Product Inspection SAFELINE

Metal Detection

Understanding Sensitivity
In Metal Detection
Maximize Performance Of Your Metal Detector

1 What Is Sensitivity?
How Is It Measured?

2 Factors That Contribute

To Metal Detector Sensitivity

3 How Direction Of Travel

Can Lead To Orientation Effect

4 Factors That Lead To

Product Effect In Metal Detection

5 When To Test
Your Metal Detection Equipment
 Sensitivity Is A Key Contributor
To Metal Detection Effectiveness

There are a number of factors that affect the sensitivity of a metal detector and the ability to find
different types of metal. It is important to understand these factors to get the most out of your metal
detection program.

This guide explains the concept of metal detector sensitivity, in the length of wires or other irregular-shaped contaminants
key factors that affect it, and why a small difference in that can be detected.
spherical sensitivity performance can mean a big difference

2
What Is Sensitivity?
How Is It Measured?

Sensitivity is the measure of a metal detector's ability to detect a

specific type and size of metal contaminant. The better the sensitivity
of the metal detector, the smaller the pieces of irregular-shaped metal
it can detect.

Metal detector performance is usually expressed by the However, in some cases, it may not be so clear. One metal
diameter of a test sphere made from a specific type of detector could outperform the other on one metal type, and
metal, such as ferrous, non-ferrous (aluminum, brass), or vice versa for another. In this case, you should consider
stainless steel. which contaminant type is most likely to occur (often this
is stainless steel) and could base your decision on which
Sensitivity should always be measured as near to the system performs best for this metal contaminant type.
center of the metal detector's aperture as possible, as
this is the least sensitive point. When comparing the Ultimately, it is best to discuss the situation with a metal
performance of different metal detectors, the clear winner detection system expert who can guide you through the
is usually the one with the best spherical sensitivity process of choosing the best overall system, as there are
across all metal types, when measured in the center of the many other factors to consider.
aperture.

3
 Factors That Contribute
To Metal Detector Sensitivity

When measuring the sensitivity of a metal detector, a test piece must be reliably detected and
rejected when passed through the center of the aperture of the metal detector. However, there is a
significant difference between the test piece's spherical sensitivity and the actual length of an
irregular-shaped or wire-type contaminant that can be detected. A number of factors can affect the
sensitivity of a metal detector. An experienced provider can help you select the right solution to
overcome these challenges.

Metal type
A HACCP audit may identify a risk of various metal types, including ferrous, non-
ferrous and stainless steel. However, the sensitivity of the metal detector can vary
depending on the type of metal contaminant present. Typically ferrous is the easiest
to detect, and stainless steel is the hardest to detect. However, as with many "rules"
there are exceptions to this.

Orientation effect
A metal detector's ability to identify a non-spherical contaminant such as wire
or swarf, is partially determined by the type of metal contaminant (ferrous, non-
ferrous or stainless steel), as well as the metal object's orientation. Orientation effect
becomes a limiting factor when the contaminant's cross-sectional area (i.e. diameter
of a wire) is less than the metal detector's spherical sensitivity.

Aperture size and product position

To maximize sensitivity, the smallest possible aperture size should normally be used.
Optimum aperture size will be dependent upon the products being inspected, and
in the case of conveyorized inspection, the dimensions and orientation of the product
on the belt.

4
Packaging material
The packaging material used to pack a product can affect sensitivity if the material is
itself conductive. The production process should be assessed to determine the best
inspection point. In some cases this may be immediately prior to packing. In other
cases, e.g. when metalized film is used, several alternatives are available, including
alternative/multiple frequencies or using a slightly larger aperture. The ultimate
critical control point (CCP) is after final packaging.

Environmental conditions
Factory conditions can also affect the metal detector's performance. It is important
to use a metal detector which has built-in Noise and Vibration Immunity to minimize
the risk of airborne electrical interference and local plant vibration affecting the metal
detector's performance.

Product characteristics
Some products are electrically conductive or magnetic and as such behave in the
same way as metal when passing through the detector. For example, products with
high moisture or salt content such as meat and poultry, exhibit this phenomenon, often
referred to as 'product effect'. The latest innovative metal detection solutions combine
two or more frequencies simultaneously along with Product Signal Suppression
technology to overcome this issue by minimizing the active product signal.

Process speed
This is not necessarily a limiting factor for most metal detection systems. However, it
is important to ensure the metal detector can operate at optimal performance levels,
taking into account any potential variations in speed or product throughput on the line.

Detector frequency
Metal detectors can be run on different operating frequencies – the optimum
frequency depends on the type of product being inspected. For dry products such
as snack foods, metal detectors are more effective at high, tuned frequencies, but
for wet products such as meat and poultry, a combination of Multi-Simultaneous
Frequency and Product Signal Suppression technology is recommended to get the
best results, while also minimizing false reject rates.

5
 How Direction Of Travel
Can Lead To Orientation Effect

A metal detector's ability to identify a contaminant is

partially determined by the type of metal, as well as the
contaminant's orientation as it passes through the metal
detector. In reality, all metals are relatively easy to detect
in dry product applications – but harder to detect when
inspecting wet products, or those packaged in metalized
film due to the product's own characteristics. However,
recent innovations in metal detection technology have
made it possible to overcome this challenge.

Contaminant Ferrous (FE) Non-Ferrous (Non-Fe) Stainless Steel (SS)

Magnetic
Magnetic Non-magnetic Usually non-magnetic
Permeability
Characteristics

Electrical
Good electrical conductor Generally good or excellent Usually poor conductors
Conductivity

Ease of
Harder to detect in wet Relatively difficult to detect
Detection
Relatively easy to detect applications due to being due to being non-magnetic
in Wet
non-magnetic* and a poor conductor*
Applications

Relative Ease of Detection When Orientation Effect Is Observed:

Position A Easy More Difficult More Difficult
Orientation

Position B More Difficult Easy Easy

Position C More Difficult Easy Easy

*Note: Using the latest metal detection technology means the detection of Non-Fe and SS metals has become
considerably easier. Product testing is highly recommended to establish likely sensitivity levels for a
specific application.

6
 A Small Change In Spherical Sensitivity –
A Big Difference In Wire Length Detection

Operating at the highest spherical sensitivity level will provide maximum protection to your brand
and company's reputation, dramatically improving your detection capability to real life contaminants
such as wires and swarf. As the chart below shows, improving detection sensitivity by 25% (going
from a ball size of 2.0 mm to 1.5 mm for example) will significantly improve the length of the wire
that can be detected, and decrease the risk of undetected metal reaching, and potentially causing
harm to, consumers.

Detectable 316 SS Wire

Detectable Stainless Steel 316 Wire Results (All Orientations)
DetectableFor Dry
Stainless SteelProduct
Dry Product 316 Wire –800k
Inspected Dry
at Product
High 800kHz
Frequency

1 mm wire 1.5 mm wire 2 mm wire 2.5 mm wire

7.00
Stainless steel
Size (mm)

6.00 is used in this

example since
(mm)

5.00
it is typically
Ball
size

4.00 more difficult

Ball316

to detect than
Steel

3.00 ferrous and

316 SS

non-ferrous
Stainless

2.00
metals.
1.00

0.00
0 5 10 15 20 25
Stainless316 SS316
Steel WireWire
Length (mm)(mm)
Length

The FDA states that a hard or sharp foreign object measuring between 7 mm to 25 mm in length may
cause a traumatic injury or present a choking hazard*.

*FDA choking hazard: http://www.fda.gov/ICECI/ComplianceManuals/CompliancePolicyGuidanceManual/ucm074554.htm

Results shown in the above chart will change when inspecting wet/conductive products and/or if using low or mid-range
frequency metal detectors. In challenging applications – where products contain high moisture or salt content, are subject
to varying temperatures, or are wrapped in metallized film – sensitivity performance will generally be worse than for dry
products. Achieving the best possible sensitivity requires use of the latest metal detection technology specifically for these
challenging applications.

Expert Support
METTLER TOLEDO offers in-house product testing to give you an indication of the sensitivity results that can be
achieved on your products. Contact us to request a test today.

7
 Factors That Lead To
Product Effect In Metal Detection

Product effect occurs when a product's own characteristics inhibit the inspection device's ability to
distinguish between the product being inspected, and a particular contaminant type. Often referred
to as a 'challenging application', this can result in potentially high false reject rates, unless the
technology in use is able to overcome product effect using innovative software algorithms.

Six key factors that contribute to product effect are highlighted below.

1 Product temperature 2 Moisture or salt content

3 Product format 4 Product consistency

Orientation on the
5 production line
6 Product size and shape

8
How To Find Smaller Metal Contaminants
For Better Brand Protection

To protect your customers, maximize efficiency and meet industry standards, manufacturers and
processors have an important role to play in identifying, implementing and maintaining an optimum
level of metal detector sensitivity.

Metal detectors may use a range of different technologies to Choosing a stable, reliable metal detector that delivers
suit the product being inspected. For example: enhanced sensitivity levels is an integral part of a food
• The optimum technology for inspecting dry products such safety program to minimize metal contamination going
as snack foods is a metal detector with ultra high-tuned undetected. However, having a metal detector is not
frequency. This will deliver exceptional sensitivity to detect enough – it must also be correctly installed, operated and
smaller pieces of metal. maintained for optimal performance.
• In challenging applications with product effect – where
products are hot, wet, chilled or cooling – a metal
detector with dual or multi-simultaneous frequency and
Product Signal Suppression technology is more effective
than tuned technology.

} Locate your local METTLER TOLEDO Safeline Sales Representative at www.mt.com/contact

9
 When To Test
Your Metal Detection Equipment

Routine performance testing is essential to meet the requirements of food safety standards and
retailer codes of practice.

The frequency of testing should consider the following It is also important to take into consideration the quarantine
stages: (or on-site storage) period for the products being produced.
• At the start and finish of daily production / shifts This is to ensure all products inspected since the last
• At regular intervals during the production run successful test can be easily recalled in the event of a failed
• At changes in production batches test, to minimize the cost of a product recall.
• After changes to machine settings
• After downtime for repairs

10
Validation, Verification And Monitoring
Ensuring Correct Equipment Performance

Validation, verification and monitoring are distinct processes. Each has a clear purpose and role to
play at different points within the equipment lifecycle.

Validation is the initial qualification of a product or process

against the stated design specification and aims to answer
the question "will this piece of equipment meet the specified
objectives?"

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White Pape
Re-validation may also be required if substantial Validation,
Verification
For Produc and Monito
ring
modifications to the equipment, or the products being t Inspection
Equipment
inspected (size, packaging material, etc.) are made at any
point after installation. The equipment manufacturer should
be able to offer you expert guidance on this process.

Verification is the periodic qualification that the equipment Contents

continues to be effective. It uses standard, formal processes 1

2
Introduction
Definitions
of Key Term
inology
3Compliance

to answer the question "is the specified equipment under

Requirements
4 Validation
Procedures
5 Verificati
on Procedur
es

control and operating as expected?" Best practice is to use

6 Routine
Performance
Monitoring
7 Supplier Procedures
Support
8 Summary

a third party – ideally the equipment manufacturer or the

9 Recommended
Reading

manufacturer's representative – to conduct your annual

performance verification. METTLER TOLEDO's qualified
service technicians can support you with this to make
compliance easier.

Routine performance monitoring (or "monitoring" for short)

differs from the processes of validation and verification Download the White Paper
in that it is a series of performance checks completed at "Validation, Verification and
frequent, regular intervals by a trained operator. These
checks are designed to determine if processes are under
Monitoring for Product Inspection
control. METTLER TOLEDO offers operator, quality and Equipment" for a detailed overview
maintenance-level training to ensure your staff understand of each process.
how to correctly perform these tests.

www.mt.com/pi-wp-vvm
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} Locate your local METTLER TOLEDO Safeline Sales Representative at www.mt.com/contact

11
 Increase Your Understanding
Of Metal Detector Testing
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Looking to understand more about how to test your metal detector to ensure 1 Validation and
Verification

you comply with food safety standards and retailer codes of practice? Understanding the
Difference

METTLER TOLEDO has produced a guide on "How to Correctly Test Your 2 Different Test Meth
ods
For Different Metal
Industrial Metal Detector." This document highlights key differences between Detectors

validation, verification and routine monitoring; explains test processes for

3 Retailer Requireme
different types of metal detectors; offers guidance on retailer requirements; Additional Test Routi
nts
nes

and explains recent innovations that make routine testing processes easier.
4 Process Innovation
s
Make Routine Testin
g Easie r

Request your FREE guide on

"How to Correctly Test Your Metal Detector." Visit:
4www.mt.com/md-how-to-test

METTLER TOLEDO Group

Product Inspection Division
Safeline Metal Detection
Local contact: www.mt.com/contacts www.mt.com/metaldetection
For more information
Subject to technical changes
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