INSPECTION CAN HELP ICE CREAM MAKER IMPROVE
FOOD SAFETY AND QUALITY
Ice cream! One of the world’s simplest and purest taste experiences. Since its introduction to Europe many centuries ago by travellers from Asia and the Middle East, ice cream has become one of the continent’s most coveted sweet treats.
Despite its simple and affordable nature, the manufacturing of ice cream is a sophisticated and highly industrial science today, with factories producing millions of litres of multiple types of ice cream to then be shipped to the far corners of the continent.
This industrialization has helped ice cream win its dominant place in the hearts of many consumers, but it can also throw up challenges in terms of detecting foreign bodies.
So, the point is that the ice cream market is highly fragmented, involving a lot of local, small, and medium-sized companies competing with the global giants. Private labels also have a fairly large portion of the market.
To compete in this ice cream market, customer loyalty and brand image are two key advantages. With many similar offerings between competitors, the trust that consumers have for your brand and product separates you from the competition.
Utilizing X-rays in food quality control is an important part of brand protection. It does this by ensuring that foreign object contamination doesn’t cause a product recall, which can be damaging for the brand and financially.
Controlling the quality of the products leaving the plant facilities is extremely important in the ice cream industry since the ingredients come from various environments where quality control is hard. Stones from the fields, glass inside ice cream, or a piece of metal wire—these foreign object contaminations can be removed with an X-ray food inspection system.
The significance of X-ray technology in the ice cream industry
X-ray machines offer unparalleled detection capabilities. They can identify substances as small as a strand of hair and a wide array of foreign materials beyond metals, including plastics, glass, and dense contaminants within packaging. This level of precision is simply unattainable with traditional metal detectors, making X-ray technology the optimal choice for comprehensive food inspection, particularly in industries like ice cream production.
One of the standout advantages of X-ray machines is their ability to inspect multiple items simultaneously. For example, in a crate containing 12 ice cream cones wrapped in aluminium foil, all 12 cones can undergo X-ray inspection simultaneously. This not only ensures thorough inspection but also eliminates the need for individual handling or rejections due to packaging materials. Such efficiency and convenience are unparalleled by metal detectors, especially in complex packaging scenarios.
The integration of X-ray machines represents a significant advancement in food safety protocols. Their unparalleled detection capabilities not only enhance consumer trust in the quality and integrity of food products but also ensure compliance with stringent industry standards. As the ice cream industry and other sectors continue to innovate, embracing X-ray technology is essential for staying ahead and ensuring uncompromised safety and quality in every product.
“The Ice Cream Times” interviewed several distinguished experts who specialize in the field of X-ray machines utilized within the ice cream industry to ensure safety and quality standards. Below are the excerpts:
A thought-provoking interview with Suresh Subramanium, a leading expert at TECHNOFOUR Electronics Pvt. Ltd. (TEPL), specialising in Product Checking Systems including Metal Detectors, Check Weighing Devices, and the latest addition, X-ray Systems
Suresh Subramaniam said there is a critical need to maintain safety and quality standards in today’s dynamic food and beverage industry and emphasized that X-ray machines are much more superior than traditional metal detectors, especially in situations where conventional approaches prove insufficient. He explained that while metal detectors are indispensable in many food applications, they encounter limitations when it comes to detecting contaminants in packaged foods wrapped in materials like aluminium foil. This limitation compromises their sensitivity and detection capabilities, leading to potential safety concerns. For example, in the case of ice cream cones packed in aluminium foil or containing metal fillers, relying solely on metal detectors can result in missed contaminants, ultimately compromising safety standards.
Subramaniam accentuated the criticality of embracing X-ray technology, particularly in situations where conventional methods like metal detectors fall short, particularly within the ice cream industry. By using cutting-edge X-ray systems from TECHNOFOUR, food manufacturers can ensure comprehensive scrutiny of their products, upholding heightened safety and quality benchmarks throughout production. The versatility and precision of X-ray machines render them essential instruments in contemporary food inspection, adeptly tackling the changing challenges presented by varied packaging materials and production demands.
Also, the Atomic Energy Regulatory Board (AERB) mandates that users of X-ray-based food scanners obtain an operating license. However, the process is conducted online and is straightforward. TEPL offers comprehensive assistance to customers to ensure they can operate the systems in accordance with the specified guidelines.
The TEPL team collects all necessary data from the customer and handles the uploading process on behalf of the customer. Furthermore, TEPL conducts regular safety audits of the X-ray systems provided to customers and issues certifications accordingly.
Suresh explicated, “The TECHNOFOUR detector utilizes an 8-row TDI array detector, renowned for its high-definition and high-speed capabilities. Beyond conventional foreign object detection, we integrate cutting-edge AI technology. This AI feature enables the detection of missing ice cream sticks and ensures their correct positioning. Furthermore, it can identify defects such as cracks or pores in the main body of the ice cream, enhancing overall inspection accuracy”.
Suresh outlined the operational efficiency of TECHNOFOUR X-ray Inspection Equipment in contaminant detection. He highlighted that their X-rays are adept at detecting high-density and medium-density metallic and non-metallic foreign objects, although they are unable to detect low-density foreign objects like hair.
The TECHNOFOUR X-ray system employs a blend of traditional algorithms and cutting-edge AI algorithms. This integration not only enhances the detection of conventional foreign objects but also improves the detection rate of materials such as aluminium foil and relatively thin foreign objects through AI algorithms. This advancement results in a significant boost in accuracy and detection rates.
“Our X-ray generator, detectors, and core components undergo rigorous testing in high environmental conditions to ensure their resilience and reliability”, he added.
Intriguing Conversation with Saikat Ghosh, Sales Product Manager at ISHIDA India Pvt Ltd., Gurugram, on Technology in X-ray Inspection Machines for Ice Cream Production
ISHIDA X-ray inspection machines are renowned for their advanced technology and versatile features that make them suitable for integration into various production processes, including ice cream manufacturing.
ISHIDA X-ray inspection machines are tailored to enhance the ice cream production process in several ways. Firstly, their high-resolution imaging technology ensures exceptional clarity and precision in detecting contaminants like metal, glass, or plastic fragments, even in minute sizes.
Moreover, these machines offer multi-level inspection capabilities, crucial for identifying contaminants both on the surface and within the ice cream product itself, thereby enhancing safety and quality standards. They are designed for seamless integration into existing production lines, offering flexible mounting options and configurations to adapt to different manufacturing setups, thus facilitating easy incorporation of X-ray inspection technology without disrupting workflow. Equipped with automatic rejection systems, ISHIDA X-ray machines swiftly remove contaminated products from the production line, minimizing the risk of tainted ice cream reaching consumers and maintaining product quality and safety.
Additionally, their user-friendly interfaces with intuitive controls and customizable settings enable operators to effortlessly configure inspection parameters and monitor the process in real-time, ensuring efficient operation and minimal downtime. Finally, ISHIDA X-ray inspection machines are designed to comply with stringent food safety standards and regulations, such as HACCP and GMP, providing ice cream manufacturers with confidence in the safety and integrity of their products.
Functioning of ISHIDA, an x-ray inspection equipment, in detecting contaminants
According to Saikat Ghosh, the ISHIDA X-ray inspection equipment excels at detecting both metallic and non-metallic contaminants in ice cream products through its advanced imaging and detection capabilities. He outlined that utilizing high-energy X-rays, ISHIDA equipment easily detects metal contaminants like ferrous, non-ferrous, and stainless-steel particles due to their high density and contrast against the product. Its high-resolution imaging accurately identifies even small fragments for swift removal.
Also, ISHIDA X-ray systems detect non-metallic contaminants like glass particles with ease, thanks to their distinct density, ensuring contaminated products are removed. It can also detect dense materials like stones, which are swiftly identified by ISHIDA equipment, preventing contamination of ice cream products.
He further highlighted that organic contaminant like hair pose challenges due to density differences, but ISHIDA’s multi-level inspection and high-resolution imaging technology, along with automatic rejection systems, ensure reliable detection and removal of contaminants. This upholds product quality, meets food safety standards, and safeguards consumer health.
Sensitivity levels and accuracy rates of x-ray machines
Saikat said that the sensitivity levels and accuracy rates of ISHIDA X-ray inspection machines are renowned for their effectiveness in detecting small metal fragments or foil contaminants typically found in ice cream manufacturing. These machines are designed to offer adjustable sensitivity levels to accommodate various product types and inspection requirements, ensuring comprehensive detection down to millimetre sizes.
Leveraging advanced image processing algorithms and detection techniques, ISHIDA X-ray machines deliver high accuracy rates in identifying metal contaminants, minimizing false positives, and enhancing overall product safety and quality. Rigorous validation and testing procedures, including performance tests with standardized samples, validate the machines’ sensitivity and accuracy, supported by ongoing calibration and maintenance for consistent performance over time.
One of the most important things is that ISHIDA implements robust design and construction techniques to withstand harsh production environments, integrating temperature and humidity controls to maintain optimal operating conditions. Critical components are sealed and protected to prevent damage from environmental factors, while comprehensive testing and quality assurance measures ensure reliability. Continuous innovation and technical support further enhance ISHIDA’s commitment to delivering reliable and efficient X-ray inspection solutions for ice cream manufacturing.
A case study:
During the deep discussion, Saikat disclosed a case study of a leading ice cream manufacturer based in southern India that faced challenges in maintaining high-quality standards and compliance with food safety regulations. These challenges included ensuring the detection and removal of contaminants like metal fragments, glass pieces, and plastic particles from its ice cream products, meeting stringent industry standards such as HACCP and GMP requirements, and minimizing product recalls and liabilities associated with contaminated products reaching consumers.
To address these concerns, the company decided to invest in ISHIDA X-ray inspection systems. After thorough discussions and technical evaluations, the company implemented ISHIDA GN series X-ray inspection systems at critical points in its production line.
The results were significant: the ISHIDA X-ray systems accurately detected and removed various contaminants, enhancing product safety and quality standards. Moreover, integrating ISHIDA X-ray inspection systems into its quality control protocols ensured compliance with industry standards and regulations, strengthening consumer confidence and the company’s reputation for food safety. Additionally, the reliable contaminant detection capabilities of ISHIDA X-ray systems led to a reduction in product recalls, minimizing potential liabilities associated with product contamination incidents.
During an engaging conversation with Prashanth Gowda, Product Manager, Asia Minebea Intec (I) Pvt. Ltd. on the topic of Minebea X-ray Inspection Equipment
Prashanth accentuated that X-ray inspection machines tailored for integration into ice cream production processes must adhere to specific criteria to ensure both product quality and safety.
And some of the important features he defined were:
X-ray Imaging Technology: Employing X-rays to generate internal structure images, these machines can effectively detect various contaminants like metal, glass, stone, plastic, and bone in ice cream production.
High-Resolution Imaging: Crucial for identifying minute contaminants, high-resolution imaging capabilities ensure the detection and removal of even tiny foreign objects from the production line.
Advanced Detection Algorithms: Modern X-ray inspection machines utilize sophisticated algorithms to accurately analyse images, distinguishing between normal product variations and actual contaminants, thus minimizing false positives and reducing product waste.
Variable Energy X-ray Technology: Some advanced machines offer variable energy settings, enabling operators to adjust X-ray penetration depth, making them ideal for inspecting ice cream products with varying densities or packaging materials.
Hygienic Design: To meet food production standards, these machines feature a hygienic design that facilitates easy cleaning and maintenance, utilises food-grade materials, and prevents debris or contaminant build-up.
Integration with Production Line: Seamless integration into the production process is essential, requiring compatibility with existing conveyor systems and real-time inspection of products as they move along the line.
User-Friendly Interface: Intuitive interfaces equipped with touchscreen controls, customizable parameters, and remote monitoring capabilities enhance operational efficiency for effective setup and operation by operators.
Compliance with Regulatory Standards: Adherence to relevant food safety regulations and standards, such as those established by the FDA in the US or EFSA in the EU, ensures compliance and upholds safety protocols within the industry.
Functioning of Minebea X-ray Equipment in Detecting Contaminants
Minebea X-ray Inspection Equipment operates with precision in detecting contaminants within ice cream products. “For metallic contaminants, our machines employ high-resolution imaging technology coupled with advanced detection algorithms to accurately pinpoint metal fragments originating from processing equipment or packaging materials. Through this system, the X-ray equipment distinguishes between the product and foreign objects, promptly alerting operators upon detection.
“While talking about non-metallic contaminants such as glass pieces, stones, or hair, specialized algorithms and imaging capabilities are utilized,” he said.
“Our equipment utilizes variable energy X-ray technology to penetrate materials of varying densities, facilitating effective detection of non-metallic contaminants. Advanced algorithms analyse X-ray images, enabling differentiation between normal product variations and irregularities caused by contaminants. This ensures even minuscule particles of glass, stones, or strands of hair are promptly identified and marked for removal from the production line”.
In fact, Minebae’s X-ray inspection machines are meticulously designed to provide exceptional sensitivity levels and accuracy rates, finely tuned to detect small metal fragments or foil contaminants commonly found in ice cream manufacturing. “Ensuring precise detection is paramount, and we achieve this through various means. Our machines boast sensitivity levels capable of detecting metal contaminants as small as 0.2 mm to 0.5 mm, depending on the model and configuration, guaranteeing the identification and removal of even the tiniest particles that could jeopardize product integrity and consumer safety”, explained Prashanth.
Likewise, Minebae’s X-ray inspection systems consistently deliver accuracy rates exceeding 99% in detecting metallic foreign objects, minimizing the occurrence of false positives and negatives. To enhance sensitivity and accuracy, the company employs advanced algorithms and image processing techniques that analyse X-ray images in real-time, distinguishing between normal product features and irregularities caused by metallic foreign objects. This sophisticated processing capability significantly reduces false alarms while maximizing detection accuracy.
One great feature is that the X-ray machines offer customizable inspection settings, empowering operators to adjust parameters such as sensitivity levels, rejection thresholds, and image processing algorithms to suit the specific requirements of their ice cream manufacturing process. This flexibility ensures optimal performance and adaptability across various product types and production environments.
Working in extreme temperatures or at high humidity levels
Minebae’s X-ray inspection machines are built with robust materials and components, including stainless steel enclosures, to withstand harsh conditions. Temperature and humidity control systems are incorporated to maintain optimal conditions, while sealed enclosures and industry-standard IP ratings prevent dust and contaminants from affecting sensitive components.
Rigorous testing ensures components can withstand prolonged exposure to challenging conditions. Regular maintenance and servicing, including inspections, cleaning, and calibration, are recommended for optimal performance. Before deployment, extensive field testing and validation are conducted to confirm performance.
Case studies
Prashanth: While I cannot provide specific case studies, I can outline hypothetical scenarios demonstrating how our X-ray inspection systems could aid ice cream manufacturers in strengthening their quality control protocols and meeting industry standards and regulations.
So, for example, if an ice cream manufacturer adopts our X-ray inspection system to elevate their quality control procedures, during routine production, the X-ray machine detects a small metal fragment in a batch of ice cream. This early detection allows the manufacturer to halt production promptly, investigate the contamination source, and prevent potentially tainted products from reaching consumers. Such proactive measures not only safeguard consumer safety but also aid the manufacturer in upholding compliance with food safety regulations.
Another ice cream manufacturer utilizes our X-ray inspection system to validate the integrity of their product packaging. The machine identifies instances of improperly sealed or damaged ice cream containers, which could compromise product quality and safety. Early detection enables the manufacturer to take corrective actions, such as resealing or replacing defective containers, before shipping the products to retailers or consumers. This proactive approach helps the manufacturer adhere to industry standards for packaging integrity and product quality.
And supposedly, a third ice cream manufacturer integrates our X-ray inspection system into their production line to prevent foreign objects, like glass shards or plastic fragments, from contaminating their products. During inspection, the machine detects a potential contaminant, prompting a thorough investigation by the manufacturer. They determine that the contaminant originated from malfunctioning equipment on the production line. By promptly addressing the issue and implementing preventive maintenance measures, the manufacturer prevents similar incidents, improves their overall quality control protocols, and ensures compliance with food safety regulations.
Mandar Kulkarni, MD, PARTH SYSTEMS (I) Pvt. Ltd., Pune, takes a deep look at innovations in X-ray inspection machines
Mandar Kulkarni emphasized that the integration of advanced technologies like AI and machine learning has revolutionized quality control protocols in ice cream manufacturing in India.
“Equipped with cutting-edge features, our X-ray inspection machines ensure food safety by swiftly identifying foreign objects in ice cream products. Through automated processes, problematic items are efficiently rejected, maintaining the integrity of the production line. Crafted with an SS304 body and food-grade belts, our systems prioritize hygiene and are complemented by an IP65 structure for easy cleaning. Furthermore, comprehensive reports, including 21 CFR compliance data, provide invaluable insights essential for food industry standards”, he informed.
Operating on the principle of density differentiation, our X-ray machines detect materials denser than ice cream or cone components, encompassing metallic and non-metallic substances. This versatility extends beyond metal detection, covering hazardous materials like stones, glass, and hard plastics, ensuring thorough quality control.
Mandar is confident that, in terms of sensitivity and accuracy, Parth System’s X-ray machines excel, detecting items as small as 0.6 mm with an accuracy rate of 98%, further bolstered by ongoing advancements in machine learning. “What is more, our machines are engineered to withstand extreme temperatures and high humidity levels, making them ideal for round-the-clock operations in diverse production environments. With a track record of 14 years in manufacturing, our commitment to quality and reliability remains unwavering. Customized to suit individual client requirements, each machine is meticulously designed to navigate varying conditions seamlessly, ensuring uninterrupted functionality”.
Mandar stressed that the adoption of X-ray inspection technology elevates ice cream production standards, offering comprehensive foreign object detection while aligning with industry regulations through CFR 21-compliant reporting. As pioneers in the field, we continue to push boundaries, delivering innovative solutions that redefine food safety and quality assurance in the ice cream manufacturing landscape.
The food industry has been using metal detectors for years, but X-ray machines are now addressing major issues. Export products must be scanned for FOD before dispatch, and it’s crucial to check finished and packed products. Using metals in food can lead to lost customers, potential cases, and a loss of brand value. In today’s social media world, these issues can spread quickly, making X-ray machines a small price to invest in.
Final take
Ice cream manufacturers prioritize safety, customer satisfaction, and industry standards. Product inspection and quality control practices are crucial for ensuring consumer safety and satisfaction. Manufacturers must identify and remove contaminants, ensure high quality, and meet client expectations.
However, it’s easy to overlook flaws in products. With consumer behaviour shifting towards quality in food purchases, it’s essential to avoid mistakes. A robust approach to product inspection reduces the risk of subpar products and their repercussions. Having effective equipment, such as an X-ray inspection system, can help in this mission.
X-rays are one of the most comprehensive forms of inspection that manufacturers can access today. It’s also compatible with food products, despite some of the myths you may have heard, making it an ideal choice for a food processing line.
X-rays work by utilizing high-energy waves to penetrate through solid materials, such as ice cream. A radiograph can then be created, allowing you to see into your product and determine anything that shouldn’t be there. It enables you to see the exact location of unwanted items, making their removal easier.
The radiograph image is coloured by density. The less dense an item is, the lighter it will appear in the image, which helps you analyse any oddities. This analysis can also be done in real-time, so you can address the issue before it moves further through production.
X-rays work on packaged ice cream products, including items contained in glass jars. Due to this, it can be a helpful form of final inspection, allowing checking output before it moves into the hands of customers.
X-ray technology can protect output from various contaminants, including those from raw materials, machinery, or user error. This enhances inspection by identifying potential issues and improving the chances of a flawless final product. X-rays offer advanced detection, enabling them to identify contaminants even at a minute level.
Myths still linger around the use of x-rays in food processing, for example, the ice cream industry, but the reality is that they’re completely safe. X-rays utilize radiation (which is often confused with radioactivity).
However, the radiation exposure is minimal, with an x-ray only passing through an item for less than a second to get an image. And ice creams will also not absorb x-rays, so there is no lasting impact. In 1999, a WHO study confirmed that x-rays do not affect food’s nutritional value or safety.