Magnetic Separation for HACCP and Supplier Audits

Food manufacturers are audited by their customers and by certification bodies. The audit checks that the plant controls its hazards. Metal is a physical hazard on almost every line, so metal control is on almost every audit.

This guide explains what auditors look for and how magnetic separation meets the requirement.

Who audits, and against what

Large retailers and food service groups audit their suppliers. Certification schemes such as BRCGS, FSSC 22000 and IFS audit against published standards. In India, FSSAI requires a food safety management system based on HACCP.

All of these expect a hazard analysis, controls at the critical points, checks on those controls and records of the checks. The wording differs. The expectation is the same.

What the auditor looks for

A hazard analysis that names metal. The plan should say where iron and steel can enter the product and which stages control it.

Physical controls in the right places. The auditor will walk the line and look for separators at intake, after stages that shed metal, and before packing. A gap between the last separator and the packing machine is a common finding.

Controls that are strong enough. Fine particles and work hardened stainless steel need high strength rods. An auditor may ask for the gauss rating and the certificate.

Evidence that the controls are checked. Cleaning logs, strength readings and inspection records. A separator with no records is treated as no control.

Action when something is found. If cleaning shows an unusual amount of metal, the plan should say what happens next. Stop the line, inspect upstream, check the sieve.

How magnetic separation meets each point

Naming the hazard. Iron and steel from raw materials, wear and maintenance are well understood. Write them into the plan at each stage.

Placement. Grids in hoppers, drawer housings in transfer lines, liquid traps in pipelines, plate and chute magnets on belts and ducts, and a final high strength unit before packing.

Strength. SMAG rods are made in four tiers, up to 13,500 gauss. The rating is stated on the tested certificate supplied with each unit.

Checks. Clean on a schedule and record what is found. Measure the surface field with a gauss meter at least once a year and compare with the certificate. Inspect the tubes and seals.

Action. Keep the collected metal from each clean in a labelled bag until the record is reviewed. An increase in quantity or a new type of fragment points to a failing part upstream.

Sampling and verification

Some auditors ask for proof that the product after the final separator is clean. A magnetic sampling probe is pushed into a sack, a bin or a flow of product and drawn out. Any iron on the probe shows that the upstream control has missed something. Recording a clean probe at a set frequency gives positive evidence that the controls work.

Preparing for the audit

• Keep the certificate of magnetic strength for every separator in one file.
• Keep the cleaning log, gauss readings and inspection records with it.
• Mark each separator with a number that matches the file.
• Make sure operators can explain the cleaning procedure and show the records.
• Review the plan after any change to the line, and record the review.

The SMAG range

Santosh Magnetic Works supplies a tested certificate of magnetic strength with every separator, and makes the magnetic sampling probe and gauss meter used for checks. See the separation range or contact us to prepare your line for audit.