Metal Detectors That Prioritise Productivity

Efficiency in food manufacturing is not just determined by processing rates or conveyor speed. As Fortress Technology highlights at PPMA 2026 (Stand E36), productivity is primarily linked to machine uptime as well as the effort required to operate equipment. By identifying and addressing machine stoppages, outdated inspection CCPs, unnecessary steps and manual reporting activities, food processors could claim back the average 20% of production time lost every week. The equivalent of 52 working days of profitable income every single year!

"Inefficiencies in food production and packing don't just impact a food processors balance sheet. They can also overwhelm your workforce and stifle business agility," highlights Fortress Technology's European Sales Director Phil Brown.

Although many processors view metal detectors as a final safety check for HACCP compliance, these inspection tools can actually be used as sophisticated diagnostic assets. For example, if a metal detector starts to detect metal, this typically indicates that a machine or process upstream is failing.

Identifying opportunities for improvement

Applying a diagnostic approach enables food metal detectors to do more than identify and reject metal contaminants. The information they provide can also help manufacturers monitor the health of the wider production line. By highlighting potential issues, this approach can support improvements that save energy and reduce product waste.

Consultative site visits by Fortress Technology consistently identify five key productivity priorities for food manufacturers - performance, product, people, process and profit. Considering each of these areas helps manufacturers identify where improvements can be made across their operations.

A recent customer assessment illustrates how this approach can work in practice. Following a short walk around the customer's facility, Phil and the team identified several opportunities for improvement and prepared a concise report outlining their findings. The customer subsequently ordered several Fortress Technology Stealth Metal Detectors.

The order included two replacement inline gravity metal detectors to inspect ingredients and seasonings before they were weighed into packaging. It also comprised two retail-specification conveyor metal detectors to carry out a final quality check.

Controlling uncontrollable costs

Unplanned downtime can be one of the largest drains on business performance. Data compiled by IDS-INDATA in 2025 suggests that hygiene protocols and equipment age are currently the primary cause of machine stoppages in UK food processing facilities.

By combining regular sanitation, calibration, inspection, preventative maintenance and timely repair, manufacturers can help ensure equipment and inspection systems operate at peak efficiency.

Analysing the type of metal detected can provide additional insight to support overall productivity. Distinguishing between ferrous, non-ferrous, and stainless steel enables maintenance teams to pinpoint the upstream process or machine that is failing, highlights metal detection expert Mike Bradley.

This technical insight allows for targeted troubleshooting before a catastrophic breakdown occurs. Most importantly it transforms a reactive safety tool into a proactive maintenance strategy that minimises unplanned downtime.

Data driven optimisation

Documentation is the ultimate proof of safety. Maintaining rigorous records provides evidence that safety procedures have been followed. Conversely, failing to keep accurate records can lead to failed audits. It can also create systemic liability, potentially resulting in Class I recalls and damaging brand equity and customer trust.

Process integration and networked communications strengthen this documentation-led approach by providing seamless connectivity across production systems. They can immediately highlight inefficiencies and potential bottlenecks across production lines, helping manufacturers identify issues quickly which can minimise machine downtime.

Automating performance verifications

Manual testing of metal detectors is labour-intensive, costly and prone to human errors. Replacing human-dependent testing with a repeatable, technology-driven approach enables food manufacturers to verify detection capabilities consistently under actual production conditions. Automating these tasks also reduces the burden on production staff.

"Automatic testing tools when implemented alongside HACCP plans add a repeatable verification layer that ensures every metal detector is functioning as expected, without requiring human intervention," expands Mike Bradley.

Corson Grain Products is one of the most recent Fortress Technology customers to activate Halo Automatic Testing on its new Stealth Gravity Metal Detector. Installed in a difficult to reach part of the factory, manual tests on gravity applications of this nature can take over 10 minutes to complete. Halo reduces the test time to less than 30 seconds, making the entire process considerably more efficient.

By integrating Halo Automatic Testing, Corson Grain Products strengthened and future-proofed its inspection program. This ensures that testing plans remain robust and adaptable as compliance and verification standards evolve within the industry.

"Using reporting technology supports manufacturers to cultivate a more positive work culture. When manual, repetitive tasks are reduced, staff gain the mental capacity to explore new ideas and creative solutions," adds Phil Brown. This shift fosters a more productive workplace defined by innovation and engagement rather than fatigue and repetition.

As production costs continue to squeeze the bottom line, Fortress Technology encourages processors to evaluate their inspection infrastructure with a critical eye. Investment decisions should consider more than the immediate demands of current output quotas; they should also address the efficiency of the processes supporting production. "More often than not, productivity is compromised by inefficient processes, not people," states Phil.