By Kati Hope, Global Key Account Manager, Mettler-Toledo Product Inspection
In a world rapidly advancing with Artificial Intelligence (AI), machine learning and, yes, even flying cars, food manufacturing still heavily relies on manual testing for metal detection, specifically for Vertical Form, Fill & Seal (VFFS) equipment. This is especially true for products like snacks, confectionery, infant formula, bulk flour and nutraceutical powders. However, manual testing has its drawbacks and can be enhanced with Automatic Test System (ATS).
ATS in Practice
ATS technology automates the testing process for vertical fall metal detectors and complements periodic manual tests. This technology replicates the detector’s centreline sensitivity, the least sensitive part of the metal detector, providing consistent and accurate results across various testing points. By calibrating the system to match the weakest point in the detector’s field, ATS offers a reliable measure of the detector’s overall performance, addressing any sensitivity variations. Traditionally, manual tests use the “drop method,” where test pieces are manually inserted into the product flow. While ATS doesn’t entirely replace manual testing, it significantly reduces the frequency of these manual interventions, enhancing efficiency and productivity.
Combating Rising Costs
Implementing ATS technology in metal detection systems offers a practical solution to manufacturing challenges such as operational safety, accuracy and product integrity.
Cost saving #1: Reduce Testing Times
ATS reduces operational costs by streamlining testing procedures. With testing times reduced to under 40 seconds, businesses benefit from enhanced efficiency and productivity. This translates into substantial savings in both time and resources, allowing companies to achieve higher throughput without compromising on safety or accuracy.
Cost saving #2: Operator Safety
ATS enhances operator safety by minimising the need for operators to work at height or reach across production equipment. This improvement not only protects workers but also reduces the potential for costly accidents. The value of operator safety of course, is priceless.
Cost saving #3: Lower the Risk of Product Recalls
With ATS’s non-invasive and automated testing, the risk of cross-contamination or product defects that can lead to costly recalls is minimised. This precision-based approach helps with product quality and consistency, reducing the likelihood of recalls by catching issues early in the production process. Additionally, the system’s automatic record-keeping provides a reliable audit trail, enhancing food safety compliance and traceability.
Cost saving #4: Increase Accuracy and Reliability
ATS technology offers unparalleled accuracy by using sophisticated algorithms to align centreline sensitivity with the edge of the aperture. This means consistent detection performance across the entire product, eliminating the variability often seen in other methods. The system’s automated calibration enhances reliability, leading to fewer errors, improved productivity, and ultimately contributing to cost savings by reducing downtime and helping to ensure consistent product quality.
Case Study
Consider a typical UK snack food manufacturer with 24 weigher/bagger lines, each running at 100 bags per minute, 20 hours a day, 360 days a year. Currently, the facility manually tests its Throat metal detectors every 2 hours, with each test taking 3 minutes. This extensive manual testing results in significant production downtime and lost product.
By using ATS technology:
- Testing is reduced to 30 seconds per test.
- Instead of losing 72,000 bags per day, the facility only loses 12,000 bags. Over a year, this translates to over 21 million bags saved.
- The required operator hours for testing drops from 4,320 hours per year to just 720 hours, saving approximately £54,000 annually.
What this shows is simple – ATS can help to drastically reduce operational costs, enhance productivity and protect product quality.
Conclusion
Adopting ATS technology in metal detection systems offers a powerful solution to the challenges faced by food manufacturers. By enhancing safety, accuracy and productivity, ATS combats rising costs while upholding product quality and brand reputation. This technology allows food manufacturers to be forward-thinking, even in a world where flying cars are soon to be the norm.
For more information: www.mt.com/md-ats-pr
