In food manufacturing, production lines are equipped with various sensors that continuously measure and adjust critical variables—pressure, flow rate, weight, solids content—to ensure consistent product quality and efficient operations. These instruments don’t just sound alarms; they feed a stream of data that enables real-time decisions and course corrections.
Yet when it comes to detecting foreign material, the tools used most often—metal detectors and conventional X-ray systems—still operate as signaling devices, not measurement tools.
They produce a binary result: pass or fail.
While that simple alert can be useful, it often lacks the depth needed to fully understand a contamination event. And in fast-moving production environments, those signals can be easy to dismiss: “It’s just packaging.” “It’s too sensitive.” “It always does that on this product.”
As a result, lines are sometimes run with reduced sensitivity—or with detection devices turned off altogether. This compromises safety and can significantly increase the size of a product hold when issues do occur.
The reality is, this pass/fail model puts a burden on food processors to interpret what that signal means—and to investigate it with rigor.
FlexXray’s Chief Product Officer Kye Luker discusses X-ray technology as a signaling vs. measurement device.
X-Ray Technology as a Measurement Device
What if our detection systems worked more like the other devices on the line—providing continuous data instead of a flashing red light?
That future isn’t far off. And in many ways, it’s already taking shape.
New technologies, including photon-counting X-ray detectors, are enabling systems to measure not just if a contaminant is present, but how much material is there, what energy level it reflects, and whether those readings are changing over time. This opens the door to richer insights—enabling food safety and quality assurance teams to pinpoint issues faster, isolate smaller batches for hold, and respond more confidently.
Consider this scenario: A bearing in a stainless steel ribbon blender is beginning to fail. Early on, it might release tiny, undetectable metal shavings. As the issue progresses, those fragments grow, eventually triggering a signal in the X-ray unit. If we had continuous measurement data, we might have noticed the subtle change in background noise long before a full failure—shrinking our hold window and preventing further risk to consumers.
FlexXray: Your Partner Between Signal and Measurement
At FlexXray, we sit in the critical middle ground between signal and full-scale measurement.
Our inspection services offer highly sensitive imaging, enhanced material detection capabilities, and detailed reporting that supports food manufacturers when their in-line systems flag an issue. While those systems may not yet provide continuous insight, FlexXray bridges the gap—helping teams isolate risk, verify product safety, and minimize waste.
We also actively evaluate cutting-edge technologies like photon-counting detectors, hyperspectral imaging, and microwave detection, so we can help you stay ahead of what’s coming next. Our goal is to help the industry evolve toward smarter, data-rich solutions that drive better decisions.
The key to protecting your brand isn’t just catching contaminants—it’s understanding the full picture behind each signal. As X-ray systems become smarter and more sensitive, they’ll do more than trigger a rejection. That means:
- Smaller, better-defined hold brackets
- Faster issue identification
- Fewer recalls and less wasted product
- Stronger support for FSQA teams
Until then—and even as that future arrives—FlexXray is here to help you navigate the space between signal and measurement.
Ready to rethink your approach to foreign material detection? Connect with us to see how smarter technology and a trusted partner can make all the difference.
