Packaging & Storage¶

CCP-5: Metal Detection & Package Integrity

Process Objective¶

Package finished products in formats that preserve quality, provide accurate weights, and ensure tamper-evident, traceable delivery to customers.

Product Silo → VFFS / Bag Filler → Weight Check → N₂ Flush → Metal Detector → X-Ray → Date Code → Palletizer → Stretch Wrapper

Unit	Type	Capacity	Accuracy	Application
VFFS	Vertical form-fill-seal	600 bph	± 2 g	10–25 kg bags
Bag filler	Open-mouth	300 bph	± 10 g	25 kg multi-ply
Bulk filler	Gravity + scale	40 MT/hr	± 0.5 kg	1 MT totes
Drum filler	Bottom-up	20 drums/hr	± 50 g	200 L oil drums
N₂ flush tunnel	Inertisation	600 bph	O₂ < 2%	Oxidative-sensitive products
Checkweigher	Dynamic	600 bph	± 0.5 g	Reject out-of-tolerance
Metal detector	Ferrous / NF / SS	600 bph	Fe 0.5, NF 0.7, SS 1.0 mm	Reject on detection

Product	Primary	Secondary	Pallet Pattern
Hull	20 kg paper/PE	40 bags on slip sheet	8 × 5
Kernel	25 kg paper	36 bags on slip sheet	6 × 6
Powder	20 kg laminated (N₂)	50 bags on slip sheet	10 × 5
Gum	15 kg paper/PE	Fiber drum, 200 kg	4 drums/pallet
Oil (retail)	1 L glass	12 bottles/case	—
Oil (bulk)	200 L drum	Single drum	4 drums/pallet
Oil (bulk)	1 MT IBC	Single IBC	1 tote/pallet

Product	Temperature	RH	Max Stack Height	FIFO
Hull	< 25°C	< 60%	8 bags	✓
Kernel	< 25°C	< 60%	8 bags	✓
Powder	< 25°C	< 50%	6 bags	✓
Gum	< 25°C	< 50%	4 drums	✓
Oil	< 20°C	—	2 drums	✓

Check	Frequency	Critical Limit	Action
Metal detector test	Every 30 min	All 3 test wands detected	Stop line, quarantine
N₂ residual O₂	Every bag (inline)	< 2%	Reject bag, check N₂ supply
Checkweigher	Every bag	Per spec ± tolerance	Reject, calibrate
Seal integrity	Every 60 min	Visual + burst test	Adjust sealer jaws