

Sometimes a cylinder or “puck” is needed to mimic product shape moving down the line. We’re not limited to any particular shape. Pucks can range from 3/4" all the way up to 8.” So, if you’re running hamburgers or some other puck shaped product, this may be the solution you need.