Escolar Documentos
Profissional Documentos
Cultura Documentos
HowtoGuideMetalDetectionFunctionality
BasicprinciplesofMetalDetection
Allgeneralpurposemetaldetectorsfunctioninthesamewayandsharemanysimilarcharacteristics,
thoughnotalldetectorsaresuitableforeveryapplication.
Therearethreetypesofmetaldetectors
ConveyorMountedSystems
Vertical(Bagfill)Packagingsystems
Pipeline(Inline)Systems
Mostmetaldetectorsinthefoodindustryarebasedonabalancedcoilsystem.Ametaldetectorwill
usuallycontain3coils.Thetransmittercoilwillgenerateafieldthatisdesignedtorevealmetalparticles
inordertomakethemdetectable.Thisprocessiscalledilluminatingthemetalparticle.Theremaining
twocoilsaredesignedasreceiversandareconnectedtogethertodetectthepresenceofanilluminated
metalparticle.Thedetectionisrelatedtotheconductiveandmagneticpropertiesofthosemetals.The
ratiooftheaperturetothesizeoftheproductisvitallyimportantinensuringoptimalperformance,due
tothesensitivitybeingmeasuredatthegeometriccentreoftheaperture.
Source:www.mt.com
Asmuchaswerelyonmetaldetectors,asameansofqualitycontrol,theyarestillunabletodetectevery
particleofmetalpassingthroughthem.Aswithanymeasuringinstrument,therearerestrictionson
accuracyandthisvariesdependingontheapplication.
Thatswhenadifferenttechnology,knownasferrousinfoildetection,comesintoplay.Thesedetectors
usestrong,permanentmagnetstocreateaconstantmagneticfield,whichisdisturbedbythe
introductionofmagneticmetals.Althoughthisequipmentonlydetectsmagnetisableferrousmetalsand
magneticstainlesssteels,itremainsacosteffectivesolutionforsomeapplications.FerrousinFoilmetal
detectorsshouldbeusedonfoilpacked,aluminiumfoiltrayandlikeproducts,asthesearecapableof
detectingferrousmetalsonlywithinfreshorfrozenproductswhicharepackedinafoilwrapping.
HowtoGuideMetalDetectionFunctionality2December2014
Page1of8
FactorsAffectingMetalDetection:
Thefactorsaffectingmetaldetectioninclude:
MetalType
MetalShape&Orientation:simplyreportingthatthedetectorlocatedanobjectinone
orientationdoesntprecludethepossibilitythatitwouldbemissedinanotherorientation.
ApertureSize/PositionintheAperture:themaximumsensitivityoccurswhenthebeltandfood
itemisclosesttotheedgeofthemetaldetectorportal.
DetectorFrequency
EnvironmentalConditions:notimpactedbyexternalelectricalinterferenceorbyplantoperating
conditionse.g.wetenvironments,areasofhighvibration,extremesoftemperatureorharsh
hygieneprocedures.Ifthecoilsystemisallowedtomoveorvibratebyjustafewmicrons,the
disturbancecouldbeenoughtocauserejectionofaperfectlyacceptableproduct.
PackagingMaterial:Differentpackagingmaterialscaneffectsensitivities.
o Paper,cardboardpackaging,takingintoaccountrecycledcontent.
o Glass(jars&bottles)
o MouldedPlastics(jars&bottle,trays)
o PolyFilm
o MetallisedPolyFilm
o AluminiumFoil
o Oxygenscavengers
o Promotionalmaterialandinserts
o Steelcans
ProductCharacteristics
o DryProductsE.g.sugar,flour,snacks,confectionery,cerealsetc:HighSensitivity
o WetProducts(producteffectapplications)E.g.readymeals,meat,fish,sauces,
preserves,etc:ReducedSensitivity
o IronrichproductsHighSensitivity
o ProductscontaininghighlevelsofsaltReducedSensitivity
o Irregularproductshapes.ReducedSensitivity
TableMetalType
MetalType
EaseofDetection
Electricalconductivity
Magneticpermeability
Ferrous
Easilydetected
Good
Magnetic
NonFerrous
Relativelyeasytodetect
Generallygoodorexcellent Nonmagnetic
StainlessSteel Relativelydifficultto
Usuallypoor
Usuallynonmagnetic
detect
HowtoGuideMetalDetectionFunctionality2December2014
Page2of8
DiagramOrientationExample
Source:www.mt.com
Sensitivity
Thesensitivityoftheequipmentisessentialindeterminingthetypeandsizeofpiecesofmetaldetected.
Theequipmentsensitivityisappropriateifallofthefollowingparametersaremet:
Thesensitivitycanbemaintainedwithoutperiodicadjustment.
Thedetectorgivesminimalfalsesignalsanddoesnotrejectgoodproduct.
Detectordoesnotgoblindafterdetectingalargemetalpiece.
Detectionindifferentorientations:theresultingdisturbancesignalcanbeonetotwoordersof
magnitudegreaterinoneorientationthantheother.Mosttestpiecesuseasphericalobject,so
thesignaltheygiveoffisthesameinanyorientation;butwhentestingareturnedforeignobject,
suchasaneedleorpieceofwire,itneedstobetestedindifferentorientationtoensuremaximum
effectiveness.
RejectMechanisms
Thereareavarietyofrejectdevicesavailablewhichmayinclude:
Carriageretractingband/Sweep/diverterarm(product<5kg)
Airblast(product<1kg).Thesecanbeunreliableifyouhaveadropinairpressure.Ensurethatthe
airpressureissufficienttocopewithanypotentialmetalcontaminantse.g.metalbolts.
Pusher(product<10kg)
Stopondetect(product<60kg)
Detectorfailsafesystemswherefitted,mustbechallengedatregularintervals(eg:startandendofshift/
day)tomakesuretheyareeffective.
Rejectconfirmationsystem:automaticbeltstopfailsafesystem,toconfirmmetalcontaminated
productshavesuccessfullyenteredtherejectbins.
HowtoGuideMetalDetectionFunctionality2December2014
Page3of8
Asmostmetaldetectorconveyorsarerelativelyshort,withtherejectsystemclosetotheconveyorout
feed,itisnotpossibletoensureanycontaminatedproductnotrejectedwillberetainedonthemetal
detectorconveyorwhenitstops.Itisthereforeimperativetostopthefollowingconveyor(orequipment)
atthesametimeandadditionaloutputsonthemetaldetectionsystemshouldbeavailabletofacilitate
this.AfterRejectConfirmationAlarmallproductshouldberemovedfromthemetaldetectorconveyor
andfollowingconveyor(orequipment)andrejectedorreinspected.
Binfullsystem:anautomaticbeltstopfailsafesystemwhichactivatesshouldtherejectproduct
collectionboxbecomefull.
Airpressuresystem:anautomaticbeltstopfailsafesystemtocoverairpressurefailurestotherejection
mechanism.Theaccesstoadjustingtheairpressureshouldberestricted.
Searchheadfailure:anautomaticbeltstopfailsafesystemtoconfirmdetectionheadfault.
Backupsensor:anautomaticbeltstopfailsafesystem,toactivateshouldproductbackupunderoutthe
feedbeltofthemetaldetector.Whereappropriateabackupsensorshouldbeinstalledtoensure
productispreventedfrombackingupontothemetaldetectorconveyor.
Bindoorunlockedalarm:anautomaticbeltstopfailsafesystemtoactivateshouldtherejectbindoorbe
leftopen/unlockedforlongerthanapresettime.
ProductTestingTestPacks
Thetestpacksmustberepresentativeoftheproductsgoingdownthelinee.g.shapeanddensity.Actual
productshouldbeusedastestpacks.Thepacksusedtomakeuptestpacksshouldbepassedthroughthe
metaldetectorbeforetheyareusedtoensurethattheydonotcontainmetal.
Detectorsmustbecheckedusingclearlyidentifiedtestpacksatthesametemperature(andtherefore
maintainedatsametemperature)asstandardproductpassingdownthelineandtestpiecesofadefined
size.
Thetestpiecesmustbepassedthroughthedetectorinthecentreoftheaperturewiththetestpack.
Consecutiveleadingandtrailingchecksmustbecompletedinlongpackstoensuretherejectmechanism
cansuccessfullyreject.Thetestmustberepresentativeofhowproductswouldnormallytravelthrough
thedetectorduringnormalproduction.
Thesiteshouldonlyusetestpieceswhicharecontrolledandthesizeofthemetalcanbeverifiede.g.they
aremanufacturedwithaserialnumberorissuedwithacertificate.Testpiecesareavailableinvarious
sizes/shapese.g.sticksorcards.Themostappropriatetypefortheproductshouldbechosen.
HowtoGuideMetalDetectionFunctionality2December2014
Page4of8
Testpacksshouldbemadeuponanhourlybasiswithproductfromtheline(sameproduct).Ifitisnot
practicaltodothisandtestpacksaremadeupinadvance,thetestpacksmustbecontrolledandlabelled
withproduct,date,testpiecesizeandtype.
ProductTestingLocationofTestPieces&ConsecutiveTests
Thetestpacksneedtobemadeuptoworstcasescenario.Thetestpiecesshouldbelocatedinthe
leading,centreandtrailingpositionsasperdiagramsbelowforthe3packconsecutivetest,andthe
leadingandtrailingedgeforthe2packFerrousinfoil.Theleadingandtrailingpositionswouldnotbe
consideredarequirementiftheproductisasmallpack(i.e.lessthan100mm).
Thetestpacksshouldbemarkedwiththelocationofthemetalifitisnotvisible.
Whereapackcontainsproductsofdifferentdensity,thelocationofthetestpiecesinthepackshouldbe
basedonworstcasescenario.
Ifthelocationofthetestpieceisnotvisibleadditionalcontrols/checksneedtobeinplacetoensurethat
thetestpiecesremainintherequiredlocationsifthepacksareusedformultiplelocationse.g.afterbeing
rejectedthetestpiecesmayhavemoved.
All3testpacks(Ferrous,NonFerrous,StainlessSteel)shouldpassthroughthedetectoroneaftereach
otherwithnormalspacing/linespeed.Thelineshouldberunningandthetestpacksintroducedinthe
placesof3uninspectedpackswherepossible.
DetectionUnit
Midpoint
Trailingedge
Leadingedge
EvenLineSpacing
ProductFlow
HowtoGuideMetalDetectionFunctionality2December2014
Page5of8
ForFerrousinFoilDetectorstwotestpacksarerequiredincludingtwoferroustestpiecesofthesame
size.
DetectionUnit
Trailingedge
Leadingedge
EvenLineSpacing
ProductFlow
ProductTestingMemoryTest
Theobjectiveofthetestistochallengetheeffectivenessoftherejectsystemsothatitdoesnotblanket
reject.
Thetestpacksshouldbesentthroughthemetaldetectorwithastandardpackinbetween(whichhas
alreadysuccessfullypassedthroughthemetaldetector).
Itisafailedtestifanyofthetestpacksarenotrejected.Ifastandardpackisrejectedthelinemustbe
stoppedandtheissueinvestigatede.g.timingofrejectmechanism.
Ifamachinestrugglestonotrejectgoodpacks,adviceshouldbesoughtfromtheequipment
manufacturer.Thecapabilityofthemachinemaybedependentonthelinespeed.
Ifasitewishestocombinetheconsecutiveandmemorytestintoonetest,theprocedurebelowis
recommended:
HowtoGuideMetalDetectionFunctionality2December2014
Page6of8
VerticalPackagingsystems
Verticalpackagingsystemsconsistofathroatmetaldetectorandabagformerbeneath.Theycanbeused
forcertainproducttypese.g.snacksandconfectionery.
Example
RejectMechanism
Ondetectionofmetalthedetectorshouldsendasignaltothebagmakertoproduceadoublebagor
stop.Thesystemshouldalsobefittedwithanaudibleand/orvisiblealarmtoindicatethatthesystemis
stoppedduetoametalcontaminationincident.
Testing
Whentestingverticalpackaginglines,ferrous,nonferrousandstainlesssteeltestpiecesshouldbe
independentlyplacedintheproductflowandsuccessfulrejectionsobserved(i.e.doublepackmadeand
audibleand/orvisualalarmactivatedandlinestops).
Confirmationmustbesoughtthatthetestpiecehasbeencapturedinthedoublepackproduced.
HowtoGuideMetalDetectionFunctionality2December2014
Page7of8
InLineDetectionSystems
Liquid,pasteandslurrytypeproductscanbeinspectedastheyarepumpedthroughapipelinepriorto
beingdispensedintothefinalpack.Thisformofinspectionisrecommendedinapplicationswherethe
productispackedinmetalcontainers(e.g.tincans).
Systemsofthistypeshouldincorporateanautomatedrejectvalvesystemimmediatelyafterthemetal
detectionheadwithanaudibleandvisualindicatortosignalwhencontaminationisfound.Contaminated
productshouldberejectedintoasuitablesecurecontainer.
Source:www.mt.com
Testing
Withpipelinesystems,testpiecesshouldideallybeplacedintheproductflowandsuccessfulrejection
observed.Ininstanceswhereplacingatestpieceintheproductflowisnotpractical,thesystemmaybe
testedbyinsertingtestpiecesbetweenthepipelineandthedetectionhead(inthedirectionofproduct
flow)andobservingtheoperationoftherejectsystem.
Source:www.mt.com
Sensitivitystandardssetintheseinstancesshouldreflectthatthetestpieceisnotpassingthroughthe
centreoftheaperture(sensitivityisthereforehigher).Intheseinstances,thesizeofthetestpieceused
shouldbeadjustedtocompensate(e.g.smallertestpiecesize)consultequipmentmanufacturerfor
advice.
HowtoGuideMetalDetectionFunctionality2December2014
Page8of8