Food Engineering logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • TOPICS
  • EXCLUSIVES
  • MEDIA
  • FOOD MASTER
  • EVENTS
  • RESOURCES
  • EMAGAZINE
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest Headlines
  • Manufacturing News
  • People & Industry News
  • Plant Openings
  • Recalls
  • Regulatory Watch
  • Supplier News
  • PRODUCTS
  • New Plant Products
  • New Retail Products
  • TOPICS
  • Alternative Protein
  • Automation
  • Cannabis
  • Cleaning | Sanitation
  • Fabulous Food Plants
  • Food Safety
  • Maintenance Strategies
  • OEE
  • Packaging
  • Sustainability
  • More
  • EXCLUSIVES
  • Plant Construction Survey
  • Plant of the Year
  • Sustainable Plant of the Year
  • State of Food Manufacturing
  • Top 100 Food & Beverage Companies
  • MEDIA
  • Podcasts
  • Videos
  • Webinars
  • White Papers
  • EVENTS
  • Food Automation & Manufacturing Symposium and Expo
  • Industry Events
  • RESOURCES
  • eNewsletter
  • Custom Content & Marketing Services
  • FE Store
  • Government Links
  • Industry Associations
  • Market Research
  • Classified Ads
  • EMAGAZINE
  • eMagazine
  • Archive Issue
  • Advertise
Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!
AutomationLatest headlinesNew Plant Products

Vision/Inspection/Detection

Fortress Technology Announces Collaboration for Halo Automatic Testing

A frozen potato going through the Halo metal detection system

Image courtesy of Fortress Technology

October 12, 2023

Fortress Technology has announced that two North American customers have collaborated to produce frozen products, including hash browns, fries and onion rings. As a supplier of frozen retail, wholesale and foodservice potato products with global distribution, automation and technology are strong features at the firm’s multiple potato processing plants. 

Alongside scales, shakers, vibrators, graders, baggers, open bag detectors, case packers, sortation conveyors, palletizers and wrappers, located towards the end of multiple processing lines are several dozen highly-sensitive stealth metal detectors. Each is supplied with Fortress customized reject conveyors. 

Metal detectors are equipped with the food safety specialist’s, Halo Automatic Testing, to perform 180 hourly quality control tests on multiple product SKUs. Fortress also designed a secure reject system. The engineering of added safeguards to quarantine metal-contaminated products prevents contaminated products from being reintroduced to the line.

Testing the performance of conveyor metal detectors manually is common. However, the challenge for an operation of this magnitude is conforming to multiple QC testing criteria set by suppliers and switching between multiple product SKUs. In this instance, the frozen products range from smaller consumer-sized bags weighing from 0.5 lbs. to restaurant-sized bulk-packaged bags of french fries exceeding 20 lbs. 

For this processor, customer QC testing standards stipulated that three metal samples—ferrous, non-ferrous and stainless steel—be tested in three different but very exact product positions as the bags of frozen potato products pass through the center of the metal detector aperture. However, performing up to 180 manual tests hourly across multiple high-speed processing lines and checking the performance of the reject system would be labor intensive, disruptive to production and damage the good product. Leading to potentially high product wastage and costly production losses due to downtime.

Rather than relying on QC technicians to perform, document and submit these repeatable inspection tests, Fortress presented a business case to adopt its Halo Automatic Testing solution. Twenty-five systems were shipped to the company’s processing plants in two phases over the last decade. 

The company states that Halo enables the frozen potato processor to program and conform to customers’ performance verification testing program, including independently testing three metals in the leading, trailing and middle of product bags every hour.

Mimicking the disturbance caused by a test contaminant calibrated to the precise size, metal type and speed that product bags pass through the metal detector aperture—up to 150ppm for this potato processor—results in substantial labor savings. It also improves the test quality and accuracy of tests, emphasizes Fortress regional sales manager Eric Garr.

Garr describes the Fortress automated testing process, “The metal detector pulls in data from the infeed photo sensor to determine when Halo must trigger and introduce the simulated test sample in the leading edge, trailing edge and middle of the bag.”  This is always programmed to be in the aperture's exact geometric center to challenge the metal detector's performance. A process that can be extremely challenging to perform manually.

The requirement to perform leading, middle and trailing edge performance verifications was requested by a fast food chain customer. “‘Product effect’ is the main rationale,” explains Garr. He clarifies that bulky frozen products weighing up to 20 lbs. could produce high levels of false rejects. This distorts the results and could lead to a potentially high volume of product waste. “By testing all three metals in three positions ensures the product is not masking the metal samples in any position and also confirms that the reject system is tracking correctly. This is especially important in frozen bulk products when the characteristics might change due to slight thawing during the inspection phase.”

Switching and adapting to different test routines is equally straightforward. “Fortress cleverly engineered Halo so that test routines can be programmed by each SKU to the conformance standards set by individual customers,” explains Garr.

This means that for customers whose standards require one pass of each metal sample every hour, the infeed sensor picks this up and communicates with Halo to perform the verification tests aligned to each product SKU. “Switching between performance verifications all happens on the fly with no impact on production,” exclaims Garr.

Each production line will only halt if the metal detector performance test or reject check fails. To assist with audit traceability, each metal detector automatically logs all the data from each test, which can be extracted by USB and reviewed using Contact Reporter software. They are providing a reliable machine performance and due diligence audit trail.

Fortress added several extra failsafe features to ensure quarantined rejected products are never reintroduced to the processing line. This includes equipping each reject bin with magnetic locks and issuing controlled security card access to authorized personnel only.

With any products rejected during the Halo test, the reject bin automatically unlocks, enabling personnel to move the bags back upstream to be re-inspected. However, to distinguish between a genuine contaminant rejection and a product isolated during the Halo performance verification test, the metal detector bin door automatically remains locked if a reject is already present. “This robust solution provides trained and authorized QA personnel only with access to remove the products in order to conduct further investigations for metal contaminations,” verifies Garr. These added safeguards help to prevent contaminated products from being reintroduced to the line.

For this processing plant, eliminating human errors, eradicating workforce safety risks, labor savings and reducing product waste means Fortress moderately estimates a payback of less than several months on the original investment.
KEYWORDS: contamination food safety frozen food metal detection vision systems

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Global Organic Food & Beverage Market to Grow

    Global Organic Food & Beverage Market to Grow

    With a CAGR of 12.07%, Bonafide Research estimates this...
    Latest headlines
  • skilled MEP worker

    Predicting Food and Beverage Manufacturing Trends for 2024

    The two words that should be kept in mind are labor and...
    Automation
    By: Derrick Teal
  • cleaning and sanitation

    The basics of cleaning and sanitation in food plants

    Sanitation maintains or restores a state of cleanliness...
    Cleaning | Sanitation
    By: Richard F. Stier
close

1 COMPLIMENTARY ARTICLE(S) LEFT

Loader

Already a Registered User? Sign in now.

Subscribe For Free!
  • eMagazine
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Customer Service

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Food Plant Openings and Expansions April 2025

Food Plant Openings and Expansions April 2025

FA&M 2025 in Rewind

FA&M 2025 in Rewind

More Videos

Popular Stories

Conagra Logo

Conagra Brands to Sell Chef Boyardee Brand to Hometown Food Company

Salt

FDA to Amend Standards of Identity to Include Salt Substitutes

Vilter IHP in plant

Industrial Heat Pumps: Sustainable Energy Solutions for Now and the Future

CHECK OUT OUR NEW ESSENTIAL TOPICS

Alternative ProteinAutomationCleaning/SanitationFabulous Food Plants

Food SafetyMaintenance StrategiesOEE

PackagingSustainability

Events

June 5, 2025

Mass Customization Driving Innovation in the Food and Beverage Industry

The food and beverage industry is at the nexus of transformative global manufacturing trends, driving a shift toward personalized, customer-centric solutions. 

June 5, 2025

How Cafe Spice Uses Automation to Propel Private Label

Learn about Cafe Spice’s new, state-of-the-art, highly automated manufacturing facility in Beacon, New York. 

View All Submit An Event

Products

Recent Advances in Ready-to-Eat Food Technology

Recent Advances in Ready-to-Eat Food Technology

See More Products

Plant of the Year

Related Articles

  • New Plant Products

    Metal Detector Testing

    See More
  • SOTO X YAMAGATA MASAMUNE Omachi Kimoto Junmai Daiginjo

    SOTO Sake Announces Collaboration Series with Japan Breweries

    See More
  • Yeast Biscuits International Patent Renaissance Bio

    Renaissance BioScience announces new patents for acrylamide-reducing yeast technology in five countries

    See More
×

Elevate your expertise in food engineering with unparalleled insights and connections.

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Food Master
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!