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Rob Stevens, Market Manager, Mettler-Toledo Safeline Metal Detection
Instant noodles, a staple of convenience, present unique challenges in maintaining food safety and quality. From the raw ingredients to the final packaging, manufacturers can face risks of metal contamination throughout the production process. Metal detection technology offers critical solutions for addressing these risks, helping manufacturers maintain high standards of food safety and product quality.
Raw Material Inspection for Instant Noodles
The journey of producing safe and high-quality instant noodles begins with the inspection of raw materials like flour and oil. These ingredients can carry contaminants such as ferrous and non-ferrous metals or stainless steel, which must be detected and removed before entering the production line. By incorporating metal detection systems early in the process, manufacturers can reduce contamination risks further along in production.
Different metal detection systems are tailored to specific raw materials. Gravity fall systems, for example, are ideal for inspecting bulk powders like flour, while pipeline systems are used for liquids or pastes. Conveyorised systems, on the other hand, can be used to inspect raw materials such as bulk bags of flour before they are used in the mixing process. Installing these systems helps minimise the likelihood of physical contaminants passing into later stages of production where they could be broken down into smaller pieces, making them harder to detect and potentially causing damage to other production equipment.
Explosion Risks with Metal Detection in Flour Handling
One significant challenge in noodle production involves the handling of flour. The dust generated during processing creates a potential explosion risk. Metal detection systems used in these environments must comply with explosion prevention regulations, such as ATEX / IECeX, to minimise these risks while maintaining product safety. In addition, the equipment must be designed with sealed housings, anti-static materials, and proper ventilation to prevent dust accumulation and ignition. Regular maintenance and cleaning protocols are also essential to reduce combustible dust build-up. By adopting explosion-proof designs and following strict regulatory standards, manufacturers can ensure both operational safety and effective contaminant detection without compromising efficiency.
Overcoming Dough Creation Challenges with Advanced Metal Detection Systems
Once raw materials pass inspection, the dough creation process introduces new challenges. Moisture and salt content in noodle dough can interfere with metal detection systems due to the phenomenon known as “product effect.” This occurs when the moisture or salt disturbs the magnetic field, similar to that of a metal contaminant, leading to false rejects, which can cause unnecessary product waste and disrupt production efficiency.
To address this issue, manufacturers use advanced metal detection systems such as Multi-Simultaneous Frequency technology and intelligent algorithms. This combined technology solution enables the system to analyse the product at multiple frequencies simultaneously, filtering out interference from moisture and salt while accurately detecting real contaminants. This significantly reduces false rejects and helps remove only truly contaminated products from the production line.
Maintaining Cleanliness and Metal-Free Production in Noodle Manufacturing
As the noodles progress through stages like sheeting, cutting, steaming and drying, the production environment becomes increasingly complex. Metal fragments from cutting blades also pose an ongoing threat, particularly as equipment wears down over time. In these stages, maintaining cleanliness is critical for protecting the safety of the final product.
Metal detection systems designed with ease of cleaning in mind are essential. Regular cleaning of equipment between production cycles helps prevent cross-contamination, and systems that can be easily disassembled or cleaned in place make it easier to maintain high standards of hygiene. By integrating metal detection systems that are compatible with cleaning protocols, manufacturers can keep their production lines free from contamination while protecting product safety.
Packaging and Final Product Inspection
Once the noodles are packaged, metal detection systems continue to play a vital role in protecting the final product’s safety. During packaging, physical contaminants such as metal fragments can still enter the product, particularly if machinery components wear down. Metal detection systems used in the final stages of production help detect any remaining metal contaminants, helping the finished product to meet safety standards.
Metal detection systems can be integrated with a dynamic checkweigher to provide a more powerful critical control point, by also verifying that portion sizes remain consistent, and preventing under- or over-filling. In addition, some metal detection systems can be integrated with data management software, providing real-time insights into production performance. This helps manufacturers identify and resolve issues more quickly, improving overall production efficiency.
Combating Costs with Early Metal Contaminant Detection
Cost control is a growing concern for manufacturers, particularly as raw material prices fluctuate, and operational costs rise. Early detection of metal contaminants using metal detection technology helps reduce waste, minimises the need for rework and lowers production downtime. By catching metal contaminants early in the production process, manufacturers can reduce the risk of product recalls, which can be both costly and damaging to brand reputation.
Advanced metal detection systems, when combined with integrated data management software like ProdX™ from Mettler-Toledo, allow manufacturers to monitor their production lines in real-time. This not only helps optimise the production process but also provides insights that can be used to improve efficiency, reduce waste and lower operational costs.
Meeting Regulatory Compliance with Metal Detection
Manufacturers of instant noodles must comply with strict food safety regulations, such as the EU’s General Food Law (EC 178/2002) and the US Food Safety Modernisation Act (FSMA). These regulations require manufacturers to implement proactive safety measures to prevent contamination at all stages of production. Metal detection technology plays a key role in meeting these regulatory requirements by detecting and removing metal contaminants, helping producers uphold the safety and integrity of their products.
Rising to the Challenge
Instant noodles, while simple in appearance, require advanced technology to meet the rigorous demands of modern food safety and quality standards. Metal detection systems provide an essential line of defence against metal contamination, helping manufacturers protect their products, maintain regulatory compliance and control costs. By implementing metal detection technology throughout the production process, manufacturers can rise to the challenge of producing safe, high-quality instant noodles that meet consumer expectations.
In addition, metal detection plays a strategic role in supporting continuous improvement within the production environment. Data collected from detection systems can be analysed to identify recurring contamination sources, allowing manufacturers to refine processes and prevent future issues. This not only strengthens compliance with global food safety certifications such as HACCP, FSSC 22000, and ISO standards but also enhances overall production efficiency. For instant noodle producers, investing in advanced detection technology is not just about meeting today’s safety requirements but about preparing for tomorrow’s regulatory and consumer demands. Ultimately, it reflects a proactive approach that protects brands, boosts consumer confidence, and ensures long-term competitiveness in a fast-growing market.