Doug,
I think it is normal for a process to produce small particles of metal.
What you are doing in the HACCP is deciding on what size metal could cause harm to the consumer. This one is always difficult one to decide, e.g. If you pack a small bag and your detector sensitivity is 1mm Ferrous then you are accepting that any ferrous metal smaller than a 1mm sphere equivalent is acceptable to pass through the process; then you pack the same product in metalised film and say your sensitivity is reduced to 2mm - this means you now accept something twice the size! You either then change the process, like putting in x-ray, throat detector, etc. or you accept the sensitivity of the machine.
What I believe is important is finding things out of the norm or that have passed through your process undetected (customer complaints).
Firstly look at your customer complaints. Do you receive any? What size are they? Have they harmed anyone? What type of metal are they? Will installing a detector prevent these complaints?
The next thing to do is closely monitor the process. You say that your magnets pick up some metal, do you know how much it usually picks up? Would you be able to put in a procedure that would identify when there was a problem? With metal detectors the important thing is to investigate the source of each piece of metal detected as soon as you can. It is useful to put an alarm on metal detectors so that the operator is alerted as soon as something is detected. You may put in you procedure that if the operator hears more than 2 rejections during a shift then this is highlighted and an investigation / decision is taken.
Sorry I seem to be rambling a bit.
Is this of any help?
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