Foil Packets packed before metal detector

I work in a company that outsources for many sauces and toppings to include in their cut-produce products (salads and side kits etc). Many suppliers offer great toppings and sauces to us in foil-lined packets/pouches.

The only problem is we have a metal detector as our final CCP which our finished product passes through after it is sealed in bags/bowls.

Because of this we cannot use any foil-lined pouches in our operation because our process will kick out any packages containing any type of metal. It can be challenging to find suppliers who will pack in plastic pouches for us.

Does anybody have a suggestion on how to overcome this limitation?

Maybe having the metal detector placed before sealing?

Or do we need to rethink our CCP position?

Any suggestions are appreciated

X-ray?

You need to be careful if metal detecting before sealing in terms of potential for contamination after detection and before sealing.

X-Ray is the only solution if you must run this way.

Or -- 

MD uncovered

Proceed to insert and overlay

Run thru X-ray

I work in a company that outsources for many sauces and toppings to include in their cut-produce products (salads and side kits etc). Many suppliers offer great toppings and sauces to us in foil-lined packets/pouches.

The only problem is we have a metal detector as our final CCP which our finished product passes through after it is sealed in bags/bowls.

Because of this we cannot use any foil-lined pouches in our operation because our process will kick out any packages containing any type of metal. It can be challenging to find suppliers who will pack in plastic pouches for us.

 

Does anybody have a suggestion on how to overcome this limitation?

Maybe having the metal detector placed before sealing?

Or do we need to rethink our CCP position?

 

Any suggestions are appreciated

Assess the risk of moving the metal detector right before sealing and working with your engineers and production team to mitigate the risk of metal inclusion after it passes through the MD, sachets are added, then sealed. In FSMA speak, you may end up having the metal detector as a process preventive control and may incorporate a specific SOP for GMP requirements of operators packing the sachets (if manual) and a routine inspection to verify as another PC. You'll also have to increase the risk level of the supplier of the packets as you'll be fully dependent on their ability to keep metal out of the sachet via a supplier preventive control.

Aluminium compatible metal detector .

As others have said...

1.  X-Ray

2.  Possible change in the packing process and/or metal detector placement in the process flow. 

If I were you I would see if putting the packets outside of the sealed container and place them on after metal detector.  But, it really depends on what is the cheapest fix to be honest.  Engineering or management may find that replacing the metal detector with an X-Ray machine is cheaper than relocating, purchasing, or moving packing equipment.

https://www.ifsqn.co...etal-packaging/

https://www.ifsqn.co...ent/#entry89639

Aluminium compatible metal detector .

Which are shocking machines...  You'll get a detection with a rusty iron nail but not much else.  Not helpful when you have a factory full of stainless steel.

As others have said...

 

1.  X-Ray

2.  Possible change in the packing process and/or metal detector placement in the process flow. 

 

If I were you I would see if putting the packets outside of the sealed container and place them on after metal detector.  But, it really depends on what is the cheapest fix to be honest.  Engineering or management may find that replacing the metal detector with an X-Ray machine is cheaper than relocating, purchasing, or moving packing equipment.

I think that could be a good solution.  Some manufacturers do this.  One thing to question though is how your supplier metal detects the packs.  Do they have an x-ray?

Which are shocking machines...  You'll get a detection with a rusty iron nail but not much else.  Not helpful when you have a factory full of stainless steel.

No direct experience but I saw this -

Magnetoreflection method detects metal contaminants in aluminum-packaging products regardless of shapes and orientation of contaminants. Stainless steel can also be detected with high sensitivity. Ideal for aluminum-packaging products such as retort pouches, chocolate and poultice.

 Al-MD.PNG   196.86KB   2 downloads

Cost may be another factor of course. And X-ray ?

No direct experience but I saw this -

 

 

Al-MD.PNG

 

Cost may be another factor of course. And X-ray ?

X-ray is of course an option.  Not seen that metal detector but the normal ones are ferrous in foil.  Of course the higher spec you go or have x-ray, the more money...

I think that could be a good solution.  Some manufacturers do this.  One thing to question though is how your supplier metal detects the packs.  Do they have an x-ray?

OP will have to conduct risk assessment to see if metal detection is needed at the supplier with the packets.  Depends on what controls for foreign material the supplier has in place and the type of equipment they run.  I would suspect the equipment and product pathways to limit any kind of potential foreign material in the first place.