NESTLE INDIA LIMITED

Submitted By
Brijesh Pratap Singh
B.Tech(EC)-0703231035
ABES ENGINEERING COLLEGE ;GHAZIABAD

1
Machine Base Training – Metal detector Part 1(Basic Theory & Principle)
 About Nestle India Limited
 Nestlé S.A. (French pronunciation: [nɛsˈle]) is the largest
nutrition and foods company in the world,founded and
headquartered in Vevey, Switzerland.

 Nestlé originated in a 1905 merger of the Anglo-Swiss Milk

Company, which was established in 1866 by brothers George
Page and Charles Page, and the Farine Lactée Henri Nestlé
Company, which was founded in 1866 by Henri Nestlé.

 Today, the company operates in 86 countries around the world

and employs nearly 283,000 individuals.

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 2
 The Company's principal activities are to manufacture
and distribute food products.

 The food products include milk and nutrition, soluable

beverage powder, coffee blends, tea, cream, chocolate,
cereals and cooking aids.

 . Milk products and nutrition accounted for 43% of

2001 gross revenues; soluable beverage powder, 29%;
prepared dishes and cooking aids, 14%; chocolate and
confectionery, 14% and other, nominal.
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 3
 Metal Detector
Theory and
Principle
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 4
 1.
General
Introduction
5
Machine Base Training – Metal detector Part 1(Basic Theory & Principle)
 Why need Metal Detectors ?
1. To protect our customers
• Bits of metal can be seriously dangerous if swallowed
esp. baby food .

2. To protect the Company’s reputation

• Deaths or injuries from swallowing metal contaminants in product, can cause
companies to go out of business or to a lesser extent, seriously damage its reputation.

3. Complying with legislation/quality control

• Ensure goods produced comply with company’s agreed assured standard e.g.
HACCP programme
• Complying with food’s regulation.
• Legal issue

4. CP 18.271 (Guidelines for installing, evaluating and testing metal detectors) states
 As the total quality of our product has to be warranted, the NQS (i) states “the
presence of metal and glass fragments must be completely avoided since these foreign
objects may cause injury to the customer ”

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 6
 Facts and Myths of Metal Detector
1. It Can :
• Sense the presence of “metals” contaminants going through its aperture
• Output a reject command (stop the line) if the measured signal exceed a set
limit (threshold)
• Go or No Go ( Policeman, speed limit)

2. It Cannot :
• Detect plastics, woods, paper etc..
• Indicate the material (brass, iron Etc..) of the contaminants
• Detect contaminants sizes below the specification value
• Measure the size of contaminants

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 7
 Overview
•Detector - picks up a signal What can
•Electronics - compare signal against set-point (Threshold)
•If Signal > Threshold  Metal Strike Alarm
cause a signal?
Only
Only want
want
THIS
THIS

False strike False strike

Unstable operation Let through
A. Metal contaminants
Unreliable operation
•Sizes/shape
D.Electronics
•Material
B.Product •Threshold
•Moisture •Stability-ABC
•Lumpy/undried •Signal processing
•Recipe-mineral Detector •Phase control
•Free-fall •Calibration

C.Installation E.Detector
•Vibration/Clearance •Position/Orientation
Electron
•EMI/RFI ics •Aperture Size
•Metal free zone •Frequency
•Static •Head power
•Earthing Most of the false strikes arise
from B and C
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 8
Physics Principles of Metal Detection
Faraday’s Law of
Electromagnetic induction
(1831)

When a magnet is moved through a

closed coil of wire, a current is
induced in the wire. The direction of
the current flow is such as to create
a magnetic field opposite in direction
to that of the change in the field
produced by the magnet…..

Michael Faraday
1791-1867

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 9
Initial application for metal detection
Marine engineers utilised Faraday’s technology, fitting wires around
the hulls of ships and attempted to detect large masses of metal
around and below them, e.g. Submarines, wrecks & mines

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 10
 How it started in the food industry
 1950’s - Food companies wanted to check for metal in
the product that they produced. Principally looking for
nuts and bolts that came from their manufacturing
process.

 1972 - A person attempted to extort money from a baby

food manufacturing company, by putting hypodermic
needles into their product. The worlds press published
the story, there was then an urgent need for all food
companies to metal detect their products.

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 11
 2.
Construction
of
Metal Detector
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 12
 General Anatomy - External

Stainless Steel Case

Touch Panel

End
Plate

Aperture Aperture IP 67 or Nema 4X

Lining Electronic Controls
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 13
 General Anatomy - Internal
Transmitter Coil in the
center of the wire former

Wire
Former

Receiver Coils on the

outside of the wire former
The casing is filled with a glass bead and resin potting for stability

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 14
 General Anatomy - Cross-Section View

Receiver Coils

Folded
Flexible Silicon Stainless
Aperture Lining Steel case

Wire Former

Glass bead & Resin

Transmitter
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 15
 3.
Principles
of
Detection
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 16
Principles of Metal Detection -"Coupling"
Transmitter Coil (Oscillator)
 The magnetic field
created by the oscillator
in the transmitter coil
results in "Coupling"
between the Transmitter
and each of the Receiver
Coils.
Magnetic
 A voltage is thus Field
"Induced" in each of the
Receiver Coils.

Machine Base Training – Metal detector Part 1(Basic Theory & Receiver Coils
Principle) 17
 Signal output – metal contaminant
n
X is a v
T 8
p u t to r from
I n o
s c illat eak-
O
Signal
o 3 0v P
Me
RX- 1 t
k,
Pea z to
h
taMle 50K Khz
V-OUT = 0 taMle 0
0 tal 100
Me
talM TX
eta
l M
eta
Mle
taM
le X- 2
talM
eta
R
Mle
talM
V eta
-O Mle
UT taM
le
Signal tal
Time
Time
Time19
14
18
10
11
12
15
16
17
13
5
6
20
0
1
2
3
4
7
8
9

0
When a metal piece enters the detector, this balanced condition is disturbed and
the detection signal V-OUT will have a value.
If this is more than a preset value (Threshold) it will be interpreted as a metal
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 18
 4.
Factors
influencing
Sensitivity
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 19
 4.1
Metal Types

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 20
 Metals are classified into 3 categories
 The ease of detection depend on 2 key properties of metal i.e.
a. Magnetic permeability (how easily they are magnetized) and
b. Electrical conductivity.
For metal detection the magnetic property is dominant.

 Ferrous
 Ferrous contamination is both magnetic and a good electrical conductor and
is easily detected. Most metal detectors are able to detect small ferrous
particles.
 Non-Ferrous
 Non-ferrous metals such as copper, lead and aluminum, are non-magnetic but
are good electrical conductors and are generally quite easy to detect.

 Stainless Steel
 Stainless steel comes in many different grades, some magnetic and some
austenitic ( totally non-magnetic ) and their conductivity is variable.
Generally most difficult to detect compared to ferrous and non-ferrous.

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 21
 How is ferrous metal detected?
Receiver Coil

Cause
A ferrous
(Magnetic)
material,
enters the
head and
moves through
the magnetic
field

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 22
 How is ferrous metal detected?
Receiver Coil

Effect Cause
This will The
magnetic
improve the field, will be
magnetic strengthen
coupling in as the
the area and ferrous
increase the metal
enters the
output of field
the receiver
coil

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 23
 How is non-ferrous metal detected?
Receiver Coil

Cause
A non-ferrous
(non-magnetic)

material, enters
the head and
moves through
the magnetic
field

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 24
 How is non-ferrous metal detected?
Receiver Coil
Cause
Effect
•The non-
This will ferrous metal
reduce the will create a
coupling in secondary
that area, and magnetic
decrease the around itself
output of the
receiver coil •This field is in
affected by opposition to
the coupling the main
in that area. magnetic field
•Net effect will
weaken the
main field

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 25
 4.2
Orientation
Effect
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 26
 Orientation Effect – Ferrous metal
 A Ferrous segment
of wire will be
easiest to detect
when presented
with its longest
dimension in the
horizontal axis.

 A Ferrous
segment of wire
is most difficult
to detect when it
is presented with
its longest
dimension on the
vertical axis.

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 27
 Orientation Effect - Non-Ferrous Metal

 A segment of Non-
Ferrous wire is
easiest to detect
when presented
with its longest
dimension in the
vertical axis.

 A segment of Non-
Ferrous wire is
most difficult to
detect when it is
presented with its
longest dimension
on the horizontal
axis.

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 28
 4.3 Vibration
 Any form of mechanical vibration to the head will disturb the magnetic field
and may cause a false triggers

 Microscopic movements of the coils relative to each other, as small as 1

micron, can cause an out-of-balance voltage and a false detect signal. The
selection of former material, coil specifications and case design are crucial.

 Sources of vibration - motors, pulleys, auto-reject devices, temperature

changes, transportation and close-by machinery

 Head must be mounted securely to permanent and rigid structure

 Shock absorber must be installed on the mounting.

Use approved design - no through bolts

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 29
 4.4 Clearance
 There must be sufficient clearance between the product chute
and the side of the detector and they must be properly centred

 Any physical contacts may transfer vibration to the head

causing false trigger

 For installations using flexible product chute, the vacuum

created during product movement will cause the flexible chute
to sometimes contract or expand resulting in occasional
physical contact with the throat, resulting in false trigger.
 Install pressure equalising line from machine hopper to MD
inlet pipe

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 30
 4.5
Product
Effect
Machine Base Training – Metal detector Part 1(Basic Theory &
Principle) 31
 Product moisture and recipe
 Any material that is a conductor of electricity will trigger the metal
detector

 Product moisture is water and it is a good conductor

 Undried product in lumpy/granular form may contain sufficient water

trapped within to trigger the metal detector.

 The rejected products may test negative after a few days as the
particles could have been broken up or the product could have
becomes drier

 Product with fortified iron content may also trigger the metal detector

Machine Base Training – Metal detector Part 1(Basic Theory &

Principle) 32
 Thank
You
33
Machine Base Training – Metal detector Part 1(Basic Theory & Principle)