1.

Introduction
 
1. Policy
Glass and Brittle Plastic:
Companyis committed to reduce, and where possible eliminate, the potential of Glass, Brittle and
Hard Plastic, Ceramics and Similar Materials contamination in the products, which are being
processed or handled at the company’s processing and storage areas.
Companywill take all possible precautions to prevent such contamination. As a consequence, the
aim of this policy is to introduce preventive measures and good manufacturing practices to
ensure that risks of such contamination are minimized.
Companyhas not permitted the use of glass, plastic and ceramic items in processing and storage
areas. Glass windows are not used within production and storage areas. Lighting fixtures
installed within production and storage areas have appropriate shelter in case of accidental
breakage of lightening source.
 
Wood:
In areas where a risk assessment has identified the potential for product contamination from
wood, the use of wood will be excluded. Where the use of wood cannot be avoided, and the risk
is managed, the condition of wood is regularly checked to ensure it is in good condition and
clean.
 
Metal:
The use of sharp metal implements, including knives, cutting blades on equipment, needles and
wires will be controlled. This includes suitable controls both into and out of the plant and
warehouse, and safe disposal.
Snap-off blade knives are not permitted in processing and storage areas.
Procedures will be developed and implemented that non-production equipment and maintenance
tools would not be left in a position that allows them to contaminate the product.
 
1. Scope
The scope of the Foreign Body Detection Policy only applies to machine product items. Some
hand packed items are subject to manual inspection.
 
1. Legal definition
A physical hazard in food is any extraneous object or foreign matter that may cause illness or
injury to the consumer.
 Foreign objects smaller than 7 mm rarely cause trauma or serious injury except in
special high-risk groups, such as infants, surgery patients and the elderly.
 Glass is the most frequently reported foreign material in food to cause illness or
injury.
 FDA Health Hazard Evaluation Board conclusions in cases of foreign materials
(1972–1997) found that 56 percent of objects 1–6 mm in size might pose a limited
acute hazard. For objects greater than 6 mm, only 2.9 percent were judged to
present no hazard.
 
1. Types of Physical Hazards
The type of foreign objects in food affects the technology needed to detect it:

1. Glass: Sharp glass contamination often occurs during filling processes in glass
containers if a container is accidentally broken. Another source, but less frequent,
is light bulbs broken during building maintenance.
2. Metal: Sharp metal objects may include screws and equipment splinters, blades,
broken veterinary needles, fragments and clippings of prior processing
procedures.
3. Plastics: Soft and hard plastics may come from packaging material of an
intermediary production phase.
 4. Wood: Wood splinters may have their origin at the farm or may come from
handling wooden pallets.
5. Stones: Small stones are more common in crops like peas or beans contaminated
during harvest.
 
1. Metal Detection
Based on risk assessment the Food Safety Team has confirmed that metal detection is a crucial
control measure to some processes to prevent any metal which may come in contact with the
product (loose nuts and bolts etc.) from being sent out to the customer. Metal in product will
affect the company’s reputation and may seriously injure the consumer if swallowed. A sensitivity
and timing check is carried out before starting production and every hour throughout production
to ensure the metal detector continues to work effectively. This procedure describes the testing
procedure of metal detectors.
 Ferrous is both magnetic and conductive so easily detected.
 Non-ferrous is non-magnetic but a good or excellent conductor so relatively easily
detected.
 Stainless steel is the most difficult contaminant to detect as it is usually non-
magnetic and a poor conductor. Stainless steel comes in various grades, some of
which are magnetic varying to totally non magnetic. Their conductivity also varies,
but is generally low. Both of these factors contribute to poor detectability.
The test sticks used are:
3.0 mm ferrous test stick
3.0 mm non-ferrous test stick
4.0 mm stainless steel stick
The QC technician and the production operator are responsible for carrying out metal
detection checks every hour. The metal detection checks are audited every month by the Quality
Assurance Manager.
Monthly inspections, maintenance and calibration are done by the equipment manufacturer,
authorized factory representative or trained contractor. 
 
1. Test
1. Place the wand or stick on the on the tubular plastic holder. In the same direction
that the conveyor runs.
2. Pass the wand and the tubular holder through the metal detector and verify if the
system is activated.
3. Repeat the same process with the rest of sticks.
4. Record the test on to the Micro-Baggers Metal Detector Log or Tunnel
Heater Metal Detector Log.
 
Rejected Products
1. Rejected packs must be investigated.
2. Pass the rejected products through the detector positioned in the same way as
they were when they originally went through the search head.
3. Then pass the same products through the search head twice more, each time
positioned in different ways.
4. If at any stage the products are rejected again, it is essential to find the
contaminant and identify it, and take any necessary action to ensure similar
contamination does not recur.
5. Fill out the Incident Report.
6. In case of false positives due to high moisture in the sample, record the number of
rejected packs per shift in the comments section, form QMR025.
 
1. If the metal detector fails to reject the testing wands
1. Stop the line and notify immediately to the supervisor.
2. Isolate all products produced since the last satisfactory test and re-screen them,
using another detector functioning to the same standard as the original system on
test, or the same detector after being recalibrated.
 3. If the product cannot be rechecked, it will be put on hold to be metal detected later.
4. Additionally, all products produced since the last clear metal detection check must
be placed on hold and rechecked.  The details must be recorded on to the Micro-
Baggers Metal Detector Log or Tunnel Heater Metal Detector Log.
5. The stock may be transferred to the warehouse if there are stored, but must be
retained in a segregated area.
6. The pallets must be clearly labeled with “do not use” tape and the notation NOT
METAL DETECTED written on the Pallet Label.
7. As product from each pallet is prepared for passing through the detector, the
existing pallet label must be removed and the pallet number, product and best
before code information, transferred to a new label.
8. When the complete pallet has been passed through the detector the operator must
sign the new label and enter the date and time.  The completed label is then
attached to the pallet.
9. A master list of pallets must be completed indicating sequential pallet numbers,
product description, date inspected (metal detection check) and signed by
supervisory management.
10. Any product failing the metal detection check must be isolated and retained for
inspection by the QA Manager.
 
1. Metal Detector Operation and Training
1. Only authorized personnel are permitted to operate the Metal Detector when they
have fully completed their training.
2. Only authorized and trained engineers are permitted to adjust metal
detector settings.
3. Records of training are fully documented and held in the Training Program Log.