News27

Product Inspection and Industrial Weighing

Meat, Poultry and Seafood

Make Every Batch Perfect with New Formulation Software

Effective Use of Space with Critical Control Points and Weighing

Unique Solutions to Inspect Pumped Products

How to Overcome Product Effect in Metal Detection

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Product Recalls Cost up to $30MCan You Afford to Take the Risk?Product recalls due to cross-contamination, labeling errors or foreign bodies being found by consumers are still a regular occurrence. What steps can processors take to avoid the risks and minimize recalls?

perienced a recall, 77% estimated the finan-cial impact to be up to $30 million, describ-ing the costs of a recall as “significant” or “catastrophic.” The cost of product recalls is giving management teams the strategic im-petus to put avoidance measures in place.

Risk mitigationReducing the risks by installing suitable weighing and inspection equipment, de-signed to perform consistently and accu-rately in demanding conditions, is a recom-mended approach. Find out how to overcome the challenges on pages 2 and 3.

Food safety scares make global headlines and a highly-publicized incident can destroy the worth of a brand name in an alarmingly short space of time. Product recalls can be very costly, and if a company is found guilty of a food hygiene breach, this can result in significant fines. Having safe, best practice production processes in place helps to avoid product recalls.

The financial impactA recent study by Covington & Burling and Ernst & Young looked at the financial impact of food recalls. For companies that had ex-

1 Reducing the Risk of Bacterial ContaminationHygienically designed weighing and inspection equip-ment enables thorough sanitation regimes to be exe-cuted quickly and efficiently, minimizing the possibil-ity of bacterial contamination. Examples include liftable floor scales, ICS bench scales with metal keypads and inspection equipment rated to IP69K, designed to per-form in harsh production environments.

` www.mt.com/ind-metal-keypad

3 Removing Physical ContaminantsInstalling detection equipment at critical control points mitigates the risk of physical contaminants being found in your products. Metal detection systems detect and re-ject unwanted metal fragments, while x-ray inspection technology detects and removes contaminants includ-ing metal, glass, dense plastics and calcified bone.

` www.mt.com/metaldetection ` www.mt.com/xray-inspection

5 Tracking Ingredients and Declaring AllergensIncorrect labeling and unexpected product and ingre-dient changes are two of the main reasons for unde-clared allergens. When manually blending spices, small errors in the recipe weighing process can lead to declaration errors. Form+ is recipe management soft-ware that provides increased traceability while guiding operators through the blending process.

` www.mt.com/Formplus

4 Checking Label AccuracyIncorrect ingredients, undeclared allergens and misla-beled products account for a large proportion of food product recalls. End-of-line vision inspection technology enables lot numbers, barcodes and ingredients on each and every product label to be checked for correctness.

` www.mt.com/civision

Adopting technology to avoid recallsDownload our white paper to find out how in-stalling solutions to check quality and control processes can avoid the risk of product recalls.www.mt.com/pi-productrecalls

Preventing Product Recalls With Proper Planning and Equipment

Whi

te P

aper

Contents

1 Introduction

2 What does a Recall Cost?

3 Reasons for Recalls

4 Control the Controllable

5 Best Practice to Minimize Recalls

6 Do the Research

Avoi

ding

Pro

duct

Rec

alls 5 Ways to Avoid Product Recalls

How Effective Weighing and Inspection Can Help

Latest FDA data, presented in the chart below, shows multiple reasons for product recalls. Installing fit-for-purpose weighing and inspection equipment with the appropriate protocols at every stage of the production process minimizes the risks, supports compliance with industry regulations and protects consumers and your brand.

39%

10% 4%

Pathogen

QualityAssurance

UnapprovedIngredient 21%

12%

8%

Undeclared Allergen

Contaminant

Mislabeled

2 Documenting Audit Trails and Collecting Data EfficientlyAccurately documenting inspection and weighing pro-cesses is essential for food safety compliance and avoiding the risk of recalls. The ability to network equipment, combined with advanced software, pro-vides a robust audit trail and reduces the need for manual data collection.

` www.mt.com/prodx ` www.mt.com/Collectplus

Top reasons for product recalls:

6%Other

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Form

ulat

ion

Softw

are

Eliminate manual errors for good Visit our formulation page to see how the new formulation management software eliminates manual errors and waste.www.mt.com/Formplus

Eliminate wasteSmall errors including losing one’s place during repetitive tasks in the formulation process can lead to waste or the loss of a full batch. Form+ allows the creation and control of recipes and workflows as defined by the formulation process. It provides tools to reduce the risk of bad batches and waste by offering: • Batch size correction in case of accidental operator over-pouring• Warnings against the selection of wrong or expired materials

Deliver repeatable consistencyConsumers expect consistently high product quality, but humans are variable by nature. Form+ guides operators through the recipe weighing process and supports the creation of workflows to ensure the recipe is performed as defined. This includes:• Clear operator guidance directly on the touchscreen of the scale terminal • Horizontal, vertical or non-sequential working mode

Replace paper-based processesForm+ eliminates paper-based working procedures, facilitates quality control and speeds up manual processes. All relevant process data is automatically stored and can easily be reviewed or printed with the built-in report function. Compliance, traceability and complete batch documentation are ensured with:• Multiple reporting and labeling options for increased batch visibility • System integration options with ERP or MES systems

Ensure operator safetyProper allergen material handling and declaration is required by global food standards and national legislations. Recipe-specific messaging in Form+ ensures operator confirmation with requirements such as allergens, safety instructions or SOPs. This messaging includes:• Allergen warning icons for increased operator safety • Display of safety instructions on how to handle ingredients and processes

Form+Efficient Recipe Management

Eliminate up to 100%

of waste

Ensure consistency

day after day

Enable paper-free processes

Allergen alerts

for safety

Make Every Batch Perfect Eliminate Waste and Errors in Formulation

When working with sensitive ingredients and complex formulations, paper-based procedures can lead to inefficiencies, manual errors and costly rework. A new state-of-the-art recipe management software offers 100 percent process control over recipe weighing operations and ensures traceable and consistent product quality.

What is Form+? Form+ is a recipe management software that guides operators through the recipe weighing pro-cess and reduces the risk of waste or wrong ingredient additions. The software is installed on a robust terminal with a touchscreen, ensuring a paper-free weighing process for daily formulation work. Weigh-and-dispense operations are tailored to your processes to keep them safe, efficient and compliant.

` www.mt.com/Formplus

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Easy

to In

tegr

ate

Solu

tions

Integrated Metal Detection and WeighingAutomated checkweighing and metal detection reduce the risks of product recalls and prevent costly product over-fill. Separate rejection of off-weight and metal contaminated products supports product quarantine regimes, while op-tional Due Diligence Kits ensure the highest process safety, supporting compliance and worker safety requirements.

` www.mt.com/checkweighing-CM33

Critical Control Points and WeighingA Cost-Effective Use of Space

Combining multiple inspection technologies into a single system establishes Critical Control Points (CCPs) with a reduced footprint. It also efficiently uses available space to make a HACCP and HARPC-compliant production line. A system designed for easy integration increases flexibility when deciding where to place a control point on the production line.

Compliance and ProductivityProdX software measures and records data from product inspection systems, for in-depth monitor-ing, performance analysis and support for GFSI required test documentation.

` www.mt.com/prodx

Due diligence for your food manufacturing processThe Due Diligence Kit integrates monitoring options to comply with safety and quality regulations within the food industry.www.mt.com/cw-due-diligence-kit

Checkweighing and X-Ray Inspection CombinedHighly sensitive x-ray inspection detects a variety of small, hidden contaminants, while precision weighing avoids costly product give-away and ensures adherence with weighing regulations. The CX35 combination system provides a compact solution ideally suited for limited factory floor space, and its hygienic design enables easy in-stallation and cleaning.

` www.mt.com/checkweighing-CX35

Label Integrity and Weight CheckReliable high-speed label inspection is critical to detect mis-labeled or defective product packaging. Automatic in-spection of label flavors, key product identifiers, allergen declarations and label quality minimizes the chance of a la-bel mix-up resulting in rework, recalls or retailer fines. Integrated with precision weighing, this com-bination system offers the highest quality as-surance in a compact machine.

` www.mt.com/checkweighing-CV35

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Met

al D

etec

tion

and

X-ra

y In

spec

tion

2. Choose the right system

If metal is the most likely contam-inant, a metal detection system is best; if other contaminants such as bone are a risk, an x-ray system is the better solution.

4. Production line integration

To achieve maximum productivity, it is important to select a pipeline system that integrates fully with other applicable equipment on the production line.

Inspecting Pumped ProductsMaking the Right Technology Choice

Inspecting processed meats, pastes and slurries in pipeline systems provides significant

productivity and quality benefits to your business. Metal detection and x-ray technologies

both work well, but how do you choose the right technology for your application?

Pipeline systems typically inspect raw product before extra value is added. Contaminantsare typically easier to detect earlier in the production process before they become dispersedin processing. Catching contaminants early reduces unnecessary product waste and helpsprevent damage to downstream processing equipment. Here we outline key factors toconsider when choosing a pipeline solution.

1. Identify the contaminant risks

Conduct a Hazard Analysis and Critical Control Points (HACCP) review to determine the most likely contaminant types.

Choosing the Right Foreign Body Detection System

METTLER TOLEDO has a range of pipeline in-spection solutions to ensure manufacturers get the most out of their investment.

• Profile Advantage pipeline systems can detect metal contaminants up to 50% smaller than traditional technology and can virtually eliminate false rejects.

` www.mt.com/md-profileadvantage

• X38 pipeline x-ray inspection systems detect a wide range of contaminants including glass, mineral stone, calcified bone, rubber, dense plastics and metal.

` www.mt.com/xray-X38

• HDS pipeline metal detection systems are designed to integrate with leading vacuum filler systems for the inspection of pumped sausage products.

` www.mt.com/md-HDS-pipeline

Improving food safety inspection of pumped productsDownload this free white paper to discover how pipeline inspection equipment can protect consumers and mini-mize the risk of recalls.www.mt.com/pi-pumped-inspection

3. System configuration

Choosing an application-specific reject mechanism is essential to ensure accurate removal of contam-inated product and to minimize un-necessary waste of good product.

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Calculate your savingsUse this free ROI calculator to see how much you could save by reducing false rejects with METTLER TOLEDO’s Profile Advantage metal detector.www.mt.com/md-ROI-pa

Chal

leng

ing

Appl

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in M

etal

Det

ectio

n How to Overcome Product EffectRobust Detection Avoids False Rejects

A phenomenon known as “Product Effect” has long been an obstacle to attaining high levels of metal contaminant detection sensitivity in the meat, poultry and seafood industries. For many years, manufacturers have been forced to compromise on detection standards. However, using multiple frequencies simultaneously and innovative software algorithms means the challenge of product effect has now been overcome.

Product effect occurs when a product’s own characteristics inhibit the inspection device’s ability to distinguish between the product being inspected and the contaminant. Six factors that contribute to product effect are detailed on the right.

Previously, the solution to overcoming product effect was to reduce the sensitivity of the metal detector, but that results in smaller con-taminants going undetected, increasing the risk to product safety and of costly product recalls.

METTLER TOLEDO’s Profile Advantage system uses a unique com-bination of Multi-Simultaneous Frequency and Product Signal Sup-pression technology (‘3S’ algorithm) to minimize the active product signal and virtually eliminate false rejects.

1What is

Product Effect?

2Why is Product

Effect Important?

3What is the Solution?

1. Product temperatureWhether a product is frozen, hot, wet, chilled or warming can have an im-pact on the product signal it emits. This variation can lead to high false rejects.

2. Product formatPackaging can affect sensitivity if the material is itself conductive. Looseproducts may exhibit a different prod-uct signal to packaged products.

3. Orientation on the production lineIf products are randomly presented as they pass through the metal detector’saperture, this can alter the active prod-uct signal.

4. Moisture or salt contentWater and saline conduct electricity and respond to magnetic fields, so the product can create a signal similar to that of a metal contaminant, making it difficult to inspect.

5. Product consistencyVariances in size and weight as well as water, salt or fat distribution canalter the active product signal of indi-vidual products.

6. Product size and shapeDifferent sized packs or different portion sizes can also result in different active product signals being generated.

How Profile Advantage technology works

6 factors that contribute to product effect

Active product signal at high and low frequencies

Step 1: ‘Scale’ Step 2: ‘Spin’ Step 3: ‘Subtract’

The ‘3S’ algorithm dramatically improves metal detection capability and virtually eliminates false rejects by minimizing the active product signal in challenging wet applications.

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For more information

Process Management at Your FingertipsEffective Software Solutions

Giving critical information to managers and process owners enhances their ability to drive efficiency and support informed decision making based on real-time, accurate data. Our advanced software solutions can help to increase productivity, improve product quality and support compliance with industry standards.

www.mt.com/ind-meat

Meet quality and compliance requirementsTake control of quality and food safety compliance. Watch our latest animation to discover how data management software, ProdX can help. ` www.mt.com/prodx

Monitor process efficiencyEfficient process and yield control doesn‘t need to be complicated. See how Collect+ allows you to collect, share and visualize your weighing results. ` www.mt.com/Collectplus

3 ways to optimize your filling processOverfilling by just one gram can result in tons of wasted material. Download the eBook to see how you can best optimize your filling processes. ` www.mt.com/ind-reduce-overfilling-costs

Solutions for Statistical Quality Control

3 Ways to Optimize Food Packaging ApplicationsReduce Overfilling and Ensure Compliance

Local contact: www.mt.com/contactsDocument No 30462851

Mettler-Toledo, LLC1900 Polaris ParkwayColumbus, OH 43240

Mettler-Toledo Product Inspection1571 Northpointe ParkwayLutz, FL 33558

Mettler-Toledo, Inc.2915 Argentia Road, Unit 6Mississauga, Ontario L5N 8G6