Pukka Pies

closed

Three Mettler ToledoT10 X-ray machines were installed at the Pukka Pies factory in Leicester. The user interface on the T10 metal detector is easy to operate with its 15in touch screen display. The Mettler Toledo X-ray system can detect contaminants down to a size of 1mm, including metal, glass, stone, plastic and bone fragments. The T10 X-ray machine has increased the level of accurate detection that can be achieved at the Pukka Pies facility and has made production easier, alongside increased product safety. Pukka Pies is a well-known UK brand and has been manufacturing products in Syston, Leicester since 1963 when the business was founded. The company is a privately owned family business and employs 250 people at the Syston facility to produce over 50 million pies, sausage rolls and pasties per year. The range of products is extensive, including pies (various flavours such as beef and onion, steak and kidney, Halal Balti and chicken and mushroom), pasties, sausage rolls, saveloys, sausages, meat puddings and even frozen puff pastry. The company claims to operate ‘the most modern pie production facility in Europe’ and with its enviable reputation for quality has the most stringent hygienic conditions. UPGRADE In April 2007, Pukka Pies decided to upgrade its X-ray detection system for the detection of the presence of foreign bodies in products from the factory. The company approached the product inspection division of Mettler Toledo for advice on the best solution. Pukka Pies needed an X-ray system with several important features. The company required: To this end, Pukka Pies invited the Mettler Toledo product inspection division to provide demonstration equipment for live factory trials against another leading supplier’s X-ray detection products. The trials demonstrated that the Mettler Toledo system could fulfil all the requirements set by Pukka Pies and was easy to use, had robust construction (IP69K moisture protection can withstand the cleaning regime), a good software interface (15in touch screen display, provides a visual referenceusing images or diagnostics data) and a library function. In addition, the system demonstrated a greater level of accuracy and had a reject system with high-quality engineering. INSTALLATION Pukka Pies placed an order for three T10 XP standalone metal detectors in 2007 with reject systems, which were promptly installed and commissioned at the Leicester factory. Previously, Pukka Pies had been using older ferrous and foil metal detectors. Brigitte Coignec, Pukka Pies senior technical manager, commented: “At Pukka Pies, our key objective is to ensure nothing less than the highest levels of product safety and validation. As our products are frequently housed in aluminium trays, classic metal detection technologies do not always provide the best way forward. Initially validating Mettler Toledo technologies on site – and at their premises – we found the company’s equipment to provide excellent results across our wide range of food products.” THE MACHINE The T10 XP, built to IP65 standards and of stainless steel construction, is capable of detecting contaminating particles down to a size as little as 1mm. It can detect metal, glass, stone and plastic, and can even detect minute bone fragments in products, which would lead to rejection. The machine has increased the level of accurate detection that can be achieved at the facility and has made production easier as well as increasing product safety. Pukka Pies is now considering moving over to a more sophisticated 100% X-ray-based detection solution for the facility. QUALITY OF INGREDIENTS Pukka Pies butchers its own meat and only uses young, lean bullock beef, which is sourced from EC-approved plants. The company audits its own suppliers and this can include site visits. There is also a policy of not using any genetically modified ingredients in the production process. All raw materials and ingredients entering the Leicester facility are inspected against strict specifications upon delivery and then each of the suppliers’ performance is monitored to maintain standards.

High