In the dynamic landscape of food processing, ensuring product safety and quality has never been more critical. As consumer expectations rise and regulatory standards become increasingly stringent, manufacturers must embrace advanced inspection technologies to stay ahead. Mettler-Toledo, a global leader in precision instruments, continues to set new benchmarks in food safety with its state-of-the-art metal detection, x-ray inspection, and checkweighing systems. These solutions not only enhance contaminant detection but also improve operational efficiency and compliance, helping food manufacturers meet the evolving demands of both domestic and international markets.
Shweta Kumari from Food Infotech had an engaging conversation with Siddarth Kachroo, Head of Sales India, Mettler-Toledo Product Inspection], who highlighted Mettler-Toledo’s latest innovations in food inspection technology, the role of digitalisation in enhancing efficiency, and how their solutions are tailored to the specific needs of the Indian food industry. He also shared insights into how the company is driving sustainability, cost-effectiveness, and after-sales support to help manufacturers maintain high-quality standards while optimising their operations.
Let’s delve into this insightful conversation to learn more about Mettler-Toledo’s pioneering advancements and how they are shaping the future of food safety and quality assurance.
- Can you share details about the newest technologies Mettler-Toledo has developed for the food processing industry in India?
The latest contamination detection solutions include our M30 R-Series metal detectors which feature modular designs and advanced algorithms capable of detecting contaminants in diverse food products, including high-moisture and densely packed items. These systems are particularly well-suited to the Indian market, where manufacturers handle a wide range of food products with varying properties, requiring high sensitivity and adaptability. Additionally, the M30 R-Series supports cost-effective scalability, making it an ideal choice for price-sensitive markets.
On the x-ray inspection front, our X12 and X16 systems cater to the unique needs of India’s food processing industry by offering advanced foreign body detection and quality control capabilities. These systems are highly effective for complex products like multi-layered or metalised packaging, which are increasingly common in the Indian market due to evolving consumer preferences and export requirements.
Beyond standalone metal detection and x-ray systems, we also offer combination systems that integrate checkweighing with a contaminant detection technology in a single unit. These systems enable manufacturers to verify both product weight and safety simultaneously, streamlining production and reducing footprint requirements on busy factory floors. This approach is particularly valuable in India, where space efficiency and multi-functional solutions are key to optimising operations.
Further, all of our systems support automation and compliance with international food safety standards, addressing the growing demand for operational efficiency and reliability in India.
- What new product inspection systems can accommodate complex products?
The X52 dual-energy x-ray system is particularly notable, offering advanced inspection capabilities for complex products, such as bags of nuts and seeds. This technology enhances detection accuracy in scenarios where traditional x-ray systems may struggle, making it ideal for the growing variety of food products in today’s market.
Additionally, with the rise of smaller, single-serving packages and high-speed production lines, our solutions are tailored to offer precision across different product sizes and weights. The ability to inspect lightweight products and verify correct fill levels supports both quality assurance and operational efficiency.
- How do your latest inspection systems address the evolving safety standards in food processing?
For metal detection, the M30 R-Series models have been developed to tackle the challenges posed by increasingly diverse food products, including those with high moisture or salt content. These systems are equipped with advanced algorithms that improve detection sensitivity while minimising false rejects.
Our x-ray solutions offer unmatched sensitivity for detecting a wide range of foreign bodies, meaning products meet rigorous compliance standards globally. These systems also include innovative software that supports automatic product setup, reducing the risk of human error and delivering consistent detection performance.
In addition to contaminant detection, our x-ray inspection solutions address quality control measures, such as verifying fill levels, detecting damaged packaging and identifying product defects. This means manufacturers can maintain both safety and quality in line with international and local regulations.
Our combination inspection systems further strengthen food safety by simultaneously verifying product weight, checking for contaminants and detecting packaging defects. These space-saving systems help manufacturers adhere to stringent safety standards while maintaining efficiency, particularly for businesses aiming to meet both domestic and export market requirements.
Moreover, our technologies support compliance with standards such as the International Featured Standards (IFS), Food Safety Modernisation Act (FSMA), the British Retail Consortium Global Standards (BRCGS) and the Food Safety and Standards Authority of India (FSSAI), which are critical for Indian food manufacturers. These capabilities are further enhanced by real-time data monitoring and reporting tools, allowing producers to track inspection performance and demonstrate compliance during audits effectively.
- What improvements have been made in your x-ray and metal detection systems to meet the current market demands?
We have significantly enhanced the functionality of our inspection systems. For instance, the X12 and X34 x-ray systems now incorporate cutting-edge image processing software for better detection sensitivity and reduced false rejections. On the metal detection front, the M30 R-Series features modular construction, improving flexibility and serviceability. These upgrades align with industry trends towards sustainability, automation and cost-efficiency, meaning that manufacturers can achieve operational excellence in competitive markets.
- How is Mettler-Toledo leveraging digitalisation to enhance operational efficiency in food inspection processes?
Digitalisation is at the core of our innovations. Software solutions like the ProdXTM data management software enable real-time monitoring of production lines, enhancing traceability and efficiency. By automating data collection and analysis, ProdXTM reduces the risk of manual errors while providing actionable insights to optimise production.
With manufacturers facing increasing raw material and operational costs, digitalisation plays a crucial role in driving efficiency and reducing waste. Our smart inspection systems help combat rising costs by improving production line productivity, reducing unnecessary product rework and preventing costly recalls.
Moreover, this software integrates seamlessly with our metal detection and x-ray inspection systems, supporting manufacturers in achieving better operational visibility and faster decision-making.
- Could you provide insights into your latest software updates for inspection equipment and their impact on productivity?
Automation and efficiency remain at the forefront of innovation, and the Mettler-Toledo solutions are leading the way in advancing food safety. Our inspection systems are designed to inspect 100% of production lines in real time, eliminating the limitations of traditional sample checks. This approach significantly reduces the risk of defective products reaching the market, meeting the growing demand for stringent production standards and quality assurance.
Key advancements include automated product setup and changeovers, which enable seamless transitions between product types with minimal downtime and no manual intervention. This not only improves overall productivity but also reduces the risk of human errors. Automated rejection systems further enhance efficiency by swiftly removing defective products from the line without interrupting production, offering reliability and high throughput.
Our systems also incorporate automated feedback to the filler machines, allowing real-time adjustments to fill levels. This maintains product consistency and accuracy, reducing waste and improving line efficiency.
Additionally, combination systems represent a transformative innovation in food inspection. By integrating technologies such as checkweighing with metal detection or x-ray inspection into a single system, manufacturers can address multiple quality control concerns simultaneously. These systems can detect foreign body contaminants like metal or glass and verify product weight, providing a holistic solution for food safety. This streamlined approach enhances accuracy, minimises downtime and supports compliance with regulatory standards across production stages.
- How does Mettler-Toledo provide cost-effective solutions for price-sensitive markets like India?
In today’s challenging economic landscape, food manufacturers in India must combat rising costs while maintaining high product quality. Our solutions help achieve this by minimising waste, reducing false rejects and automating quality control processes to cut down on manual labour.
Another significant innovation is our Automatic Test System (ATS), which automates the performance testing of vertical metal detection systems. By eliminating the need for manual intervention during test routines, ATS reduces labour costs, saves time and increases line efficiency. This is particularly beneficial for manufacturers in high-speed production environments or those managing multiple product changeovers.
Additionally, we support cost-effectiveness through regional service centres and streamlined maintenance protocols. These services lower total cost of ownership by reducing downtime and being sure systems operate efficiently over their lifecycle.
- What role does sustainability play in your product development and manufacturing processes?
Our advanced inspection systems are designed to reduce waste, optimise energy usage and enhance overall efficiency. By enabling accurate product inspections, these systems minimise product loss and support resource conservation throughout production.
Additionally, our solutions contribute to sustainability by reducing false-rejects and product recalls, which can result in significant material and energy savings.
Our efforts align with global environmental initiatives and regulatory standards, meaning manufacturers can achieve their sustainability targets while maintaining compliance.
In 2024, we achieved carbon neutral status for the fifth consecutive year. Additionally, we are on track to achieve our goal of sending zero waste to landfill by 2025.
In 2023, the company made substantial strides toward our sustainability objectives. Efforts include accelerating the adoption of electric vehicles, ramping up solar power and district heating capacities and re-achieving targets for sourcing 100% renewable electricity. These achievements reinforce our commitment to sustainability and contribute to our 2030 science-based targets for emissions reduction.
- How do you support your customers with after-sales services to maintain equipment performance and safety?
We offer a comprehensive range of after-sales services, including preventative maintenance, calibration support and training programmes for operators. Our service teams provide quick response times and local expertise, meaning minimal disruption to production. Additionally, features like remote diagnostics enable real-time troubleshooting, keeping equipment operational and reducing downtime for our customers.
- Can you share any success stories or case studies of Indian food manufacturers using your products to improve their operations?
Our high-speed checkweighers, metal detectors and x-ray inspection systems have enabled manufacturers to automate their processes, improving productivity and reducing manual intervention. By integrating with Manufacturing Execution Systems (MES) and Smart Factory environments, our equipment supports real-time data analysis, allowing businesses to make quick, informed decisions and optimise production lines.
For mid-market customers, newly launched products like the M31 metal detector and X12 x-ray system provide advanced detection capabilities, offering higher sensitivity and lower false reject rates (FRR). These innovations allow businesses to achieve the same high-level performance expected by large-scale manufacturers while maintaining cost-effectiveness.
Additionally, our high-speed multi-evaluation checkweighers have helped many FMCG manufacturers automate end-of-line weighing processes, improving accuracy and compliance while keeping up with fast-paced production environments.
Mettler-Toledo technologies continue to support businesses across the food industry in combatting rising costs and meeting stringent quality and safety standards while driving operational efficiency.