Mettler-Toledo Product Inspection is back in the Indian Market yet again with its newly launched innovative solution, X52 Dual Energy X-Ray Inspection System that completes its X2 series. This solution is primarily aimed at solving the problems faced by the food processors, especially when it comes to meeting the demands of challenging applications in packaged food products.
Claus from Food Infotech had a chat with Siddharth Kachroo, Head of Sales, Product Inspection, Mettler-Toledo India Pvt. Ltd., who discussed on the recent advanced product inspection solution introduced by the company for the food processors, including sharing more details about the HiGain+ DE detector technology and its features and capabilities that have been incorporated in their newly introduced X52 X-ray solution, their key suggestions for food processors who are aiming to build a robust culture of food safety in their manufacturing processes and much more.
Read: June Issue of Food Infotech Magazine.
Would you please start by letting us know what are the latest developments happening at Mettler-Toledo, particularly with regard to your company’s recently introduced product inspection solutions for the food processors?
We recently introduced the groundbreaking X52 X-ray Inspection System as part of our X2 Series, setting a new standard in detection capabilities at a competitive price point. The X52 is designed to meet the demands of challenging applications in packaged products, offering unparalleled adaptability with its proprietary software.
It seamlessly transitions between single energy and dual energy modes, optimizing performance for each application. In single energy mode, the X52 identifies contaminants such as metal, glass, mineral stone and dense plastics, offering thorough inspection for product safety. Dual energy mode enhances accuracy by analyZing material densities, providing an advanced level of detection to protect consumer well-being and uphold industry standards.
The X52 complements the existing X12 and X32 systems, each designed for high performance and advanced sensitivity in x-ray inspection. The X12 offers outstanding contaminant detection with its HiGain detector at an affordable price, while the X32 features the HiGain+ detector for enhanced sensitivity and product integrity performance, available in standard and custom configurations. Together, these systems provide comprehensive x-ray inspection solutions, helping manufacturers maintain high standards of food safety and quality.
Your company will be exhibiting some of your product inspection solutions for the snacks industry at the SnackEx Expo that will be held in June in Sweden. What major barriers/challenges faced by snacks manufacturers have you been able to address this time through your solutions?
Snack manufacturers face several significant challenges, such as inspecting different pack types, particularly metallized film packaging, where metal can interfere with some inspection technologies. Overlapping products can also cause inspection issues as some contaminants may be hidden when inspected. Additionally, testing the sensitivity and performance of contaminant detection solutions, especially in vertical applications where the inspection technology is located at height, has been a challenge. However, these challenges can be overcome by advanced product inspection solutions.
At SnackEx Expo, visitors can explore how Mettler-Toledo addresses these challenges with advanced metal detection and x-ray inspection systems. For metal detection, a unique cut-away of the T-Series throat metal detector will provide visitors with an immersive experience, allowing them to witness firsthand the inner mechanisms of Automatic Test System (ATS). Throat metal detectors are typically used to inspect products such as crisps, sweets, nuts and cereals in Vertical Form, Fill and Seal processes. ATS from Mettler-Toledo is a value-added accessory that can be supplied at the point of sale or retro-fitted to compatible vertical metal detectors and provides accurate and safe metal detector testing. There are a number of benefits to automatic testing compared to manual testing – which visitors to SnackEx can learn more about at the Mettler-Toledo stand.
For x-ray inspection, visitors will get the chance to explore the X12, a high-performance x-ray inspection system within our X2 Series. The X12 sets a high standard in detection capabilities. Its HiGain detector generates sharper images, enabling outstanding detection of a wide range of physical contaminants, including glass, metal, mineral stone, calcified bone and dense plastic and rubber compounds.
In addition to contaminant detection, the X12 performs several quality control checks, such as fill level control. This means the technology can identify if crisps are stacked correctly in a tube or if a snack box is missing a component. These quality control checks are crucial for upholding brand integrity, avoiding consumer disappointment and preventing product recalls. Visitors to our booth can learn more about how the X12 operates at high line speeds while providing comprehensive safety and quality for snack products.
Could you share some of the key features brought in by your company in the X52 Dual Energy X-ray inspection system? What are some of the major problems that this solution aims to address for the food processors?
The X52 Dual Energy X-ray inspection system introduces several groundbreaking features designed to meet the evolving needs of food processors. One of the standout features of the X52 is its unparalleled adaptability, driven by proprietary software that allows seamless transitions between single energy, dual energy or both modes. This adaptability offers optimised performance tailored to each specific application, promising unmatched precision and reliability.
In single energy mode, the X52 effectively identifies contaminants such as metal, glass, mineral stone and dense plastics based on their material composition. Dual energy mode further enhances accuracy by analyzing the densities of materials, providing an advanced level of detection that protects consumer well-being and upholds industry standards. This dual functionality addresses the challenge of detecting a wide range of contaminants in diverse food products.
The X52 also excels in efficiency and accuracy by helping to reduce false rejects. Its advanced technology means that only genuine contaminants are identified, minimizing unnecessary production halts and disruptions. This precision helps food processors maintain seamless operations, maximise uptime and reduce overall costs. By detecting contaminants accurately and efficiently, the X52 boosts productivity and sets a new standard in x-ray inspection technology.
Another major problem the X52 addresses is the need for future-proofing manufacturing operations. Its adaptable nature accommodates evolving product lines and applications, promoting sustainability and cost savings by consolidating multiple detection capabilities into a single machine. This reduces the need for additional equipment and provides manufacturers with peace of mind as they navigate changing industry landscapes, meaning they can meet both current and future production demands efficiently and effectively.
The X52’s advanced technology also includes the Advanced Material Discrimination (AMD) algorithm and ContamPlus software, which increase sensitivity and accuracy. These features allow the system to see through packaging materials and inspect contents with exceptional precision, even in challenging scenarios like overlapping products and varying thicknesses. This innovative approach offers thorough inspection and preserves product integrity, ultimately facilitating consumer safety.
Please share a little about the HiGain+ DE detector technology introduced by your company in your newly released X52 X-ray solution and how is it different from the technology that was in use earlier? Further, what are the key benefits that accrue to the food processors from the use of this solution?
The HiGain+ DE detector technology introduced in our newly released X52 X-ray solution represents a significant advancement in detection capability, particularly for low-density contaminants such as calcified bone, glass and rubber. This technology utilizes Advanced Material Discrimination (AMD) software, which is proprietary to our company and specifically designed for dual energy applications.
The key difference from previous technologies lies in the improved ability to detect these low-density contaminants with greater accuracy and efficiency. The X52 Dual Energy system employs AMD to capture two images of the product being inspected. These images are then processed to eliminate background noise and highlight any low-density contaminants by leveraging high-contrast differences.
The benefits to food processors utilizing this solution are substantial. Firstly, the enhanced detection capability means a higher level of food safety assurance, as even small or difficult-to-detect contaminants can be identified reliably. This can help protect consumers against substandard product and minimize the risk of product recalls or reputational damage to the food processor. Additionally, the use of AMD technology improves operational efficiency by reducing false positives, thus optimising overall productivity.
Overall, the HiGain+ DE detector technology integrated into the X52 X-Ray solution offers a comprehensive and advanced solution for food processors seeking to maintain the highest standards of quality and safety in their products.
If I were to ask you how have the accuracy levels for detection of contaminants in your X52 X-ray solution improved as compared to the last one, what would your answer be?
The accuracy levels for detection of contaminants in our X52 X-ray solution have significantly improved. With the implementation of dual energy technology, our x-ray inspection solution is suited to traditional applications addressed by single energy systems and also excels in detecting low-density contaminants.
The X52 Dual Energy system offers enhanced capability in identifying challenging contaminants such as non-calcified bone, low mineral glass or rubber. These contaminants, often difficult to detect due to their low density and presence within complex, overlapping products are now efficiently identified by our advanced technology.
To illustrate, consider a bag of pasta as a complex, overlapping product. Traditional single energy systems may struggle to accurately identify contaminants within such products due to the mixed density and noise present in the image. However, with our dual energy system, multiple images are captured and contrasted, effectively stripping away the product noise and providing clear identification of contaminants.
Therefore, customers using the X52 Dual Energy system will experience a significant improvement in the detection of low-density contaminants. This advancement in accuracy means higher levels of food safety and quality assurance, offering our customers peace of mind and confidence in their inspection processes.
Please brief us a little on the X12 and X32 models in your X2 Series X-ray Inspection systems, along with the benefits that they offer for the food processors.
The X12 and X32 models cater to varying needs within the food processing industry. The X12, designed for smaller production lines, offers compact yet powerful inspection capabilities, offering reliable detection of contaminants and defects without compromising space efficiency.
On the other hand, the X32 is a versatile solution suitable for medium to large-scale production facilities, providing advanced features and customizable options to meet diverse application requirements. Both models prioritize enhanced food safety by employing advanced inspection technologies, facilitating compliance with regulatory standards and guidelines such as the Hazard Analysis and Critical Control Point (HACCP) principles and the U.S. Food and Drug Administration (FDA) guidelines.
Both X-Ray solutions contribute to increased productivity by streamlining inspection processes, minimizing manual intervention and working at high production speeds. Their flexible integration capabilities allow seamless adaptation to existing production lines, meaning minimal disruptions and facilitating cost-effective solutions for food processors.
What’s the kind of service and support that Food Processors can expect to receive from Mettler-Toledo for ensuring optimum performance in their production operations?
Food processors partnering with us can expect comprehensive service and support throughout the entire lifecycle of their inspection technologies. From the initial stages of identifying the most suitable product inspection solution for their specific application to installation, training and ongoing maintenance, we are committed to optimum performance and efficiency.
Our service offerings encompass a range of options tailored to meet the diverse needs of our customers. Firstly, we provide expert guidance during the selection process, helping food processors choose the right inspection solution to meet their unique requirements and production challenges. Once the system is chosen, our team manages the installation process efficiently, with minimal disruption to production schedules.
Training is a vital aspect of our support services. We offer comprehensive training programmes to empower operators with the knowledge and skills required to operate the equipment effectively and maximise its capabilities. This includes training in system operation, maintenance procedures and troubleshooting techniques, enabling customers to optimize performance and minimize downtime.
In addition to training, we provide various service contracts designed to provide ongoing support and maintenance. These contracts offer different levels of coverage and support, allowing customers to choose the option that best suits their needs and budget. From basic service agreements to comprehensive maintenance plans, our contracts help with long-term reliability and performance of the equipment.
Furthermore, we offer spare parts kits tailored to specific systems, which help to minimize downtime in the event of component failures or routine maintenance needs. These kits contain essential components and consumables, meaning that customers have everything they need to keep their equipment running smoothly.
Can you explain in detail on the role played by Mettler-Toledo in helping food processors streamline their food safety compliance?
Mettler-Toledo aids food manufacturers in achieving streamlined food safety compliance through our advanced inspection systems and data management solutions. The inspection technologies capture crucial data during their operation, providing detailed reports on detected contaminants and product quality metrics. Additionally, our ProdX data management software solution centralizes inspection data, enabling real-time access and analysis across multiple production lines. By leveraging these tools, food manufacturers can facilitate due diligence, meet regulatory requirements and enhance overall product safety and quality, instilling trust in consumers and regulatory bodies alike.
Ahead of Food Safety Day, do you have any suggestions for food processors that are looking to build a solid culture of food safety in their manufacturing processes?
Ahead of World Food Safety Day, food processors aiming to foster a robust culture of food safety in their manufacturing processes can take several proactive steps. Firstly, investing in advanced contaminant detection technology such as metal detectors and x-ray systems can swiftly identify and remove contaminated or defective products from the production line, mitigating the risk of compromised products reaching consumers.
Regulatory requirements, including the EU Directive 1169/2011 and U.S. FDA regulations, mandate precise labelling of product contents, nutritional information and allergen warnings, crucial for consumer safety and transparency. Our vision inspection systems help food manufacturers comply with these regulations thereby protecting the consumer against incorrect labelling.
Secondly, comprehensive staff training on food safety best practices and the proper use of inspection technology is crucial for effective implementation.
Thirdly, implementing a Hazard Analysis and Critical Control Points (HACCP) plan enables proactive identification and control of potential hazards in the production process, bolstering preventive measures.
Lastly, regular review and updating of food safety procedures to align with emerging technology and best practices are essential for maintaining effectiveness and compliance. By adhering to these strategies, food manufacturers can cultivate a strong food safety culture, safeguarding their brand reputation and achieving consumer safety.
