Introduction

Food safety is non-negotiable in the poultry industry. Contaminants such as metal fragments, bone shards, and dense plastics can jeopardize consumer health, damage brand reputation, and trigger costly recalls. That’s why metal detection and x-ray inspection systems are vital components of any modern poultry processing line. These technologies work silently in the background to catch invisible hazards — but understanding how they work and when to use each is critical for compliance and operational efficiency.

This article explores the principles, equipment types, applications, limitations, and best practices associated with metal detectors and x-ray machines used in poultry processing.

Why Foreign Object Detection Matters

• Broken blades or machinery parts during deboning or portioning
• Metal tags or fasteners from transport crates or bird ID systems
• Bone fragments missed during deboning
• Consumer-detectable hard plastics or rubber (e.g. gloves, seals)

In most countries, food safety regulations require detection systems to catch these hazards before products reach consumers. Failing to detect foreign bodies can lead to:

• Expensive product recalls
• Lawsuits and brand damage
• Export restrictions or failed audits
• Loss of retailer contracts
• Criminal liability in extreme cases

Metal Detection in Poultry Processing

How Metal Detectors Work

Metal detectors generate a high-frequency electromagnetic field within a detection tunnel. When a product containing metal passes through the field, it disrupts the signal and triggers a reject mechanism.

• Ferrous metals (iron-based): easiest to detect due to high magnetic permeability
• Non-ferrous metals (aluminium, brass): detectable but harder
• Stainless steel: most difficult to detect, especially if non-magnetic (e.g. 316)

Types of Metal Detectors

• Conveyor Metal Detectors: Products move on a belt through the detection tunnel, often with reject bins or air-blast pushers
• Pipeline Metal Detectors: Used for slurry products like ground poultry; paired with pumps
• Gravity-Fed Metal Detectors: Used for powders or granular ingredients

Pros of Metal Detectors

• Cost-effective
• Fast, minimal footprint
• Effective for unpackaged products
• Detects ferrous and non-ferrous metals

Limitations

• Can’t detect non-metal contaminants (glass, bone, plastic)
• Affected by foil packaging and moisture
• Sensitivity impacted by temperature and salt content

X-Ray Inspection Systems

How X-Ray Systems Work

X-ray systems capture high-resolution images of product density. Materials with different density from the product — like bone, glass, or metal — are detected as anomalies and rejected.

Where X-Ray Excels

• Works with metallic packaging
• Detects fine bone fragments in breast fillets or nuggets
• Detects rubber, plastic, Teflon
• Checks component placement (e.g. correct nugget count)

Types of X-Ray Equipment

• Conveyor X-Ray Systems: For tray-packed or bulk products
• Compact X-Ray Units: Great for whole birds or cut parts
• Multi-Lane X-Ray Machines: Scans multiple lines at once

Pros of X-Ray

• Detects wider range of contaminants
• Works with foil packaging
• Captures fill-level and integrity data
• Compact models now available

Limitations

• Higher upfront cost
• Requires safety precautions
• More complex maintenance
• May struggle with low-density materials

Metal Detector vs. X-Ray: Which Should You Choose?

Feature	Metal Detector	X-Ray System
Detects Metal	✅ Yes	✅ Yes
Detects Bone	❌ No	✅ Yes
Detects Plastic/Rubber	❌ No	✅ Sometimes
Compatible with Foil	❌ No	✅ Yes
Cost (Initial)	£	£££
Maintenance	Low	Medium–High
Best Use	Unpackaged raw poultry	Packaged or complex goods

Best Practices for Using Detection Equipment

• Calibrate frequently for sensitivity
• Use certified test cards
• Automate rejection mechanisms
• Log all detections, calibrations, verifications
• Train staff on alarm response

Regulatory Compliance

Detection systems support compliance with:

• HACCP
• IFS / BRCGS
• USDA / FSIS / EU Hygiene Package

Modern systems integrate into traceability and SCADA for full audit trails.

Final Thoughts

Whether you're a small or large poultry processor, metal detection and x-ray systems are essential. They protect consumers, ensure compliance, and maintain brand trust.

Evaluate your line’s highest-risk points and choose the system(s) that suit your packaging and product type.

If you're sourcing metal detectors or x-ray machines — new or refurbished — contact us today. We’ll help find the right system for your facility and budget.