Case study: Metal detectors ensure product purity at American Pop Corn Company
Key Highlights
- Eriez equipment's practicality and user-friendly interface influenced the company's decision, leading to smooth integration and effective monitoring.
- Since installing Eriez metal detectors, the company has not encountered any metal-related consumer complaints.
- Plans are underway to install additional Eriez metal detectors upstream in the processing mill for comprehensive metal control.
Established in 1914, the American Pop Corn Company holds the distinction of being the oldest popcorn company in the United States. With a legacy spanning over a century, the company has become well known for pleasing taste buds worldwide with its JOLLY TIME Pop Corn brand. Dubbed "The Official Snack of Happiness," JOLLY TIME is enjoyed in every corner of the United States and across 23 different countries. Based in Sioux City, Iowa, this family-owned and operated business is renowned for its wide range of offerings, including a wide variety of microwave popcorn flavors as well as white and yellow popcorn kernels.
Adding metal detection to complement existing equipment safeguards
The leadership team at the American Pop Corn Company demonstrates an unwavering dedication to product quality, emphasized by their commitment to sourcing premium corn kernels from local farmers. In their continuous quest for quality assurance, the company has invested in metal detection technology to complement its existing equipment safeguards. As Dave Sitzmann, vice president of production, points out, “Metal detectors are an additional measure by which the American Pop Corn Company fulfills its promise of delivering top-notch snacks to our cherished customers.”
In the past, the American Pop Corn Company didn't employ metal detectors, instead relying on x-ray technology. Explaining the decision, Sitzmann says, "Our microwavable packages are designed with an aluminum susceptor patch, and we required a means to detect any foreign objects that might inadvertently be present within these packages. Given that traditional metal detectors are not suited for this specific task, we chose to implement x-ray detection technology on those particular production lines.” He adds that the plant’s other production lines, where they package raw kernels in poly bags, plastic jars, and bulk bags, also did not have any metal detection devices in place at that time.
In 2019, the American Pop Corn Company achieved British Retail Consortium (BRC) certification in line with Global Food Safety Initiative (GFSI) standards. Simultaneously, they were working diligently to adhere to new protocols set forth by the Food Safety Modernization Act (FSMA). To address mounting customer inquiries concerning foreign material control and meet heightened regulations, the company decided to implement comprehensive metal control measures across all production lines, reinforcing consumer trust in the safety of their food products.
Eriez metal detection equipment provides practicality and user-friendliness
When it came to acquiring metal detection equipment, Sitzmann recalled the connection his manufacturing representative had with Eriez, a global leader in separation technology and a prominent manufacturer of metal detection equipment. The representative, Jeanne Anderson of Industrial Motion Technologies, Inc., enthusiastically endorsed Eriez as a top choice for such technology, which prompted Sitzmann to include Eriez on his list of options.
Initially, he also evaluated other metal detection and x-ray detection systems. During this evaluation process, Sitzmann conducted an online mock assessment with his Eriez representative to gain a deeper understanding of the functionality and user interface of the Eriez equipment. Ultimately, the decision to opt for Eriez metal detection equipment over competitive units was driven by the practicality and user-friendliness of Eriez' screen interface.
After selecting Eriez metal detection equipment, the American Pop Corn Company proceeded to place orders for a diverse range of vibratory feeder options. This strategic move was necessitated by the various product types and distinct stages in the production process, all requiring tailored solutions to maintain the purity of the popcorn. According to Sitzmann, everything has progressed smoothly since the arrival of the first Eriez metal detector in Sioux City.
“Our key performance indicators (KPIs) are meticulously monitored during our monthly food safety and quality system review meetings. We've been methodically tracking consumer complaints for more than 15 years as part of these meetings. Of particular focus is the identification of any complaints related to foreign materials. Since the installation of Eriez equipment in 2019, we've not encountered a single instance of metal contamination reaching consumers. This KPI represents a straightforward and easily assessable metric. It’s simple; with Eriez, we've consistently maintained our commitment to ensuring that no metal materials of any type have ever made it to our consumers.”
Company plans to add additional Eriez metal detector upstream in processing mill
Sitzmann notes that their high satisfaction with Eriez equipment has opened the door to new projects. The American Pop Corn Company is set to install an Eriez metal detector upstream, specifically in their processing mill, to ensure comprehensive metal detection at the end of the cleaning process. Sitzmann explains, "While our current Eriez metal detectors mainly focus on inspecting packages at the end of the line, this new installation will be strategically placed upstream to prevent metal from even getting to the point of packaging.”
Sitzman expresses confidence in the enduring partnership between Eriez and the American Pop Corn Company. He states, "We truly appreciate the reliability of Eriez metal detectors and intend to keep incorporating them into our production lines as needed. With the invaluable support of Jeanne Anderson, Eriez has consistently proven to be a trusted manufacturer, and we see no need to consider other options."
About the Author
Brandon Laine
Brandon Laine is technical sales representative at Eriez, a global provider of magnetic separation, flotation, metal detection, and material handling equipment to the mining, food, recycling, packaging, aggregate, and other processing industries.