FA-MD & FA-CW Series: Integrated Metal Detection & Checkweighing for Food Processing Excellence
For bulk food processors—from cocoa bean roasters to snack ingredient manufacturers—unpackaged, free-flowing production stages pose dual risks: metal contamination (from equipment wear or raw material impurities) and weight inconsistencies. These threats can trigger costly recalls, HACCP non-compliance, and eroded trust from brand partners. That’s why North American Cocoa Producers Ltd. (NACP)—a leading supplier of chocolate chips and cocoa derivatives to North America’s top bakeries—partnered with Shanghai Fanchi-tech Machinery Co., Ltd. to deploy our FA-MD Series Bulk Gravity Metal Detector and FA-CW Series Checkweigher—a seamless integrated solution engineered to address the unique challenges of bulk processing, as validated by industry-leading workflows.
The Challenge: Securing Bulk Flows & Ensuring Compliance
Before partnering with Fanchi-tech, NACP faced critical pain points identical to many bulk food processors:
- Free-flowing cocoa beans and semi-finished chocolate chips risked metal contamination across unpackaged stages, with no consistent detection at key process points.
- Manual weight checks post-processing were slow and error-prone, leading to 5% of finished batches failing weight compliance standards.
- Legacy equipment lacked automated validation and data tracking, making HACCP audits cumbersome and reactive.
- Metallic final packaging meant post-sealing detection was impossible—requiring airtight pre-packaging inspection.
Integrated Solution: FA-MD Series (Metal Detection) + FA-CW Series (Checkweighing)
Fanchi-tech’s dual-system approach embeds safety and precision into NACP’s bulk workflow, mirroring the rigor of top-tier processing standards:
1. FA-MD Series: Gravity-Fed Metal Detection for Bulk Flows
Engineered for seamless integration into free-flowing bulk processes, the FA-MD Series eliminates contamination risks at critical stages:
- Gravity-Fed Design: Product flows via food-grade pipes directly through the FA-MD’s search head aperture—no disruptions to throughput, perfectly aligning with unpackaged processing rhythms.
- Precision Detection Mechanism: Inside the search head, three coils deliver industry-leading sensitivity:
- A central transmitter coil (powered by a high-frequency oscillator) generates an electromagnetic field (operating frequency similar to radio broadcasting).
- Two symmetric receiver coils (equidistant from the transmitter) cancel induced voltages when balanced—producing zero output if no metal is present.
- Metal contaminants (ferrous, non-ferrous, stainless steel) disrupt the field, triggering an unbalanced signal. A high-speed reject mechanism diverts contaminated product in milliseconds, minimizing waste of high-value ingredients.
2. FA-CW Series: High-Accuracy Checkweighing for Bulk Batches
Complementing the FA-MD Series, the FA-CW Series ensures weight compliance before final packaging:
- Bulk-to-Pack Precision: Calibrated for post-processing weight verification, the FA-CW handles batch sizes from 5kg to 50kg with ±1g accuracy, detecting underweight or overweight batches before they reach the packaging line.
- Seamless Line Sync: Adjustable conveyor speeds (10–60m/min) match NACP’s bulk flow rates, while 100+ product profile storage allows quick switches between SKUs (e.g., chocolate chips, cocoa powder).
- Auto-Reject Integration: Non-compliant batches trigger a synchronized reject mechanism, working in tandem with the FA-MD Series to remove defective product without halting production.
Strategic Placement: HACCP Critical Control Points (CCPs)
Following industry best practices, Fanchi-tech positioned the FA-MD and FA-CW systems at two non-negotiable CCPs:
1. Raw Ingredient Inlet (FA-MD Series)
Bulk cocoa beans are gravity-fed from silos through the FA-MD before roasting/grinding. This catches contaminants early—rejecting impaired product before value is added and preventing impurities from dispersing into larger batches. In HACCP terms, this is a foundational control point, eliminating risks at the source.
2. Pre-Packaging Final Check (FA-MD + FA-CW Series)
Between the vertical form-fill-seal (VFFS) machine and multi-head weigher, the two systems work in sequence:
- The FA-MD performs a final metal detection check (critical for product destined for metallic packaging, where post-sealing inspection is impossible).
- The FA-CW verifies batch weight compliance, ensuring consistency for brand partners and regulatory standards.
This dual check provides a “last line of defense” before products are sealed, guaranteeing both metal-free and weight-compliant output.
HACCP Compliance & Data-Driven Monitoring
To streamline audits and proactive maintenance, both systems integrate Fanchi-tech’s industry-exclusive features:
- Fanchi Performance Validation (FPV): Automatically prompts operators to conduct sensitivity (for FA-MD) and accuracy (for FA-CW) checks at pre-set intervals (every 4 hours at NACP). A yellow indicator light signals pending tests; a red light activates (and logs the lapse) if uncompleted within 30 minutes—ensuring no gaps in compliance.
- Fanchi SmartNet Centralized Data System: All FA-MD and FA-CW units are networked to a central PC, auto-collecting test results, reject logs, and weight data. This mirrors the power of enterprise-level monitoring, allowing NACP to:
- Track contamination trends (e.g., a spike in rejects signals equipment wear).
- Store audit-ready records for FDA, HACCP, and SQF 2000 compliance.
- Analyze weight data to optimize processing efficiency and reduce waste.
Customer Verdict: “Seamless, Proactive Control”
“The FA-MD and FA-CW Series transformed our approach to safety and compliance,” says Mark Thompson, NACP’s Engineering & Maintenance Manager. “Before Fanchi-tech, we were reactive—chasing issues after they occurred. Now, the gravity-fed FA-MD catches contaminants early, the FA-CW eliminates weight errors, and SmartNet lets us spot trends before they become problems. We haven’t had a single contamination or weight-related complaint since installation, and HACCP audits are now a breeze.”
Since deploying the integrated solution:
- NACP reduced contamination-related downtime by 100%.
- Cut weight non-compliance from 5% to 0.
- Streamlined audit preparation time by 70% (thanks to Fanchi SmartNet).
- Achieved 100% compliance with FDA and HACCP standards.
Why Fanchi-tech for Bulk Food Processing?
For processors like NACP, our integrated FA-MD and FA-CW Series deliver more than equipment—they deliver peace of mind:
- Bulk-Specific Design: Gravity-fed FA-MD and high-capacity FA-CW are built for the unique demands of unpackaged, free-flowing products.
- Seamless Integration: The two systems sync with existing lines, no costly reconfiguration required.
- Global Compliance: Fully certified to FDA, EU 178/2002, and HACCP standards—ready for international markets.
Take the Next Step: Secure Your Bulk Processing Line
Don’t let contamination or weight errors risk your business. Contact Kerry Wang (Food Processing Equipment Specialist) to schedule a free virtual demo of the FA-MD and FA-CW Series—we’ll test your bulk product samples (free of charge) to tailor a solution for your workflow.
Shanghai Fanchi-tech Machinery Co., Ltd.
- Email: fanchitech@outlook.com
- Website: www.fanchitechnology.com
Post time: Dec-15-2025