There are a growing range of foreign body contamination risks in food manufacturing. Where undetected, such foreign bodies can result in customer harm, brand reputational damage, legal action, and financial loss. However, you can be assured of reliable foreign body detection with X-ray inspection technology.
More accurate than metal detectors, X-ray systems are designed for high-detection sensitivity and low rejection rates across a variety of food types. That said, X-ray inspection should be seen as a vital strategic investment rather than a luxury or optional upgrade.
Read on as we highlight the value of Ishida’s advanced X-ray inspection technology and its relevance to modern food safety here.
Evolving Risks
The most common foreign bodies detected in food production include metal, glass, plastic, bone, and rubber, all of which pose significant physical risks. As supply chains become increasingly complex and product variety expands, the chances of encountering such foreign bodies rise. Each extra step, whether it be in production or processing, makes it more likely that they will enter the food stream. It becomes more difficult to monitor and contain the contamination risks as more products, ingredients, and packaging types are introduced.
Take a look at these foreign body recall statistics:
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Metal was the number one cause of physical recalls across several major markets: Germany (52%), UK (45%), and USA (36%), according to a review conducted by BRCGS in 2024
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The UK’s Food Standards Agency reported a 10% increase in food recalls during 2024, with foreign body contamination being one of the main drivers
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Data from Traceone shows that the number of US food recalls went up by 15% from 2020 to 2024, with foreign object contamination accounting for 11.4% of such recalls.
X-ray Inspection vs Metal Detection
Realising the expanding range of foreign body contamination risks, food manufacturers must decide whether to invest in X-ray or metal detection technology. X-ray is the obvious choice for reasons of performance, sensitivity, and compliance.
Metal detectors can only be relied on for the detection of metals and conductive objects. Besides these foreign bodies, X-ray systems enable the reliable detection of materials such as glass, stone, and plastic. X-ray technologies are also unaffected by the “product effect”, as with the inclusion of high moisture, salt, or fat content, which may otherwise impact sensitivity and result in false readings.
Where metal detectors struggle with the inspection of metalised packaging (e.g. foil, cans), X-ray systems work with all packaging types. Indeed, X-ray systems can be relied upon regardless of the product composition or packaging, with detection based on density differences. X-ray technology also enables the identification of minuscule contaminants, reliably pinpointing their precise product location.
Additional capabilities of X-ray machines include:
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Quality control checking - ensuring the identification of fill levels, missing components, seal integrity, and mass measurement
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Defect monitoring - with the assured detection of broken products, underfilled packages, and trapped product in seals.
While metal detection is generally faster, it can be affected by environmental factors such as magnetic fields and vibrations. There have also been great improvements in the speed of X-ray detection, ensuring the balance of accuracy with production line efficiency. X-ray machines are manufactured in line with regulatory and retail standards too, with the assurance of due diligence and brand protection.
Case in Point: Frost Baker Products
Specialising in the bakery of high-quality croissants, Slovakia’s Frost Prešov is among the growing number of food manufacturers to have realised the benefits of X-ray technologies. More specifically, the leading croissant producer has been able to enhance quality control through the integration of three Ishida IX-EN-2493 X-ray Inspection systems. Food safety has been optimised and consistent quality assured across the filled croissant range.
Integrated across three product lines, Ishida’s X-ray technologies allow for the inspection of an estimated 18,000 croissant packs per hour. Running continuously, the X-ray systems reliably detect and reject packs containing contaminants such as metal and rubber. With testing having taken place at Ishida’s UK HQ, the X-ray machines also ensure the detection of croissants with missing and defective fillings.
Frost’s Technical Manager, Vladimir Varga, said, “Of particular benefit to us is that we don’t have to adjust settings when changing fillings, so this greatly simplifies our production planning. [Ishida has been a] huge help in enabling us to solve some technical production issues, working directly with us to ensure that the solution met our exact needs. For that reason, we have a lot of confidence in both the equipment and in Ishida as a brand.”
The Frost example reflects the value of Ishida’s X-ray inspection as a strategic investment for the maintenance of premium product quality and protection of brand reputation. No matter the food product characteristics, Ishida ensures the accurate and reliable detection of foreign bodies. With the assurance of fewer recalls and customer complaints, you can have greater confidence in your brand.
Next Level Inspection
Greatly expanding the range of inspection capabilities, there’s no denying the strategic importance of investment in X-ray. No matter your food production focuses, you can rely on Ishida X-ray technologies for improved safety, efficiency, and compliance. With a choice of six X-ray models, plus ancillary items, you can be certain of finding the ideal solution.
Get in touch today and find out how you can achieve food safety excellence and market leadership with Ishida technologies.