60-second interview

What do you do? Christy Draus, Eagle Product Inspection

By Jenny Eagle contact

- Last updated on GMT

Top 6 inspection challenges for snack manufacturers

Related tags: X-ray inspection, Hazard analysis and critical control points, Food

As part of FoodProductionDaily’s ongoing series of 60-second interviews with the movers and shakers of the food and beverage industry, we caught up with Christy Draus, marketing manager, Eagle Product Inspection.

Draus manages all areas of the company marketing program and initiatives to drive strategy and business development across North America, Latin America, Europe, the Middle East, South Africa and Asia Pacific.

Christy Draus
Christy Draus

With over 13 years of experience in business-to-business environments she has worked for Advantec, Nilla Shields, Cox Radio and Camden Property Management.

She believes as public scrutiny of food manufacturers continues to escalate and consumers increasingly turn to social media to voice complaints, snack processors have become more reliant on food inspection equipment to protect consumers and reduce the risk of brand-damaging product recalls to stay ahead of their rivals.

What are the top six challenges manufacturers face when inspecting snacks?
The challenges manufacturers face when striving to produce safe and quality-assured snacks are; 

Variety of potential contaminants
Often snacks contain a variety of ingredients that are open to different types of contaminants. Fruits, vegetables and nuts may be contaminated with stones or a piece of wire from the farm, while dairy products can be suspect to metal or plastics from processing. 

High salt content of products
Many snacks, such as nuts and potato chips, contain high doses of salt and are conductive. When they pass through a metal detector, they can create a disturbance of the detection field, triggering false rejects. Product temperature and moisture content can also affect a metal detector's detection sensitivity.

Metal packaging
Metalized film and foil are used to package various snacks, including energy bars and chocolate. Inspecting these products using metal detectors can lead to reductions in the level of achievable sensitivity. In some cases, if the metalized film is especially thick, it's preferable to inspect products before packing.

Variations in product density
Many snacks, such as bags of trail mix and granola bars, contain high variations in density because of the multitude of ingredients. Finding physical contaminants in these products can prove challenging for traditional x-ray inspection systems as the varying densities create 'busy' x-ray images.

Contaminants similar to product
Color and hand sorting are frequently used to remove rocks and other visual defects from loose flow bulk snacks foods, such as almonds, but neither method is entirely accurate as stones are similar in shape and color to the product. Visual inspection methods are also limited to the top layer, which means anything that can’t be seen, won't be identified or removed. 

Quality assurance
Proper portioning and seal integrity are another two major concerns for snack manufacturers. Individual bars and boxes with multiple bars can be underweight, overweight, deformed or broken. Additionally, during the sealing process, bits of food can get trapped in product seals, creating a faulty seal and causing food spoilage. To overcome such issues, manufacturers have traditionally installed a range of inspection equipment on their production lines, including checkweighers, metal detectors and vision systems. 

In your opinion, which technology is ideal for contaminant detection?
Different snacks and packaging types require different product inspection systems and selecting the right technology is crucial to guarantee maximum detection sensitivity and high throughput.

In many cases, there's only one suitable machine (metal detection or x-ray inspection) and in many others, either technology could be used. Occasions also exist where it may be necessary to install both technologies at different Critical Control Points (CCPs) on the same line.

For cost-effectiveness, metal detectors usually offer the best technology when looking to detect ferrous and non-ferrous metal, stainless steel and aluminium contaminants. A metal detection search head also takes up less space than an x-ray inspection system. This means that for applications where installation space is limited and metal is the only likely contaminant, a metal detector may be the best option.

X-ray inspection systems are just as adept as metal detectors at finding metal and provide unrivalled detection of non-metallic contaminants, including glass, mineral stone, calcified bone and high-density plastics. The latest x-ray inspection equipment is simultaneously capable of performing additional quality assurance checks such as measuring mass, checking fill levels, and detecting missing and damaged products, and identifying seasoning agglomerates such as flavour or powder lumps.

How many separate machines does a manufacturer need to cover all areas of safety and quality assurance?
Advanced x-ray food inspection equipment is capable of providing safety and quality assurance at every stage of production for unpackaged and packaged snack applications, and eliminates the need for multiple inspection machines on one line by performing the following quality checks:

Fill level
Modern x-ray inspection systems allow manufacturers to set maximum and minimum fill levels and will reject products that fall outside these pre-set parameters. Fill levels can also be adjusted by adding an optional feedback to the filling machine, which is beneficial for staged products, such as cans of crisps. Filler feedback control can reduce product giveaway and customer complaints by assuring the customer receives exactly what they expect every time.

Component counts
X-ray inspection equipment is capable of detecting missing, deformed or broken snacks. X-ray food inspection systems can look inside final sealed packaging to check that all components are present, for example that the right number of cereal bars are inside each box. By counting cookies and crackers that can’t be seen or counted by cameras or human eyesight, systems can help to reduce customer complaints. 

Seal integrity
The integrity of airtight seals in vital to the quality control of food produce. X-ray machines are capable of preventing food spoilage by identifying obstructions in packaging seals. Ensuring seal integrity is an important step in the prevention of microbiological contamination and any resulting product recall this could cause. Seal integrity checks by x-ray inspection machines can prevent customers rejecting a spoiled product or sticky packaging. 

Mass measurement
X-ray food inspection systems can help snack manufacturers exert better quality control by measuring overall and zoned mass. Mass measurement is effective on high-speed lines where traditional in-line weighing systems may not be practical or offer the same level of accuracy. It’s also useful when space limitations mean manufacturers can’t accommodate separate machines and need all checks to be simultaneously carried out – in one machine. For products in defined compartments, x-ray inspection systems are available that can provide results for individual zones.

Unlike checkweighers, which can only measure the total weight of a box of snack bars, x-ray inspection equipment can measure the weight of a box of snack bars and the weight of each individual snack bar inside the box.

Can product inspection equipment help manufacturers to comply with ever-increasing regulations?
Following a number of highly-publicized food safety scandals in recent years, global safety regulations are increasingly far-reaching and more stringent. Examples include the Food Safety Modernization Act (FSMA), which aims to ensure the US food supply is safe by shifting the focus from responding to contamination to preventing it, and China's revamped food safety law, which came into effect in October 2015, and imposes criminal liability for unsafe food. 

On top of this, snack manufacturers in the US face increasing pressure to achieve Safe Quality Food (SQF) compliance. X-ray food inspection systems can meet the rigorous requirements necessary to achieve SQF certification with features like validation mode for login credentials and XML files for data storage that support manufacturers' audit processes.

Product inspection equipment can also comply with Hazard Analysis and Critical Control Points (HACCP) principles, as well as achieve certification to the following Global Food Safety Initiative (GFSI)-recognized schemes:

  • The British Retail Consortium's (BRC) Global Standard for Food Safety
  • International Featured Standard (IFS)
  • ISO 22000:2005 

Why is data collection and storage so important?
The ability to swiftly identify and isolate unsafe food is crucial to ensure snack safety and avoid product recalls.

The latest x-ray inspection equipment makes product traceability effortless by recording valuable production data and machine status information, and enabling quick and easy access to it.

X-ray systems store images of all rejected packs, which are date and time stamped with the product name and can be taken off the x-ray machine and stored on a manufacturer's computer in chronological order. These offer excellent traceability on any complaints or returns as the production times/codes can be immediately cross-referenced.

By recording large amounts of useful information, x-ray machines can also help to identify trends and instigate preventive action to reduce the occurrence of contamination.

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