The packaging section of the bakery handles over 300 artisan products across six lines, one of which can handle two product streams.
Products range from cookies to farmhouse bloomers and French sticks, often in production runs that last 20 or 30 minutes.
Each metal detection system acts as a critical control point (CCP) at the end of a packaging line.
Frontline Packaging was the main contractor for the packaging installation at the unnamed retailer.
Tony Hacker, managing director of the firm, said the size range and frequent changeovers meant there is a lot of non-standard engineering in the lines.
“The time pressure was also extreme, with the initial enquiry arriving with us in February and a deadline to go live in June,” he said.
“With the COP (code of practice) and the huge product range, the spec I was putting out to suppliers was as long as your arm, plus their response needed to be quick.”
Machines were customised, for example on the line for baguettes, the pusher and reject bin needed to be enlarged to handle the awkward shape.
Systems were also fitted with custom-built guards to protect them from trollies manoeuvring around the site once the bakery was up and running.