guest speaker andrew frei · slider bed. metal detection –the basics • typical metal detector...
TRANSCRIPT
![Page 1: Guest Speaker Andrew Frei · Slider Bed. Metal Detection –The Basics • Typical Metal Detector Conveyor Reject Options. Applications –Drop Through / Gravity • Ideally suited](https://reader033.vdocuments.us/reader033/viewer/2022042621/5f5a1f7d06ee1776356d419d/html5/thumbnails/1.jpg)
Guest Speaker – Andrew Frei
• Regional Manager of Fortress Technology
Managing Northeastern, South central regions of the US along
with Western Canada
• 30 years experience in product inspection equipment applications
• Knowledgeable with food safety standards (i.e. HACCP, FSMA,
BRC) and issues in the milling industry
• Worked with Fortune 500 and local customers to provide cost
effective metal detection solutions for product and equipment
protection
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Metal Detector Basics
Milling Industry
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• Custom manufactures our equipment and software, to suit a customers’ needs,
applications and specifications
• Never Obsolete Commitment: detectors are always upgradable
• Simple Operation | Outstanding Reliability | Exceptional Performance
Who We Are
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The Global Supplier
Installed detectors
Representatives
SOUTH AMERICA:
São Paulo, Brazil
EUROPE:
Banbury, UK
NORTH AMERICA:
Toronto, Canada
Manufacturing Sites:
AUSTRALIA/ASIA:
Dynamic Inspection
Cambridge, New Zealand
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THE BASICS
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Metal Detection – The Basics
• Balanced Coil
Receiver 2
Transmitter CoilReceiver 1
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Metal Detection – The Basics
• Balanced Coil
Receiver 2Receiver 1
Transmitter Coil
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Vertical Coil
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Vertical Coil
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Vertical Coil
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Vertical Coil
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Vertical Coil
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Vertical Coil
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Vertical Coil
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Vertical Coil
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Metal Detection – The Basics
• Product Effect
Conductive Scale Magnetic Scale
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Metal Detection – The Basics
• Types of Metal – Detection Ratios
2.00mm Ferrous
2.00mm Non-Ferrous
3.00mm Stainless
Dry Product Mode
(Example of Ratios ONLY)
Wet Product Mode
2.00mm Ferrous
3.00mm Non-Ferrous
4.00mm Stainless
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Metal Detection – The Basics
• Typical Guidelines for Sensitivity
Dry Product
Ferrous & Non Ferrous
Wet Product
Ferrous Non FerrousAperture Height
≤ 50 mm (2 In)
≤ 125 mm (5 In)
≤ 200 mm (8 In)
< 0.8 mm < 0.8 mm < 1.2 mm
< 1.0 mm < 1.0 mm < 1.5 mm
< 1.5 mm < 1.5 mm < 2.2 mm
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Sphere Size vs. Volume
0.524
4.189
14.137
0
2
4
6
8
10
12
14
16
1 2 3
Diameter - Volume Plot
Sphere size (mm)
Volu
me o
f M
eta
l (m
m³)
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Metal Detection – The Basics
• Sensitivity
Aperture Size
1 2
3
Position in Aperture
1 2 3
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Metal Detection – The Basics
• Shapes & Orientation of Metals
A B C
Ferrous Wires:
• A - Easiest position, biggest signal.
• B, C - Hardest Position, smallest signal.
Non-Ferrous and Stainless Steel Wires:
• B, C - Easiest position, biggest signal.
• A - Hardest position, smallest signal.
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Metal Detection – The Basics
• Metal-free Area
Total Metal Free Area
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Applications
VectorPharmaceutical Gravity Pipeline
Large Bag Vertex
Web
Modular
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Applications – Conveyor
• Ideally suited for:
Packaged products of any kind
Bulk flow solids and powders
• Critical design factors:
Aperture size
Product rates
Reject design
Testability
Compliance factors
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Metal Detection – The Basics
• Detector Performance Isolated rollers - prevents loops
High quality belt – metal-free, carbon-free, interlocked finger
Splice or plastic modular belt (white or natural)
Low vibration and static
Adequate metal-free area
6. Roller Isolation
3. Clearance 4. Foot Isolation
5. Metal Free Belt1. Metal Free Area
2. Non-Metallic
Slider Bed
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Metal Detection – The Basics
• Typical Metal Detector Conveyor Reject Options
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Applications – Drop Through / Gravity
• Ideally suited for inspecting dry, free flowing products such as:
Grains, flours, cereals
Rice, nuts, sugar
Plastic pellets and flakes
• Critical design factors:
Flow rate
Bulk density
Free fall distance
Pipe size
Space available
Testing procedure (insert + recovery)
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Applications – Drop Through / Gravity
Good Product Output
Reject Output
De
tecto
r To
Va
lve
Dis
tan
ce
Product Freefall Start Point (Test Piece Access)
Plastic Pipe Selection
Detector
Ove
rall
Le
ng
th
Dro
p H
eig
ht
Dis
tan
ce
D1
D2
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Applications - Pipeline
• Ideally suited for inspecting liquid, slurries, or paste products that can be pumped through, such as:
Sauces, dairy products, meat slurries, Juices etc.
• Critical design factors:
Pipe I.D.
Pipe clamp connection style (tri-clamp, I-line etc)
Product flow rate (GMP)
Product viscosity
Product temperature range
Product pressure
Expected cleanup procedures (wash down, pipe pig, etc.)
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Applications - Pipeline
FlowGood
Product
RejectedProduct
D1
Detector
Reject Valve
Non Metallic Pipe Section
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Food Safety Audit
Metal Detectors
• Metal Detectors have been reported as a leading
cause of audit non-conformances
Most common issues:
Lack of training / knowledge at all levels
Lack of commitment at management levels
Improper test procedures
Equipment function failures
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1) How to test? Test methods?
2) When to test? How frequently?
3) What to test with? What size & type of metal, and what
encapsulation type
(Test wand, card, ball, other)?
4) Basic Test Procedures
5) What to do with the results
(Test records, pass/fail,
decisions & actions)?
Testing Metal Detectors
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Testing Metal Detectors
1) How to test?
Minimum considerations:
• Center of aperture
• Consistent position
• Speed same as product speed
• Number of passes/tests
• Use product where feasible
• Test must include rejection device
• Safety of procedure
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2) When to test?
Minimum considerations:
• Shift change or shorter regular interval
(ie: every 4 hours)
• Product change
• Application change (speed, reject position, etc.)
• After line maintenance
• Consider the logistics of a test failure
Testing Metal Detectors
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3) What to test with?
Minimum considerations:
• Choose Sphere sizes that are reliably detectable
• Stainless Steel sample always;
• Ferrous & Non-Ferrous can be at lesser frequency
• Form of test sphere encapsulation should suit the application (size,
colour differential)
• Certified test samples
Testing Metal Detectors
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4) Basic Test Procedures?• Test sample should travel through the centre of the aperture
• Use ‘real’ product to carry the test sample whenever possible
• The test sample must be allowed to be rejected and enter the
reject bin
• Record results
Testing Metal Detectors
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5) What to do with results?
Minimum considerations:
• Manual record of each test event
• System of collection/storage of records
• Easy method to decide pass/fail
• Clear action upon test failure
Testing Metal Detectors
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Test Documentation
• Example of
daily test log
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Test Data Automation
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Failsafe Systems
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Failsafe Systems
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Testing of Failsafe Systems
During an Audit, Proof of failsafe sensing
devices may need to be demonstrated.
• In-feed eye blocked / misaligned
• Reject bin full
• Reject confirm fail
• No / low air
• Belt stop / start timing compensation
• Reject exit eye blocked
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Food Safety Audit
Audit Preparation• Know GFSI scheme requirements
• Training for all levels of staff up-to-date
• Metal Detection equipment reviewed
Condition and Operation
Scheme requirements
• Test Samples – certified and appropriate size
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Audit Preparation• Audit team: review documentation & procedures
Accurate
Current
Compliance
• Detector calibration certificates from recognized source
• Test procedures, critical limits and report records
• Maintenance records and/or agreements
Food Safety Audit
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Rejected Product• Isolate – Locked Bins/Enclosures
• Examine/Re-inspect
• Use of Off Line or Lab Metal Detectors
• Identify metal
• Identify Source
Food Safety Audit
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Summary• Training, Training, Training
All levels of staff should be proficient
Management especially
• Documentation
All pertinent documentation organized and available
• Recall Procedures
Everyone on the audit team should know
• Metal Detector Supplier
Source for training and information
Food Safety Audit
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Events and Data Logging
CONTACT Software
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OVERVIEW
Contact Communication system is designed
to help with quality assurance record-
keeping and reporting.
Contact Service
Database
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• Reject types: Reject : Reject event from normal operation.
Reject Counter Cleared : Indicates counter was cleared by operator.
Photo Peak : Peak from a product in which metal was not detected.
o Used for statistical analysis for discrete products.
Auto-Test
Test Request : Test done as part of a test request (FE, NFE, SS)
• Date & time
• Signal – Indicates the magnitude of the reject signal.
REJECTS
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Contact Reporter
Contact Reporter Software
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OVERVIEW
• Windows applications
• Displays detector status
• Generates reports on information collected Reports can be exported to PDF or EXCEL
• Multiple languages
(English, French, Spanish, Portuguese, German)
Contact Service
Database
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REPORTS : PRODUCT LIST
Provides a list of parameters for all defined products on a detector.
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Metal Detection Systems
• Contacting Fortress Technology
HeadquarterFortress Technology Inc.
Toronto, Canada
Phone: (416) 754-2898
Fax: (416) 754-2976
Email:
EuropeFortress Technology (Europe) Ltd.
Banbury, UK
Phone: +44 (0) 1295 256266
Fax: +44 (0) 1295 255987
Email: [email protected]
South AmericaFortress Technology
Sistemas de Inspeção Ltda.
São Paulo, Brazil
Phone: +55 11 3641 6153
Fax: +55 11 3641 6153
Email: [email protected]
www.fortresstechnology.com
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Thank you for your attention!