Detectability is also governed by other factors, such as the nature of the contaminated product, line speed and orientation, and the settings of the inspection machines. In principle, if the target metals are detectable at a significant size then detectable plastics will also be identified and rejected. It is good practice for food producers to test detectable materials by deliberately placing them in their products and using their metal detection or X-ray inspection systems to detect.
Metal or plastic pieces that contaminate can be of various sizes. All detectable plastic products, in whole or part, are detectable, but like metals there is a minimum size that the material cannot be identified, even with correctly configured metal and X-ray inspection systems. In fact, the latest consultation document from BRC Global Standards (Issue 8) proposes, “Pens used in open product areas shall be controlled to minimize risk of physical contamination (e.g. designed without small parts and detectable by foreign body detection equipment).”
There is no 100 percent guarantee of zero risk, but the smallest undetectable pieces are likely to be under the threshold of threat to the consumer.
There are many variations between inspection machines, products, and packaging, making it essential for users of detectable plastic materials and equipment to carry out their own tests on site to validate the detectability of the products and reduce the risks of contaminated product.
An audit of the plastic tools and materials used in processing areas can identify the extent of the risks, tools, and materials that need to be replaced by detectable alternatives. There are many detectable versions of standard tools available today. Tailormade designs can also be produced. Examples include a recently developed detectable plastic pig for cleaning food and beverage pipelines, and a detectable tray and lid system designed for specific processing needs, which is now offered for general sale.
These products satisfy the need for detectability in metal and X-ray inspection systems, but don’t forget that the designs must also perform as well as the standard plastic products they replace.
Also remember that color coding detectable plastic helps restrict use of tools to specific areas or shifts to heighten the level of control of microbial cross-contamination. More users of detectable tools are specifying that a unique identity is engraved on their products to improve security and provide a means of tracing the origin of mislaid tools.
For food manufacturers that are supplying private or own label products, the power of the buyer to dictate the food safety standards becomes a key stimulus of plastic management. Several retailers and food service companies have their own set of standards, such as the U.K.’s biggest retailer Tesco and Walmart in the U.S. that demand certification by third-party auditors who adhere to standards set by the Global Food Safety Initiative.
Blunden is the marketing and communications consultant at Detectamet Ltd. Reach him at [email protected].
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