Five steps to optimum product inspection

In 2011 the UK Food Standards Agency (FSA) reported 93 incidents of physical contamination, lower than the 2010 figures, but nearly double those from 2009. There are often serious consequences to a product recall, which can include the financial cost of sanctions, fines and damaged machines.

This can also have immediate implications on the company's share price and impact on consumer confidence, which can hinder growth for a significant period after the incident itself.

To protect your brand, certain steps must be taken to ensure optimum product inspection for both you and your manufacturing line.

Understand the regulations

Ensure you understand the food standards relevant to your organization. Select technology that can ensure compliance with global and local regulations. Checkweighers, metal detectors, x-ray and vision inspection systems must all satisfy legislation, such as that of the FSA, to guarantee process and product security.

Choose technology that meets industry standards, particularly those encompassed by the Global Food Safety Initiative (GFSI), which includes British Retail Consortium (BRC) Global Standards International Food Standard (IFS) and FSSC 22000 schemes.

Requirements do not end with food safety legislation. For example, checkweighers: ensure you comply with other regulations, such as the UK's Weights and Measures Act.

Know your product

Also consider the nature of your product. Is it liquid, powdered or solid? Is it dry or wet, loose or packed? What is its density and thickness? What packaging format are you using? Is it individually wrapped or in bulk loose flow?

Determine where on the line your product needs to be inspected, as well as the contaminants you are looking for. To detect glass fragments in liquids packaged in domed-base containers, you should be using an x-ray system with specially angled beams to eliminate the effects of inspection blind spots, placed at the end of the production line.

If you are detecting metal contaminants in free-falling powdered or granular food products, you should install a high sensitivity metal detector with advanced analytical software, placed directly between a multi-head weigher and the vertical fill, form seal machine.

Be aware of factors that could limit inspection sensitivity, such as product technology, potential contaminants and environmental factors.

Food packed in a limited space environment may require a metal detector fitted with Internal Cancellation Field (ICF) technology. This will allow you to install the machine in close proximity to other metal equipment without detection interference.

Increase risk awareness

Undertake a comprehensive Hazard Analysis and Critical Control Points (HACCP) audit to systematically identify manufacturing risks and ensure you incorporate the means to mitigate and correct them before a contamination incident occurs.

HACCP analysis enables you to identify the most likely form of contamination, whether it is metals, glass, bone or plastics, and other quality defects. These include missing or broken product, damaged packaging or inconsistent fill levels.

Optimize productivity

Choose efficient, easy-to-use and flexible product inspection equipment that is capable of enhancing productivity as well as boosting product quality. 'Condition Monitoring' features in metal detectors can improve line efficiency by identifying potentially adverse trends early and providing advance warning to machine operatives.

These systems can avert detection failures and boost Original Equipment Effectiveness (OEE). Intuitive touchscreen detector controls can simplify the set-up process for new products, thereby further boosting productivity.

Rely on the experts

Purchasing product inspection equipment suitable to your line needs can appear, on first sight, a daunting task. Plus, with continually changing food safety regulations, there is added pressure to stay updated with new developments. Carefully select an equipment provider you can rely on. Partners with worldwide expertise can advise on the best product inspection equipment for your needs.

Neil Giles is the marketing communications manager for the Product Inspection Division of Mettler-Toledo. Based in the UK, he specializes across all three main product inspection technologies, X-ray, metal detection and checkweighing.