Are you asking the right food safety questions?

In the fast-paced world of food production, safety isn’t just a box to tick – it’s the backbone of consumer trust and brand reputation.

For bakery and snack manufacturers, navigating rising costs, stringent regulations and ever-watchful consumers present both challenges and opportunities. Meeting rigorous safety and quality standards is no longer optional: it’s a chance to stand out in a crowded market.

Thanks to cutting-edge technologies, the game has changed. From detecting contaminants to ensuring perfect labelling and consistency, tools like metal detectors, x-ray systems and vision inspection solutions are revolutionising how safety is maintained.

In this Quick Bites Q&A, we caught up with Mike Pipe, head of Global Sales & Product Management for Mettler-Toledo Safeline X-ray to tackle the most pressing questions in the bakery and snacks arena.

How can I benefit from product inspection?

Product inspection is the backbone of food safety, helping manufacturers deliver products that are safe, complete and meet the highest standards of quality.

These systems work in real-time to identify contaminants and defects, ensuring that only compliant products reach consumers. Beyond safeguarding safety, they also streamline compliance with food safety regulations, giving manufacturers confidence in their processes and products.

What specific functions do product inspection systems provide?

Inspection systems are multi-tasking workhorses in food manufacturing.

They detect and reject foreign materials like metal, glass or plastic to protect consumers from harm. They also ensure that products meet exact fill levels, avoiding under- or overfilled packages that can either anger customers or eat into profits. Additionally, they verify packaging labels for accuracy, catching errors like missing allergen warnings before products leave the factory.

Together, these functions help manufacturers avoid costly recalls while reinforcing consumer trust.

What do these systems detect?

From rogue shards of metal to dense plastic fragments, inspection systems are built to uncover what shouldn’t be there.

Metal detectors can identify ferrous, non-ferrous and stainless steel particles as small as 0.3mm, while x-ray systems go further, detecting materials like bone and rubber. Their effectiveness depends on factors like the contaminant’s size, location and the product’s density, but the result is always the same: safer products and fewer surprises on the production line.

How can fill levels be controlled in manufacturing?

Managing fill levels isn’t just about avoiding waste; it’s about delivering consistency.

Dynamic checkweighers integrated into production lines ensure that every package meets precise weight requirements, automatically rejecting those that don’t. By reducing overfill, they protect margins, while compliance with regulations ensures products remain on shelves, not flagged by inspectors.

Why is early detection of contaminants important?

Catching contamination early in production is like stopping a leak before it floods. By identifying issues at the start, manufacturers avoid wasting resources on products that will never make it to market.

Early detection also prevents contaminants from breaking down further into smaller, harder-to-detect pieces, ensuring safer, higher-quality products while minimising the risk of recalls.

What are the benefits of x-ray inspection systems?

X-ray inspection systems provide a deep dive into product safety, quite literally. By visualising the contents of packages, they uncover contaminants that would go unnoticed by the naked eye. These systems operate seamlessly inline, ensuring every product is checked without disrupting production, all while preserving the integrity of the packaging.

Why are vision inspection systems necessary?

In a world where a mislabelled allergen warning can trigger a costly recall – or even worse: putting a life at stake – vision inspection systems are the ultimate quality control. They verify packaging meets strict standards, from ingredient lists to barcode accuracy.

Over time, this meticulous attention to detail not only avoids expensive mistakes but also reinforces consumer trust in a brand.

What are the consequences of not meeting GFSI standards?

Product inspection systems are essential to meet Global Food Safety Initiative (GFSI) standards, which demand rigorous controls to eliminate contamination risks.

Failing to comply with these standards can have severe repercussions, starting with the risk of product recalls that can incur significant financial losses and damage brand reputation. Non-compliance can also lead to the loss of certifications, making it difficult to maintain partnerships with retailers and distributors who require adherence to these global benchmarks. Beyond the business impact, it jeopardizes consumer trust, potentially leading to long-term harm to the brand and market share.

How do I choose the right metal detection solution?

Choosing the perfect metal detection system is less about guesswork and more about precision. The best system depends on the type of product being inspected: dry or non-conductive goods often require high-frequency detectors, while moist or salty items benefit from lower frequencies. For more complex needs, advanced systems with multi-frequency capabilities or even x-ray solutions may be the answer.

The key is tailoring the solution to the product, production line and regulatory requirements to ensure seamless safety and compliance.