FEATURE INSPECTION, TEST & MEASUREMENT
INLINE INSPECTION GIVES zero metal contamination
Since an inline inspection system from Fortress Technology was installed for an Asian sauce manufacturer the customer reports zero metal contamination of products leaving the factory
reject,” says Kevin Shackell, head of UK sales at Fortress. “By essentially filtering out the external ‘noise’ our FM software boosts sensitivity by up to 40% when inspecting conductive products.”
SCREENING 1 LITRE EVERY 25 SECONDS Typically, Shoda’s ‘vat room’ processes either one batch of 3.5 tonnes of sauce per day or several smaller batches of 550kg. With up to three product changeovers per
The certified Phantom pipeline stores up to 99 products in its memory and can be cleaned in situ for easy product changeover
F
ortress Technology has installed its fifth Phantom pipeline metal detector at
Shoda Sauces in Abertillery, Wales. The in-line inspection system is the most sensitive method available for screening piped sauces of varying viscosities and since purchasing its first Fortress equipment in 2004 the producer hasn’t received a single customer report of metallic contamination from products leaving its factory. “If we look back over the past 11 years since we started working with Fortress we have had zero incidents with metal. Fortress metal detectors are like the Fort Knox of the inspection world; nothing gets past them, they are completely failsafe,” says engineering manager Gareth Law. Japanese-owned Shoda Sauces
manufactures oriental sauces, from soy, oyster and hoisin, to blackbean, yellowbean and chilli sauces. The majority of these are supplied to food and ready meals manufacturers across the UK and Europe, ultimately ending up in products on sale in multiple retailers.
METAL DETECTION CRITICAL Regardless of who the end customer is Shoda’s commitment to food safety is the same and absolute. A BRC accredited company, Shoda treats metal detection as a critical control point in its HACCP plan. “No matter where you fit in the food supply chain you have to supply safe food
12 JULY/AUGUST 2016 | FACTORY EQUIPMENT
and metal detectors are crucial in providing that assurance; we cannot afford to be without them,” continues Law. The past decade has seen the company
experiencing controlled growth which has accelerated in the past 18 months. This growth in demand combined with the unreliability of existing equipment prompted Shoda to invest in a Fortress pipeline metal detector in January. The Phantom pipeline system detects metal contamination in pumped liquids and pastes conveyed through a non-metallic pipe. As with the previously purchased Fortress detectors this latest purchase was for the company’s ‘vat room’ for screening liquids as they are piped into 1000ltr IBCs (intermediate bulk containers), pallecons, 12.5ltr and 2.5ltr jerry cans and 5kg buckets. There are two overriding advantages to using pipelines for this application. As pipelines are in-process detectors they do not occupy additional floor space or incur labour costs. Furthermore, inspecting in-line achieves
far greater sensitivity than passing packaged product through a conveyorised detector head as the aperture is far smaller so more sensitive. The pipelines at Shoda were specified with 110mm apertures. In this application the salt content of some of the sauces could potentially have compromised sensitivity. “Soy sauces generate what we call product signal which can trigger a false
day it is important than equipment is easy to clean and able to switch quickly between different products. With its IP69K rating, 304 stainless steel construction, extra rugged BSH casing and Auto Cal set up system, the Phantom fits the brief. “We clean down at the start and end of production and between every batch,” explains Law. “The Phantom pipeline helps to minimise cleaning time as it can be left in-line during wash down. It can store up to 99 different products in its memory and programming new recipes is very easy.” Line speeds are dependent on viscosity but typical throughput is around 1 litre every 25 seconds. In addition to its bulk sauce business Shoda Foods has a sauce sachet operation. The detectors it uses on these lines are nearing the end of the lives and Shoda is looking to upgrade them to robust conveyor-style Fortress systems.
ABILITY TO UPGRADE EQUIPMENT Further expansion is planned to include a new bottling facility with the view to enter the retail markets. The ability to upgrade Fortress inspection equipment so it complies with the latest wholesale and retailer Codes of Practice and maintains Shoda’s 11-year unblemished metal contaminant record fills the team with confidence. “We know their equipment and we know
the company,” concludes Law. “For us, it is all about building relationships with suppliers so they get to know our needs. Fortress understands that if a metal detector isn’t working we can’t pack product which is why it engineers equipment that is built to last and in our experience, totally reliable.”
Fortress Technology T: 01295 256266
www.fortresstechnology.co.uk
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