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In recent years, technological advancements have revolutionized the way we design and manufacture products. X-ray inspection equipment is no exception to this trend. The physical hazard in food, pharmaceuticals and other industries has led to the growing demand for more sophisticated X-ray inspection equipment. This has prompted manufacturers to rethink and redesign their approach towards designing X-ray inspection equipment.
However, the first step in designing any inspection equipment is to understand its purpose and requirements. And when it comes to X-ray inspection equipment, there are several factors that need to be considered.
- The type of product being inspected (food, pharmaceuticals, electronics etc.)
- The size and shape of the product
- The sensitivity and resolution required for accurate detection
- Any regulatory standards that need to be met
With these concerns in mind, let’s explore the process of designing X-ray inspection equipment from the ground up.
Why Design X-Ray Inspection Systems From The Ground Up?
When evaluating potential new x-ray product inspection equipment, it’s important to be aware that many system suppliers will try to adapt designs that are used in general packaging for use in hostile and harsh environments. Although such ‘off-the-shelf’ systems may initially appear cheaper, choosing an x-ray product inspection equipment supplier that designs systems from the ground up will ensure they’ve analyzed the pain points within a specific industry and responded with an advanced solution to meet those challenges.
From sanitary construction to advanced x-ray inspection technology, an x-ray system that’s been specifically designed from the ground up to suit a particular application and environment will ensure it matches your production needs entirely, while helping to facilitate compliance with global food safety and retailer standards.
A custom approach means meeting exactly where and how the line runs, to provide ergonomic, hygienic, and easy-to-use solutions. For instance, in meat, poultry, and seafood inspection, the detection system is designed to avoid harborage points for bacteria, helping with sanitizing and cleaning for optimal food safety.
Overall, choosing an x-ray product inspection equipment supplier that designs from the ground up means they will have a deep understanding of industry regulations and standards. This expertise allows them to create innovative solutions that provide accurate and reliable detection of contaminants while also adhering to strict safety guidelines.
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Key Considerations in Designing X-Ray Product Inspection Systems
Customization for Specific Industries
Different industries have unique challenges and requirements when it comes to x-ray product inspection. For example, the food industry requires inspection equipment that can detect even the smallest foreign objects in their products, such as metal fragments or glass shards, to ensure consumer safety.
In red meat and poultry, for instance, x-ray systems need to be able to detect and reject even the smallest bone fragments, which can be a common contaminant in ground products. This requires highly sensitive detectors and advanced software algorithms that can differentiate between different types of materials.
Seafood products may require systems that can function even with high levels of moisture and salt content, while also having the ability to detect small defects in packaging along with contaminants.
Fruits and vegetables also pose their own challenges, as they may have varying densities and shapes that can make it difficult for traditional x-ray systems to accurately detect foreign objects. This is where customization comes into play, as x-ray equipment suppliers can design specific solutions for each industry’s unique needs.
Resolution and image clarity are also crucial factors to consider when designing an x-ray inspection system. Higher resolution allows for better detection of smaller contaminants, while clear imaging can help identify any defects or inconsistencies in the product.
And of course, speed levels are also a key consideration. Production lines often operate at high speeds, so x-ray inspection systems must be able to keep up without compromising accuracy.
Compliance with Industry Standards
In addition to customization options, x-ray inspection systems help food manufacturers meet food safety management system requirements such as Hazard Analysis and Critical Control Points (HACCP) guidelines which help gain compliance with other standards such as BRCGS.
X-ray inspection aids manufacturers in HACCP plans by serving as preventative measures against foreign body contamination when positioned at critical control points. Additionally, advanced software in X-ray systems can provide traceability, helping identify where a contaminant may have entered the production line. These are two key ways X-ray technology supports HACCP compliance. Moreover, under the FSMA, equipment validation has become a new requirement. X-ray systems come with validation documentation to ensure they meet necessary regulatory standards.
Integration with Production Lines
Another key consideration in designing x-ray product inspection systems is integration with existing production lines.
This requires careful planning and coordination between the x-ray inspection system manufacturer and the production line team. Factors such as conveyor belt speed, placement of the system within the production line, and communication with other equipment must all be taken into account to ensure smooth operation.
Integration also involves considering factors such as space constraints, speed of production, and ease of maintenance, as these can all impact the overall efficiency and effectiveness of the system.
Essential Features for Effective X-Ray Inspection Equipment
High Detection Accuracy and Sensitivity
One of the most crucial features of an x-ray product inspection system is its ability to accurately detect and identify defects or contaminants in products. This requires a high level of sensitivity, ensuring that even the smallest particles or foreign objects are detected.
The accuracy of detection also plays a significant role in reducing false alarms, which can disrupt production and lead to unnecessary waste. X-ray systems with advanced imaging technology, such as multi-energy imaging, can enhance detection capabilities and reduce false alarms.
User-Friendly Interface and Software
The interface and software of an x-ray inspection system should be designed with the user in mind. It should be intuitive, easy to navigate, and provide clear imaging. The ability to easily customize settings for different products also improves efficiency and flexibility. In poultry inspection, for example, the system should have settings to differentiate between bone and metal or other common contaminants.
Durability and Hygienic Design
When it comes to safety, the food industry is under constant scrutiny. Physical hazards in food safety pose a significant risk to consumers and can cause expensive product recalls. Pressure from consumers, governing bodies, and retailers is increasing for stricter measures in production, leading to greater emphasis on the hygienic design of product inspection equipment. Hence, x-ray inspection systems must be designed with hygienic materials that are easy to clean, corrosion-resistant, and can withstand harsh production environments
To reduce the risk of microbiological contamination outbreaks, ease of access for cleaning is paramount in x-ray inspection systems, as is eliminating areas that could harbor and promote the growth of bacteria. Both these challenges should be addressed at the initial design stage. Part of the process for sanitary and hygienic design is ensuring product inspection equipment is easy to inspect once cleaned to ensure the process has been adequately carried out. The latest x-ray inspection systems on the market enable line of sight inspections to be conducted quickly, minimizing downtime and reducing operating costs.
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Optimizing the Design Process for X-Ray Inspection Solutions
POD and Testing
The integration of x-ray inspection systems into the production process can be complex and challenging due to a variety of factors, such as product variability, packaging diversity, and production line constraints. Therefore, it is essential that manufacturers have a thorough understanding of their products and production processes to optimize the design process for x-ray inspection solutions.
Testing is a critical step in this optimization process. Manufacturers should work closely with x-ray inspection equipment suppliers to develop custom solutions that meet their specific needs. This involves conducting rigorous testing to ensure its performance meets required standards and specifications.
While this may add time to the design process, it ultimately results in a more efficient and effective solution for ensuring product safety and quality. Iterative design and testing enables manufacturers to identify and address any potential issues before the system is fully implemented, reducing the risk of costly errors or malfunctions.
This way, the inspection equipment can be thoroughly tested to mimic realistic conditions as best as possible, simulating the production environment and ensuring that it can handle any variations in product size, shape, or packaging. This testing phase also allows for adjustments to be made to optimize the system’s performance, such as fine-tuning detection sensitivity levels.
Designing from the Ground Up for the Red Meat, Poultry, and Seafood Industry
Hygienic design applications are most common in the meat, poultry and seafood industry as a large percentage of these products are provided to consumers in the raw state. However, a growing number of manufacturers outside this industry are turning to hygienically-designed product inspection equipment to provide an extra layer of protection against product recalls.
Therefore it is essential for x-ray inspection machines to adhere to strict sanitary and hygienic design principles. This means using materials that are resistant to corrosion and easy to clean, such as stainless steel and non-toxic plastics.
Systems built to North American Meat Institute (NAMI) standards are designed so that there are no harborage areas where products can accumulate and create a microbiological risk, but the design is also very operations-centric.
A system designed from the ground up for these industries will have a far more attractive total cost of ownership (TCO), a longer life, and will deliver a far bigger incremental value to a customer.
It’s often assumed that product inspection technologies need a ‘hall pass’ when it comes to hygienic design and that a compromise is needed to achieve the desired inspection results to the detriment of the hygienic element. However, that’s a myth. Providing a system is designed from the ground up, to suit a specific industry and application, all the necessary boxes can be ticked along the way.
IP69 and Hygienic Design Are Different – Fact!
Hygienic design is often confused with IP69, but they are not the same thing. An IP69 rating doesn’t mean a system is hygienic. IP69 is an ingress protection rating which ensures that cabinets and enclosures won’t leak when washed down. It has nothing to do with the sanitation of the system and how well it’s been designed in terms of hygiene. In fact, systems are available that are IP69-rated but not hygienically designed. Watch our webinar “Sanitary Design is More than Just a Rating” for more information.
Therefore, it is important for these industries to prioritize hygienic design when selecting product inspection technologies. A system specifically designed for this industry will not only meet necessary hygiene standards but also provide long-term benefits in terms of cost-effectiveness, increased productivity, and improved overall food safety.
As food inspection solutions continue to evolve, it is important for companies to stay informed about the latest technologies and their benefits. By understanding the importance of hygienic design and its impact on food safety, companies can make more well-informed decisions when selecting product inspection equipment for their facilities.
Perfect your product inspection with custom x-ray inspection equipment designed by Eagle PI. Contact us or book a product test today to see how we can help improve your food safety processes. >>> Get in Touch
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