Code of Practice for Metal Detection & X-ray Systems

Author: Sarah Ogston-Gray Applicable to: Product: Country: Group Date Revised: 375 Food

Date Issued: 02/06/09

Revision Due: 02/06/10

Legal and Technical Document Matrix No.

Tesco Stores Ltd. All Rights Reserved. Tesco supplies this document for use of the immediate recipient Aims : To set a common standard for the detection of metal (and other foreign body) contamination of Tesco food products. Objective : To reduce the risk of contaminated product reaching the customer, and achieve the best possible detection of metal foreign bodies in final packed product. Scope : To cover all aspects of metal contamination in Tesco food products (including pet food). Contents: 1. Introduction and Overview This COP is structured in 3 main sections: General Metal Detection Systems, Metal Detectors and X-ray. 2. General Metal Detection Systems 2.1 Location of Metal Detection System 2.2 General Sensitivity 2.3 General Testing 2.4 Calibration/Maintenance 2.5 Detector Failure 2.6 Rejected Product 2.7 Training 3 Metal Detectors 3.1 Factors Effecting Metal Detection 3.2 Metal Detectors (3 types) 3.2.1 Conveyor Mounted Systems 3.2.2 Vertical Packaging Systems 3.2.3 Pipeline Systems

X-ray 4.1 Principles of X ray 4.2 Benefits of X-ray 4.3 X-ray Equipment 4.4 Sensitivity 4.5 Testing 4.6 Reject Mechanisms 4.7 Plaster Control Appendix I Factors Effecting Metal Detection Appendix II, III, V Guidelines on Sensitivity Appendix V Foreign Body Densities Acknowledgements
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1.

INTRODUCTION AND OVERVIEW

Even with the most stringent controls possible on production techniques, metal contamination can and does occur. Every sieving, crushing, cutting, mincing, mixing or packing process introduces a potential risk of contamination. All Tesco suppliers and their suppliers must have in place appropriate systems for the prevention of metal contamination. These must include good working practices to prevent metal contamination backed up by effective metal detection and rejection systems, this may also include the use of magnets, e.g. on mechanical sieves. Appropriate metal detection systems may include: Metal Detection or X-ray. The system must be appropriate for the product being produced. This COP must be read in conjunction with Tesco Food Manufacturing Standard (TFMS). Any failures to meet this COP need to be discussed with the relevant Tesco Category Technical Manager (CTM) or Senior Tesco Technical Manager e.g. LTM (Non UK). If the system is effective the Tesco CTM may provide an approved deviation to the site with agreement that the requirements be fully met when the system is upgraded or new equipment is purchased. 2. GENERAL METAL DETECTION SYSTEMS
Base Medium High Aspiration

P P

R O R

Section
15.1

Item Metal Detection

Detail All products must be examined through a metal detection or x-ray detection system. Documented justification, based on risk assessment must be given if metal detection (or X-ray) is not in place.

Base

The risk assessment must be approved by Tesco CTM. Filtration may be an acceptable alternative to metal detection however this needs to be justified through risk assessment and approved by Tesco CTM. Magnets may be in place in some sites (in addition to other controls), which must be inspected at a pre-determined frequency. 2.1 Location of Metal Detection Systems

Metal detection inspection systems should be located at the end of the product packaging process, or as close as possible to the finished packing point and in-line with the main production flow. Individual packs must be checked where possible. If this it is not possible this must be approved by Tesco CTM.
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O 15.5

Equipment Foreign Body Detection

All foreign body detectors must be located as close as possible to the finished packaging point unless authorised by the Tesco Technical Manager.

Some processes may use metal detection systems upstream in the process for quality or equipment protection purposes. This COP relates to the final Critical Control Point (CCP) metal detection system.

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2.2
P R O

General Sensitivities
Section Base Medium High Aspiration Base Item Detail

O 15.3

Equipment

Foreign body detection equipment (metal detector, x-ray, colour sorter or magnets) must be specified as appropriate for the products that are being examined. Equipment must be upgraded to improve detection sensitivity where advances in detection are developed. The operation and sensitivity of the detector in use must be well understood by relevant site personnel. All foreign body detectors must have adequate security devices, so only authorised personnel have access to alter settings.

O 15.6

Base

Equipment Foreign Body Detection

Sites must work to achieve optimum levels of sensitivity in conjunction with the equipment manufacturer (i.e. the smallest metal pieces which can be consistently detected not a high level of false rejects), and approved by your Tesco TM. The sensitivity settings should to be documented. 2.3
P

General Testing
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R O 15.10

Testing of Equipment

The foreign body detector must be fully operational at the start of production. An effective testing method must be in place and all checks must be documented. Detectors must be checked at the beginning and end of production (for Tesco product) and minimum hourly unless agreed otherwise with Tesco.

All checks on the metal detection system must be documented and signed by the trained individual who has carried out the check. The actual time should be recorded. These checks should include: - Start of production, hourly, end of production - No .of rejects - Fail safe checks (where applicable) - Corrective actions for any failed checks - Investigation on rejected product Confirmation of metal checks should be recorded as Pass/P or Fail/F (or equivalent in local language). Ticks and dashes should be avoided. 2.4
P R O

Maintenance / Calibration (All Metal Detection Systems)

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15.9

Equipment

The foreign body detection system must be serviced at regular intervals, either by the equipment manufacturer or trained contractors (minimum annually).

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It is generally not possible to calibrate metal detectors but they need to be serviced regularly. The whole system needs to be checked e.g. sensitivities, rejection, fail safes etc. All new metal detection system installations should be checked by engineers from the equipment supplier. Evidence of a satisfactory installation should be verified and documented before production commences. Systems should also be re-validated in the event of their being re-located within the manufacturing environment and should be re-validated on an annual basis thereafter. The system must be serviced at regular intervals, either through a service contract entered into with the manufacturer, or on site engineers trained by the manufacturer (documentary evidence of training must be retained). A stock of suitable spare parts should be maintained. 2.5
P R O

Detector Failure (All Metal Detection Systems)

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15.13

Detector Failure

In the event of a metal detector test failing (whether due to failure to detect a test piece or failure to reject product) all material that has been checked since the previous satisfactory test must be isolated and retested through a unit that has been confirmed to be working correctly. A detailed procedure must be in place to handle incidents when metal is found in material. A full investigation must take place to ensure the source of contamination is identified and the risk of other materials being contaminated must be assessed. Corrective actions must be put in place to prevent a recurrence. Record details of the investigation.

Any test piece which fails to be detected is considered to be a failed test. The line must be stopped (where possible) and product isolated (using hold procedure) from the last good check. The equipment must be fixed by an engineer prior to production re-starting. The re-testing of product which has been isolated after a test failure must be documented on the metal detection records. 2.6 Rejected product (All Metal Detection Systems) If product is rejected it must be investigated for metal contamination. If the product is temperature controlled or delicate it should be disposed of due to the risk of temperature abuse. Ideally all rejected product should be disposed of, however if there is a high level of rejected product it should be successfully passed through the detector 3 times in different orientations. If it fails on one of these occasions it should be investigated for metal contamination and disposed of. If the product successfully passes 3 times it can be accepted. Rejected product collection box release keys should be held by nominated staff only. If multiple rejects are observed the line should be stopped for investigation. If a combined metal detection and check weighing system is in use. The system must be set up so that the metal detection rejection always overrides the weight rejection if the two occur together. 2.7
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Training (All Metal Detection Systems)

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15.14

Training

1.15

Base

Training

All staff involved with foreign body detection must be trained not only in the technical and operational aspects but also the principles of metal and foreign body detection to ensure full understanding of the purpose. Personnel in the factory who monitor CCPs must have an understanding of HACCP and have specific training against the latest version of the relevant monitoring procedure.

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METAL DETECTION

Most metal detectors in the food industry are based on a balanced coil system. A metal detector will usually contain 3 coils. The transmitter coil will generate a field that is designed to reveal metal particles in order to make them detectable. This process is called illuminating the metal particle. The remaining two coils are designed as receivers and are connected together to detect the presence of an illuminated metal particle. The detection is related to the conductive and magnetic properties of those metals. 3.1 Factors Affecting Metal Detection: The detail of the factors affecting metal detection are in Appendix I. - Metal Type (App 1a Fig 1) - Metal Shape & Orientation (App 1b Fig 2) - Aperture Size / Position in the Aperture (App 1c Fig 3) - Detector Frequency (App 1d Fig 4) - Environmental Conditions (App 1e) - Packaging Material (App 1f) - Product Characteristics (App 1g) 3.2 Type of Metal Detectors There are 3 main types of metal detectors: Conveyor Mounted Systems (3.2.1) Vertical Packaging systems (3.2.2) Pipeline Systems (3.2.3)
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O 15.4

Equipment Metal Detectors

All metal detectors must have the capability of detecting ferrous, non-ferrous and stainless steel (with the exception of foil packed products or similar metalized films).

If it is not possible to use a conveyor mounted system the metal detection system should be agreed with your Tesco CTM. Ferrous in Foil metal detectors should be used on foil packed products. 3.2.1 Conveyor Mounted Systems

3.2.1.1 Sensitivity In appendix II there is a table which gives guidance on realistic achievable metal detection equipment sensitivity. For products which are greater in size than those stated in appendix II, or in instances where the levels of performance cannot be met, consult with equipment manufacturers. Acceptable levels of sensitivities must be agreed with Tesco TM and detailed on specifications. The sensitivity of the equipment is essential in determining the type and size of pieces of metal detected. The equipment sensitivity is appropriate if all of the following parameters are met:- The sensitivity can be maintained without periodic adjustment. - The detector gives minimal false signals and does not reject good product. - Detector does not go blind after detecting a large metal piece. - Detection in different orientations. (for further information on sensitivity contact your equipment manufacturer)
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3.2.1.2.
P R O

Reject Mechanisms
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O 15.7

Equipment Conveyor Systems

A conveyor type detection system must have: An effective automatic rejection system A locked box to receive rejected product A fully enclosed area around the search head and rejection box A visual or audible alarm system in the event of detection Belt stop systems may only be used for bulk or sensitive items. Where belt stop systems are in use these must have a visual or audible alarm.

There are a variety of reject devices available which may include:Carriage retracting band Air blast (these can be unreliable if you have a drop in air pressure). Ensure that the air pressure is sufficient to cope with any potential metal contaminants e.g. metal bolts. Sweep/diverter arm Pusher If the area around the search head and rejection box is not fully enclosed an action plan needs to be agreed with Tesco CTM in order to rectify. The reject box should be locked when access is not required to retrieve product. The key /secure code should not be accessible to unauthorised personnel e.g. not left on the line. The reject box should be enclosed so that it would not be possible for someone to retrieve product from the bin without opening the locked box. If the equipment does not have a visual or audible alarm a bin full fail safe must be in place. An approved deviation may be given by the Tesco CTM if the system is effective. 3.2.1.3 Belt Stops The use of belt stop systems needs to be approved by Tesco CTM. The belt must stop immediately. All products must be removed from the line for investigation. The re-start procedure must be secure and only implemented by nominated personnel (i.e. key holder or security code). 3.2.1.4 Testing Conveyor Metal Detector Systems
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R O 15.10

Testing of Equipment

Conveyor Metal Detector Systems Detectors must be checked using clearly identified test packs at the same temperature as standard product passing down the line and test pieces of a defined size (based on risk assessment). The test pieces must be passed through the detector in the centre of the aperture with the test pack unless agreed otherwise with Tesco. Test packs must be passed successfully through the metal detector prior to being used for the check. Test packs must be allowed to be rejected fully into the bin. Consecutive leading and trailing checks must be completed in long packs to ensure the reject mechanism can successfully reject. The test must be representative of how products would normally travel through the detector during normal production.

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The test packs must be representative of the products going down the line e.g. shape and density. Actual product should be used as test packs unless agreed with Tesco CTM. The packs used to make up test packs should be passed through the metal detector before they are used to ensure that they do not contain metal.

The site should only use test pieces which are controlled and the size of the metal can be verified e.g. they are manufactured with a serial number or issued with a certificate. The test pieces must be passed through the detector in the centre of the aperture because this is the least sensitive part. This could be in the centre of the pack, on top or underneath. If the test piece is not in the centre of the pack then it must be attached to the product. If it is not possible to place the test pieces in the centre of the pack (e.g. frozen product and this is the centre of the aperture) it needs to be agreed with the Tesco CTM Tesco packs should be made up on an hourly basis with product from the line. If it is not practical to do this and test packs are made up in advance, the test packs must be controlled and labelled with product, date, test piece size and type. If the product is temperature controlled it must be kept at the same temperature as the product going down the production line. Test packs should be disposed of at the end of the shift. The use of test packs over a longer period of time must be approved by Tesco CTM. If packs are made up in advance and the test piece is not visible Tesco may request that the packs be opened to verify the test piece size and type during an audit or visit. Product Testing - Consecutive Test All test packs (Ferrous, Non Ferrous, Stainless Steel) should pass through the detector one after each other with normal spacing/line speed. The line should be running where possible.

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For Ferrous in Foil Detectors two test packs are required including two ferrous test pieces of the same size.

Product Testing - Memory Test The test packs should be sent through the metal detector with a standard pack in between (which has already passed through the metal detector). This should be carried out at the start and end of a shift and be documented.
DETECTOR HEAD

PRODUCT

(TEST)

PRODUCT (STD)

PRODUCT

(TEST)

PRODUCT (STD)

PRODUCT

(TEST)

It is a failed test if any of the test packs are not rejected. If a standard pack is rejected the line must be stopped and the issue should be investigated e.g. timing of reject mechanism. Product Testing Leading and Trailing Consecutive leading and trailing checks must be completed in long packs to ensure the reject mechanism can successfully reject. A pack is considered to be long if it is greater in length that the depth of the detector head (see diagram below). These checks should be completed hourly as per the consecutive test above. Depth of Detector Head

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The test should be completed as above. The 1st pack should contain the metal at the front of the pack and the last pack should have the test piece at the back of the pack. The test packs should be marked with the location of the metal if it is not visible. The Consecutive, Memory test and Leading and Trailing test (where appropriate) should be completed as per this COP. (the Consecutive and Leading and Trailing tests may be combined into one test) Deviations from this will need to be agreed with Tesco CTM. 3.2.1.5 Fail Safes Systems
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R O 15.11

Fail Safe Systems

Detector fail safe systems where fitted, must be challenged at regular intervals (minimum start and end of day) to make sure they are effective. Reject confirmation Bin full Air pressure low Search head failure Back-up sensor

Electronic equipment for metal detection is generally very efficient in terms of performance, however, with poor working methods or incorrect set up you could potentially have a machine which could let metal through. The following fail safe systems are available: Reject confirmation system: automatic belt stop fail safe system, to confirm metal contaminated products have not successfully entered the reject bins. Bin full system: an automatic belt stop fail safe system which activates should the reject product collection box become full. Air pressure system: an automatic belt stop fail safe system, to cover air pressure failures to the rejection mechanism. Search head failure: an automatic belt stop fail safe system to confirm detection head fault. Back up sensor: an automatic belt stop fail safe system, to activate should product back up under out the feed belt of the metal detector.

A method for checking fail safe systems should be developed where possible (e.g. a method forsearch head failure may not be feasible). If fail safes are not in place, the sites need to discuss with the relevant Tesco CTM. When new equipment is purchased fail safe devices are strongly recommended. The need for fail safes may become a future requirement. 3.2.1.6 Multi-Packs Where products are sold as a multi-pack, the individual items must be metal detected. Where this is not possible this must be agreed by your Tesco CTM.

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3.2.2

Vertical Packaging systems

Vertical packaging systems consist of a throat metal detector and a bag former beneath. They can be used for certain product types e.g. snacks and confectionary. Please see an example below:

3.2.2.1 Sensitivity In appendix III there is a table which gives guidance on realistic achievable metal detection equipment sensitivity. Typical sensitivity values can vary for processes of this type but the data is provided as an indication of sensitivity attainable. For metal detectors with a minimum aperture dimension greater than those stated in appendix III, or in instances where the levels of performance cannot be met, consult with equipment manufacturers and acceptable level of sensitivities must be agreed with Tesco TM. The controls for sensitivity must be secure and only possible by nominated personnel (i.e. key holder or security code). 3.2.2.2. Reject Mechanism On detection of metal the detector should send a signal to the bag-maker to produce a double bag or stop. The system should also be fitted with an audible and/or visible alarm to indicate that the system is stopped due to a metal contamination incident. The re-start procedure must be secure and only possible by nominated personnel (i.e. key holder or security code). 3.2.2.3. Testing
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R O 15.10

Testing of Equipment

Inline Systems An effective testing method must be in place for the equipment. Refer to advice from the equipment manufacturer.

When testing vertical packaging lines, ferrous, non-ferrous and stainless steel test pieces should be independently placed in the product flow and successful rejections observed (i.e. double pack made and audible and/or visual alarm activated and line stops). Only a nominated key-holder should be permitted to re-start the system. Confirmation must be sought that the test piece has been captured in the double pack produced.

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3.2.3

Pipeline Systems

Liquid, paste and slurry type products can be inspected as they are pumped through a pipeline prior to being dispensed into the final pack. This form of inspection is recommended in applications where the product is packed in metal containers - e.g. tin cans. Systems of this type should incorporate an automated reject valve system immediately after the metal detection head with an audible and visual indicator to signal when contamination is found. Contaminated product should be rejected into a suitable secure container.

3.2.3.1 Sensitivity In appendix IV there is a table which gives guidance on realistic achievable metal detection equipment sensitivity. Typical sensitivity values can vary for processes of this type but the data is provided as an indication of sensitivity attainable. For metal detectors with a minimum aperture dimension greater than those stated in appendix IV, or in instances where the above levels of performance cannot be met, consult with equipment manufacturers and acceptable level of sensitivities must be agreed with Tesco TM. The controls for sensitivity must be secure and only possible by nominated personnel (i.e. key holder or security code). 3.2.3.2. Reject Mechanism Systems of this type should incorporate an automated reject valve system immediately after the metal detection head with an audible and visual indicator to signal when contamination is found. Contaminated product should be rejected into a suitable secure container. 3.2.3.3 Testing With pipeline systems, test pieces should ideally be placed in the product flow and successful rejection observed. In instances where placing a test piece in the product flow is not practical, the system may be tested by inserting test pieces between the pipeline and the detection head (in the direction of product flow) and observing the operation of the reject system.

Sensitivity standards set in these instances should reflect that the test piece is not passing through the centre of the aperture (sensitivity is therefore higher). In these instances, the size of the test piece used should be adjusted to compensate (e.g. smaller test piece size).
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4.

X-RAY

4.1 Principles of X-ray This system uses a generator to project a beam of low energy X-rays through the product onto a sensor. The action of the product moving through the beam results in a greyscale image being produced. This greyscale image is then analysed for various abnormalities (contamination / product integrity faults). 4.2 Benefits of X-ray In many cases better detection will be achieved over conventional methods due to:- No effect from packaging (metallised film or foil packaging). - No effect from product (moisture / temperature / conductivity etc). Does not suffer from ferrous / non-ferrous / stainless differentiation (except aluminium). Detects some non-metallic contaminants glass, stone, bone, dense plastics and rubbers. Inspection of product in glass jars and metal cans. 4.3 X-ray Equipment There are 2 main types of X-ray equipment: - Conveyor System - Pipeline System 4.4 Sensitivity The ability of the X-ray to detect foreign bodies relates to the density of the contaminant. (See Appendix V) The capability of the equipment used should be related to the potential contamination risks inherent with the process and product. 4.5 Testing Please refer to manufacturer guidelines for testing procedure. The test piece size and materials should be agreed with Tesco TM.
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R O 15.10

Testing of Equipment

X-Ray Detection Systems The test pieces must be placed in the worst case scenario area. Refer to advice from the equipment manufacturer.

Please refer to metal detection section 3.2 for testing procedures and test pack make up. 4.6 Rejection Mechanism / Failsafe (See section 3.2.1.5)

4.7 Plaster Control In some circumstances metal detectable plasters may not be picked up by X-ray equipment. In these circumstances additional plaster controls need to be implemented (see below)
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O 10.6.2

Plaster Control

There should be plaster reconciliation at the end of the day or shift.

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Appendix I Factors Affecting Metal Detection 1a) Figure 1: Table metal type

1b) Figure 2 Diagram Orientation

1c) Figure 3 Aperture

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1d) Figure 4 - Frequency

Traditionally range between 10kHz to 1MHz Generally: - Lower frequencies = poorer sensitivity. - Higher frequencies = better sensitivity 8 particularly to non-ferrous and stainless steel 1e) - Environmental Conditions Systems should be specified in conjunction with the equipment supplier (where possible) to ensure they can perform effectively in the intended working environment. Performance should not be adversely affected by external electrical interference or by plant operating conditions e.g. wet environments, areas of high vibration, extremes of temperature or harsh hygiene procedures. 1f) - Packaging Material Different packaging materials can effect sensitivities (refer to equipment manufacturer) Paper, cardboard packaging Glass (jars & bottles) Moulded Plastics (jars & bottles) Poly Film Metallised Poly Film Aluminium Foil 1g) - Product Characteristics Dry Products - E.g. sugar, flour, snacks, confectionery, cereals, etc. 8 High Sensitivity Wet Products (product effect applications) - E.g. ready meals, meat, fish, sauces, preserves, etc. 8 Reduced Sensitivity

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Appendix II Recommended Sensitivity (mm) based on Pack size (Conveyor Systems)

DRY PRODUCT INCLUDING NONMETALLISED FILM PACKED PRODUCTS NonFerrous/ Aluminium Stainless Steel 316 Ferrous WET PRODUCTS and METALLISED FILM PACKED PRODUCTS NonFerrous/ Aluminium Stainless Steel 316 Ferrous ALUMINIUM FOIL PACKED PRODUCTS

PRODUCT HEIGHT

NonFerrous/ Aluminium 2.0 2.5 2.8 3.2 3.0 4.0

Up to 50mm 50mm - 100mm 100mm 150mm 150mm 200mm

1.0 1.2 1.5 1.8

1.2 1.5 2.0 2.2

1.5 2.0 2.5 3.0

1.8 2.0 2.5 3.0

2.5 2.8 3.5 4.0

3.5 4.0 4.5 5.0

1.0 4.0 1.0 - 4.0 1.0 6.0 1.0 6.0

Appendix III Recommended Sensitivity (mm) based on Aperture Diameter (Vertical Packaging)

APERTURE DIAMETER

DRY PRODUCT INCLUDING NON-METALLISED FILM PACKED PRODUCTS NonFerrous/ Aluminiu m Stainles s Steel 316 Ferrous

WET/FROZEN PRODUCTS and METALLISED FILM PACKED PRODUCTS NonFerrous/ Aluminiu m Stainles s Steel 316 2.5 3.0 3.5 4.0 Ferrous

Up to 100mm 100mm - 150mm 150mm 200mm 200mm 250mm

1.0 1.2 1.5 1.8

1.2 1.5 1.8 2.0

1.5 1.8 2.0 2.5

1.5 1.8 2.0 2.5

Appendix IV Recommended Sensitivity (mm) based on Aperture Diameter (Pipeline Systems)

INTERNAL PIPE DIAMETER Ferro us WET PRODUCTS Stainl ess Steel 316 Non Ferro us/ Alumi nium

Up to 50mm 50mm - 100mm

1.5 2.5

2.5 3.0

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Stainless Steel 316 -

Ferrous

Appendix V

Foreign Body Densities

Density Chart (kg/m3) Water Hair Cherry Pit Insects Wood (Oak) PP Ice UHMW Nylon PVC Teflon Bone Stone Glass Aluminum Iron Steel Stainless Steel
Acknowledgments This COP was developed in consultation with Mettler-Toledo and Loma Systems.

1.0 0.32 0.56 0.59 0.65 0.9 0.92 0.94 1.15 1.7 2.19 2.2 2.52 2.6 2.71 7.15 7.86 7.93

Most food product

Not Detectable by X-ray

Detectable by X-ray dependent on products thickness/homogeneity/density and size of contaminant

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