Metal Separation in the Conveying of Bulk Materials which complies with the International Food Standard
Comprehensive systems are in short supply
Chapter 5 (Measurement, Analysis, Improvement) of the International Food Standard (IFS) handbook specifies the necessary standards to be achieved with respect to metals and contaminants. Food producers must take every precaution to detect and prevent contamination from metal or other foreign materials at the earliest opportunity. Should the IFS audit inspection reveal shortcomings in the detection of metal contaminants, the effects are far-reaching; the IFS certification system will not allow for a certificate to be issued at the point of detection, nor further up the supply chain. Clearly then, it is important that producers and users of bulk food ingredients also incorporate metal detection at the earliest stage of their processes even though few companies focus on systems for this specialist area. However, S+S Metallsuchgeräte GmbH of Schönberg, Bavaria is one of the leading manufacturers of industrial metal detection equipment and offers a comprehensive range of specialised systems for industry dealing with bulk foodstuffs.
Inspecting for foreign contaminants starts at Goods-In
In general, food manufacturers incorporate metal detection as part of their routine contaminant-control process. These systems are usually integrated into the final conveyors of the manufacturing process and can be obtained from most suppliers of metal detection equipment.
However, risk analysis reveals that metal contaminants can be recognized and removed efficiently much earlier in the process. Contaminants arise from a huge variety of different sources; raw materials, filter and knife breakages, damaged machinery, operator negligence or equipment wear and tear. Key disadvantages for incorporating metal detection at the end of the production process on packed end-product are a lack of precision in locating the source of contamination and unnecessary losses in finished goods. These losses can be reduced considerably if raw ingredients eg grain, rice, flour, herbs, seeds or dried fruit are examined on delivery and prior to the production process, by the use of strong permanent magnets and/or metal detectors. For this specialist application S+S GmbH has developed a range of equipment which can be incorporated into free-fall pipes, vacuum and pressure pipes. The company also offers multi-segment metal detectors to inspect product flow on conveyor belts or chutes, providing precise detection and separation of any metal-contaminated products.
Advantages of metal detection prior to and during the production process
1. Early detection offers the opportunity to analyse and identify the source of the contamination (supplier, load, machinery, timing, frequency distribution). The digital metal detectors offer data recording which can be analysed on a pc. This complies with the requirements of HACCP (Hazard Analysis and Critical Control Points) and IFS.
2. Metal contaminants can be removed early, before they are subjected to milling or chopping processes which would further fragment the particles to the extent that they may be too small to be picked up at the end-control point.
3. Costly damage to cutting machinery, extruders or calander rollers can be prevented thereby reducing the likelihood of further contamination.
Standard and specialist solutions for all process stages, types of manufacture and conveying systems
Magnet systems ensure the efficient removal of the tiniest ferrous metal and magnetic stainless steel particles. Typically, magnetic grid systems and inline or roller magnets are used, utilizing neodymium magnetic material which has a magnetic strength eleven times stronger than normal ferrite. Non-magnetic metals are removed by using electronic metal separators. A combination of magnet and electronic separation systems offers a highly effective and comprehensive method of removing all metal contaminants with the added advantage of low mechanical wear and tear as the separator mechanism is only required for the removal of non-magnetic materials.
S+S offers an extensive range of metal detection and separation solutions for every type of conveying system used in the Food Industry. If the product is being conveyed on belts or chutes the MAG series of metal separators is able to remove with pinpoint accuracy even the tiniest of metal particles from the product flow.
For free-fall applications the RAPID series of metal separators is most effective at removing metal particles from bulk material via a reject outlet. This range has been specially designed to meet the exacting hygiene standards of the Food Industry. The RZ tunnel metal detectors are built with circular openings and are generally used with bagging machinery, multi-head weighers and form, fill and seal machines; where metal detection raises an alarm signal.
The GF range of metal separators is intended for integration into vacuum and pressure pipes. They have been designed for the efficient and reliable rejection of metal contaminants, without interruption to the flow of material, even at high conveying speeds. At the end of the production process, the CONSENSE system offers complete assurance combining a metal separation unit with a conveyor to provide final inspection of packed foods, predominantly destined for the consumer.
At the heart of the S+S metal separator systems is the GENIUS-QUATTRO operation and control unit which, utilizing digital signal processing technology, ensures that the detector head is finely tuned to operate at optimum efficiency:
The “product compensation” system prevents false alarms of the metal separator caused by the product itself (eg through salt, moisture content etc). Additionally, “product tracking” allows the automatic adjustment of the “product compensation” to accommodate minor changes in product characteristics eg fluctuations in recipe, moisture levels and the effects of temperature (thawing). Both features secure optimal detection sensitivity whilst minimizing false alarms to maintain a continuous production cycle. The reject/separation system is fully controllable to meet the customer’s precise specifications.
The S+S Self Learn system ensures that once the optimal machine parameters have been established for a particular product they can be recalled again in seconds. Furthermore, this Self Learn system can accommodate product changes without any interruption to the production process.
A Set-Up Memory ensures that all machine data is stored even in the event of changes in electronics or interruptions to electrical supplies. The comprehensive suite of data records allows an instantaneous view of process control or the post-production analysis of system performance and inspection records to support Quality Certification. The equipment includes a fully-integrated report generator which will prepare statistical information for printing or further processing by pc.
S+S machines are renowned worldwide for their reliability, sensitivity and efficiency in the production environment. They are at the cutting edge of technology and incorporate the most modern metal detection and digital processing techniques.
Food Standard Metal Separation
Metal Separation in the Conveying of Bulk Materials which complies with the International Food Standard
Comprehensive systems are in short supply
Chapter 5 (Measurement, Analysis, Improvement) of the International Food Standard (IFS) handbook specifies the necessary standards to be achieved with respect to metals and contaminants. Food producers must take every precaution to detect and prevent contamination from metal or other foreign materials at the earliest opportunity. Should the IFS audit inspection reveal shortcomings in the detection of metal contaminants, the effects are far-reaching; the IFS certification system will not allow for a certificate to be issued at the point of detection, nor further up the supply chain. Clearly then, it is important that producers and users of bulk food ingredients also incorporate metal detection at the earliest stage of their processes even though few companies focus on systems for this specialist area. However, S+S Metallsuchgeräte GmbH of Schönberg, Bavaria is one of the leading manufacturers of industrial metal detection equipment and offers a comprehensive range of specialised systems for industry dealing with bulk foodstuffs.
Inspecting for foreign contaminants starts at Goods-In
In general, food manufacturers incorporate metal detection as part of their routine contaminant-control process. These systems are usually integrated into the final conveyors of the manufacturing process and can be obtained from most suppliers of metal detection equipment.
However, risk analysis reveals that metal contaminants can be recognized and removed efficiently much earlier in the process. Contaminants arise from a huge variety of different sources; raw materials, filter and knife breakages, damaged machinery, operator negligence or equipment wear and tear. Key disadvantages for incorporating metal detection at the end of the production process on packed end-product are a lack of precision in locating the source of contamination and unnecessary losses in finished goods. These losses can be reduced considerably if raw ingredients eg grain, rice, flour, herbs, seeds or dried fruit are examined on delivery and prior to the production process, by the use of strong permanent magnets and/or metal detectors. For this specialist application S+S GmbH has developed a range of equipment which can be incorporated into free-fall pipes, vacuum and pressure pipes. The company also offers multi-segment metal detectors to inspect product flow on conveyor belts or chutes, providing precise detection and separation of any metal-contaminated products.
Advantages of metal detection prior to and during the production process
1. Early detection offers the opportunity to analyse and identify the source of the contamination (supplier, load, machinery, timing, frequency distribution). The digital metal detectors offer data recording which can be analysed on a pc. This complies with the requirements of HACCP (Hazard Analysis and Critical Control Points) and IFS.
2. Metal contaminants can be removed early, before they are subjected to milling or chopping processes which would further fragment the particles to the extent that they may be too small to be picked up at the end-control point.
3. Costly damage to cutting machinery, extruders or calander rollers can be prevented thereby reducing the likelihood of further contamination.
Standard and specialist solutions for all process stages, types of manufacture and conveying systems
Magnet systems ensure the efficient removal of the tiniest ferrous metal and magnetic stainless steel particles. Typically, magnetic grid systems and inline or roller magnets are used, utilizing neodymium magnetic material which has a magnetic strength eleven times stronger than normal ferrite. Non-magnetic metals are removed by using electronic metal separators. A combination of magnet and electronic separation systems offers a highly effective and comprehensive method of removing all metal contaminants with the added advantage of low mechanical wear and tear as the separator mechanism is only required for the removal of non-magnetic materials.
S+S offers an extensive range of metal detection and separation solutions for every type of conveying system used in the Food Industry. If the product is being conveyed on belts or chutes the MAG series of metal separators is able to remove with pinpoint accuracy even the tiniest of metal particles from the product flow.
For free-fall applications the RAPID series of metal separators is most effective at removing metal particles from bulk material via a reject outlet. This range has been specially designed to meet the exacting hygiene standards of the Food Industry. The RZ tunnel metal detectors are built with circular openings and are generally used with bagging machinery, multi-head weighers and form, fill and seal machines; where metal detection raises an alarm signal.
The GF range of metal separators is intended for integration into vacuum and pressure pipes. They have been designed for the efficient and reliable rejection of metal contaminants, without interruption to the flow of material, even at high conveying speeds. At the end of the production process, the CONSENSE system offers complete assurance combining a metal separation unit with a conveyor to provide final inspection of packed foods, predominantly destined for the consumer.
At the heart of the S+S metal separator systems is the GENIUS-QUATTRO operation and control unit which, utilizing digital signal processing technology, ensures that the detector head is finely tuned to operate at optimum efficiency:
The “product compensation” system prevents false alarms of the metal separator caused by the product itself (eg through salt, moisture content etc). Additionally, “product tracking” allows the automatic adjustment of the “product compensation” to accommodate minor changes in product characteristics eg fluctuations in recipe, moisture levels and the effects of temperature (thawing). Both features secure optimal detection sensitivity whilst minimizing false alarms to maintain a continuous production cycle. The reject/separation system is fully controllable to meet the customer’s precise specifications.
The S+S Self Learn system ensures that once the optimal machine parameters have been established for a particular product they can be recalled again in seconds. Furthermore, this Self Learn system can accommodate product changes without any interruption to the production process.
A Set-Up Memory ensures that all machine data is stored even in the event of changes in electronics or interruptions to electrical supplies. The comprehensive suite of data records allows an instantaneous view of process control or the post-production analysis of system performance and inspection records to support Quality Certification. The equipment includes a fully-integrated report generator which will prepare statistical information for printing or further processing by pc.
S+S machines are renowned worldwide for their reliability, sensitivity and efficiency in the production environment. They are at the cutting edge of technology and incorporate the most modern metal detection and digital processing techniques.
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The GF metal separator is a compact unit which can be easily built into vacuum or pressure pipes with connectors to meet the needs of the customer
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