Snacks and confectionery Fast and safe packaging

Metal detection systems specialise in the detection of metallic contaminants such as ferrous, non-ferrous and stainless steel particles. They generate an electromagnetic field and identify metal particles that interfere with this field. Metal detection systems can be used at various points in the production line, whether for inspecting raw materials before the start of production or at the end of the production line after primary packaging. However, the most frequently chosen installation location in the production of snacks and confectionery is immediately before packaging. The products are weighed using multi-head weighing technology, fall through the metal detector and enter the bag, which is then sealed. The technology is ideal for high-speed production environments where fast and accurate detection of metallic contaminants is required. Inspection at this point minimises the risk of metallic contaminants in the final product and avoids any inspection limitations of the packaging material during primary or secondary packaging. Technologies such as Mettler-Toledo's Automated Test System (ATS), which not only improves test accuracy and shortens test time, but also reduces the number of operators required to perform the tests from two to one, can further increase productivity. In terms of total cost of ownership, metal detection technology is the best choice at this critical control point (CCP). Metal detection systems deliver efficient and accurate results in both horizontal and vertical applications. Vertical inspection systems, particularly utilising free-fall metal detectors in vertical form fill seal (VFFS) applications, are proving to be highly effective in the inspection of products such as snacks and crisps. These metal detection systems are installed between the weigher and the bag machine, allowing free-falling products to be inspected as they travel through the system. This method detects foreign objects before packaging, which is particularly beneficial in high-speed production environments. X-ray inspection systems are ideal for detecting a wide range of foreign bodies in packaged products, both in primary and secondary packaging. X-ray inspection enables the detection of glass, metal, stones, dense plastics, rubber compounds and even agglomerates - a problem often faced by chip manufacturers. Agglomerates or clumped seasoning powder can form during the manufacturing process and affect product quality by altering flavour, texture and appearance. The X-rays penetrate the packaging and identify foreign bodies contained therein based on differences in density. While inline inspection is effective for individual tubular bags, for example, end-of-line inspection, such as scanning an entire box of chocolate bars, offers additional benefits. This means that each box is thoroughly inspected for foreign bodies before it reaches the retailer. This multi-stage inspection process significantly improves product safety and quality control. In addition to foreign body detection, x-ray inspection systems perform a range of integrity checks such as verifying product shape, determining mass, detecting missing or broken products and checking for correct fill level. This further improves quality control and minimises the risk of defective products reaching consumers. The selection of the most suitable technology for a production line depends on the product type and the risk of contamination. Metal detection systems are ideal for inspecting products before packaging or during primary packaging. Early detection of metal contaminants at this stage saves manufacturers production costs. X-ray inspection systems are favoured for packaged products where detection of a wider range of contaminants is required. They are suitable for packaged products and offer optional quality and integrity checks that can take place simultaneously, usually at the end of the line.

A major issue for manufacturers in this industry is cost pressure. In particular, the fact that many snack and confectionery products are sold at low prices makes it difficult to invest in high-end product inspection systems. While the upfront cost of metal detection or x-ray inspection systems may seem high, these technologies can significantly reduce the cost of recalls and potential reputational damage. Utilising AI-driven functions with a focus on sustainability offers manufacturers additional support. By optimising inspection efficiency with intelligent algorithms, manufacturers can reduce energy consumption and minimise waste, ultimately reducing operating costs.

Particularly in confectionery and snack production, where complex machinery and moulds are often used, there is a risk of plastic contaminants entering products alongside metal contaminants. Plastic foreign bodies can result from wear on moulds, broken machine parts or damaged packaging materials. Robust detection systems are therefore essential. X-ray inspection systems offer an effective solution for detecting plastic contaminants based on their density, even when the difference in density between the plastic and the product itself is minimal. Despite the challenges, x-ray inspection systems can be accurately calibrated to detect different types of plastics, from dense polypropylene fragments to lighter plastic films, in applications with a wide range of product types. Confectionery products, whose ingredients can vary greatly in texture and density, can pose problems for traditional inspection methods when it comes to detecting plastic contaminants. However, x-ray inspection technologies offer greater detection sensitivity and reliability, ensuring products always meet stringent safety and quality standards. This minimises the risk of plastic contaminants reaching consumers and protects brand reputation.

Increasingly stringent regulations, such as the Natasha Act passed in the UK, have made the verification of labelling and allergen claims critical aspects of food safety. The Natasha Act stipulates that all pre-packaged foods intended for direct sale must have a full list of ingredients with clear allergen labelling. This regulation aims to protect all consumers with food allergies and give them access to important information about the products they consume. Automated visual inspection systems play a crucial role in fulfilling these requirements by verifying the information on the labels. They help to maintain compliance, avoid costly recalls and protect the health of consumers. The systems capture high-resolution images of individual product packs as they pass through the production line. They use advanced algorithms to analyse the images and check whether the labels are marked with the correct information, such as lists of ingredients and allergen information. They also recognise printing errors, missing information or incorrect labels.

Another integral part of modern snack and confectionery production is data management, which enables manufacturers to monitor and optimise their production processes and comply with auditing requirements. optimisation of their production processes and compliance with audit requirements. Added to this are predictive maintenance and real-time analyses, which can help to increase produc tivity. These data management systems enable manufacturers to proactively address production issues, reduce downtime and improve product safety. With Mettler-Toledo's ProdX data management software, manufacturers benefit from real-time data collection and analysis for improved compliance and quality assurance. The data management software efficiently tracks and documents product inspection data, providing the essential foundation for meeting product safety standards and optimising operational efficiency.