Why Magnetic Separation and Metal Detection is Vital for HACCP & Supplier Audits

One of the greatest challenges to processing industries is ensuring maximum integrity of the finished product. Failure to do so could have disastrous consequences, such as:

• Injury or harm to the consumer
• Expensive product recalls or scrappage or penalty clauses
• Damage to the brand and corporate reputation
• Production stoppages or process downtime
• Damage to process equipment

Hazard & Critical Control Points (HACCP)

HACCP analysis is an internationally recognised system for identifying potential risks and implementing preventative measures to eliminate or minimise hazards. This involves:

• Conducting hazard analysis
• Identifying critical control points
• Establishing critical limits
• Establishing monitoring processes
• Establishing corrective actions
• Maintaining maintenance and incident records

Read our guide to magnetic separators

Product Safety Management & Supplier Audits

It is the responsibility of processors to ensure that the end product; be it food, pharmaceutical, chemical or any other produce, is safe and of good quality. Many retailers now audit their suppliers' safety management systems in line with EU Regulation 852/2005 and ISO 22000. The Global Food Safety Initiative (GFSI) has also specified a number of food safety management systems including SQF, FSA, BRC, FDA, FSSC 22000.

Process Contamination Risks

Process contamination risks come in many forms. The main groups include biological hazards (such as bacteria or viruses), chemical hazards (such as pesticides, additives and allergens) and physical hazards (such as metal, glass and plastics).

HACCP and Metal Contamination

Metal is a common type of contamination in processing industries such as food, pharmaceutical and chemical. It can enter the process through incoming ingredients, equipment wear, or even human error. Typical metal contamination can include screws, bolts, broken machine parts, screen wire, metal tags or fine particle surface wear. Effective separation systems are, therefore, a vital part of HACCP plans, providing protection for consumers, process equipment, and brand or retailer reputation.

HACCP and Separation and Detection

A robust HACCP system with high quality metal separation and detection systems gives many advantages:

• Allows monitoring of incoming goods from suppliers
• Prevents metal contamination from entering the process
• Gives an early indication of machine wear or failure
• Having control points reduces unplanned maintenance and disruption

Types of Magnetic Separation and Detection Systems from Eclipse Magnetics

Eclipse Magnetics offers a comprehensive range of solutions designed for every stage of production:

Magnetic Grids or Grates
Simple, cost-effective protection for gravity-fed lines handling powders and granulates. These grids capture fine ferrous particles that metal detectors physically can’t detect due to the size, making them perfect for bolstering HACCP compliance.

Housed Easy-Clean Magnetic Grids
High-intensity Easy Clean separators housed in a stainless steel fabricated body for hygienic environments. They can be installed at inlet/outlet points, below silos and pre & post machinery, such as rotary valves, mills, sifters, etc. Easy-clean designs reduce downtime and meet food-grade standards. These can be utilised to protect machinery and the material being conveyed.

Auto-Shuttle and Auto-Rota Systems
Fully automated, self-cleaning separators for continuous 24/7 operation. Ideal for high-volume processing where manual cleaning is impractical. Available fully ATEX certified.

Pneumag Magnetic Separators
The Eclipse Magnetics’ Pneumag is designed to be installed in vacuum and pressure conveying pipes (lean/dilute phase), these units are designed specifically for pipelines conveying fine powder material, a typical installation would see Pneumags installed on entry to a silo (tanker discharging) and then inside the factory where the material is being transferred to the point of use. Higher pressure versions are also available for medium phase application at 2-3 barg pressure.

High-Intensity Liquid Traps
Installed on pressurised transfer lines, these separators safeguard liquid products such as syrups, chocolate, and sauces. Option to add a steam/water jacket to keep products such as chocolate in a liquid form.

Metal Detectors/Separators
Metal detectors can be utilised in combination with a magnet separator or stand alone. They can detect and reject contaminants from all metal groups; ferrous, non-ferrous and stainless steels. Units are available for various conveying methods and are also available fully ATEX certified.

Integration with HACCP
Our Range of Magnetic Separators and Metal Detection systems can be strategically placed at Critical Control Points, such as raw material intake, post-silo discharge, pre and post blenders and pre-packaging to ensure compliance with food safety standards like BRC, IFS, and GFSI. Eclipse Magnetics also offer; where applicable; ATEX-certified units for hazardous environments, making them suitable for a wide range of applications.

Explore more related topics to Magnetic Separation 

• Guide to Selecting the Right Magnetic Separator 
• Magnetic Separators in the Sugar Industry
• Magnetic Separators in Chemical Processing
• Magnetic Separators in Virgin & Recycled Plastic Industry

For more information, please contact us  or read more about our range of magnetic separation and  metal detection products