Metal Detection Critical Control Point Procedure

Purpose. Sets out how metal detectors on packing lines are tested, monitored, recorded and verified, and what to do when a test fails or product is rejected.

1.Critical limit

Every metal detector on a packing line is a critical control point in the HACCP plan. The detector must detect and reject the ferrous, non-ferrous and stainless steel test pieces specified for that line at the sensitivity recorded in the HACCP plan. Product that has not passed through a functioning metal detector must not be released.

2.Testing frequency

The operator must test the detector with all three test pieces at line start, every hour during production, at every product change and at the end of the run. Each test must be recorded in the critical control point monitoring log with the time, the test pieces, the result and the operator's initials.

• Line start
• Every hour
• Every product change
• End of run

3.Test method

Each test piece is passed through the detector in the product, at the leading edge, the centre and the trailing edge of the pack, and the reject must operate on every pass. The operator must confirm the rejected pack has been removed from the line and returned to the test station.

4.Test failure

If any test piece is not detected or rejected, the operator must stop the line, place all product packed since the last passed test on hold with a hold label and notify the line leader and the quality assurance officer. The detector must not be returned to service until it has been checked, adjusted or repaired and has passed a full test. The event must be recorded in the non-conformance register.

5.Product rejects

Any pack rejected during production must be examined by the line leader. If metal is found, the source must be investigated immediately, the line inspected for damage and all product from the batch placed on hold until the investigation is complete. Every reject must be recorded in the monitoring log.

6.Verification

The quality assurance officer will verify the monitoring log every shift and sign the verification. Test pieces will be checked against their certificate monthly and detectors will be calibrated by engineering to the schedule in the calibration register.