Over the past 50 years, J&J Snack Foods has transformed from a humble pretzel processor to become a leader in baked goods, frozen beverages and frozen novelty products with 4,200 employees across 18 production facilities.
Along with size comes increasing responsibilities to quality and food safety. Although familiar with metal detectors, the company decided to install X-ray systems on a new line and two existing lines in an upgrade at its Moosic, Pa., facility, which makes variety packs of frozen novelties: Italian ice sorbets, frozen juices and ice cream. Up to eight separate lanes run different products at once.
“We decided to go with X-ray systems instead of metal detectors on these lines because we wanted to maximize our detection capabilities,” says Carissa Chrobak, food safety quality control manager at J&J Snack Foods.
“First, X-rays detect all dense foreign material and automatically reject contaminated packages. Second, some of our packages have foil lids, which is a problem for metal detectors. Finally, we sometimes use our X-rays to inspect the volume of product in a cup or the placement of product components in a package. For example, we have a package for club stores that contains tubes of Italian ice, and X-ray inspection lets us confirm the tubes are oriented correctly.”
So the company installed three X-ray systems from Mettler-Toledo Safeline, including an X33 model in 2017 and another X33 and a two-lane X36 model last year.
“We have checkweighers and other equipment from Mettler-Toledo, so they were our first choice when we decided to install X-rays at our Moosic facility,” says Ernest Fogle, vice president of research and development in J&J's frozen desserts division. “We wanted X-rays that offered impressive sensitivity, ease of use and reliability at an affordable price. We spoke with multiple suppliers, including our sales rep Bob Hatala of Reliant Packaging Machinery, and it was clear that Mettler-Toledo was the best fit.”
Products from J&J Snack Foods go to market under 25 house brands – including icons like ICEE, Luigi’s Italian Ice and Tio Pepe’s Churros – as well as customers’ private labels.
The versatile X36 X-ray system inspects similar products, such as different flavors, at the same time on two side-by-side conveyors while keeping the two product types separate. Handling 250 cups per minute, the line inspects Italian ice sorbets, frozen juice and ice cream in 2- or 4-oz. cups with foil lids or 6-oz. cups with paper locking lids.
The X36 is equipped with several options including a Safeline pneumatic reject device, an electronic bin for storing rejected products and a buzzer that alerts the operator when a package is rejected.
J&J Snack Foods selected the single-lane X33 X-ray system for each of its two high-throughput frozen dessert and beverage packaging lines. These lines handle a variety of different poly-based cups, ranging in size from 3 to 4.4 oz., at 250 cups per minute. Like the X36 system, they’re equipped with Safeline pneumatic reject devices, electronic bins and alarms.
Both the X33 and X36 models achieve the same high detection sensitivity as their previous-generation SmartChek and AdvanChek models but feature 20-watt generators, which consume one fifth of the power.
“We’re constantly looking for ways to minimize the energy we consume in order to reduce our environmental impact and improve our bottom line,” says Jay Montomery, vice president and general manager at J&J Snack Foods. “These Safeline systems help support our goal to be as green as possible.”
