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#1 EStefana

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Posted 16 May 2020 - 04:46 PM

Hello everyone. 
 
I have this question regarding a procedure in case that your metal detector is obsolete and needs to be replaced with completely new equipment. 
 
We have this issue with our metal detector that almost whenever is tested with a piece of metal, to see if it works, the detector detects the metal and takes out the product on which was put the piece of metal but it does not stop, it continues to take out the products continuously, taking out all the good products from the line, meaning in a lot of a good product loss.
 
To stop this happening we have to reset the metal detector and stop the line production. So, we know that the metal detector will take out the product with metal included but it is almost impossible for us to take the test hourly and stop the line everytime so that we can reset the metal detector (it is a PCC step, we have to test it hourly). 
 
Taking into consideration that the metal detector is obsolete and the maintenance team can not repair it anymore we have started looking for a supplier of metal detectors and we found one but it takes time until they come to take measurements, produce the equipment, install it and everything. This procedure would take at least a month.
 
What can a producer do during this time without stopping production considering that a lot of orders have to be honored in time and considering that the detector still removes the products with the metal but testing it hourly (PCC) involves a lot of products and time loss? 
 
Thank you,


#2 Charles.C

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Posted 16 May 2020 - 10:08 PM

 

Hello everyone. 
 
I have this question regarding a procedure in case that your metal detector is obsolete and needs to be replaced with completely new equipment. 
 
We have this issue with our metal detector that almost whenever is tested with a piece of metal, to see if it works, the detector detects the metal and takes out the product on which was put the piece of metal but it does not stop, it continues to take out the products continuously, taking out all the good products from the line, meaning in a lot of a good product loss.
 
To stop this happening we have to reset the metal detector and stop the line production. So, we know that the metal detector will take out the product with metal included but it is almost impossible for us to take the test hourly and stop the line everytime so that we can reset the metal detector (it is a PCC step, we have to test it hourly). 
 
Taking into consideration that the metal detector is obsolete and the maintenance team can not repair it anymore we have started looking for a supplier of metal detectors and we found one but it takes time until they come to take measurements, produce the equipment, install it and everything. This procedure would take at least a month.
 
What can a producer do during this time without stopping production considering that a lot of orders have to be honored in time and considering that the detector still removes the products with the metal but testing it hourly (PCC) involves a lot of products and time loss? 
 
Thank you,

 

 

IMEX it takes 1-2 days to install a metal detector. I suggest to find another supplier.

 

I assume the metal detector step is a CCP.

 

Regarding yr specific query, I can see 2 possibilities -

 

(a) accept a time loss for 1 month.

(b) modify yr haccp plan so that the MD is no longer a CCP.

 

If you do not wish to use the MD for one month, i think this is similar to a previous thread where the poster asked for options in the case that the MD(CCP) failed and no backup. haccp plan was unchangeable.  IIRC only suggestions were to stop Production or rent use of a MD while repairs carried out


Kind Regards,

 

Charles.C


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#3 FoodSafetyPlanet

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Posted 18 May 2020 - 10:46 AM

HI Es,

 

Refer to your metal detector manual and see if there is a "test mode" you can activate before you test.



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#4 SQFconsultant

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Posted 18 May 2020 - 07:36 PM

Sounds like you are dealing with a metal detector rep and not a direct source, there is no way it should take that long, even if a dealer had to get one crated and shipped in the maximum might be 5-7 days. 

 

Problem with waiting 30 days is how long are you going to wait if you need technician service.

 

I'd be looking for a different dealer that has stock or can get one in overnight freight, if it is a critical need for your process.

 

As Charles mentioned I'd consider the change to not making the MD a CCP, I have a client that did exactly that several years ago.

 

If you have to shut-down for 30 days that will be very expensive metal detector, I'd save some money and pay more now for fast delivery than go out of business for a while  waiting on a piece of equipment.


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Glenn Oster
 
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#5 EStefana

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Posted 04 June 2020 - 01:10 PM

Sounds like you are dealing with a metal detector rep and not a direct source, there is no way it should take that long, even if a dealer had to get one crated and shipped in the maximum might be 5-7 days. 

 

Problem with waiting 30 days is how long are you going to wait if you need technician service.

 

I'd be looking for a different dealer that has stock or can get one in overnight freight, if it is a critical need for your process.

 

As Charles mentioned I'd consider the change to not making the MD a CCP, I have a client that did exactly that several years ago.

 

If you have to shut-down for 30 days that will be very expensive metal detector, I'd save some money and pay more now for fast delivery than go out of business for a while  waiting on a piece of equipment.

Hello,
 
Thank you for the advice. Though, how can I take out a CCP? Can I take it out temporarily until our metal detector is being replaced? (I gave a presumed period of 30 days including also the days in which the metal detector will be tested and set, as an idea, maybe it will not take that long, anyhow, even a week could be much to stop the production). The idea is that the metal detector is for final packages. I do not have any control points after the metal detector, after it the products are being palletized. I do have metal sieves on the flux that could chip anytime and get into my packages. Well, the possibility for this to happen is very low but still, this is why the metal detector was made a CCP in the first place. I cannot see the way I can take out my CCP. Maybe you could give me some ideas?
 
 
Thank you,





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