Reducing Costs and Protecting Food Safety with Physical Contamination Detection

When Chewters Chocolates in Canada made the shift to automate its production and packaging line to become more productive and efficient, the company looked to advanced contamination detection technologies.

What they discovered was that a move to inline metal detection and x-ray inspection systems didn’t just help maintain compliance - it also helped them avoid false rejects, reduce product waste, confirm quality control and supported their rapid scale-up to meet growing market demand.

Twin Pressures: Food Safety and Operational Cost
Physical contamination - whether from metal, calcified bone, glass or dense plastics - remains one of the most common causes of food recalls globally.

At the same time, manufacturers are being asked to do more with less. Ingredient prices, energy costs, labor shortages and tariffs are squeezing margins.

While packaging formats evolve and retailers demand consistent product quality at speed. This has forced many manufacturers to re-evaluate their approach to risk and efficiency.

Rather than treating contaminant detection systems as purely protective measures, more companies are asking: can this technology help me prevent waste? Avoid overfilling? Detect equipment faults early? Meet retailer codes of conduct more reliably?

Contamination Detection: A Multi-Purpose Investment
Modern contamination detection technologies offer benefits far beyond detecting and rejecting foreign bodies; they help to reduce product giveaway and protect bottom line profits.

When connected with other management systems, they can help optimize line performance and support traceability during audits. In short, they’re part of the broader efficiency toolkit - not just a safety net.

Where Contamination Detection Belongs on the Line - and Why It Matters
Physical contamination detection equipment typically sits at Critical Control Points (CCPs): inspecting raw materials at the start of production and then throat metal detectors at bagging stations or pipeline detectors for liquids, pastes or slurries prior to packaging, to provide early intervention.

X-ray inspection systems are often used at the end of the line before or after final packaging. Catching an issue closer to the point of origin can prevent full-batch losses or line stoppages further downstream.

For example, integrating a gravity fall metal detector to inspect powdered or granular ingredients prior to processing allows manufacturers to reject contaminated product before further value is added, reducing both product and packaging waste.

Similarly, placing x-ray systems mid-line - particularly on high-speed operations - helps isolate problems before value is added through secondary packaging or labelling.

Cleaning, Maintenance and Operational Efficiency
Cost isn’t just lost through product giveaway or false rejections - it’s also in maintenance time, cleaning routines and machine downtime. Older detection systems often require more frequent calibration and labor-intensive cleaning.

Cost Avoidance Through Better Detection and Data
The direct cost of a recall can reach millions - especially when it involves high-risk products or multiple SKUs.

“Prevention remains the strongest defence against product recalls,” said Chris Plant, Head of Market Management, Mettler-Toledo. “Effective foreign body detection systems not only reduce risk but also demonstrate that a manufacturer is acting responsibly to protect public health.”

Beyond recall avoidance, foreign body contamination detection technologies contribute to cost protection in subtler ways. Systems that detect trends such as thawing product due to issues upstream, or those with the ability to predict  potential maintenance issues - like a slowly degrading blade - can prevent expensive, large-scale issues from developing.

Supporting Audit Readiness and Traceability
Contamination detection systems also play a crucial role in compliance - not just by rejecting physical contaminants, but by providing traceable data for regulators. Modern systems can automatically log reject events, performance monitoring tests and machine status, reducing paperwork and accelerating audit prep.

Further, these systems can play a direct role in compliance with internationally recognized food safety standards, including the BRCGS, which highlights physical contaminant control as a core requirement for certification.

“Contamination detection systems are essential in demonstrating due diligence,” says Mercè Sánchez, Food Programme Manager, BRCGS. “Being able to provide consistent, documented evidence of physical contaminant control is a core requirement for certification audits”.

Automated testing features, such as programmable test schedules, step-by-step instructions and digital test result archiving, help offer consistency across shifts. This supports both internal quality benchmarking and external verification during third-party inspections.

Manufacturers can take product safety to the next level with data management software such as ProdXTM from Mettler-Toledo. This software monitors, reports and collates all product inspection activities in real-time. Not only does this save manufacturers’ time and money by automating quality control processes, it helps with regulatory compliance, auditing, and traceability which is essential for brand protection in the event of a recall. 

Protecting What Matters Most
In today’s manufacturing environment, every decision must contribute to both compliance and competitiveness. Contamination detection technologies are increasingly valued for their impact on productivity, traceability and bottom-line performance.

Whether avoiding waste, preventing recalls or preparing for the next audit, metal detection and x-ray inspection systems are now core to operational strategy - not just food safety. And in a market where every gram, second and unit counts, they may well be the smartest investment a manufacturer makes.