How Food Producers Can Rethink Foreign Material Inspection
Featured on: Food Safety Matters, a Food Safety Magazine podcast
Speaker: Kye Luker, Chief Product Officer
Foreign material contamination (FMC) continues to be one of the most persistent challenges facing food producers today. In this episode of Food Safety Matters, Kye Luker, Chief Product Officer at FlexXray, joins the conversation to discuss why FMC remains such a difficult issue, the evolution of X-ray inspection technology, and how producers can rethink their approach to FMC incidents.
Key Takeaways
- FMC is driven by production speed, complexity, and supplier variability
- Traditional inspection methods—especially metal detection—aren’t enough
- FlexXray offers unmatched expertise, specialized technology, and capacity
- External inspection is not just for emergencies; it’s a strategic advantage in quality
- X-ray technology continues to evolve, and producers must evolve with it
Why FMC Remains a Challenge
Today’s food production environments are moving faster than ever. With just-in-time inventory strategies and increasing demand, manufacturers are operating at extreme speed and scale. But with that speed comes complexity, and with that complexity, risk(s). A single contaminated ingredient, even something as minor as a spice in a breading blend, can cause major product holds or recalls.
While many processors still rely on traditional metal detection, these systems have seen little advancement over the past 50 years. And while X-ray inspection technology has matured, many in-line systems are limited in their ability to detect small or low-density materials. As Kye mentioned, “In-line equipment is really just a signaling device. It tells you there’s a problem—but doesn’t give you the clarity to solve it.”
How Third-Party Inspection Providers Fill the Gap
FlexXray was built to slow the process down and take a different approach. Our model is designed around three key advantages:
- Expertise
The FlexXray team is trained to understand the nuances of X-ray inspection—something most processors rely on vendors to provide.
- Technology
FlexXray’s systems are optimized to detect materials that in-line systems can’t catch at high speeds. For example, slowing inspection from 100 feet per minute to just 20 dramatically improves image clarity and accuracy.
- Capacity
With the ability to process large volumes through strategically-located facilities, we help get product back into the supply chain faster.
External vs. In-House Inspection
In-house systems are optimized for speed, but not always accuracy. You lose the ability to find small things when you’re running full production speeds. In contrast, FlexXray provides high-resolution inspection under ideal conditions. Our trained teams and facilities give producers the confidence that nothing slips through the cracks.
FlexXray becomes a true partner in a processor’s quality system—there in case of an emergency, and ideally, already integrated before one happens. Manufacturers can use FlexXray’s data to validate supplier quality, ensure proper release protocols, and support new product launches.
“We’re seeing more companies bring us in during line validation or supplier onboarding,” Kye explains. “It’s not just about emergency inspections. It’s about building a better system from day one.”
Innovation on the Horizon
The X-ray landscape is evolving rapidly. Just five years ago, certain contaminants were thought to be impossible to detect with X-ray. Today, advancements like computed tomography (CT) and higher-density imaging have changed what’s possible.
These innovations are particularly valuable in a world of viral product launches, rapidly scaling co-manufacturing partnerships, and stricter supplier expectations. As processors push for speed and consistency, external inspection services like FlexXray are becoming an indispensable part of the toolkit.
Ready to learn more? Get in touch with your new inspection partner today!
