A nightmare in food production: How a single metal shaving nearly cost the plant CZK 1.2 million
Metal contamination in production? A problem that can cost hundreds of thousands.
An example of a solution in which we used multi-stage magnetic separation to help capture metal particles generated by wear on a screw conveyor.
Production is running at full capacity. Deadlines are tight. Then comes the shock – an inspection detects a microscopic metal shaving in the finished product.
At that moment, the entire operation comes to a halt. If contamination is confirmed throughout the batch, production must be stopped, the material disposed of and the resulting losses can run into hundreds of thousands or even millions of Czech crowns.
Our client found themselves in exactly this situation. The cause was inconspicuous but dangerous – wear on the screw conveyor, which was releasing microscopic metal particles into the mixture.
🔍 Where was the problem?
As the material was transported by the screw conveyor, metal-on-metal abrasion occurred. This produced fine metal particles that were not visible to the naked eye.
Although the standard inspection at the end of the line detected the problem, it did so only after the entire batch had already been rendered unusable.
📉 Impact of the contamination
⛔ Production shutdown
Every line stoppage means lost time, pressure on deadlines and higher operating costs.
🧪 Batch write-off
Metal contamination may require the disposal of both the finished product and the raw materials.
⚠️ Risk of customer complaints
A contaminated product puts quality, safety and the brand’s reputation at risk.
📊 What did the installation of magnetic separators achieve?
⚙️ Our solution
We designed a multi-stage magnetic separation system tailored precisely to the point where the contamination originated.
1. Capture at the source
A magnetic grate installed directly behind the screw captures metal particles immediately after they are generated.
2. Secondary cleaning during transport
The retractable MSV magnetic separator removes fine metal contaminants during material transport.
3. Final product protection
The final inspection point protects the finished product before dispatch or the final stage of production.
💰 What did we achieve?
Metal contamination is not just a technical problem. It represents hidden losses that can cost you millions.
Would you like to protect your production from metal contamination?
We will design a suitable magnetic separation solution based on the type of material, the production line and the high-risk point in the production process.
Inquire about our services - you will receive an offer within 48 hours
Please describe your needs as precisely as possible. We will send you a confirmation of your request and redirect you to a suitable specialist. He or she can contact you for further details at the contacts listed.
