Foreign material contamination (FMC) continues to challenge food producers, even as in-line detection technology advances rapidly. According to the 2025 FlexXray Benchmark Report, nearly 70% of producers plan to invest in in-line detection technology over the next three years. But the data reveals another key insight: technology alone does not guarantee detection.
Advances in in-line machines promise faster, more precise identification of contaminants, but success depends on how that technology is applied, scaled, and interpreted.
Technology Drives Progress, But Has Limits
We mentioned that 70% of producers plan to invest in in-line detection technology over the next three years, with roughly one-quarter of those planning significant upgrades. The other 30% of respondents intend to maintain current technology levels. Those numbers indicate an industry-wide push to modernize in-house detection capabilities.
Investment in technology is unsurprising. The food industry has continuously adopted new tools to protect products as production scales. What is surprising is who is catching contamination first. Across facilities surveyed, humans—not machines—remain the most common identifier of potential foreign material issues, particularly during scheduled checks, line changeovers, and other routine inspection points.
This finding underscores a fundamental truth: detection technology enhances capability, but it cannot replace the situational awareness, judgment, and contextual understanding that human operators provide.
In-Line Inspection Pitfalls to Avoid
Modern detection systems deliver unprecedented speed, sensitivity, and consistency. They have transformed what’s possible on the production line and continue to push the boundaries of FMC mitigation. However, the data highlights several limitations that every producer should understand:
1. You can’t find what you’re not looking for.
Detection technology is only as effective as its configuration and focus. FlexXray has seen instances where contaminants appeared off-schedule or outside standard product parameters—events that traditional setups would have missed.
2. Production speed doesn’t equal inspection scale.
High-throughput lines can challenge detection technology. Just because a system operates at production speed doesn’t mean it inspects every potential risk with the same fidelity. Aligning inspection capability with production throughput is critical to ensure nothing slips through.
3. Not all technology is created equal.
Detection systems can operate as either a red flag—triggering alerts when a threshold is exceeded—or a spotlight, highlighting areas of interest for closer review. Understanding the difference and selecting the right approach for your product and line conditions can be the difference between catching a contaminant early and missing it entirely.
4. Configuration and application matter.
Even advanced systems can fail if deployed generically. FlexXray works with producers to tailor technology to the unique characteristics of the product, the production line, and potential contamination scenarios, ensuring the system is focused where it matters most.
What Makes Detection Successful?
This year’s Benchmark Report reinforces a critical point: technology is necessary, but not always sufficient. Effective FMC control comes from a proactive, holistic approach.
Building a Proactive Response to FMC >>>
By combining right-fit technology, systematic inspection processes, increased operational expertise and continuous optimization based on previous event data, producers can leverage their technology as a useful tool in contamination prevention.
Key Takeaways for Producers
- Invest in technology, but focus on application. Advanced systems only work if they’re configured for our product, line, and potential risks.
- Scale detection with inspection needs. High throughput can challenge accuracy—align your systems accordingly.
- Choose the right detection strategy. Red flag vs. spotlight processes have different advantages.
- Use data to refine and optimize. Continuous improvement ensures technology adapts to changing production conditions and contamination risks.
The 2025 FlexXray Benchmark Report makes it clear: automation cannot replace insight. Technology has advanced significantly, but it is not a one-size-fits-all solution. Detection success comes from a combination of right-fit technology, system design, operational expertise, and ongoing optimization.
FlexXray partners with producers to ensure that detection technology is applied correctly, scaled properly, and integrated strategically, helping you catch the contaminants you might otherwise miss.
