Smart Multi-Frequency Metal Detector for Frozen Food Production Line

Industry: Frozen Food | Location: United States

Customer Challenge

A frozen food processor in California was struggling with metal detection in their frozen product line. Frozen foods present unique challenges for metal detection:

1. High product effect — frozen products with high moisture and salt content create significant "product effect" that can mask metal signals, causing both false rejects and missed contaminants
2. Cold, wet operating environment — The production area operates at 5°C (41°F) with frequent washdowns, requiring equipment that can withstand harsh conditions
3. Regulatory pressure — FSMA (Food Safety Modernization Act) requirements mandated more rigorous foreign object control, and their existing detector could not provide the required detection sensitivity
4. High false reject rate — Their previous single-frequency detector had 15+ false rejects per day, causing production line stoppages and product waste

The factory needed a detector that could:
• Operate reliably in cold, wet, high-pressure washdown environments
• Overcome product effect from frozen, high-salt products
• Achieve reliable detection of 1.0mm Fe spheres and smaller
• Reduce false rejects to less than 1 per day
• Provide audit-ready documentation for FSMA inspections
• Handle high-speed production (up to 60 packages/minute)

DORIA Solution

DORIA supplied a 2026 new generation smart multi-frequency metal detector, specifically calibrated for frozen food products. The system features:

• Multi-frequency synchronous detection technology — simultaneously operates on multiple frequencies to distinguish metal signals from product effect
• Intelligent anti-interference algorithms — machine-learning based signal processing that adapts to product variations
• IP69K washdown rating — withstands high-pressure, high-temperature washdown (up to 80°C / 176°F)
• Cold-environment optimized electronics — designed for reliable operation down to 0°C (32°F)
• Full-color touch screen with intuitive user interface
• Automatic product learning and calibration — one-button setup for new products
• Real-time production monitoring with statistical reporting
• Tool-free belt removal for cleaning and maintenance
• Multiple rejection system options (air blast, pusher, diverter)

The detector was installed on the frozen meal packaging line, with an air-blast rejection system that removes contaminated packages without stopping production.

Results & Benefits

After 6 months of operation, the factory reported:

• 40% improvement in detection sensitivity compared to previous detector
• 99.8% detection rate for 1.0mm Fe spheres
• Reduced false rejects from 15+/day to less than 1/day
• Zero production line stoppages due to metal detection issues
• Passed FSMA inspection with zero findings
• Reduced product waste by approximately $8,000/month
• Improved overall equipment effectiveness (OEE) by 12%
• Payback period: approximately 5 months

Customer Feedback

"The multi-frequency technology is a game-changer for frozen products. We used to fight with false rejects every single day — now it's almost zero. The IP69K construction holds up perfectly in our washdown environment, and the touch screen is so easy to use that our operators learned it in 10 minutes. This detector paid for itself in less than 5 months just from reduced product waste."

— Plant Engineer, Frozen Food Processing Facility, California, USA

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