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X ray in food safety
- 1. Food Safety From Food Processor to End User Presented by Ayush Kumar 13/IFT/006 Presented to Pushpendra Sir
- 2. Goals Identify critical inspection locations within a production line Compare traditional vs. current inspection capabilities Analyze applications and inspection successes
- 3. Why Inspect? Source: ExpertRECALL Improved food safety Better quality control Reduce the potential of a recall
- 4. Why Inspect With X-ray? More consistent performance • Fresh or frozen, wet or dry • Not affected by humidity or other equipment Can provide traceability • System can auto-store images of every rejected product • Facilitates, supports more detailed HACCP logs Will detect more contaminates • Bone, glass, metal, ceramic, dense plastic Final package inspection • Check weigh, clip detection, missing products, voids, etc.
- 5. What’s Driving X-ray Inspection? Retailers demanding higher quality • Metal specifications are tightening • Want to detect bone & other materials Improvements in HAACP standards • Knowing what is entering your plant • Respond to issues earlier in the process
- 6. What’s Driving X-ray Inspection? Automated deboning is creating more chips & splinters • Greater potential for customer complaints • Protecting your and your customers’ brands Potential premium for inspected product
- 7. Where Can X-ray Be Applied? Incoming product • Trim meat or frozen blocks • Detect bones or other contaminates
- 8. Where Can X-ray Be Applied? Meat from a debone line • Bone chips or fragments • Fillets, tenders, legs, and thighs
- 9. Individual packages inspection • Bags or trays • Check weigh & Foreign Material Detection • Missing clips or voids in chubs • Piece count or orientation Where Can X-ray Be Applied?
- 10. Application Examples 2.0-3.0mm bones in poultry breast meat One customer was able to reduce bone count from over 1,200 per load to less than 4
- 11. Bone Fragments In Tenders
- 15. What Can Be Detected? Calcified bones – >2.0mm thickness Metal Spheres – 0.5mm diameter stainless steel Wire – 0.2mm diameter by 2.0mm long Glass sphere – 1.0 to 1.5mm diameter Ceramic – 1.0 to 1.5mm diameter
- 16. Technology X-ray Highlights • Excellent detection capabilities • 2 basic product parameters: • Density – Lighter, less dense contaminants are harder to detect • Thickness - Thinner product is easier to inspect
- 18. Thank You!
Editor's Notes
- The primary goal of this webinar is to review various applications in a plant environment where x-ray systems can be utilized. X-ray is simply not only for bone detection. It can replace other more traditional inspection systems while providing a higher level of capability and traceability. The implementation of x-ray systems in your facility will certainly be a step forward in improved food safety and quality. It will help you meet the QA demands of your customers now and into the future.
- There are a number of different areas within a facility where various contaminates can be detected and removed from the product. We will review some of these areas and discuss the pros and cons of each. We will compare x-ray capabilities with the more traditional metal detectors and check weighers. And finally we will review some specific applications for x-ray along with a review of the technology.
- While there can be any number of reasons for including inspection systems as part of your SOP procedures, two of the primary reasons are the prevention of a product recall and the protection of your brand name. This chart shows that 19% of recalls from Q1 2012 thru Q1 2113 were due to foreign contaminates. The amount of product recalled from extraneous material was roughly 10% of the 3.9 million pounds of product that was recalled. The protection of your brand, or your customer’s brand, is helped by preventing a recall but it is also helped by minimizing customer complaints. If you can eliminate a bone fragment or piece of metal that can chip a tooth or puncture a gum, it goes a long way in helping to protect the brand. This is even more important as the younger generation of consumers moves towards a greater variety of bone free products.
- - Using x-ray technology as opposed to metal detectors offers several advantages. The most important is that the systems detection capabilities do not change over time. Once the machine has been properly set up, its performance is extremely repeatable. Unlike with a metal detector, the x-ray does not care if the product is fresh or frozen, wet or dry, has been marinated in a briney solution, or if the ambient temperature or humidity changes. You do not have to make adjustments during the day as conditiosn change. The unit is also not susceptible to noise from either RF or nearby moving equipment. -The x-ray can provide traceability by providing an image of every product that has been inspected. These images can be retained indefinitely and become part of your permanent QA / traceability program. The x-ray has much better detection capabilities for metal and in addition can detect glass, ceramics, stones, calcified bones, and some hard plastics. A typical MD can detect stainless in the 5-6mm diameter range while an X-ray can easily detect down to the 0.6-0.7mm range on an individual item or package and down to 2mm on a full case. As standards are continually strengthened, this capability will become even more important. In addition to FOD the x-ray can provide a level of package inspection. It can be used for virtual check weighing, for identifying missing clips on a chub, for detecting air pockets or voids in a product, and for product orientation and piece count.
- Higher quality demands from retailers: for them this is a big part of protecting their brand names. They are requiring that more product is being inspected and that the detection capabilities are higher than what can be achieved without x-ray. Bones are becoming a bigger and bigger issue. In some cases the end user is specifying x-ray and even purchasing systems to be used by suppliers. HAACP and food safety: production facilities are being pressured from all sides to improve food safety. This comes from the government, from their customers, and from inside their own organizations. One of the firsts steps in the process should be the inspection of any products that enter your facility. What exactly has been delivered? Are there any FOD’s? Also, the earlier in the process that a product can be inspected, the lower the negative cost implications of any contaminates. Get it out of your product supply before you marinate, before adding spices, before it is further processed in your facility.
- With manual deboning of legs and thighs, there was a significantly smaller potential for bone chips or splinters. This mostly only happened if a leg was broken earlier in the process, prior to debone. With some automatic machines however the incidence of bones being shattered as part of the debone process has greatly increased. A good example is if a thigh is loaded backwards. These small bones chips are hard to detect – the only way they can really be found is via x-ray. White meat deboning has issues as well for both manual cone lines and automated lines. The meat will have fan bones, pulley bones, or scapula. Some national chains have even required that if automatic deboning equipment is used in the process then x-ray inspection is a requirement. Some companies are willing to pay a premium for meat that has been inspected and virtually guaranteed bone free. I have seen some examples for high volume products where the payback has been measured in weeks based solely on the premium price for bone free products. I have seen the premium from $0.03 per pound to as much as $0.50 /lb.
- Inspection of incoming product to your facility: Who is supplying meat to your facility? What kind of inspection or food safety program do they have in place? Does the product contain bones or other contaminates? In today’s environment it is becoming even more important to fully understand exactly what is coming into your facility. You certainly do not want to discover any contaminates after the fact when it is much more difficult and significantly more expensive to remedy.
- In a poultry facility that debones front halves and legs or thighs there will most definitely be bones in the final product. As demand for boneless product continues to increase it is not only important to improve the deboning process itself, but it is also important to inspect the deboned product so that any remaining bone fragments can be removed.
- X-ray systems can be used to inspect the final packaged product. Not only can the system look for contaminates, it can also be used for final package inspection. Virtual check weighing accurate to within roughly 1-3% of package weight Can detect missing or multiple clips on chubs Can see voids inside products or packages Can detect pieces missing from packages Can detect product in the seal area of certain packages.