The top ten questions to help understand food safety, answered

In a world where food safety is non-negotiable and consumer expectations are at an all-time high, food and beverage manufacturers face the daunting challenge of reliably delivering safe, high-quality products. As operational costs rise and regulatory scrutiny intensifies, the need for effective product inspection technologies has never been greater.

Embracing these technologies is not just about compliance; it’s about building consumer trust and protecting your brand’s reputation. To help you navigate this essential aspect of food production, we’ve compiled the top ten questions that we are often asked about the role of product inspection within food safety. By reading this article, you will then hopefully understand the critical role that product inspection technologies play in maintaining food safety.

Mike Pipe, Head of Global Sales & Product Management, Mettler-Toledo Safeline X-ray

1. How does the food and beverage industry benefit from product inspection?

Product inspection systems play a vital role in delivering correct, complete and safe products. These solutions facilitate inline inspections for various food types, preventing contaminated or defective products from reaching consumers. Additionally, robust inspection protocols help maintain both safety and quality standards, supporting compliance with food safety regulations.

2. What specific functions do product inspection systems conduct in food manufacturing?

Product inspection systems are critical in maintaining high standards in food manufacturing, as they perform multiple essential functions:

• - Contamination Detection: These systems are designed to detect and reject foreign contaminants in real-time, meaning that products are safe for consumption. By identifying hazards such as metal, glass, bone and dense plastic, manufacturers can prevent harmful materials from reaching consumers at any stage of the production line.
• - Fill Level Control: Precision weighing systems help verify that product packages meet specified fill levels, aiding in compliance with Weights & Measures legislation. This prevents both underfilling and overfilling, reducing costly product giveaway and offering consistency in packaging.

This comprehensive approach not only minimizes the likelihood of costly recalls but also reinforces brand reputation by helping to make sure only high quality, safe and compliant products reach consumers.

3. What types of physical contamination can product inspection equipment find?

Modern product inspection systems can detect a range of contaminants. Metal detection systems can detect and reject ferrous, non-ferrous and stainless steel contaminants as small as 0.3mm. X-ray inspection systems can detect and reject metal, glass, dense plastics, bone and rubber. The sensitivity of detection typically depends on factors such as the size and location of the foreign body, the speed of the production line, and the density of both the product and the contaminant. By understanding the capabilities of each inspection solution, manufacturers can tailor their strategies to combat specific risks effectively. Partnering with an experienced product inspection solutions provider will help manufacturers decide whether a metal detector or x-ray inspection system is the most appropriate solution – sometimes both systems are needed at different points along the production line.

Mettler-Toledo's C33 checkweigher   

4. How can I control fill levels in manufacturing?

Fill level control can be effectively managed by integrating inspection equipment into the production line. Dynamic checkweighers are the most effective solution for verifying the weight of packages, making sure they meet specified fill levels. This prevents under- or overfilled products from reaching the market. These systems automatically remove non-compliant packages from the line, maintaining consistency and quality. By employing dynamic checkweighers, manufacturers can comply with Weights & Measures legislation and protect bottom line profits by avoiding unnecessary product giveaway.

5. What are the benefits of incorporating contamination detection systems early in food production?

Incorporating contamination detection systems early in the production process offers numerous advantages, especially in preventing foreign bodies from reaching consumers. Early detection allows manufacturers to identify and eliminate contaminants such as ferrous and non-ferrous metals, glass and dense plastics at the beginning stages of production, before additional value is added to the product. This not only minimizes waste and reduces the risk of recalls but also optimises the overall production process. Early detection improves the chances of detecting the physical contaminants before they are broken down further and removing contaminated products from the production process, meaning a safer, higher-quality product that builds consumer trust.

6. How do I choose the right metal detection solution with so many options available?

Selecting the right metal detection system can feel overwhelming, but there are some simple guidelines to help you get started. For dry or non-conductive products, a detector using higher-frequency technology (800-900kHz) will often yield the best results. However, for products with high salt or moisture content, lower frequencies (50-200kHz) tend to be more effective. That said, the most advanced systems use multiple frequencies simultaneously, employing smart algorithms to eliminate interference from conductive products. In some cases, x-ray inspection may be a better choice, especially for products packaged in conductive materials. Testing the system with your product before committing to a solution is the best way to be sure it meets your specific needs.

7. What are the benefits of using an x-ray inspection system in food production?

X-ray inspection systems enhance product safety by identifying foreign objects and verifying product and package integrity. These systems perform inline checks, enabling manufacturers to detect contaminants while also confirming that packaging is intact. By visualizing package contents, systems can identify contaminants that may not be visible to the naked eye. Investing in x-ray technology allows manufacturers to minimize the risk of product recalls and associated costs, ultimately protecting their brand reputation.

Sesame bars going through Mettler-Toledo's X2  x-ray inspection system 

8. Can product inspection technology help with traceability and data collection?

Product inspection systems generate runtime data, which they can transmit to central control systems – allowing for real-time views of system performance. Other data includes logging changes to system settings and recording the results of system tests – such as those done to verify metal detector performance. This helps simplify the record-keeping processes required for proving due diligence in the event of a product recall or audit.

X6 x-ray inspection system

9. How can physical contamination detection help manufacturers comply with Global Food Safety Initiative (GFSI) standards?

Integrating metal detection and x-ray inspection into the production process helps manufacturers meet Global Food Safety Initiative (GFSI) standards. These systems identify and eliminate foreign bodies, reducing the risk of recalls and protecting the brand’s reputation. Demonstrating compliance with these rigorous standards enhances credibility in the market and reassures consumers of a manufacturer’s commitment to food safety. Complementary software can make compliance easier to achieve, by automating processes for recording and storing essential data from the applicable foreign body detection system that is required for audits.

10. How do I decide which product inspection solution best fits my needs?

Choosing the right product inspection solution can be complex. That is why we would advise you to contact a product inspection technology expert to advise you of the best system based on your:

• - Application
• - Production line
• - Critical Control Points (CCPs) i.e. points of weakness on your line
• - Packaging format, material and size
• - Compliance needs
• - Budget

By assessing specific requirements, manufacturers can select the most effective solution that aligns with their  production goals and safety standards.

Conclusion

Food safety is critical. Understanding the value of product inspection is essential for manufacturers as the systems not only enhance product quality and safety but also protect brand reputation and reduce the risk of costly recalls. With the right product inspection solutions in place, food manufacturers can navigate industry challenges more effectively, positioning themselves for sustainable growth and success.

For more information: www.mt.com/pi-pr