Automatic testing eliminates human error risks and reduces food waste by scheduling hourly checks without stopping food production lines.
In 2010, Fortress Technology became the first inspection company globally to automate routine safety checks of food metal detectors. The Halo Automatic Testing System continues to be the cornerstone of ensuring food metal detectors are repeatably challenged under true production conditions.
Phil Brown, European Sales Director, draws on over 15 years of quantifiable data and customer feedback to explain how the Fortress Technology system eliminates human errors. In addition to reducing food waste and accelerating ROI, Phil Brown addresses how the system improves operational efficiency and enhances safety standards. He also discusses cost and upgrade options and describes why customers with newer Fortress Technology metal detectors are increasingly activating Halo.
What is the cost of the Halo Automatic Testing System?
The Halo Automatic Testing System is typically a single capital investment that is integrated on an individual Fortress Technology gravity, pipeline or conveyor metal detector. Once purchased, there is no recurring subscription fees to operate the device.
Customers report that the principal value comes from the long-term operational savings. By automating routine checks on our metal detectors, the Halo Automatic Testing System reduces the labour time and production interruptions caused by hourly manual testing. In many facilities, the ROI of the Fortress Technology system due to efficiency savings can be realised in less than 12 months.
Can I add Halo to my existing Fortress Technology equipment?
Every new Fortress Technology metal detector is manufactured as ‘Halo Ready’. For facilities with existing infrastructure, upgrading may be a viable option for these newer models. The feasibility of this depends entirely on the specific stock model, the application type (gravity, pipeline or conveyor) and the original date of manufacture. If it is a ‘Halo Ready’ unit, it allows food manufacturers to modernise their safety protocols without the capital expenditure of a full system replacement.
If upgrading is not feasible due to the age of metal detectors, it may be valuable to calculate what you are losing in product waste, spending on labour to perform manual tests and how long the metal detector is down for between each test. Then compare this to installing a new, higher performance metal detector with a Halo Automatic Testing System installed. Our Halo ROI calculator can help put everything into context.
Do I have to test every food metal detector in my factory, and if so, how often?
Yes, the testing of food metal detectors is essential. Food manufacturers must regularly verify the functionality of their metal detection systems as part of mandated food safety and quality assurance programs, including HACCP and GFSI. It applies to every type of food metal detector, even the most expensive and reliable models.
These routine checks confirm that the system is detecting metal contaminations that are a risk for their process and that all affected products are being rejected. This helps to maintain food safety and audit compliance.
Industry standards typically require metal detector testing at the start and end of every shift, at consistent intervals during production, often hourly, and using critical limits that mitigate hazards to an acceptable level. Manual testing is possible, but this is time consuming, labour intensive and requires thorough documentation of every result. The test samples on manual checks should be placed in the product, and the result must be documented to comply with HACCP and GFSI requirements.
Automatic metal detector testing offers a superior alternative by generating a precise, calibrated signal that challenges the detector with controlled repeatability that human testing simply cannot match.
How easy and quickly can Halo be rolled out?
The Halo Automatic Testing System is intentionally designed for quick and simple deployment. On compatible systems, the hardware is already in place, so setup typically takes several minutes. Most installations can be completed without complex commissioning.
Facilities also have the flexibility to trigger tests manually via the Fortress Technology HMI or pre-program them at specific intervals to align with internal quality control policies.
Is extra software required to run Halo?
No. Every test with the Halo Automatic Testing System can either be scheduled to run automatically at a defined time or activated by pushing a button on the HMI. This can be pre-programmed and doesn’t require additional software to run the test.
To assist with reporting, Contact Reporter is included on all Fortress Technology metal detectors. Contact Reporter generates the necessary PDF or Excel reports, capturing all testing events and detector activity for long-term storage.
For optimal reporting efficiency processors may implement Contact 4.0. This platform provides real-time networked monitoring across multiple production lines and can automatically transfer your testing data to your centralised management system. Contact 4.0 can make your test documentation process more efficient.
What does a Halo report look like?
Each Halo report generates a tamperproof electronic record that includes:
- Exact date and time of the test
- Metal type (ferrous, non-ferrous, stainless steel)
- Resulting signal strength to prove sensitivity limits for each metal
- Detector status and verification of the reject mechanism response
- Pass/fail results and associated event logs for any faults.
Digital files are available for instant retrieval. This provides absolute transparency and concrete evidence of repeatable performance in the event of an audit or retailer request.
Will automatic testing become the norm?
Over the last decade Fortress Technology has observed a significant shift in customers implementing automated test verifications. Human-centric testing protocols are inherently vulnerable to fatigue, inconsistency and procedural drift. In high-volume environments, these small errors can lead to significant non-compliance issues during audits, or worse a product recall.
Our customers are the biggest advocates of the Halo Automatic Testing System. Manufacturers indicate that with the implementation of automated testing, process and safety checks are seamlessly incorporated into workflows, eliminating potential disruptions and bottlenecks.
Read the Fortress Technology whitepaper Failsafe Metal Detector Testing to Heighten Food Safety Compliance for more information.