FlexXray has done just that. The Texas-based provider of x-ray and CT inspection technology recently released its third Foreign Material Contamination in Food Benchmark Report. FlexXray surveyed more than 170 food safety and manufacturing professionals across North America to learn more about how the industry identifies, manages and protects against foreign material contamination.

The report focuses on three areas: detection, frequency and mitigation of foreign material events. Notably, roughly three-quarters (74%) of survey respondents say they have a foreign material event at least quarterly, which is the same as 2025. FlexXray noted those that reported a monthly or weekly foreign material event were “more likely to say the problem was getting worse” that facilities with less frequent events.

In terms of type of foreign material, plastic took the top spot, with 37% of respondents reporting frequent challenges with it. Metal followed closely with 34%. This is concerning, as FlexXray notes, since there are “several redundant ways” to discover metal contaminants, but plastic “currently has none that are proven at scale.”

What are the sources of these contaminants? Nearly half of respondents (49%) say they come from supplier or ingredient inputs, followed by packaging (34%), natural sources, such as stone or wood (30%), and organic material (10%), such as bones. Respondents also pointed toward missing o-rings and gaskets (30%) and tool and employee entry (24%).

For those experiencing recurring contamination events connected to supplier or ingredient inputs, FlexRay suggests more frequent or a more technical supplier verification process, even beyond annual or certification inspections.

And how are food manufacturers addressing and preventing contamination events? Most respondents (82%) employ metal detectors, which isn’t a surprise, since this technology has had decades to become an industry standard. Nearly half (47%) use sieves and screens, while 39% use x-ray and 35% use magnetic sorters. Only 14% use optical sorting, and 3% use microwave.

The good news is that the majority of respondents plan to maintain or expand their investment in detection technologies by the end of 2027. In fact, nearly half (49%) said they will have some increase, while 10% said they will see a large increase.

Several respondents (47%) say they’re evaluating x-ray for future use, which could help with concerns over plastic contamination. Respondents are also considering metal/magnet upgrades (18%), AI and machine vision (10%), CT scanning (6%) and optical sorting (5%).

Of course, inspection and detection requirements will vary by company, facility and product line, but as FlexXray notes, it’s crucial that food manufacturers are realistic about their needs and capabilities.

“The producers making real progress aren’t necessarily the ones with the most equipment — they’re the ones willing to look honestly at what their current program can and can’t catch, and adjust from there,” the company wrote.