Reducing the Risk of Metal Contamination in Food Processing

Due to population growth and changing demand patterns, it is estimated that food production will need to grow by as much as 50% by 2050. In addition to radical changes in primary food supply such as animal and crop farming, food manufacturers will need to carry some of the burden. With an estimated 14% of food wasted between the original source and retail outlet, it is clear manufacturers can make a tangible difference by reducing food contamination and waste during processing. So, how can companies prevent metal contamination in food?

Contamination risks come in many forms. The most common being biological hazards (such as bacteria and viruses), chemical hazards (such as pesticides and allergens), and physical hazards (such as metal, glass, and plastics).

Metal contamination is a common cause of food waste and food product recalls. With the correct preventative solutions in place, it is also one that can be significantly reduced.

How Does Metal Enter The Process?

To combat metal contamination, we must understand where the potential risks of ingress exist.

The risk of metal contamination has increased significantly as greater demands have been placed on the food production infrastructure. Increasing output and efficiency has added more exposure to metal objects during the cultivating and manufacturing cycle. Early in the cycle, modern farming techniques have increased the risk of items such as screws, staples, and machinery fragments entering the process. 

Increasing demands for processed food have given rise to bulk output and large-scale factories. These have increased the exposure to metal, as most automated processing machinery, such as chutes, conveyors, grinders, and packaging equipment, consists of metal surfaces or metal components. Due to natural abrasive wear or corrosion, metal fragments can break away and contaminate the product.

Specific examples of metal contamination can include:

Metal in Raw Materials or Packaging: tags, staples, wire mesh, screens, metal strapping, natural metals from soil/water contamination.

In Process Metal Contamination: machinery and equipment wear, machinery components, human error: tools, screws, buttons, keys, hair clips, wire, etc.

Learn more about metal contamination in the food production line here

The Consequences Of Metal Contamination In Food Processing

Allowing contamination into the food production cycle can result in serious consequences both financially and to consumer safety.

At the consumer end, there is the serious risk of human or animal injury. Or resultant compensation claims and legal costs. There are also the potential dire consequences of falling sales following a loss of confidence in a particular brand.

At the operational end, metal contamination can cause damage to expensive machinery, costly production downtime, raw material, and finished product scrappage costs.

How to Prevent Metal Contamination In Food Manufacturing

It is now commonplace for major retailers to demand that their suppliers implement auditable safety management systems. Most of these systems are based on Hazard & Critical Control Point (HACCP) analysis, an internationally recognised system for reducing risk.

A robust HACCP system demands that potential hazards and their route of ingress are identified, and suitable prevention methods are implemented to reduce the risk. The key points of HACCP are:

• Conducting potential hazard analysis
• Identifying critical control and risk points
• Establishing critical limits
• Establishing monitoring processes
• Installing detection and removal mechanisms
• Establishing corrective action procedures
• Maintaining audit records

Specific measures to reduce risk might include using only high-quality metal-free packaging for raw materials, regular inspections of process equipment, robust supplier audits, and following Good Manufacturing Practice (GMP) guidelines.

Also, employee codes of practice restrict the use or wearing of hazardous items around or near direct production lines. Investing in high-quality metal separation and detection systems is also a safeguard to prevent ferrous or non-ferrous metals contaminating food. 

Learn more about implementing HACCP here

Magnetic Separation And Detection Systems For Food

Should metal contamination enter the process, magnetic separation and detection systems are widely used to ensure that the finished product is safe and metal-free.

Magnetic separation systems extract ferrous metals and some grades of stainless steel from incoming ingredients and in-process food. As outlined earlier, manufacturing equipment or other potential contamination sources have a significant steel or iron content. Advanced magnetic technology creates a high-intensity magnetic field with the ability to extract even the finest particles in addition to larger tramp metals. 

Magnetic separators are available in various designs to suit gravity, pneumatic, or conveyor feed systems. There are different options to suit granular, powder, grain, pellet, or liquid form finished goods and ingredients.

Metal detectors are also an option to identify and remove ferrous and most non-ferrous, e.g., aluminium, copper, brass, contamination from the direct flow of processing lines. Models are available to suit gravity, free fall, pneumatic, and conveyor feed lines. There are also options available to detect metals in various food types, including chilled, frozen, packaged, dry granules, powders, and liquids. They are available complete with automatic reject mechanisms.

X-rays or scanners and visual inspection systems such as high-definition cameras are also available as further checks on food and ingredient purity. These methods can identify non-metallic contamination like plastics or glass.

View our full range of magnetic separation and metal detection products for the food industry here

In Summary 

Minimising food contamination at the processing stage is vital to ensure consumer safety and protect manufacturers against financial and reputation losses. It can also make a major contribution to minimising food waste, which will be critical if future world food demands are to be achieved.

As far as metal contamination is concerned, the benefit of past experience and technological advancements have ensured that the right tools and equipment are now available to almost eliminate this risk. High-quality separation and detection equipment used in conjunction with robust systems, procedures, training, planning, and monitoring can make a positive difference to reducing food waste.

Consult the Experts

Eclipse Magnetics provide a comprehensive range of magnetic separators and metal detectors. We also offer a magnetic separator testing and validation service. To find out more about our product portfolio, click here. If you would like to arrange a site visit from one of our sales engineers to discuss your project, please contact us.