We dont have test cards. Currently we run a jar thru the machine with the contaminate attached. We are most concerned with metal but it is also able to detect glass.
Ok, I don't get this if I'm honest. To run an x-ray you should have proper, validated, certificated and calibrated test cards which are the equivalent of your metal detector test sticks for metal detection. I don't see how you can just stick on a potential contaminant if I'm understanding this correctly? This is the kind of thing I'm talking about. http://www.detectame...-test-cards.php
Also how are you ever going to be able to detect glass if the product is packed in glass? I don't understand that? You are asking the machine to ignore glass and look for glass at the same time. In my experience this may only be possible if the types of glass you are looking for are different or you have some very careful set up basically using the x-ray as a vision system "ignore this part of the picture but look here" if you get what I mean? But the latter is very tricky. If you're not able to competently check for glass you may be muddying the water with metal. You're getting all these false rejects probably because you're trying to reject glass contamination which is difficult to set up as I've explained but could be risking letting out a product with metal in. Once you're into processing rejects from an x-ray or metal detector it needs VERY careful control. Fundamentally I would question if your x-ray really can do what your supplier says it can, i.e. detect glass. In the meantime you're running a line saying it's ok "it's just learning our product" to which I feel a bit panicky!
I don't think you should be running a line while a product is being learned. The learning process should be part of set up / validation etc. At the moment you don't know whether your x-ray is effective and you're not trusting it. Not a sensible nor duly diligent place to be IMO.
At best, and not all retailers like this, you should pass any supposed "false rejects" back through your x-ray 3 times and only pack them if they pass all three times but I'd be very wary of that.