FA-MD Metal Detectors: Safeguarding Bulk Biscuit Production for Global Snack Brands
For manufacturers of bulk biscuits and cookies, contamination risks are amplified by high-speed production lines, large batch sizes, and the abrasive nature of dough mixing and cutting equipment. Even a single microscopic metal fragment in a 1,000kg bulk shipment can lead to costly recalls, lost retailer trust, and brand damage. This is why Bisco Global, a leading European biscuit producer with 50,000 tonnes annual output, turned to Shanghai Fanchi-tech Machinery Co., Ltd. to deploy our FA-MD Metal Detectors—specifically engineered for bulk biscuit inspection.
The Challenge: Contamination Risks in High-Volume Bulk Biscuit Lines
Bisco Global runs 24/7 production lines that produce 12 tonnes of bulk butter cookies, shortbread, and digestives daily. Its process relies on heavy-duty stainless-steel mixers, rotary moulders, and wire-cut machines—equipment that sheds tiny metal shavings during routine wear. In early 2025, a customer complaint about a metal fragment in a bulk biscuit shipment triggered a mandatory recall, costing Bisco Global €42,000 in direct expenses and damaging its relationship with a major UK supermarket chain.
Their existing inspection system failed to address key pain points:
- Blind Spots in Bulk Flow: The old detector could not consistently scan the uneven, high-volume flow of loose biscuits, missing 30% of test fragments in internal audits.
- False Rejects from Product Effect: Oily butter coatings and high-moisture dough distorted the detector’s signal, causing 8% false rejects weekly and wasting 200+ kg of product.
- Slow Calibration for SKU Changes: Switching between 12 biscuit varieties took 15 minutes per line, creating bottlenecks during peak production shifts.
“Bulk biscuit production leaves no room for error—our customers expect zero contamination, and our margins can’t absorb waste or recalls,” says Sarah Voss, Bisco Global’s Supply Chain Director. “We needed a detector that could keep up with our 1,200kg/hour speed and reliably catch the smallest metal fragments.”
The Solution: FA-MD Metal Detectors for Bulk Biscuit Inspection
After testing 3 competitors, Bisco Global selected Fanchi-tech’s FA-MD Metal Detectors for their ability to handle the unique challenges of bulk biscuit production. Here’s how the FA-MD addressed their critical needs:
1. Optimized Detection for Bulk Biscuit Flow
The FA-MD features a wide, low-profile conveyor and advanced signal processing that compensates for the uneven distribution of loose biscuits. For Bisco Global’s butter cookie line, it was calibrated to:
- Detect ferrous fragments as small as 0.6mm (common from mixer blades).
- Identify non-ferrous aluminum particles (from conveyor wear) at 0.8mm.
- Catch stainless steel shavings (from rotary moulders) at 0.9mm.
During on-site validation, the FA-MD detected 98% of test fragments in bulk biscuit flow—eliminating the blind spots that plagued Bisco Global’s old system.
2. Minimized False Rejects with Product-Specific Tuning
The FA-MD’s variable frequency technology (50–100kHz) adapts to the conductivity of oily biscuit coatings and high-moisture dough. Bisco Global’s false reject rate dropped from 8% to 0.7% within the first month, reducing product waste by 180 kg weekly.
3. Fast SKU Switchover & Hygiene Compliance
The FA-MD’s touchscreen control panel stores pre-programmed settings for all 12 biscuit varieties, allowing operators to switch profiles in 25 seconds—down from 15 minutes with their old system. Its IP65-rated, crevice-free stainless-steel build withstands daily washdowns, passing Bisco Global’s BRC Grade A hygiene audits with zero non-conformities.
The Outcome: 100% Contamination Capture & Zero Recalls
In the 6 months since installing 4 FA-MD units:
- 12 Critical Contaminant Catches: The FA-MD detected 0.6–0.9mm metal fragments (7 from mixer blades, 5 from rotary moulders) in bulk batches, preventing 3 potential recalls and an estimated €55,000 in costs.
- 91% Reduction in False Rejects: The 0.7% false reject rate saved Bisco Global €1,200 monthly in material waste.
- 12% Faster Line Efficiency: The 25-second SKU switchovers added 4 hours of production capacity weekly, helping Bisco Global meet its 2025 export growth target.
“The FA-MD has become our first line of defense,” says Voss. “Our operators love its reliability, and our retail partners now recognize us as a leader in food safety.”
Why Fanchi-tech’s FA-MD Is the Industry Standard for Bulk Biscuit Producers
For brands like Bisco Global, the FA-MD delivers more than inspection—it provides:
- Bulk-Flow Expertise: Designed to handle the uneven distribution of loose biscuits, snacks, and cereals.
- Global Support: 24/7 technical assistance and a 2-year warranty, with spare parts stocked in Europe and North America.
- Scalable Design: Easy to integrate with existing lines or expand as production grows.
Secure Your Bulk Biscuit Lines Today
If you’re a bulk biscuit or snack producer facing contamination risks, contact Kerry Wang to arrange a free virtual demo or on-site trial of the FA-MD Metal Detector. We’ll test the unit with your specific biscuit products to validate performance for your line speed and SKU mix.
Shanghai Fanchi-tech Machinery Co., Ltd.
- Email: fanchitech@outlook.com
- Website: www.fanchitechnology.com
Post time: Jan-22-2026