FA-MD Series Metal Detectors: Powering Scalable Food Safety for Expanding Meat Processors
For meat processors undergoing rapid growth, scaling production lines without compromising food safety or operational efficiency is a make-or-break challenge. This is why Maplewood Meats—a U.S.-based premium protein producer founded in 1961—partnered with Shanghai Fanchi-tech Machinery Co., Ltd. to deploy our FA-MD Series Metal Detectors during its transformative expansion from 2 to 9 production lines. The move, which included relocating to a larger facility in Massachusetts and expanding its product range to include shaved steak, gourmet patties, turkey products, and meatballs, demanded a robust, reliable metal detection solution that could keep pace with growth while ensuring zero margin for error.
The Challenge: Scaling Up Without Cutting Corners
As Maplewood Meats scaled from 2 to 9 “ready-to-cook” production lines, the company faced critical operational hurdles:
- Stricter Food Safety Demands: With an expanding product portfolio and increased supply to foodservice, retail, and wholesale customers, compliance with global food safety standards (FDA, HACCP) became more non-negotiable.
- High-Speed, High-SKU Operations: The need to move faster, manage diverse products (from delicate shaved steak to dense meatballs), and minimize downtime required equipment that wouldn’t hinder throughput.
- Operator Efficiency: With more lines came more staff to train—equipment needed to be intuitive, uniform across lines, and not prone to confusion.
- Zero Tolerance for Contamination: Metal fragments from processing equipment (e.g., blades, grinders) posed significant risks to consumer safety and brand reputation, requiring detection of even the smallest particles.
“Scaling up wasn’t just about adding lines—it was about functioning flawlessly with zero room for error,” explains Mike Harrison, Director of Food Safety and Quality Assurance at Maplewood Meats. “Metal detection was a critical control point, and we needed a solution that could keep up with our growth without compromising safety or efficiency.”
The Solution: FA-MD Series Metal Detectors
After evaluating options, Maplewood Meats chose Fanchi-tech’s FA-MD Series Metal Detectors—installing 8 units in palletizing areas (with a ninth underway) to cover all production lines. Designed for challenging meat processing applications (high-moisture, conductive products), the FA-MD Series was the perfect fit for the company’s “ready-to-cook” portfolio.
Key Factors Behind the Decision
- Proven Performance with Challenging Meats: The FA-MD Series excels at detecting metal in high-moisture, fatty, or conductive meat products—eliminating false alarms caused by product interference (a common pain point in meat processing).
- Trusted Partnership & Expert Support: Fanchi-tech’s commitment to education and training aligned with Maplewood’s need to upskill staff. Our team didn’t just install equipment—we ensured operators understood how and why the technology works.
- Responsive Customer Service: Quick lead times and a knowledgeable support team addressed Maplewood’s urgent scaling needs, minimizing delays in production line expansion.
- Compact, Line-Friendly Design: The FA-MD’s space-saving footprint integrated seamlessly into existing workflows, supporting the company’s goal of maintaining a clean, organized facility.
“The training from Fanchi-tech was outstanding,” says Mike Harrison. “They didn’t just show us how to run the machines—they educated us on metal detection principles. That level of expertise makes a huge difference in how confidently we manage food safety.”
The Outcome: Seamless Scaling with Zero Compromises
Since deploying the FA-MD Series, Maplewood Meats has achieved transformative results across its 9 production lines:
- Consistent Food Safety Assurance: Uniform detection performance across all lines ensures zero margin for error, meeting strict FDA and HACCP requirements.
- Micro-Fragment Detection: The FA-MD Series detects even the smallest metal particles (ferrous: 0.5mm, non-ferrous: 0.7mm, stainless steel: 1.0mm)—critical for catching wear fragments from grinders, blades, or conveyor parts.
- Zero Production Disruption: The system automatically stops when metal is detected, allowing quick removal of contaminated product without halting the entire line—ensuring seamless operations.
- Minimal Customer Complaints: Foreign object-related complaints remain below key performance indicators, protecting Maplewood’s reputation as a premium protein supplier.
- Operator-Friendly Uniformity: Consistent design and intuitive controls across all FA-MD units make training and daily use simple, even with a growing team.
- Supports Expansion Goals: The reliable performance of the FA-MD Series has given Maplewood the confidence to continue scaling, with room to add more lines as demand grows.
“The FA-MD metal detectors have been a game-changer for our expansion,” adds Mike Harrison. “They integrate perfectly into our workflows, require minimal training, and deliver the safety assurance we need to grow with confidence. We couldn’t have scaled this quickly without them.”
Why Fanchi-tech for Scaling Meat Processors?
For companies like Maplewood Meats, the FA-MD Series offers more than metal detection—it’s a growth enabler:
- Challenging Product Expertise: Optimized for high-moisture, conductive meat products, eliminating false alarms and ensuring reliable detection.
- Scalable Design: Compact, uniform units that integrate seamlessly into new or existing lines, supporting growth from 2 to 20+ production lines.
- Expert Support & Training: Comprehensive on-site training and responsive service ensure your team can maximize equipment performance from day one.
- Compliance Readiness: Meets global food safety standards (FDA, HACCP, SQF) to keep your products market-ready, even as regulations tighten.
- Proven Reliability: Built for 24/7 meat processing environments, with durable construction that withstands frequent washdowns and heavy use.
Take the Next Step: Scale Safely with Fanchi-tech
If you’re expanding your meat processing operations and need a metal detection solution that keeps pace with growth, contact Kerry Wang (Food Safety Equipment Specialist) to schedule a free virtual demo of the FA-MD Series. We’ll tailor the solution to your product range, line speed, and scaling goals—with free sample testing to prove performance.
Shanghai Fanchi-tech Machinery Co., Ltd.
- Email: fanchitech@outlook.com
- Website: www.fanchitechnology.com
Post time: Dec-24-2025