FA-MD Metal Detectors: Safeguarding Small-Pack Snack Production by Catching Microscopic Contaminants
For small-pack food producers, even a 0.5mm metallic fragment in a 15g almond crisp or 5g cheese seasoning sachet can trigger retail recalls, erode brand trust, and incur thousands in compliance fines. This is why BrightSnack Co.—a Netherlands-based snack manufacturer specializing in 5–100g packaged products (mini almond crisps, 30g quinoa energy bars, and single-serve seasoning sachets)—partnered with Shanghai Fanchi-tech Machinery Co., Ltd. to deploy our FA-MD High-Sensitivity Metal Detectors (the stainless-steel units pictured in the factory layout above). Over 6 months of use, the FA-MD systems have become non-negotiable to BrightSnack’s quality control, catching microscopic metal debris while aligning with their high-speed, hygiene-critical workflow.
Company Background: Small Packs, Big Compliance Stakes
Founded in 2018 in Rotterdam, BrightSnack supplies 55 metric tonnes of small-pack snacks weekly to European retailers including Albert Heijn, Lidl, and Delhaize. Its core products—15g “Mini Almond Crunch” (a top-seller) and 5g “Parmesan Seasoning Sachets”—are produced on 8 high-speed lines (60–75 packs per minute).
Production involves precision cutting (almonds), grinding (seasoning powders), and heat-sealing—processes that rely on sharp stainless-steel blades and grinders. In 2024, a near-miss incident catalyzed their search for better inspection: a routine in-house test found a 0.6mm stainless-steel blade fragment in a batch of Mini Almond Crunch, just 2 hours before the shipment was set to leave for Albert Heijn. The batch was destroyed, but the close call exposed a gap: their old metal detector (a budget generic model) failed to detect fragments smaller than 1mm.
The Specific Challenges BrightSnack Faced
Beyond the near-recall, three critical pain points drove their search for a new solution:
- Microscopic Contaminant Blind Spots: Their prior detector could only spot fragments ≥1mm—but blades used for almond cutting shed 0.5–0.8mm shavings during routine wear.
- Product Interference: High-fat (almonds) and high-sugar (energy bars) products distorted the signal of their old detector, causing 12% false rejects weekly (wasting 30+ kg of snacks monthly).
- Hygiene & Line Speed Constraints: BrightSnack’s EU BRC Grade A facility requires daily high-pressure washdowns—their old detector’s plastic components and crevices trapped food residue, failing monthly hygiene audits. Additionally, switching between 22 SKUs (from 5g sachets to 100g energy bars) took 10+ minutes per line with manual parameter adjustments.
- Remote Support Gaps: Their previous supplier had no EU-based service teams—downtime from a sensor fault in 2023 lasted 48 hours, costing €1,800 in lost production.
The Solution: FA-MD Metal Detectors (Pictured Factory Units)
After testing 3 competitors’ systems, BrightSnack selected Fanchi-tech’s FA-MD Metal Detectors for their product-specific calibration, hygiene design, and regional support. Here’s how the units (visible in the factory image) addressed their needs:
1. Microscopic Detection Precision (Tailored to Small Packs)
The FA-MD uses variable frequency technology (50–100kHz) to adapt to product conductivity:
- For 15g Mini Almond Crunch (high-fat): Calibrated to 85kHz, detecting ferrous fragments as small as 0.5mm, non-ferrous (aluminum) at 0.7mm, and stainless steel at 0.8mm.
- For 5g Parmesan Sachets (fine powder): Calibrated to 70kHz, with sensitivity tuned to avoid false rejects from seasoning particle density while catching 0.6mm blade shavings.
During on-site calibration (led by Fanchi-tech’s Kerry Wang and EU-based service engineer Tom Van der Meer), the FA-MD detected a 0.5mm stainless-steel fragment hidden in a test almond crisp batch—something their old detector missed entirely.
2. Hygiene-Compliant Design (Matching Factory Layout Needs)
The FA-MD units in the image feature:
- 304 food-grade stainless steel construction (no plastic components) with smooth, crevice-free surfaces—compatible with BrightSnack’s daily high-pressure washdowns (IP66-rated).
- Elevated conveyor belts (visible in the foreground) that prevent food buildup under the line, passing BRC hygiene audits with zero deductions post-installation.
3. Rapid SKU Switchovers (Built for 22 Product Types)
The FA-MD’s touchscreen control panel (seen on the top of each unit) stores pre-programmed settings for all 22 BrightSnack SKUs. For example:
- Switching from 15g Almond Crunch to 30g Energy Bars takes 30 seconds: Operators select the SKU code, and the detector auto-adjusts frequency and sensitivity—down from 10+ minutes with their old system.
4. Regional Support (Avoiding Costly Downtime)
Fanchi-tech’s EU service team (based in Amsterdam) provided:
- 3 days of on-site training for 12 BrightSnack operators (covering calibration, reject system troubleshooting, and daily maintenance).
- A quarterly maintenance contract: Monthly remote sensor checks, and 24-hour response time for urgent issues. In March 2025, a conveyor belt sensor fault was resolved via video call in 15 minutes—no production downtime.
The Outcome: Hard Data & Operator Feedback
In the 6 months since installing 8 FA-MD units (the full set pictured in the factory):
- 12 Microscopic Contaminant Catches: The FA-MD detected 0.5–0.8mm metallic fragments (8 stainless-steel blade shavings, 4 aluminum grinder pieces) in production batches—preventing 3 potential retail complaints and an estimated €2,500 in recall costs.
- 90% Reduction in False Rejects: From 12% weekly false rejects to 1.2%, saving 27+ kg of snacks monthly (€420 in material costs).
- Faster Line Efficiency: SKU changeover time dropped by 95%, adding 2 hours of production capacity weekly.
- Operator Endorsement: “The old detector felt like a guessing game—we’d adjust settings and cross our fingers,” says Sophie Dekker, a BrightSnack line operator. “The FA-MD’s one-touch SKU recall means I spend less time troubleshooting and more time keeping the line moving.”
Why Fanchi-tech’s FA-MD for Small-Pack Producers?
For brands like BrightSnack, the FA-MD delivers value beyond detection:
- Product-Specific Calibration: No one-size-fits-all settings—tuned to high-fat, high-sugar, or fine-powder small packs.
- Hygiene-First Build: BRC/FSMA-compliant design that passes rigorous food facility audits.
- Regional Support: Local service teams that minimize downtime for global producers.
Take the Next Step: Test FA-MD on Your Small-Pack Lines
If you’re a small-pack food producer struggling with microscopic contaminants, product interference, or hygiene compliance, contact Kerry Wang (Food Inspection Specialist) to arrange a free on-site demo (or virtual test with your product samples). We’ll calibrate the FA-MD to your specific SKUs and share real-time detection data.
Shanghai Fanchi-tech Machinery Co., Ltd.
- Email: fanchitech@outlook.com
- Website: www.fanchitechnology.com
Post time: Jan-07-2026