bizerba inspection guide

Control

Quality

Safety

Audit

Installation conditionsSystems Audits Combination with Bizerba software

Combination with Bizerba hardware

Directives and certification

TechnologiesPrefaceBizerba Inspection Guide

Bizerba Inspection Guide

Bizerba Inspection Guide Installation conditionsSystems Audits Combination with Bizerba software



TechnologiesPreface

Table of Contents1 | Preface

2 | Technologies

2.1 Metal detection

2.1.1 Terminology

2.1.2 Functionality

2.1.3 Sensitivity

2.2 X-ray inspection

2.2.1 Terminology

2.2.2 Functionality

2.2.3 Health safety of X-rays

2.2.4 Sensitivity

2.3 Camera systems

2.3.1 Terminology

2.3.2 Functionality

3 | Directives and certification

3.1 Foreign bodies

3.2 Labeling

4 | The right system for the imposed requirement

4.1 Foreign body detection

4.1.1 Overview: What can be detected

4.1.2 Reasons of a detection

4.1.2.1 Product effect on a metal detector

4.1.2.2 Density on a X-ray system

4.2 Camera systems

4.2.1 Overview: What can be checked

4.2.1.1 Product check

4.2.1.2 Seal check

4.2.1.3 Label check

4.3 Product tests

5 | Installation conditions

5.1 General

5.2 Selection of the correct control point

5.3 Space requirement

5.3.1 Metal detector: Metal-free zone

5.3.2 Metal detector: Environment

5.3.3 Metal detector: Tunnel

6 | Audits

6.1 Point in time for an audit

6.2 Performing an audit

6.3 Documentation of an audit

7 | Combination with Bizerba software

8 | Combination with Bizerba hardware

9 | Contact




TechnologiesPreface

1. Preface

Product safety is the most sensitive subject in the food industry. In Europe alone there are about 3,000 recalls due to soiled or incorrectly labeled products every year.

This is a time-consuming and costly situation for manufacturers involv-ing by far more than just a logistical effort: Consumer confidence must be retained or regained and the brand image protected from possible dam-age. Inspection systems help manufacturers to prevent such a situation from happening in the first place. Digital solutions offer 100 % product re-liability and complete tracking. Only food of perfect quality is supplied to the market: Free from foreign bodies, hygienically packaged, labeled with ideally positioned labels containing the right information which is easy to read.




Preface Technologies

2. Technologies

For the inspection of food in the production line different technologies (metal detectors, X-ray systems, camera inspection systems) may be used. This results in various systems with manifold functions, possibilities and properties.

This chapter explains the functionality behind the individual technologies.





Stainless steel housingOne transmitter coil

Two receive coilsControl unitTunnel

Inner lining made of plastic

2.1 Metal detection

2.1.1 Terminology 2.1.2 FunctionalityA metal detector is fitted with three coils: One transmitter coil and two receive coils. The receive coils both have the exact same distance to the transmitter coil.




TechnologiesPreface Technologies

The transmitter coil generates a permanent electromagnetic field. The receive coils receive this signal. If both receive coils receive an identical value, no metal was detected in the tunnel. The products to be inspected must be taught to the machine during a teach-in process. After a certain number of test runs the machine has then saved the product effect (chapter 4.1.2.1).

The electromagnetic field will be disturbed if metal gets in the tunnel. While the metal part runs through, different values are therefore measured on both receive coils. This difference leads to a positive detection of metal.

The measured values are processed in the control unit. The control unit forwards the result to allow a separation of the detections.




TechnologiesPreface Technologies

Scanning sensitivity of the metal detector

Product sensitivity

Operating sensitivity

2.1.3 SensitivityThe decisive performance feature of a metal detector is the sensitivity. This is the ability of the metal detector to detect possibly small metal contaminations. The data sheet of the metal detector contains optimal values under best possible conditions. Product effect (chapter 4) and external interference factors (chapter 5) impact the performance of the device. The measurement is always taken in the center of the tunnel which is the most unfavorable location for a detection (here, this is the largest distance to the coil).

Shape and position of the contamination play a major role for the detection. Balls represent the most difficult shape of a contamination. Compared to the volume they have the largest surface. For oblong shapes the alignment is of importance. Depending on the material different detection results will be achieved. Bizerba recommends to check both alignments for all tests and audits.

Alignment of the products

Detection of iron

Good

Poor

Detection of stainless steel and non-ferrous metals

Poor

Good





Signal element

Detector

X-ray beam

X-ray tube

Conveyor belt

Protective covers with radiation protection curtain

Analog data processing device / image processing PC

2.2 X-ray inspection

2.2.1 Terminology 2.2.2 Functionality

The X-rays penetrate the product. It absorbs the radiation (weakens the radiation) based on density and thickness and generates a shaded X-ray image. The more radiation is absorbed the darker is the shadow at this point (the absorption of the radiation depends on the density). If a second object (foreign bodies such as bones or metal) has a higher density, more radiation is absorbed at these locations. This means that these locations can be recognized on the X-ray image as a dark shadow/spot.

Crunchy cereal

Crunchy cereal with screw





2.2.3 Health safety of X-rays

The term »X-ray« is often associated with an unpleasant sensation. The radiation coming from an X-ray inspection system, however, is very minimal. The legal limit value in Germany is at 1,000 μSv per year (DIN 54113).

If an employee would work on the device at a distance of 10 cm for one year, 40 hours weekly, the annual value would be at 416 μSv and therefore well below the limit value.

For comparison: The terrestrial radiation in Germany is 2,100 μSv on average per year.

For products, the limit value is at 500,000 μSv at 10 MeV according to the EU Directive 1999/2/EC. The radiation having an effect on the products here, is with 53 μSv at 50 keV approx. one hundred times lower than the limit value and therefore completely harmless.

X-rays belong to ionizing radiation. This, however, is no radioactive radia-tion. As per EU Directive 1999/2/EC, Bizerba X-ray systems can be used for foreign body control in food even in case of organic products due to the very low radiation energy. X-ray systems are subject to the German X-ray Regulation and require approval.

Please note country-specific regulations.

To protect staff from X-rays in production, X-ray inspection systems are fitted with a protective cover before and after the X-ray field. Radiation protective curtains are mounted under the protective cover. They shield the radiation which would otherwise get to the outside through the opening while products are passing.

1 Terrestrial radiation is a radiation which is omnipresent on the earth.





Factors X-ray source

Conveyingspeed

Wavelength,density,

thickness

Contaminations

Detector pixel size

2.2.4 SensitivitySame as with a metal detector the main performance feature of an X-ray inspection system is the sensitivity. This is the ability of the X-ray system to detect the smallest contaminations.

There are numerous influencing factors acting on the sensitivity which may also have an impact on each other:

• The larger the pixel size the lower is the resolution and the lower the detection accuracy.

• The higher the conveying speed the lower is the detection accuracy. • The greater the contamination the higher is the detection probability. • The higher the density the better is the detectability. • The stronger the X-ray tube the higher is the detection accuracy.





Signal element

Operating element

ConveyorCamera with polarization filter

Lighting

2.3 Camera systems

2.3.1 TerminologyCamera systems can be integrated in the production line in two versions: as a stand-alone device and integrated in a packaging machine line. Inspection is possible for both variants from the top and/or from the bottom.

Stand-alone device





Line-by-line transmission of the image data

Image block

2.3.2 FunctionalityThe image of the camera unit is transmitted line by line to a computer. The images are recorded in black and white. This has the advantage that the resolution is four times higher than with color images. This increases accuracy.

Depending on the light conditions the color of the lighting and the polariza-tion filter will be adapted. This can significantly contribute to the quality enhancement of the image. As you can see in the image, the results of the images differ strongly depending on the color of the lighting.

The computer then deter-mines based on saved algorithms if the checked product is okay and graphic ally represents the result for the operator:

Color imageBlack and white image

Green lightNormal light Red light



TechnologiesPreface Directives and certification

3. Directives and certification




Codex Alimentarus

Certifications and customer requirements

Directives

National laws

3.1 Foreign bodies

The basis for all guidelines is the Codex Alimentarius. It comprises standards of the United Nations for food. These standards are specified in guidelines such as the General Food Law of the European Commission or the HACCP. These requirements are then specified again by the customer of the food manufacturers (e.g. Marks & Spencer) or commercial quality programs (e.g. IFS). Usually, they define own requirements on food safety which normally significantly exceed the guidelines.

• IFS (International Food Standard) www.ifs-certification.com/index.php/de

• Codex Alimentarus www.codexalimentarius.net

• BRC www.brc.org.uk

• HACCP www.fda.gov/food/guidance-regulation -food-and-dietary-supplements/hazard -analysis-critical-control-point-haccp

Guidelines such as the BRC or IFS do not specify precise minimum requirements in terms of what size of a foreign body has to be found. Here, solely an overview of the usually detectable foreign body sizes is provided:

BRC for metal detectors (Version 2011)

Quicklinks

Ferro

us

Ferro

us

Ferro

us

Stain

less

steel

316

Stain

less

steel

316

Stain

less

steel

316

Non-ferro

us

meta

l/Alu

min

um

Non-ferro

us

meta

l/Alu

min

um

Non-ferro

us

meta

l/Alu

min

um

1,0 mm

1,2 mm

1,5 mm

1,8 mm

1,8 mm

2,0 mm

2,5 mm

3,0 mm

1,0–4,0 mm

1,0–4,0 mm

1,0–6,0 mm

1,0–6,0 mm

1,2 mm

1,5 mm

2,0 mm

2,2 mm

2,5 mm

2,8 mm

3,5 mm

4,0 mm

—

—

—

—

1,5 mm

2,0 mm

2,5 mm

3,0 mm

3,5 mm

4,0 mm

4,5 mm

5,0 mm

—

—

—

—

Product height

Up to 50 mm

50–100 mm

100–150 mm

150–200 mm

Dry products including products packaged without

metal-coated film

Wet products and products packaged in

metal-coated film

Products packaged in aluminum foil

https://www.ifs-certification.com/index.php/de/

https://www.fda.gov/food/guidance-regulation-food-and-dietary-supplements/hazard-analysis-critical-control-point-haccp

http://www.fao.org/fao-who-codexalimentarius/en/

https://brc.org.uk




The guidelines are regularly revised, updated and adapted to the current standards on the market.

Many retail chain stores customize this information again to their requirements. When directly buying from the manufacturer, the manufacturer has to know which standards he has to meet. If a retail chain store can not identify itself with an existing standard it can set an own quality standard and determine how and how often checks will take place and what else the manufacturers have to consider.

IFS for X-ray inspection systems (Version 2017)

Bizerba recommends the following values as a reference size irrespective of the product type:

3.2 Labeling

The EU Food Information Regulation (LMIV) requires that food manufacturers provide nutri-tional and allergen information on nutrition fact labels on packaged food. Also substances being processed in the same company and which could be included in smallest amounts in the end product (e.g. “May contain traces of nuts”) must be indicated.

To make sure that all information configured by the manufacturer is properly applied and printed on the package a label inspection system may be integrated in the production line. This ensures that legal requirements are met and only properly labeled merchandise leaves the factory.

Bizerba recommends to have labels checked at the following points: • At the beginning of the production shift • Every 30 minutes during production/shift • At a batch change, e.g. of packaging materials or labels • After a production stop and breaks • At the end of the production shift

Plast

ic/Paper

Ferro

us

Meta

llize

d

foil

Non-ferro

us

meta

l/

A

lum

inum

Cans

Stain

less

ste

el 316

0,8 mm

2,0 mm

2,0 mm

2,0 mm

3,5 mm

3,5 mm

1,5 mm

1,5 mm

2,0 mm

2,5 mm

3,0 mm

0,8 mm

2,0 mm

2,0 mm

2,0 mm

3,5 mm

3,5 mm

2,0 mm

2,0 mm

2,5 mm

3,0 mm

3,5 mm

1,2 mm

2,5 mm

3,0 mm

3,0 mm

5,0 mm

5,0 mm

2,5 mm

2,5 mm

3,5 mm

4,0 mm

4,5 mm

Typical contamination sizes (ball diameter) in different packaging types

Metal detector

Material

Metal

Aluminum

Glass

Nonmetallic minerals

Bones

Dense plastic

Product height

Up to 25 mm

25–75 mm

75–125 mm

125–175 mm

Bizerba Inspection Guide Installation conditions Audits Combination with Bizerba software



TechnologiesPreface Systems

4. The right system for the imposed requirement





4.1 Foreign body detection

For the foreign body detection numerous parameters have to be considered for decision making. A final informed decision can only be made after a manufacturer test with the original product. In general, not all foreign bodies can be found. As regards metal detection only metals can be found. For X-ray inspection the difference of the density between product and foreign body must be large enough.

For decision making the following question is decisive: “Which foreign bodies do I want to check in which product and in which packaging?”

4.1.1 Overview: What can be detected

4.1.2 Reasons of a detection

Basically, with a metal detector only metal can be detected, with an X-ray system also other contaminations. This chapter explains in detail what is possible with which system.

Not every foreign body in every product may be detected. The size of the contamination is decisive. The larger the contamination the easier it can be detected. For the metal detector, additionally the position of the contamination (chapter 2.1.3) and the product effect have to be considered, for the X-ray inspection system the difference in density.

Tray/c

ups/bow

ls

Boxes/ca

rtons

Meta

l

Stone/G

lass

Hair/finger n

ails

Textil

e fibers

Plast

ics

Bottles/

glass

ware

/

cans

other

non-m

etals

Wound p

last

er with

meta

l thre

ads

Vermin

/inse

cts

Alum

inize

d

pack

ages

Flow

pack

/pouch

es/

sa

chets

1

1

1

1

1

1

3

1

3

3

3

3

3

2

1

1

1

2

3

2

1

3

3

3

2

1

Type of packaging Foreign bodies*

Legend

1 Suitable for use | 2 Possibly suitable for use for the respective application | 3 Not suitable for this purpose

*Foreign bodies irrespective of the packaging type

Inspection system

Metal detector

X-ray system





4.1.2.1 Product effect on a metal detector

Due to its individual composition each product has an electrical intrinsic conductivity.

This is influenced among other things by the following factors: • Moisture • Salt content • Temperature • Packaging material • Consistency and density • Size • Alignment on the conveyor

The electric intrinsic conductivity is called »product effect« or »product angle« and can be calculated for different products.

Detection difficulties arise when the product effect is similar to the conductivity of the searched contamination (see graphics on the right). The bigger the difference of the product angle between product and contamination the easier the contamination can be detected. It is very easy, for example, to detect stainless steel (VA) or non-ferrous metals (Non-Fe) in sugar since the relevant angles are wide enough. It is more difficult to detect stainless steel in meat as these values are not too far apart.

This problem can be solved when the device learns the product. This compensates the product effect. However, this reduces the sensitivity depending on the product. Each product must be learned. Otherwise, the basic value is not known and the device could perhaps reject non-contaminated products.

Frozen meat

180°0°

Non-Fe

Rolls

Meat

Chicken wings

Fe

Cereal

Sugar

CheeseSausages / cold cuts

Ready meal

VA





4.1.2.2 Density on a X-ray system

Whether an undesired foreign body can be detected in a product depends on the density and thickness of the foreign body.

Only if the gray value on the X-ray image significantly differs from the product the contamination can be detected. Consequently it is very easy to detect contaminations having a high density (e.g. metals) whereas organic contaminations (e.g. wood) are almost not detectable.

Difficult Good Very good

Density g/cm3 20 4 6 8 10 12

Detectability by means of X-ray

Lead

Copper

Brass

Iron

Stainless steel

Ceramic

Aluminum

Nonmetallic minerals

Glass

Teflon

PVC

Nylon

PA

Rubber

PP

PE

Wood

Bones





4.2.1.2 Seal check

4.2.1.1 Product check4.2 Camera systems

In terms of camera systems a distinction is made between three different inspection categories: Product, seal and label check. Based on the requirement a matching system may be selected.

4.2.1 Overview: What can be checked

Depending on the system products can be inspected based on defined quality features, seals be checked for contaminations and packages for incorrect labels.

The seal check controls the seal of packages. This avoids leaky packages in retail. Otherwise, the product would get in contact with oxygen and spoil. A seal might become leaky due to contamination (e.g. cheese in the area of the seal) or due to errors of the packaging machine (e.g. air pockets).

Since each product package is different a manufacturer test is necessary in advance.

During a product check or classification the product itself is checked. Based on predefined parameters it is checked if the product is faulty or has visual defects. This allows an assessment or classification of the product or a rejection of non-conforming products. It can be checked, for example, if cookies are complete or if they were broken during the production process.





4.2.1.3 Label check

During the label check the packages are checked based on predefined parameters.

These parameters are divided into the following categories:

Label

• Correct label • Presence • Placement • Alignment

Text recognition (OCR)

• Text reading • Sell-by date • Weight / price

Read codes

• 1D (e.g. barcodes) • 2D (e.g. QR codes)

4.3 Product tests

To ensure 100% reliability for the detection of foreign body right from the start, individual packages are tested in a manufacturer test with different devices. This applies to packages for which a detection system can not be suggested offhand. This allows best possible device selection. The test report contains forecasts in terms of what size of the detection from which material can be found under lab conditions. For seal checks it is always necessary to test some test packages at the manufacturer. This ensures that the machine meets the imposed requirements.

Bizerba Inspection Guide Systems Audits Combination with Bizerba software



TechnologiesPreface Installation conditions

5. Installation conditions





Ja

No

5.1 General

For the installation of inspection systems a few things have to be considered. In addition to the construction requirements and the selection of the optimal control points many other surrounding factors play a major role in terms of the choice of the location.

5.2 Selection of the correct control points

Inspection systems are installed at »Critical Control Points« (CCP) in the production line. Raw materials are at best directly checked at goods re-ceiving. This avoids possible foreign bodies from getting in the production in the first place. All further control points are selected as soon as possible after a contamination risk to prevent contaminations from getting in pro-duction any further. After having excluded all risks for a contamination of the product a final control has to be made. An optimal final control point, for example for a sausage production, is after the packaging machine.

This HACCP decision tree helps to choose a control point:

Change level, process or productPreventative measures to find foreign bodies are already in place?

The risk can be eliminated at this point?

The risk can be eliminated at a following level or be reduced to an acceptable level?

Foreign body control is necessary for safety at this production step?

A contamination is possible at this point or the risk can incur an unacceptable level?

No CCP

CCP

Yes

No

No

Yes

No

No

Yes

Yes





5.3 Space requirement

Optimal use of space often represents a challenge in production plants. Due to the following aspects, metal detectors need more space than the specified device dimensions. For X-ray and camera inspection systems the additionally needed protective space has already been considered when designed.

5.3.1 Metal detector: Metal-free zone

The electromagnetic field of the metal detector goes beyond the outer dimensions of the device. This results in an area on both sides of the metal detector in which metal must not be installed. This would disturb the field and impact the sensitivity of the device. The area of the »metal-free zone« can be broken down into two zones: The static and the dynamic zone. In the static zone there must be no permanently installed metal parts. In the dynamic zone there must be no movable metal parts (e.g. motors or ejection devices). The size of the individual zones depends on the design and coil size of the device.

Static zone

Dynamic zone

Metal detector





5.3.2 Metal detector: Environment 5.3.3 Metal detector: Tunnel

When choosing a place for the metal detector the environment has to be kept in mind.

The following factors can negatively impact the metal detection: • Electromagnetism (e.g. electric motors) • Electrostatic discharge (ESD protection) • Vibrations (e.g. passing vehicles) • Poor voltage source (e.g. voltage fluctuations) • One-sided warming up (e.g. heater) • Nearby foreign metals • Temperature and moisture (changed product effect)

For the integration in an existing line it must be ensured that there is a metal-free zone and that the used conveying system does not consist of metal parts.

Metal contaminations are found hardest in the center of the metal detector since this is the largest distance to the coil. Consequently, it is recommended to adapt the tunnel size to the product and to have as few airspaces as possible (Bizerba recommends approx. 2.5 cm).

Bizerba Inspection Guide Installation conditionsSystems Combination with Bizerba software



TechnologiesPreface Audits

6. Audits

Audits have to be carried out on a regular basis in a food production plant. In doing so, it is checked and ensured that the device works properly.

The audit is carried out with specially prepared test packages and the result logged.





6.1 Point in time for an audit 6.2 Performing an audit

The point in time for an audit must be defined ahead by the relevant production plant and may perhaps be stipulated by a guideline.

Bizerba recommends audits at the following times: • At the beginning and end of each production day • At defined time intervals during a production day (at least hourly) • When beginning a new batch or a new product • After settings were changed on the device • After label roll change

The food manufacturer defines certain sizes in which he wants to detect foreign bodies of a certain material. Test samples of the relevant size simulate the contamination.

Bizerba recommends to position the test samples made of different materials (stainless steel, ferrous metal, non-ferrous metal) at a place of a non-contaminated package where detection is most difficult. In case of the metal detector this place would be the center of the tunnel. At least three packages should be prepared. The foreign bodies are thereby placed at a package at the front edge of the product, at another package at the rear edge and at a package in the center of the package.

The packages must be conveyed through the system during an audit. Each of the packages must be completely detected and completely rejected. Only in doing so it can be ensured that the system properly detects and rejects contaminated packages.

If the audit should be negative, the cause must be found and eliminated right away before production resumes. The products manufactured since the last audit must be considered as suspicious and be treated accordingly.

The test samples must originate from a certified manufacturer for test samples. Bizerba offers the optimal test samples for the devices as accessories.





6.3 Documentation of an audit

The results of the tests performed will be documented to show that all requirements of guidelines or manufacturer requirements (chapter 3) were carried out. Due to regular audits which are representing a reliable process, efficiency in production can be increased and recalls which can damage a company’s image be avoided. In combination with a matching software solution (chapter 7) the audit results will be visually shown in digital, paperless reports, evaluated and saved. Manual intervention by the customer is not necessary here.

Bizerba Inspection Guide Installation conditionsSystems Audits Combination with Bizerba hardware


TechnologiesPreface Combination with Bizerba software

7. Combination with Bizerba software

Installation conditionsSystems Audits Combination with Bizerba software



TechnologiesPreface

BRAIN2

With our intelligent industrial software BRAIN2 you gain maximum transparency and complete traceability along your sup-ply chain. Matching your needs the soft-ware modules can be easily integrated in your company processes via interfaces. They record production data in real time, manage and analyze data efficiently or safely control production processes. Automatically create reports and statis-tics. Save pictures including date and time for the duration of a product‘s shelf life. This is one of many options in order to document your production.

Digital control




TechnologiesPreface

Centrally manage master and configura-tion data such as PLU and customer data on your Bizerba devices using this app and with minimal time effort.

BRAIN2 Data_Maintenance Central master data management

With the BRAIN2 Capture app you record and evaluate among other things the process data of your Bizerba inspection systems in a quick, easy and efficient manner.

BRAIN2 Capture Perfect data flow

Automatically create backups via app. Data centrally saved to the BRAIN2 database can be easily restored via GUI or directly on the device. For a fast start-up you can simply clone device data.

BRAIN2 Safety_Service Backed up data

BRAIN2 OEE records key metrics of your production, evaluates them and calculates the OEE value from the collected data records. The ideal basis for optimization processes.

BRAIN2 OEE Transparent numbers



TechnologiesPreface Combination with Bizerba hardware

8. Combination with Bizerba hardware



TechnologiesPreface Combination with Bizerba hardware

Dynamic check-weighers

Price labeler

Our verifiable dynamic checkweighers and our fully automatic weigh price labelers are optionally available with an integrated metal detection system.

Expand your systems in a flexible way with a camera system or an X-ray system.

At Bizerba you receive a tailor-made solution consisting of state-of-the-art hardware and perfectly matched software along the entire production line. Contact our experts. They will configure an optimal solution for your production.




TechnologiesPreface

Bizerba SE & Co. KG Wilhelm-Kraut-Straße 65 72336 Balingen Germany T +49 74 33 12-0 F +49 74 33 12-2696 www.bizerba.com

Or, schedule an appointment:

Learn more about our inspection systems here

www.bizerba.com/inspectionsystems

https://www.bizerba.com/en/products/product-overview.html?selectedProductGroup=403326

bizerba inspection guide

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