INDUSTRY FOCUS FOOD & BEVERAGE FAILSAFE METAL DETECTION IS ON THE INCLINE


Product inspection is now more efficient at Dutch company Vepo Cheese thanks to the installation of Interceptor Metal Detectors from Fortress Technology


W


ith a high rate of automation in its two Dutch cheese factories in


Bodegraven and Oudewater (close to Gouda), Vepo Cheese prides itself on production efficiency. Slicing, grating, cubing, portioning and packaging millions of kilos of hard cheese a year, the family business recently upgraded all of its production lines with a new incline layout comprising seven Interceptor Metal Detectors from Fortress Technology. Having replaced its obsolete metal


detectors with a used Fortress unit three years ago, Vepo was already won over by the Fortress difference, especially the company’s ‘Always Upgradeable’ technology guarantee. For the Oudewater site, high performance, future proofing and an independent reject system on each line were important criteria. And Vepo knew instantly that they wanted Fortress metal detectors. Approaching Dutch manufacturer


Jansen Control Systems to design the compact incline inspection lines, each integrated with a vertical packaging machine, Vepo first examined the Stealth machine. But they decided on the Fortress Interceptor when Jansen’s managing director Gerard Schuurman explained its increased sensitivity and advantages in cheese applications. Schuurman explained how these


variations in density combined with the product effect could react in different ways in the magnetic field of a traditional food metal detector. “Not addressing product effect can lead to higher product waste. Vepo was especially taken by the Interceptor’s increased sensitivity. Keen to introduce a more fail safe solution at their Oudewater facility, Vepo wanted a metal detection solution that could increase the inspection pace in order to keep up with their growing production demands.” Fortress European managing director


Phil Brown said: “Inspecting wet products has for many years presented cheese makers with a number of challenges. Water like metal is conductive. And cheese is inherently a wet and conductive product that also contains mineral content like salt. Accurate detection also depends on the size, shape and orientation of metal particles.” The Interceptor overrides the propensity


of ‘wet’ product effects that can drown out the signal, in particular the signals caused by a stainless steel contaminant. Software


28 JULY/AUGUST 2020 | PROCESS & CONTROL


algorithms make this possible by distinguishing between signals specific to the product and those that flag up anomalies. By singling out low-frequency signals, the Interceptor leaves the stainless steel signal more readily identifiable in the higher-frequency range. As a result, the system can pinpoint


metal fragments with dimensions half those detectable with the previous generation of equipment, with greater reliability. The result of separating these two readings is any metal signal, as a result of a genuine contamination, isn’t swamped by product effect. The ability to isolate rejected packs


without interrupting the production flow was also important to Vepo. On previous inspection lines, Vepo didn’t have an automated reject system. If a contaminated pack was identified the belt would stop and an operative would have to intervene, a business interruption that impacted productivity. Technical operations manager at Vepo,


Hugo van Put said: “From a quality assurance perspective, we are extremely satisfied. The automated reject system also gives us 100% control over production. There’s less human involvement, therefore less risk of human error. This also lowers the risk of a metal contaminant slipping through the safety net. From an efficiency perspective, continuous production is one of the main benefits.” In order to keep the footprint small and


for smooth, seamless production, Jansen developed an incline conveyor that could be fully integrated with the Interceptor metal detector, vertical packing system and periphery equipment. Other features comprised an easy to


clean conveyor belt and a robust easy-to- empty bin trolley that could stand up to the weight of heavy packs dropping in. All of the inspection lines were installed


Vepo Cheese’s new incline layout comprises the highly sensitive Fortress Interceptor metal detectors. The identical systems reduce maintenance and spare part costs


within a day, ensuring minimal loss of production time. “The Jansen team worked extremely closely with Vepo’s technical and quality managers to ensure the systems were thoroughly tested in order to guarantee a smooth installation,” said Schuurman. Measuring just 1m at its widest point


and just under 3m in length, Jansen also combined two conveyors into one which helped to reduce the number of controls. Within two hours of installation per line, the factory was running at full capacity accurately inspecting large quantities of grated cheese bags per shift. “Fortress metal detectors are really sensitive. This helps us to feel confident that the risks of contaminants are minimal, with less chance of a food safety issue,” said van Put. “Having the double readings within the Interceptor system also lowers the risk of false positive rejects, which saves on food waste.” Another advantage of the newly fully


The ability to isolate rejected packs without interrupting the production flow is a big benefit for Vepo


integrated packing system is the processing transparency. Each metal detector features Contact Reporter software. Data from each packaging line is collated in a common collection system, enabling quality assurance and production leaders to monitor processing and inspection performance from a centralised location. This automated record keeper developed by Fortress also helps the factory to keep track of and record logs for rejects, tests and process settings. Commenting on the installation, van Put


concluded: “We are extremely satisfied with the innovation and level of industry knowledge and support that Jansen and Fortress deliver between them... Efficiency is integral to our production process, and the two teams understand exactly where we are coming from in terms of balancing product quality and enhancing operational productivity.”


Fortress Technology www.fortresstechnology.co.uk


/ PROCESS&CONTROL


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