X-Ray False Positives

We make dietary supplements powders.  Sometimes when running packets through the X-ray machines we have a high rejection rate due to non-uniform particle sizes.  We have had the rep for the X-ray machine out but he cannot train the machine to accept the packets with the larger particles.  It amounts to a sizeable amount of waste.  Because the packets are foil, we can't use a metal detector.  I can't not use the x-ray machine.  So is there a way to show these packets are acceptable so they can be passed for use?

So, you know that there is no metal inside the packages the machine rejects? How are you sure, exactly?

IIRC some metal detectors will work with Al-foil packaging..

Hi Parkman,

What is the detection limit of your X-ray machine (Stone,metal & glass)??.

Better Find out which material (Ingredient) makes X- ray to reject the packets??

Use smaller particle size ingredient to avoid rejections.

We ran into this at my previous job.  We ended up doing what Charles.C mentioned above - we had to go to another X-ray company and get a model that is designed for foil packets.  It took some time to dial it in (the technician did that for us, and it took him nearly an entire day of running packets through!), but once he did, we rarely had a false reject after.

The wrong equipment will cost you MUCH more in time wasted (as well as product wasted) than buying the right equipment will cost in this case!

^{I am from a company manufacturing x-ray inspection machines.} 

^{Powders in metalized pouches is one of the most common applications for x-ray.  A good x-ray machine should be able to keep false rejects at very low levels.}