Outlook 2025: Food safety trends and better product inspection

The history of the food industry shows that even the most robust food safety systems can be compromised at any given point due to internal and external factors. Last year alone several breaches made the news: the US FDA reported an incident where plastic and metal were found in frozen raw ground beef. Another FDA recall involved hummus that contained “foreign material”. In Singapore, US-made granola bars were recalled due to the risk of metal contamination. It appears that product recalls and scandals cannot be thoroughly avoided, but certainly breaches that lead to contamination can be mitigated at every stage of production and within the supply chain. FoodPacific Manufacturing Journal asked Ken Loh, Business Development Manager, Mettler-Toledo, to discuss the latest trends in food safety.

 

Ken Loh, Business Development Manager, Mettler-Toledo

 

 

How would you assess food safety in different Southeast Asian countries? Could you please expand on your answer with a few examples?

Food safety in Southeast Asia continues to evolve as countries adopt new technologies and regulatory standards to address contamination risks.

 

Nations with a strong export focus are implementing stricter food safety protocols. X-ray inspection systems have become key, providing reliable detection of foreign bodies like metal, glass and calcified bone whilst simultaneously completing a large range of quality assurance checks on the product and packaging. These inspection systems help manufacturers meet both local and international food safety standards, reducing contamination risks in packaged foods and protecting consumers from substandard product.

 

However, not all countries are progressing at the same pace. Some are still updating regulatory frameworks and adopting new technologies. This highlights the importance of accessible x-ray solutions, which help manufacturers raise safety standards without heavy financial investment. These adaptable systems make it easier for diverse markets to improve food safety.

 

Which food safety trends are further emerging, and why?

One emerging trend is the increasing focus on retailer compliance standards. Retailers are striving to lead in food safety to protect their brand reputation and consumer trust. As consumers demand more transparency, retailers are adopting more stringent requirements for suppliers. This is especially evident in global supply chains, where larger retailers set the bar for product inspection and contamination control.

 

Another trend is the growing adoption of x-ray inspection systems. X-ray technology is becoming the preferred choice for manufacturers aiming to improve product integrity. These systems can detect a variety of contaminants, complete quality assurance checks plus are suitable for complex or multi-lane production lines. Manufacturers are adopting these solutions to meet higher retailer demands and regulatory standards.

 

Sesame bars going through the X-2 advanced x-ray inspection system 

 

 

In addition to compliance and technology, sustainability is emerging as a key driver in food safety. Reducing food waste is a priority, and x-ray systems contribute to this by improving the accuracy of product rejection, reducing unnecessary disposal of safe products.

 

Lastly, automation and digitalization are becoming central to food safety. Automated systems streamline inspection processes, improve detection accuracy and provide real-time monitoring, reducing human error and maintaining consistency across operations.

 

 

On-screen messages provide operators with visual feedback on the Automatic Test System (ATS) test status.

 

 

Worker safety is improved as operators no longer need to stretch across production line equipment to test it with Mettler-Toledo Automatic Test System (ATS).

 

 

Based on your experience working with companies in the F&B sector, what are the obstacles to maintaining consistent product quality?

One challenge is the increasing complexity of products. As items become more intricate, with overlapping layers or materials like metalised packaging films, detection sensitivity can be compromised. Manufacturers must adapt their inspection systems to address these challenges and/or integrate solutions capable of identifying foreign body contaminants in overlapping products, such as advanced x-ray inspection technologies.

 

Identifying Critical Control Points (CCPs) in the production process can also be difficult. Proper calibration is needed to achieve reliable inspection results, especially in high-throughput environments. High-speed production lines combined with complex products make maintaining accurate detection harder.

 

Additionally, balancing efficiency and inspection accuracy requires regular system maintenance. Without consistent upkeep, systems may underperform, leading to potential gaps in product quality. As production demands grow, continuous monitoring and adjustment of equipment is critical to maintain reliable inspection results.

 

At Mettler-Toledo, what are some of the technological innovations in the process, from monitoring raw material to logistics, for the food industry?

Mettler-Toledo offers innovations that improve productivity across the production cycle. The X2 and X6 Series provide advanced x-ray inspection capabilities, detecting contaminants from raw materials to finished products. These systems are designed to handle a wide range of packaging formats and production speeds, enhancing flexibility. Automatic Test System (ATS) available on vertical metal detection solutions from Mettler-Toledo automates routine metal detector testing, improving product accuracy and reducing downtime. This technology not only enhances performance but also boosts operator safety by minimising the need for manual intervention. By automating critical processes, it helps manufacturers maintain compliance while optimising overall production efficiency.

 

When connected to one or more Mettler-Toledo product inspection systems, ProdX™ software takes food safety to the next level. It offers real-time monitoring and recording of inspection devices with indefinite, safe data storage. This allows manufacturers to save time and money by automating essential quality control processes. ProdX™ makes food safety compliance easier to achieve by automatically recording all equipment testing routines, rejected items and relevant quality incidents. The data is then available for archiving and printing in standard report formats to mete audit requirements and prove due diligence.

 

How has automation integration changed the inspection of processed and packaged foods in recent years?

Automation has transformed food inspection by integrating combination systems, which combine various inspection technologies like checkweighing with either metal detection or x-ray inspection into a single, streamlined process. The combined system can be further complemented by integrating vision inspection. These systems are designed to address a range of product integrity concerns, from detecting foreign body contaminants like metal and glass to verifying product weight and proper labelling. This flexibility increases productivity and reduces downtime. Additionally, combination systems offer a holistic approach by performing multiple quality assurance checks simultaneously, improving accuracy, reducing the risk of human error and supporting compliance across various stages of production.

 

Do you foresee advances in automation driving companies to upgrade to new equipment, even if it is more costly for them?

Yes, automation advances will likely drive companies to upgrade equipment despite higher initial costs. Manufacturers recognise the long-term benefits, including reduced waste, increased throughput and improved product quality. By focusing on total cost of ownership (TCO) and return on investment (ROI), the long-term benefits of automation outweigh the upfront cost. Automating manual processes also enables manufacturers to shift human resources to more value-added activities to further improve efficiency.

 

In the past year or so, have you observed an increase in SMEs keen on adopting advanced product inspection solutions?

Yes, many SMEs, particularly those seeking to supply global retailers, are increasingly adopting advanced inspection systems. These businesses are recognising that larger retailers demand higher compliance standards, requiring investment in more sophisticated solutions like x-ray systems. The availability of affordable solutions, such as the X2 and X16, has made these technologies more accessible to smaller companies without prohibitive costs.

 

What should companies watch for when investing in product inspection equipment?

When investing in product inspection equipment, companies should conduct thorough testing before committing. There may be multiple solutions that can be used to address a production challenge, so working with a supplier who provides a broad range of options is key. Local service support is vital, as well as the supplier’s experience with local and global food safety regulations. Other key considerations include service contracts and equipment warranties, which help achieve long-term reliability and compliance.