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Rising to the occasion

A bakery installs new metal detectors to reduce downtime and guarantee the quality of its organic and preservative-free breads.

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For Fitzroy Alexander, owner of Traditional Breads in Lynn, MA, inspecting breads for contaminants is the “last line of defense” before the product enters the warehouse for shipping.


The process begins with the dough, which is mixed and formed into loaves. Next, it is placed in a proofer oven where it rises, at which point it is baked. After cooling for about two hours, the bread is flash-frozen, ready for packaging.

Loaves are manually packed into plastic liners and then hand-packed into corrugated cases. After the cases are sealed with a Little David case sealer from Loveshaw (www.loveshaw.com), they are ready to enter the metal detection system for a final check.

From dough to downtime

A reliable inspection system is paramount, but the company’s finicky metal detector was giving out false readings, which frequently brought the line to a grinding halt. “It wasn’t very accurate,” says Alexander. “Every two minutes it would give me a positive reading when it wasn’t positive, and that was enough to make my hair stand on end.” When the machine gave a false reading, the case of bread in question would have to be removed from the line and each loaf of bread had to be run through the machine individually. With an average of 30 loaves per case, the process was extremely labor intensive.  “You’d put them through and find there’s nothing wrong,” says Alexander. “It really slowed things down.”

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