AUTOMATION SOLUTIONS DETECTION DUALITY

One of the best advantages to inspection and detection systems is peace of mind.

By Jim Parsons 

The combination E-Z Tec® Dual-Beam Multi-Zone X-Ray and Metal Detector System from Eriez offers optimal detection and precise rejection of virtually any foreign object for packaged or bulk flow applications.

It is what it is” is a phrase that gets tossed around quite a bit in the business world today. Depending on the context, it can mean acceptance of a situation or factors beyond one’s control, or signify an inability to take action because either the answers are not known or the resources aren’t available.

For packaging system owners, the phrase takes on a different meaning when it comes to inspection and detection technology.

These systems and their components are designed to ensure that products really are what they are—the specified mixture of ingredients, the proper container, the correct labeling information, etc. They must also be able to tell them if a package is what it shouldn’t be—leaking, contaminated or defective.

As such, inspection and detection technology should provide owners with the duality of peace of mind (reducing costs and eliminating human error along the way) and as much information as possible about each product that rolls down the line.

The types of information owners want and need continue to grow according to Ray Spurgeon, product manager for Eriez, Erie, Pa.

“In researching the capabilities of x-ray equipment, for example, customers are requiring more than detection of metal contaminants and foreign objects,” Spurgeon says. “They want mass detection, fill level detection, detection of packaging voids and missing objects in packaged goods and product irregularities.”

To help meet these multifaceted inspection needs Eriez introduced an extra wide combination E-Z Tec® Dual-Beam Multi-Zone X-Ray and Metal Detector System. This state-of-the-art device offers optimal detection and precise rejection of virtually any foreign object for packaged or bulk flow applications. 

Spurgeon says the E-Z Tec® X-Ray system can detect ferrous, nonferrous, stainless steel and non-metallic materials such as stone, glass, bone and some plastics. It can also provide the best possible detection for aluminum, the most difficult metal for most x-ray machines to spot.

Lock Inspection’s Insight metal detectors feature a Direct Digital Signal (DDS) screen that clearly displays the product signature detail necessary to achieve perfect product set-ups and sensitivity.

“Now, processors can use both technologies to improve their food safety,” he says.

The E-Z Tec® system also offers zone detection as packaged or raw product moves through the unit. Rather than rejecting an entire row of product, the system will pinpoint a single product with a foreign object for precise rejection, allowing non-contaminated product to proceed.

“This will save thousands of dollars in re-work and labor,” says Spurgeon.

The dual beam technology of the E-Z Tec® system also provides coverage for a conveyor belt more than 40 inches wide, nearly double the coverage of existing systems. The ability to locate the beam close to the products also helps lower energy usage.

The Eriez E-Z Tec® DSP Metal Detector complements the dual beam x-ray system by detecting ferrous, nonferrous, stainless steel and aluminium objects in packaged and raw product. The standard three-coil aperture arrangement sends a signal to the unit’s control for digital processing. Both the x-ray and metal detector can be monitored and controlled remotely through the use of Eriez E-Z Link™ software. 

TECHNOLOGY TRANSFER

Another familiar saying—what is sauce for the goose is sauce for the gander—also applies to inspection and detection technology. In other words, a good idea for one segment of the packaging industry is very likely a good idea for another.

Variable frequency search heads allow LOMA System’s Loma’s IQ3 metal detector to be configured with the optimal frequency for multiple types of products and packaging materials.

Kevin Jesch, inspection systems product manager for Heat and Control, Inc., Hayward, Calif., notes that in the pharmaceutical industry, FDA Title 21 CFR Part 11 requires metal detectors to have the ability to store and report all product inspection results and events related to the metal detector, including changes to settings or change of product being inspected.

“This historical data is critical for fast, accurate tracing of contaminated products and for evaluating the operating efficiency of the manufacturing line,” Jesch says. “It makes sense that food companies could benefit from that same kind of traceability.”

Mark D’Onofrio, president of Lock Inspection Systems, Inc., Fitchburg, Mass., states that the focus on traceability within the food industry is already on the rise, with special emphasis being placed on more diligent plant audits.

“In many cases, lapses are being found within the metal detection programs of food manufacturers and co-packers,” D’Onofrio says. “There’s growing recognition that metal detectors need to be modernized to assist food companies in closing the gap between simply placing detectors on the line and creating an effective metal detection program.”

That includes having a comprehensive tracking/data-collection system in place so that companies can prove that the detectors are compliant and working properly. Unfortunately, D’Onofrio adds, “many companies have old detection systems in place and cannot meet sensitivity standards that have been established in the industry.”

Metal detector manufacturers are responding to this increasing scrutiny on food and beverage products. For example, CEIA USA Ltd., Twinsburg, Ohio, developed the THS 21 metal detector to provide those packagers with the same level of traceability for a wide range of products.

Sound and Sensitive Testing Pre-filled syringes have become one of the most critical ready-to-use products in the pharmaceutical industry today—and for good reason. They’re safe, convenient, easy for healthcare providers and patients to use and eliminate any guesswork about the dosage they contain. PTI’s non-destructive VeriPac 455 Micro Leak Tester permits highly sensitive detection of defects in many types of pharmaceutical packaging and containers, empty and prefilled syringes, liquid-filled and lyophilized vials, ampoules and other liquid filled containers. But as this popularity has led to an increase in the production of pre-filled syringes, it has also heightened the need for a reliable, non-destructive test method to verify the closure integrity of each unit, particularly the highly sensitive detection of micro-scale leaks. “The packaging industry as a whole has recognized the need for more advanced technologies for package testing and the benefit of excluding subjectivity from the testing process that eliminates misleading results and variances from one operator to another,” says Heinz Wolf, general manager of PTI Inspection Systems, Tuckahoe, N.Y.  Wolf adds that destructive testing methods such as dye ingress, water bath or human vision have long been used in the industry, “but they have obvious limitations.” A proven alternative method of non-destructive testing is vacuum decay, which can be performed in any sequence and even repeatedly on a single sample. PTI has applied this technology into its new VeriPac 455 Micro Leak Tester, a versatile device that can be used for both pre-filled and empty syringes and many other types of pharmaceutical packaging and containers such as liquid-filled and lyophilized vials and ampoules. As with PTI’s other VeriPac test systems, the 455 utilizes the non-destructive vacuum decay leak test technology that follows the ASTM (American Society for Testing and Materials) test method F2338, which was developed using PTI instruments, and is recognized by the FDA as a standard for package integrity testing. The VeriPac 455 starts each test cycle from absolute vacuum, which results in the improvement of the test sensitivity.   “Using an inspection technology that conforms to uniform standards such as the ASTM simplifies the inspection and validation processes,” Wolf says. “VeriPac’s inspection method is more efficient, cost effective and reliable than destructive methods because less waste is produced.” What’s more, the VeriPac system can be incorporated into protocols at any point in the handling process as they are non-destructive, non-invasive and require no sample preparation. Applications include stability studies, clinical studies, quality assurance testing and production statistical process control (SPC). The VeriPac 455 also features a new patent pending dual vacuum transducer technology that has increased test sensitivity and produces the same test result for identical packages regardless of location, altitude and weather changes. Other new features include improved Internet connectivity and networking capabilities that facilitate remote operation, system monitoring and troubleshooting. Along with easier setup and operation, “PTI has also built in various levels of security and accessibility for operators, supervisors and technical personnel, all of which can be customized according to each company’s preference and needs,” Wolf says.

“The THS 21 also reduces the occurrence of set-up errors and false reject signals, significantly reducing product waste and downtime,” Jesch says. “CEIA’s simple auto-learn set-up, more than 500 product memory settings and single-pass product learning procedure also reduce operator errors and changeover time.”

With the THS 21, an administrator can set up specific user names and define access to parameters on an item-by-item basis. The user name is stored along with any changes that are made to detection parameters—the same accountability control required for pharmaceuticals by 21 CFR.

In addition to its versatility and greater security, traceability and reliability in product testing, the THS 21 offers the option of Ethernet or Bluetooth connectivity for easy programming and remote data collection/management, high immunity to environmental interference and a stainless steel housing for IP69K-rated protection.

The foreground supression feature of Banner Engineering’s WORLD-BEAM® QS18 Adjustable-Field Sensor is helpful for inspection applications where the product or packaging color change against a bright and consistent background.

Lock Inspection’s new Insight line of metal detectors features an integrated digital head and advanced OPTIX detector management software that provide higher sensitivity to all metal types along with improved stability to vibration and complex product signals. A Direct Digital Signal (DDS) screen clearly displays the product signature detail necessary to achieve perfect product set-ups and sensitivity.

Insight also comes standard with a USB connection that allows a company’s quality control staff to gather shift reports using a standard memory stick. The OPTIX software provides complete networking and data-collection, including Ethernet, wireless or SCADA (supervisory control and data acquisition).

D’Onofrio recognizes that at a time when everyone is keeping a close watch on their budgets, some companies may still be tempted to stick with their existing manual product tracking systems and attempt to save money by turning to used products.

“More often than not, they are buying the wrong detector for their particular application,” he says, noting that older systems have neither the sensitivity nor the modern communications options that the industry now requires.

“They should look at metal detection as a sound, long-term investment in both their product quality and corporate reputation,” D’Onofrio adds.

REWRITING THE RULES OF DETECTION

Another shortcoming of older food processing metal detectors is their reliance on a technique called “phasing” to ignore a product effect and detect metal.

“The phasing algorithms in a detector’s digital signal processor often ignore situations where the densities of the product and contaminant are the same,” explains Bob Ries, lead product manager for Thermo Fisher Scientific, Waltham, Mass. “An example would be detecting non-magnetic stainless steel in highly conductive products such as wet, salty cheese or bread.” 

To improve the detectability of metals in these common applications, Thermo Fisher has augmented its APEX metal detectors with Intellitrack XR (IXR) software. According to Ries, IXR learns the complete, sinusoidal X and R signals of a product as it passes through the aperture of the detector and subtracts or cancels them out continuously. 

“This leaves behind only the additional signals caused by the metal itself,” he explains.

New inspection tools and lighting systems enable the Laetus high-resolution INSPECT wt to handle a wider range of both routine and application-specific inspection tasks.

The software also continuously adjusts the signal to compensate for product changes or drift, enabling APEX metal detectors to seamlessly handle overlapping signals from adjacent products when they are placed close to each other on a conveyor belt. 

“The result is up to 50 percent smaller metal can be detected in certain applications because it is never ‘phased’ out as in the traditional technique,” Ries says. “What’s more, the software virtually eliminates annoying false rejects.”

IXR software runs on all versions and models of Thermo Fisher’s APEX metal detectors and can be incorporated into those already in operation.

CUSTOMIZED CONSISTENCY

A consumer would never handle a piece of meat the same way as a loaf of bread or a block of cheese. So why should packagers expect their metal detectors to function that way?

But if they’re using traditional metal detectors with search heads pre-set to a specific frequency, that’s exactly what they’re doing.

According to Michael Freeman, product marketing manager for Loma Systems, Carol Stream, Ill., the detector’s frequency is determined either by testing the customer’s product, providing a specific frequency or using anecdotal evidence based on past experience.

“If the frequency is too low, contaminants can be missed,” Freeman says. “If the frequency is too high, excessive false rejects can occur because the machine will be detecting the product signature as a contaminant.”

Variable frequency search heads, such as those used in Loma’s IQ3 metal detector, eliminate the need to compromise between sensitivity and false rejects. The machine can be configured with the optimal frequency for every product that the customer produces, with unique product signatures stored in memory for recall when production changes.

Variable frequency also allows the machine to “learn” new products and set the correct frequency based on the product signal that is being generated at that moment in time.

“Variable frequency also allows you to tune the machine to compensate for different types of packaging material by tuning out the signals they generate,” Freeman adds.

With memory for more than 100 unique product profiles in its memory, the IQ3 can balance sensitivity and reduction of false rejects for a wide range of current and future product runs. Users can quickly configure each profile by running a “training” cycle, eliminating the need for a service technician.

The IQ3 comes with a single line, text display while its cousin, the IQ3+, offers a full color, touchscreen display that is icon driven. The IQ3+ gives the operators true multi-lingual capabilities, as well as a built-in operator’s manual, Ethernet and USB connections for data gathering and OPC compatible software for integration into existing SCADA systems.

Both the IQ3 and IQ3+ are built to meet or exceed IP69K standards for harsh environments, and are available in several configurations and sizes to handle everything from dry bulk powders to bakery and snack foods to pumped sauces and ground meat products.

“They also can be integrated into the Loma LCW checkweighing system to provide a complete package for the detection of metal contaminates and over/under-weight situations,” Freeman adds.

SPEAKING OF PROTECTION

Another common assumption with potentially devastating consequences for packagers is mislabeled products.

“This is particularly true for manufacturers that produce multiple types of products,” says Scott Stone, marketing manager with Mettler-Toledo CI-Vision, Aurora, Ill. “It takes only a handful of mislabeled items to force a recall, which can ruin both brand image and profits. And even if the mistake is discovered before the product leaves the plant, there’s still the costly matter of wasted product to deal with.”

The CI-Vision Label Inspection System can help prevent these problems thanks to its ability to inspect labels on any type of container—bottles, tubes, pouches, plastic containers, boxes, etc.—at speeds up to 4,000 parts per minute. The system verifies that the label is correct in both content and product match and checks details such as the bar code, expiration date, text, images and label placement.

Newly developed software in the CI-Vision Label Inspection System also helps discourage operators from any temptation to bypass the quality inspection process, a disturbing issue that has accompanied the increase in high-speed inspection capacity and accuracy according to Stone.

“The innovative software prevents any circumvention of the quality process by monitoring line speed variations and how products are presented to the system via the captured inspection images,” he says. “If the system detects a problem, it can be set up to take protective actions ranging from sounding an alarm to shutting down the entire line.”

TOOLING UP FOR INVINVIBLE INSPECTIONS

Laetus of Rockway, N.J.,  has also introduced several new inspection tools and lighting systems aimed at ensuring complete packaging security of pharmaceutical products, and eliminate the risks associated with manual inspection errors.

Designed for Leatus’ INSPECT wt multi-functional camera based inspection system, the products include a Pattern Matching tool that verifies the completeness of a graphic image such as a logo, or various kit items (e.g.,  syringes, moisture pack and stem).

A Grid Integrity tool verifies the coverage of pixels in an area to verify that a pouch contains the correct amount of capsules or tablets, regardless of position.  It can also verify the proper amount of bottles in a case, or the presence of outserts on bottle tops, as well as verify dosing cups are present in the correct color and correctly positioned on bottle tops. 

Other new alignment and distance measurement tools ensure the correct placement of labels, text, bar codes or other graphics on a package. Each INSPECT wt camera is paired with a maintenance-free LED lighting system offering a multitude of lighting types for a variety of materials, including light sensitive items.

FORWARD LOOKING SENSORS

When a photoelectric sensor is used to inspect food packaging, its job is to detect each package while ignoring targets in the background. This method is simple and usually effective when the reflected light is consistent enough to be reliably detected from one product to the next.

With the new Intellitrack XR software feature, Thermo Scientific’s APEX metal detectors can better detect non-magnetic stainless steel and similar highly conductive products.

But problems can arise when the product coloring is inconsistent—a natural occurrence with food products—as objects varying in color reflect different amounts of light. And if the background is brighter than the target, false and missed readings are almost assured.

Unless the user can count on there being absolutely no variability in product appearance or operating conditions, conventional photoelectric sensors will always be consistent in producing inconsistent results. One way to overcome the challenges of variability is the WORLD-BEAM® QS18 Adjustable-Field Sensor from Banner Engineering, Minneapolis, Minn. 

“The QS18 features a foreground suppression feature that switches its output based upon the distance to the object using the triangulation principle,” says Dennis Smith, Banner’s technical marketing manager. “This makes the sensor particularly useful in applications where the product or packaging color change, while the background is bright and consistent.”

In these instances, Smith explains, the sensor detects a constant background, such as a conveyor bed, and switches its output when the object appears in the foreground—providing consistent detection regardless of variations in product color.

The QS18 also features no dead zone, enabling the sensor to activate for very dark objects that pass in close proximity—something that background suppression sensors can’t always do.

“Because wide variances in product and packaging color and reflectivity do not influence the sensor’s results, the QS18’s foreground suppression sensing simplifies product changeover,” Smith says. “This makes the sensor suitable for existing product mixes, and provides flexibility for future additions and modifications.”  

Jim Parsons has written about business and technology issues for more than 14 years.