Rob Stevens, Market Manager, Mettler-Toledo Product Inspection
In the bustling environment of a snack manufacturing facility, the day begins early, long before the first rays of sunlight peek over the horizon. The factory hums to life as conveyor belts start rolling, and production lines are set in motion. Today, like every day, the focus is on maintaining high standards of product quality and safety, a task that becomes particularly challenging when dealing with vertical fall applications in the production line.
Morning Shift: Tackling Space Constraints and Sensitivity Challenges
As the morning shift begins, operators and quality assurance teams are already on high alert. One of the primary challenges in vertical production lines is the limited space available for critical control points (CCPs). In these scenarios, traditional contamination detection methods can fall short.
The factory relies on advanced solutions, such as Throat metal detectors, which are specifically designed for tight and inaccessible spaces. These detectors are essential for identifying ferrous and non-ferrous metals, as well as stainless steel contaminants, across a range of snack ingredients. Throat metal detectors are perfect for Vertical Form Fill and Seal (VFFS) applications, such as packaged products like crisps, nuts, sweets and pretzels. The Throat metal detectors sit just before the bagger machine to inspect products for metal contamination before they enter the packet. Consistent, reliable inspection performance at high speeds is essential to maintain productivity on the line; accurate detection is essential for brand protection.
Gravity fall metal detection systems are much more suited to protecting free-flowing powders such as finely ground spices, cocoa powder and granulated sugar because of their exceptional sensitivity and precision rejection systems. Timing is everything, as the products flow at pace through the vertical line.
Midday: Performance Testing and Health & Safety
As the day progresses, the focus shifts to routine performance testing of the metal detectors – which takes place more than once throughout the day. Traditional testing methods require physical access to the metal detector, which in vertical applications often means working at significant heights. This not only complicates the testing process but also poses health and safety risks. Operators might have to climb ladders and reach across equipment, increasing the chance of accidents.
To address these concerns, the factory utilises Automatic Test Systems (ATS). This innovative system automates the metal detector testing process, eliminating the need for manual insertion of test samples. By placing a device inside the metal detector’s aperture, ATS accurately tests the centreline sensitivity, the most challenging area to monitor. This method not only simplifies testing but also improves accuracy of the test, reducing the likelihood of contamination or recalls.
Afternoon: Maintaining Product Quality and Safety
By the afternoon, the factory’s operations are in full swing. Maintaining product quality is paramount, particularly for delicate snack ingredients like fine chocolate powder used in truffles. In such cases, the ATS system’s non-invasive testing method is crucial. It prevents test samples from contacting the product, thereby minimising any risk of cross-contamination. This feature is especially important in gravity-fed applications, where maintaining product integrity is critical.
The day progresses with a continuous focus on monitoring and adjusting the systems as needed. The factory’s commitment to high standards is evident in every aspect of the production process, from the choice of metal detection equipment to the rigorous testing protocols. Productivity is maintained, and compliance made easier, through the factory’s use of ProdX™. This data management software by Mettler-Toledo automatically records all the routine performance monitoring test results digitally, making it easy to document all rejected product incidents and the corrective actions taken, and providing standard and custom reports as evidence for audits.
Evening: Wrapping Up and Reflecting
As the evening approaches and the factory begins to wind down, the day’s work is reviewed. The use of metal detection systems, combined with ATS, has once again demonstrated its value in managing the complexities of vertical production lines. The day concludes with a sense of accomplishment, knowing that the products leaving the factory meet the highest standards of quality and safety.
In the competitive world of snack manufacturing, where every detail counts, the right technology and procedures make all the difference. As the lights dim and the machines quiet, preparations begin for another day, ready to tackle the challenges and uphold the standards that define the industry.
Find out more in this eGuide:
www.mt.com/pi-snackseguide
