Kati Hope, Global Account Manager, Mettler-Toledo Product Inspection
Potato-based food – the trend that shows no signs of slowing. As a staple ingredient, potatoes are here to stay. Global potato production exceeded 376 million metric tons in 2021, with China, India, Ukraine and Russia leading the charge1. Whether it’s French fries, potato waffles or mash, the popularity of potato-based products in ready meals and snacks continues to grow. In 2021 alone, the US processed over 270 million centum weight (cwt) of potatoes for use in products like chips and fries2. This high demand means that food manufacturers must continuously raise the bar in terms of the safety and quality checks applied throughout the production process, so that potato-based foods are free from physical contaminants.
The ongoing threat of physical toxins and foreign bodies invading the potato-based food supply is a near-constant risk and a very serious threat, despite technological advances and the close attention paid to food safety procedures. This is especially true for potato-derived products like chips, which are often processed from raw potatoes that come directly from the field.
The US Department of Agriculture’s Food Safety and Inspection Service reported in 2019 that over a quarter of product recalls that year were due to the presence of “extraneous material” in food products3. These incidents underscore the imperative need for all food manufacturers, including those producing potato-based products, to proactively address, detect and eliminate physical contaminants to maintain the integrity of their products.
The consequences of contamination are not only immediate but can have enduring impacts. Factors such as the severity of a product recall, post-recall efforts and the brand equity of the company influence consumer perceptions. The intricate interplay between remedy and brand equity, particularly during high-severity failures, underscores the importance of a strategic and comprehensive response to contamination incidents.
Understanding Contamination Dynamics
The story of potato-based food begins where soil meets seed – a sprawling expanse of farms, orchards and fields, cultivating the very essence of potato-derived sustenance. It is here where potatoes flourish under the sun’s nurturing warmth that a complex narrative of potential contaminants emerges. Within the vastness of these agricultural landscapes, where the earth is sown, tended and harvested, it is easy to see how metals and rock particles find their way into the potato-based production process.
Contamination complexities unfold from the natural harvest to the production line, with challenges intensifying as these contaminants hide within potatoes. Detecting them becomes tricky due to differences in size and density, especially when a contaminant matches the density of the product or its packaging – a challenge for traditional inspection methods.
Each product and application require a unique detection solution, adding layers of complexity. Potato food manufacturers, bridging nature and technology, must tread this landscape with precision, understanding the subtle nuances of size, density and the stealthy entry of foreign elements into potato-derived products like chips, crisps and potato waffles.
Identifying Weaknesses in the Production Line
Food safety risks from physical contamination can occur anywhere along the production line, from the raw material stage to packaging. The good news is that there are formal frameworks available to aid food businesses in evaluating their manufacturing methods and the most vulnerable points to foreign body contamination.
Hazard Analysis and Critical Control Point (HACCP) and Hazard Analysis Risk-based Preventive Controls (HARPC) audits are intended to assist manufacturers in identifying these vulnerable potential points of contamination. While HARPC aids in planning to mitigate against situations like intentional adulteration, food fraud and terrorist activities, HACCP assists in identifying the danger of infection. Potato food manufacturers face particular challenges, as raw potatoes can sometimes carry soil or foreign matter directly from the field. The earlier a hazard can be discovered throughout the production process, the better.
All manufacturers will be able to set up control points so that checks and systems are properly positioned to help remove food safety hazards based on the findings of these audits. These are referred to as Preventative Control Points (PCPs) and Critical Control Points (CCPs), respectively. A strategy to reduce the risks of physical contamination can be put in place by understanding how contamination happens and identifying weak spots in the potato production process.
Implementing Multi-layered Defence Strategies
Establishing robust defences against foreign body contamination is pivotal and demands a strategic approach across diverse production stages. The potato-based food manufacturing process necessitates a comprehensive three-tiered defence.
Commencing at the initial stage of raw material inspection, early detection involves scrutinising incoming materials like potatoes for potato-based ready meals, crisps and potato chips. Detecting physical contaminants at this juncture not only helps with the purity of the raw materials but also shields downstream processing equipment from potential harm caused by undetected contaminants, such as stones in a batch of potatoes. This proactive step aims to eradicate foreign bodies before value-adding production processes begin, minimising the risk of contaminants reaching advanced stages of production and escalating costs.
The second line of defence is at an identified CCP during the production process. When inspecting bulk or loose-flow products, it is crucial to virtually eliminate debris that might be generated as a by-product of peeling, cutting and processing at this stage. A meticulous inspection at this phase leads to contaminants being intercepted, e.g. a stone or even golf ball from a field, before becoming integral components of the final product or damaging machinery.
End-of-Line Inspection is essential but should not serve as the sole line of defence. This inspection serves as a last-resort measure, identifying any contaminants introduced during the packaging process, such as metal splinters from broken machinery. However, reliance solely on this stage can prove less cost-effective. Manufacturers of potato-based products should prioritise identifying weak points in the production process early on, before additional valuable ingredients are introduced. This early identification not only minimises operational costs and waste but also leads to a proactive stance against potential contamination risks.
Selecting Appropriate Technology
The selection of inspection technology is crucial in manufacturing potato-based foods, to aid in the identification and removal of physical contaminants. The two main inspection methods, metal detection and x-ray inspection, are closely related to the traits of any potential contaminants, the particular product and its use, including the type of packaging.
Metal detection systems prove highly effective when dealing with metal contaminants in potato-based foods. On the other hand, x-ray systems excel in identifying metal as well as other non-metallic foreign bodies, offering a valuable solution for maintaining the integrity of potato snacks and processed potato products. The selection process is not solely contingent on the type of contaminant; considerations extend to the packaging material. For instance, products encased in aluminium foil can pose challenges for metal detectors but align seamlessly with x-ray inspection systems.
In scenarios where a potato-based snack, such as protein chips, undergoes packaging in a gravity-fed environment with limited insertion space (typical in applications like vertical form, fill, and seal processes), metal detection systems are the preferred choice. However, the versatility of x-ray technology extends beyond mere contaminant detection. It facilitates additional product integrity checks, including counting components, identifying missing or broken items, assessing packaging damage, monitoring fill levels, measuring headspace and detecting any product trapped in the film or seal.
Future-proofing Detection Capabilities
It is wise to maximise the ability to identify contaminants for a particular product or application, and product inspection systems should always be configured for success. But specifications shift. New demands are made on manufacturing facilities as a result of the introduction of new goods, processes and equipment. Therefore, while making decisions on contaminant detection equipment, potato-based food producers should consider future requirements in order to give themselves and their clients the assurance that strong quality assurance will continue to be in existence.
While still meeting regulatory and efficiency criteria, modular systems assist businesses in adapting to these changing needs. Floor space is a big issue in many factories. Combination systems, which combine several inspection methods, can help to solve this issue. One example is the combination of checkweighing with metal detection or x-ray solutions.
Investing in inspection systems with digital data gathering capabilities, which support shifting supply chain and compliance requirements, is another way to prepare for the future. Alternatively, using inspection technologies that make it easier to undertake preventative maintenance to improve inspection performance right away and lower total cost of ownership can be key.
Embracing Digitalisation
Digital technology is changing the supply chain for the entire food production industry, including the rapidly growing potato-based food sector. Real-time monitoring and control of automated inspection devices, as well as the gathering of performance data, are all included in digitalisation. Transparency and traceability are made available to all stakeholders in a supply chain by connecting these technologies and data streams. This transparency and traceability are particularly beneficial in the potato industry, where consistent quality and safety are critical due to the high demand for crisps, chips and other potato products. In the event of a product recall, having immediate access to traceability data is essential for swift action.
The growth of digital systems and networked supply chains to support higher quality requirements in production strengthens the link between digitalisation and food safety even more. In addition to enabling complete documentation for compliance, this may enable producers of potato-based products to rapidly determine when machinery is not operating effectively and take appropriate action.
Although the digitisation process is not without expenses and difficulties, the majority of potato food manufacturers already gather data from their inspection processes in some way. That is made simpler by digitalisation, which also improves operational effectiveness and efficiency and makes it easier to demonstrate compliance and due diligence. Undoubtedly, one of the major developments in recent times within the food industry is digitalisation. Potato-based food manufacturers who start now will be prepared for the time when a nice-to-have becomes a must-have in the digital supply chain.
Conclusion
With more and more people consuming potato-based foods – from mash to potato cakes – manufacturers must take a proactive and holistic approach to maintaining high standards of product safety. As demand for potato-derived products continues to rise globally, being sure that safety protocols are digitised and efficient is becoming increasingly important.
Understanding potential risks, developing robust plans and embracing technologies like digitalisation are crucial for immediate and future needs. Data-driven decision-making, alongside alternative inspection technologies, contributes to enhancing production line efficiencies and compliance, particularly in the production of potato-based snacks.
So, whether you love potatoes in the form of crispy fries or chunky chips, food manufacturers must take considered steps toward reducing the chance of expensive product recalls and maintaining company reputation. With a strong, decisive and technologically smart approach to foreign body detection in potato-based food manufacturing, the future is looking crisp and golden.
For more insights, click here to download a white paper on metal detection and x-ray inspection or visit www.mt.com/md-xr-eguide-pr
1 https://www.statista.com/topics/2379/potato-industry/#topicOverview
2 https://www.statista.com/topics/2379/potato-industry/#topicOverview
3 https://www.fsis.usda.gov/