en Sesotec GmbH - RSS Feed Sesotec GmbH - RSS Feed https://www.sesotec.com Sesotec GmbH https://www.sesotec.com/sites/593fc2aac25e5b0640a20ff8/theme/images/sesotec_logo_264x60.png?1591082886 Sesotec GmbH - RSS Feed https://www.sesotec.com <![CDATA[How food safety standards impact production]]> 2020-05-20 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/how-food-safety-standards-impact-production https://www.sesotec.com/emea/en/resources/blog/how-food-safety-standards-impact-production Food Safety

Ensuring food safety is the overarching concern that connects food industry players from all parts of the food supply chain. Food safety standards are omnipresent in the manufacture and production of food products and a substantial portion of a food producer’s expenditure is dedicated to their food safety management system.

In manufacturing, food safety management systems are designed to address two types of food safety standards: legal food safety requirements as defined by governmental agencies and food safety certifications obtained from private, third-party auditing firms.

Legally speaking, food manufacturers are only required to comply with the food safety legislation of the countries in which they do business. By comparison, obtaining additional, internationally recognised food safety certifications from third-party auditing firms is optional.

The challenges of food safety management for manufacturers

Ensuring food safety is an intensive and continuous process. Implementing and maintaining an effective food safety management system invariably demands the investment of nontrivial amounts of time and money.

All international food regulations are built around an HACCP concept: they identify potential food safety hazards and critical control points and specify proactive means by which to control for and prevent these hazards. The more potential hazards inherent to a food manufacturing process, the more robust the food safety audit and controls must be.

The exact amount of resources a manufacturer should expect to invest in food safety management depends largely on the foodstuffs produced and the scope of production. Food manufacturing facilities that run highly complex operations consisting of hundreds of employees and dozens of distinct processing steps should expect to invest more time and resources into achieving compliance.

Time invested in food safety

Not all working hours in a food manufacturing facility are spent on production. An important number of working hours are devoted to tasks related to food safety. These activities include, among others:

  • Employee education – All employees who come into contact with food products over the course of their workday must be trained in food safety protocol. In addition to certifying new hires, employees need to partake in recertification sessions on a regular basis.
  • Documentation and recordkeeping – From equipment cleaning protocol to the materials used in food-contact applications, most every aspect of the food production process must be documented.
  • Inspections – From raw ingredient intake to in-process inspection to final quality checks, food products are inspected many times on their journey through the supply chain. Distinct quality control measures are carried out at each individual stage.
  • Hygiene and cleaning – Facilities and all food-contact equipment therein must be sanitised at regular intervals. All employees working in food-contact roles must also take time to ensure they are following proper hygiene protocols.
  • Audits – A requirement for obtaining food safety certification from a third-party agency, audits can span several months and include extensive preparation, consulting, on-site visits and follow-up communication.
  • Validation and verification – It is not enough to simply implement a food safety management system; food manufacturers must also regularly prove that their system works. Validation concerns collecting evidence that the chosen food safety methods are effective for the application, while verification concerns confirming that implemented processes are working as expected.

Money invested in food safety

Ensuring food safety in a manufacturing environment also requires financial investment. Some of the costs involved in a robust food safety management system include:

  • Certification – Obtaining and renewing certification with third-party auditors involves several upfront costs. For an initial on-site audit, food manufacturers should expect to spend between €5,000 and €10,000, not including additional travel costs. After receiving certification, there are also yearly membership fees.
  • Food Safety Systems Manager salaries – Many larger food production businesses have a dedicated role or team responsible for the management of food safety activities.
  • Food safety technology – From advanced contaminant detection equipment, to automatic temperature controls, to hygienically designed processing equipment, a large portion of the total cost of food safety goes towards investing in the proper technology to reliably reduce risk.
  • Equipment maintenance and servicing – Food processing and inspection equipment must be regularly serviced in order to prevent malfunctions and unplanned downtime. Should machinery deteriorate, foreign objects may contaminate food products. Computerised food safety technology, such as contaminant detection equipment, must also undergo software updates.

Food safety as an economic imperative

Despite the hefty upfront and ongoing costs of achieving and maintaining compliance, food safety remains crucial to the economic viability of a food manufacturing business.

Because food law (and the rigor with which it is enforced) can vary from region to region, global market leaders within the food industry demand that all upstream and downstream partners with whom they work provide evidence as to the effectiveness of their food safety system.

In addition to granting access to lucrative international markets, a robust food safety management system can provide highly precise data that can be leveraged to improve productivity and prevent recalls.

Preventing recalls

Though ensuring food safety is a time- and resource-intensive endeavour, the effort and costs involved are negligible compared to fallout of product recalls.

Globalization and digitalization have amplified the corporate consequences of contaminated food products entering the market. Not only is executing a recall more costly and difficult when goods have been shipped across the globe, but the news of recalls can now spread faster and further via social media and other digital channels.

Product recalls are truly disastrous for food industry businesses. In addition to the hefty price tag of organizing and executing a recall, companies may also incur untold losses due to the resulting decline in consumer trust. Both can be devastating to the ongoing economic viability of a company.

A third-party food safety audit can help illuminate the blind spots in a production line. These blind spots, if neglected, could lead to a contaminated product making its way onto consumers’ plates. Through continued investment in advanced food safety technology and more robust and transparent food safety management policies, food manufacturers can continuously shrink the likelihood of a recall.

Efficiency gains

Improving a facility’s food safety management system can do more for a manufacturer than simply win them the certification necessary to access international markets. By implementing a modern and robust food safety concept, manufacturers can also reap rewards in terms of production efficiency.

For many food manufacturers, obtaining an internationally-recognised certification in food safety involves implementing a meticulous protocol for ongoing documentation and updating the food safety technology within their facilities. Where intelligent inspection equipment meets rigorous documentation, there is valuable data to be gleaned.

By improving and expanding contaminant detection equipment and record-keeping practices, food manufacturers can win cost-saving insights into their production processes, reduce excessive food waste and quickly trace food safety threats right to the source.

An effective food safety management system can also help manufacturers to rapidly ramp up production in times of crisis. Should production output need to quickly multiply in order to deliver basic foodstuffs to a public in need, a robust and reliable food safety management system can be scaled up to accommodate a higher output without compromising on quality.

Conclusions: What is the purpose of a food safety management system?

Because food safety is a series of preventative procedures, it can sometimes be challenging to ascertain what a food industry business can gain financially from their implementation. How does one assign an exact monetary value to food safety failures that may have happened, but didn’t?

The purpose of a food safety management system is to ensure that a food production facility is using state-of-the-art technology, science and protocol to minimise the risk of contaminated products reaching consumers. From preventing to recalls, to navigating the global supply chain, to increasing productivity: when food manufacturers modernise their production facilities according to international standards, they become better prepared to handle the economic challenges of the modern food industry.

eBook: Driving Impact – Safe food and saving food

The world population stood at 7.71 billion in 2019. That figure is set to reach 9.74 billion in 2050. In order to secure the global supply of food in the future, waste must be reduced and productivity increased. In our eBook we show you, amongst others, what challenges the development of the world's population and especially food safety pose for manufacturers and processors and how they can still be mastered.

<![CDATA[How plastics processors use recyclates profitably]]> 2020-05-19 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/how-plastics-processors-use-recyclates-profitably https://www.sesotec.com/emea/en/resources/blog/how-plastics-processors-use-recyclates-profitably Circular Economy

Why recyclates increase profitability

Recyclates have many advantages – for processors, consumers and the environment. Although the price of recyclates fluctuates, it is generally lower than the cost of new materials. There is also a long-term trend towards greater environmental consciousness in society at large, which make it more important that companies actively address environmental issues. Customers notice the proportion of recyclate materials used, and some even demand their use, so companies are increasingly committing to using certain ratios of recyclates.

Recyclates accounted for approximately 12.3% of the total volume of plastics processed in Germany in 2017. An industry comparison shows that significant quantities of recyclates were used in agriculture (34.9%), construction (21.5%) and packaging applications (9.1%).* That is a win for the environment, because using recyclates preserves resources. It is clear that the circular economy is becoming an important megatrend. But to make use of recyclates and truly close the plastic cycle, they have to be constantly available in sufficient quantities, and meet certain quality standards. That still isn’t always the case.

Why is quality testing necessary?

“The recyclates available on the free market may contain a variety of polymers and even metals,” says Tim Hencken, CEO of Sitraplas GmbH, a producer of engineering-grade plastic compounds, who buys and uses recyclates every day (> Read our Case Study about Sitraplas here). But where do the impurities come from?

A closer look shows that there are many sources of impurities in delivered recycled goods. One reason is that today’s packaging and products are often made from various types plastic, in a variety of colours and a range of materials. Beverage bottles and their lids are often made from different types of plastic. And plastic soap dispensers usually have a metal spring. If the different materials are not correctly identified, separated and sorted in the plastic recycling process, then they are mixed and shredded, and end up in recyclates.

What is the potential impact?

If the recyclates are impure, it has consequences. For example, foreign plastics can change the physical properties of products made from recyclates. That has a negative impact on product quality, leading to complaints. Incorrect colours result in discolouration, another reason for complaints. Metal impurities are the most common type of contamination in recyclates.

They can damage machinery – resulting in downtime, production outages and financial losses. And they increase the use of replacement parts and maintenance work, which significantly reduces the service life of parts that come into contact with the product. In short: production becomes less efficient. “Impurities can, for example, clog screens or damage plasticising screws. We have to avoid that at all costs,” says Hencken.

How can metal impurities be avoided?

Plastics processors must consider how metal impurities can be reliably removed from recyclates. Since metal is often hard to identify in product flows, that is a significant challenge. Metal particles are virtually invisible when mixed in with granulate. However, there are other ways to detect them.

Recognising and interpreting signs

Specific signs that recyclates contain metals include the constant clogging of screens in extrusion or injection-moulding machines with metals, or the need to regularly clear screen changers of included metal or melt.

Frequent blockages of injection-moulding tool channels by metal parts also indicate the presence of metals in the product flow. Metal inclusion in finished products is also a clear sign of contamination.

Implementing detection and separation

Plastics processors have a number of ways to prevent metal impurities. They can assess the quality of material from recyclers by inspecting incoming goods through the installation of material analysis and metal detection systems. Material analysis systems automatically examine and document the composition of incoming material, allowing the plastics processor to immediately determine and survey recyclate quality.

Installing metal detectors with integrated separating units at the start of the production process, and at other critical points, protects products and systems by removing metals. State-of-the-art detection systems can identify and separate even the smallest metal particles. That is decisive, because the smaller the particles that are detected and eliminated, the better the protection against damage and complaints. 

Magnet separators are also used, but are not sufficient on their own – because they only remove magnetic metals. They cannot eliminate stainless steel and other non-magnetic metals, such as copper, brass or aluminium. A magnet separator should, therefore, always be used in combination with a metal detector – to sort out iron in advance and thereby relieve the burden on the downstream metal detector.


The use of recyclates is increasing, making material analysis systems and metal detectors more important. The limited availability of recyclates forces plastics processors to acquire them from a variety of suppliers. That means uniform quality is usually not guaranteed. However, extremely precise analysis and detection systems allow plastics processors to purchase recyclates without risk, further increasing the profitability of their production processes. Ultimately, material analysis systems and metal detectors make an important contribution to cost-effectively closing the plastic cycle.

White Paper: Important factors when buying a metal detector for plastics processing machines

How easy is it to install the metal detector in the production line – and how easy is it for your staff to operate the device? In our white paper, we will take a closer look at these two factors and show you why you should take them into account when making your decisions.

<![CDATA[Sitraplas: Risk-free recyclate processing]]> 2020-05-14 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sitraplas-risk-free-recyclate-processing https://www.sesotec.com/emea/en/resources/blog/sitraplas-risk-free-recyclate-processing Case Studies

The Sitraplas team, over 40 employees strong, works in state-of-the-art production and laboratory facilities to quickly and reliably implement individual solutions. Their compounds are used by customers all over the world in challenging applications in the automotive, electrical engineering, and electronics industries, among others.

The problem: metallic impurities in purchased recyclate

Separately purchased recyclate often contains various different polymers as well as metal contaminants such as aluminum, brass, and stainless steel. Depending on the size of these contaminants, metallic particles can impede the plastic production process by clogging screens or damaging screws. In other cases, metallic impurities can also lead to contaminated end products. Such scenarios must be avoided at all costs, as machine downtime and product recalls are enormously costly both for production and a company’s image. Furthermore, contaminated end products must be disposed of, leading to a tremendous volume of waste.

The solution: metal separators that detect and separate the finest metal particles

To prevent downtime and recalls, Sitraplas uses GF Primus metal separators from Sesotec. These metal separators are installed in pneumatic conveying systems, where they detect metallic contaminants within the recyclate as they pass through, reliably rejecting them in a fraction of a second. All of this is possible without interrupting the material flow and without reducing the speed of conveyance.

The outcome: reliable processes, high product quality, increased profitability

Sesotec’s GF metal separators play a key role in helping to protect Sitraplas’ machinery, preserve the quality of their products, and keep their facilities operating efficiently. Furthermore, the rejected contaminants are automatically collected so they can be analyzed for important information about the quality of the purchased recyclate.

„Thanks to Sesotec’s metal separators, we’ve had zero incoming complaints about metallic contaminants,” says Tim Hencken, Managing Director of Sitraplas. “They have led to a noticeable improvement in the performance of our processing equipment, eliminating the risks involved in working with recyclate.“

Bartosch Jauernik, Product Manager for the Plastics Industry at Sesotec, adds: “In this way, our metal separators are doing their part to contribute to the establishment of a sustainable and profitable circular economy.”

Download Case Study

 Sitraplas: Risk-free recyclate processing

<![CDATA[Best colour sorting technology ensures purest seeds]]> 2020-05-14 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/best-colour-sorting-technology-ensures-purest-seeds https://www.sesotec.com/emea/en/resources/blog/best-colour-sorting-technology-ensures-purest-seeds Case Studies

The problem: manual sorting of seeds is time-consuming and costly

The work of the experimental station is characterised by practical experiments, special cultures are examined in small quantities and many different batches make the process complex. In addition, the seeds to be processed are differentiated according to size, colour and shape as well as to different degrees of contamination. The manual sorting of the seeds is time-consuming and causes very high personnel costs.

The solution: highly modern colour sorting technology for small seed quantities

Sesotec ASM supplied the intelligent optical sorter QUASAR 1000 for the sorting of small seed´s quantities. Thanks to the high-resolution true-color cameras, the device can detect the finest color differences with the highest precision and eliminate off-colors. This guarantees maximum purity with minimum loss of g ood material.

The sorter is very compact, the operation is easy to understand. Additional benefits are the good price-performance ratio and the excellent quality.

The customer benefit: high-quality seed with less time and personnel costs

The installation of the intelligent optical sorter QUASAR 1000 has significantly improved the cleaning process in the test station in terms of accuracy and speed. The pre-cleaning is still carried out with simple devices, the post-sorting is no longer necessary and saves personnel costs. The whole process takes less time and gives a very high seed purity.

„Until now, we have sorted the seeds by hand and our team was busy with it for days. Definitely, the new sorter makes our work easier, which we are very pleased about,“ emphasizes test station manager Doris Lengauer. „We are also very satisfied with the machine in terms of price-performance, operability and product results, as well as with the support provided by the Sesotec staff“.

Download Case Study

 Best colour sorting technology ensures purest seeds

<![CDATA[Statement from Sesotec on digitalization in the time of Corona]]> 2020-05-12 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/statement-from-sesotec-on-digitalization-in-the-time-of-corona https://www.sesotec.com/emea/en/resources/blog/statement-from-sesotec-on-digitalization-in-the-time-of-corona Company

Dear customers and partners, 

In an interview about the Coronavirus pandemic, philosopher Wilhelm Schmid said the following: "These are unusual times. And unusual times are times of learning." One example of learning is the accelerating pace at which companies are digitalizing as a result of this crisis. Before the pandemic, digitalization was often mentioned as a goal or buzzword. Now, digitalization is a pragmatic and necessary approach to daily business. 

The implementation of digital solutions is no longer being hemmed by an attitude of “we’ve always done it this way.” Companies are learning in real-time how and where digitalization can work for them. With this crisis has come the realization that digital processes and platforms are often simpler, faster, cheaper, and therefore more efficient overall. 

Many of us have been delighted to take part in quick and productive digital meetings which, prior to Coronavirus, would have demanded hours of our physical presence. And with home office solutions allowing a certain degree of personal freedom, many companies are seeing improvements in employee motivation. In the realm of customer support, remote service solutions that make use of augmented reality are delivering notable benefits in terms of productivity and security. And while trade fairs have been cancelled or postponed, there are still opportunities to connect digitally. Sesotec, for example, is hosting a virtual exhibition stand (-> visit our virtual stand).  

Digitalization fosters a new type of cooperation. Mutual trust is paramount in order to facilitate the secure exchange of data. The better this exchange works, the more successful the cooperation. 

Despite the challenges, the Corona crisis is an opportunity for all of us. We are experiencing rapid progress and seeing digital technologies establish themselves as the new standards. But we are also learning that not everything can or should be digitalized.  

Under no circumstances should companies fall back into inefficient working methods and old silo mentalities once the crisis is over. Furthermore, according to Reinhard Loske, Professor of Sustainability and Social Design at the Cusanus University in Bernkastel-Kues, life after Corona will not be the same as life before the pandemic. Beyond the implications for our climate, such a return would be neither generationally appropriate nor sustainable. 

We are glad to stand by you, even in difficult times.


Best regards and stay healthy, 

Marc Setzen, CEO

<![CDATA[When the machine stops, you can count on us]]> 2020-05-05 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/when-the-machine-stops-you-can-count-on-us https://www.sesotec.com/emea/en/resources/blog/when-the-machine-stops-you-can-count-on-us Company

In a time when personal contact and travel must be reduced to a minimum, essential businesses are forced to restructure the way they access production facilities. The coronavirus crisis had made it abundantly clear: innovative service solutions are of vital importance to ongoing plant availability.  

To ensure that metal detectors, X-ray inspection devices, sorting and material analysis systems continue to function reliably, Sesotec offers remote support from its headquarters in Germany. Their services include the following:  

Telephone support - Sesotec hotline

Many questions and problems can be addressed through a phone call. Sesotec offers free telephone support between 6 AM and 8 PM CET during the week, and between 8 AM and 5PM CET on the weekends.

Contact Sesotec service representatives for product inspection devices:

Tel. +49 (0) 8554 - 308 173
Email service.msg@sesotec.com

Contact Sesotec service representatives for sorting systems:

Tel. +49 (0) 8554 - 308 129
Email service.sorting@sesotec.com


Remote access

Errors in metal detectors, X-ray inspection devices, sorting and material analysis systems can frequently be corrected via remote access. Sesotec service technicians can access the software via Ethernet in order to troubleshoot, optimize, and set parameters. This data will then be processed in the Sesotec Service Center and sent to the customer as feedback.

Many Sesotec devices offer remote servicing functionality as standard. Any customer who wishes to confirm whether their Sesotec system has remote access capabilities can simply complete the contact form at this URL: https://www.sesotec.com/emea/en/lp/remote-support.


Remote support with augmented reality

Sesotec also offers video-based support using augmented reality technologies. Customers can download a free app to their PC, smartphone, or tablet and forward the access data to Sesotec. This way, Sesotec representatives can provide step-by-step support until the issue has been resolved.


Express service for spare parts

The Sesotec Service Center keeps a stockpile of all current circuit boards, as well as many older models. Spare parts can be shipped within 24 hours on weekdays. The boards are largely pre-programmed so that customers can simply "plug and play.” Sesotec representatives can give step-by-step guidance via telephone as the customer replaces the part. 


Markus Grimm, Group Director of Service at Sesotec summarizes: "We currently provide up to five remote support sessions per day, accessing our customers' systems and solving many problems online without the need for an onsite visit. The advantages for our customers are obvious: high plant availability, process reliability, and productivity, as well as no travel costs. Furthermore, these benefits are universal, and not exclusive to times of crisis or unplanned downtime. In light of the current coronavirus situation, we are offering our remote support services to all our customers free of charge for the next six months.”
<![CDATA[How better food safety technology can help minimise waste]]> 2020-03-31 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/how-better-food-safety-technology-can-help-minimise-waste https://www.sesotec.com/emea/en/resources/blog/how-better-food-safety-technology-can-help-minimise-waste Food Safety

From farm to factory to fork, nearly 1.3 billion tons and 1 trillion USD worth of food products slip through the cracks of the global food supply chain each year. According to studies by the United Nations, roughly a third of all food products end up discarded, constituting a tremendous waste of natural resources, labour and capital, and amounting to a major source of needless greenhouse gas emissions.

In a supply chain that grows more intricate with each passing year, the problem of global food waste is not attributable to any single player in the food production life cycle alone. Food waste happens at every stage of food production and consumption, and the volume of waste differs dramatically by region. In industrial nations, the largest volume of food is wasted at the hands of end-consumers. In developing nations, however, the FAO cites a lack of infrastructure to facilitate coordination between farmers, manufacturers and distributors as the most significant source of food waste.

Share of Food Waste in Germany by Value Chain Sector - 2015 (Source: bmel.de pg. 4)

In developed nations, nearly a fifth of food wastage happens during manufacturing and production. Beyond the environmental impact of food processing waste, there is a sizable financial incentive for manufacturers to reduce food waste within their facilities. In the face of narrowing profit margins and a rising pressure to ramp up productivity in order to feed a growing global population, reducing industrial food waste may be a necessity in order to remain competitive in a changing market.

Causes of food processing waste

There are many causes of industrial food waste, some of which are avoidable while others are virtually inevitable. In terms of preventable and recurring waste, inefficient working procedures and inadequate employee training are amongst the major drivers of wasted food in manufacturing environments. A study by researchers at Brunel University London and Ghent University found that roughly 11 per cent of all food processing waste was due to routine human errors. However irregular and monumental product losses can also occur in the face of unforeseen power outages, natural disasters or unplanned downtime due to equipment failure.

But paradoxically, food safety protocol is another major contributor to the problem of pre-consumer food waste. In order to ensure that no contaminated or otherwise defective products end up on consumers’ plates, global food safety standards are designed to diminish risk at every turn. This means that even the slightest detectable chance of contamination within a product results in its rejection from the production line.  

The role of food safety technology in reducing pre-consumer food waste

While a zero-tolerance approach to food safety risks is crucial to protecting consumers from foodborne illness and injury, unoptimised inspection systems may be wasting a disproportionately high amount of food. Between traceability issues, product recalls and false rejects, inferior food safety technology may be contributing to food waste problems.

Innovative contaminant detection and inspection technology makes it possible to both maintain compliance with rigorous food safety standards and minimise the volume of food discarded during manufacturing. Here is how improving the food safety devices within a manufacturing facility can help reduce food processing waste:

1. Early detection of contaminated products

End-of-line product inspection is a necessary feature in any food manufacturing facility, ensuring that packaged products are safe to continue their journey along the supply chain. But relying on end-of-line inspection alone to control for physical contamination in food products has several downsides. One of these downsides is a higher volume of food waste.

Food products may become physically contaminated at any juncture in the production line. It may even be the case that raw ingredients arrive at the facilities already harbouring physical contaminants. If there are no controls in place to screen for contaminants until the final stage of production, a contaminated food product may have made a complete journey through the manufacturing process before being identified and rejected. In this scenario, it is not just the contaminated product that is being thrown out, but also all the additional ingredients, energy and resources that went into its processing up until that point.

Product purity is best ensured when food manufacturing facilities implement a sophisticated, multi-tiered food safety concept in which food products are inspected at several critical control points along the production line. By integrating advanced detection technology at strategic processing junctures, such as at raw-ingredient intake and after mechanical processes like pulverisation, physical contaminants can be identified and rejected at the source. This not only provides more precise data in regards to tracing contaminants, but it also saves companies from investing resources into products that will only be rejected later and prevents foreign bodies from dispersing and contaminating further product batches.


2. Avoiding the waste associated with food recalls

Food product recalls are on the rise worldwide. In the United Kingdom alone, food recalls across all product categories increased 40 per cent over the course of the 2018 calendar year. An unfortunate but often necessary measure, food recalls are imperative in order to prevent illness and injury. But in terms of food waste, the tradeoff is enormous.

When food products are recalled, it is not just the contaminated products that get thrown out. Rightly preferring to err on the side of caution, companies and consumers toss out a tremendous of volume of food that may actually be safe to consume. A single contaminated specimen entering the market could theoretically lead to the waste of thousands of pounds of perfectly edible food products.

No food manufacturer wants to recall a food product. Beyond the lost resources and high costs of pulling products from store shelves, recalls wreak serious damage to a company’s reputation. Reliable food safety technology is key to preventing consumer injury, food wastage and the PR crisis that follows in the wake of a product recall.


3. Reducing false rejects caused by product effect

Amongst the most complex challenges in metal contaminant detection is the phenomenon of “product effect.” Some common food products such as fresh fish, meat and dairy have a moisture- and salt-content that creates the right conditions for the product to have a certain electrical conductivity. This can lead these perfectly safe products to trigger the rejection mechanism on industrial metal detectors meant to control for the presence of foreign bodies in food.

International food safety standards demand that any food rejected by a contaminant detector is discarded, even if a false reject due product effect is suspected. A metal detector that is not properly configured to adjust for product effect can lead to a high rate of false rejects, resulting in unnecessary food waste. Industrial metal detectors used to inspect foods with high moisture and saline levels must be equipped with intelligent software that is flexible enough to accommodate such adjustments.

The most advanced industrial metal detectors use artificial intelligence in order to differentiate between metal contaminants and the product effect generated by meat, fish and dairy products. These innovative, AI-integrated metal detectors can both reduce the food waste associated with false rejects and improve the overall accuracy of product inspection.

In other cases, it may be necessary to employ x-ray inspection technology instead of metal detectors in order to prevent excessive food waste due to false rejects.



In order to meaningfully address the problem of food waste, players at every stage in the food product life cycle must take action to reduce waste within their sphere of influence. In food manufacturing, the financial and ethical imperatives to minimise industrial food waste may at times conflict with critical food safety measures. Advanced food safety technology can help eliminate the friction between these two important causes. In addition to diminishing the threats that physical contaminants can pose to consumer health, the improved accuracy of a robust inspection system can prevent large amounts of food and valuable resources from ending up in the bin.

About Sesotec

For more than 40 years, Sesotec has been a market leader in the field of contaminant removal and sorting technology. We develop both standardised and customised food safety solutions for food and beverage manufacturers around the world.

eBook: Driving Impact – Safe food and saving food

The world population stood at 7.71 billion in 2019. That figure is set to reach 9.74 billion in 2050. In order to secure the global supply of food in the future, waste must be reduced and productivity increased. In our eBook we show you, amongst others, what challenges the development of the world's population and especially food safety pose for manufacturers and processors and how they can still be mastered.

<![CDATA[Profitable recycling – how recyclers can work efficiently]]> 2020-03-30 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/profitable-recycling-how-recyclers-can-work-efficiently https://www.sesotec.com/emea/en/resources/blog/profitable-recycling-how-recyclers-can-work-efficiently Circular Economy

Recyclate is the name of the recycling industry’s key material. But what exactly is it? The word is an umbrella term that describes materials produced in the recycling process. There are various forms of recyclates, such as ground materials, regranulate or regenerate. Ground materials are produced by grinding plastic. Regranulate is made by turning ground material into granulate by means of a melting process. Regenerate is also produced in a melting process. However, additives are used to improve the properties of the material. Unlike ground materials, regenerates and regranulate have a uniform granule size and are free of dust.

How are recyclates produced?

Many things that people discard – such as plastic bottles, boxes or pots – can be used as source materials for recyclates. Recycling firms use a precisely coordinated procedure to process these waste materials. The resulting recyclate is mixed with other raw materials to make new products – or new products are made using recyclate alone. Such products may include packaging, as well as textiles and furniture.

Recyclate quality is important

Special recyclate is required to make these high-quality products, and can be sold for higher prices. To get as much high-quality plastic as possible, recycling companies need large quantities of recyclable material. Functioning collection systems, such as Germany’s yellow bins, are needed to secure that supply. According to the industry association PlasticsEurope, more than 8 million tonnes of used plastics were collected in this way in Europe in 2016.    

Plastic waste: quantity counts

The greater the quantity of plastic collected, the higher the amount of material that can be used to produce high-quality products. For recyclers, the right composition and quality, as well as the right quantity, are of the essence.

Room for growth in recycling

The quantity of available used plastic in Europe could be higher. Only around a third of the plastic used on the continent is recycled. The rest ends up in landfill or is incinerated.

What is more, the plastic waste that is collected often does not have the hoped-for composition and may contain household waste or even metal parts. An investigation by the website Plastverarbeiter showed that the permissible level of impurities was exceeded in 80% of samples. Appropriate technology can be used to remove all the material that cannot be recycled, but that increases costs. The resulting waste also has to be disposed of, costing recyclers even more money.

Composition and type of packaging are important

The type of packing disposed is another factor that can make recycling more difficult. For example, black bottles take more work to sort than clear ones. Their remains are also rarely reused, because manufacturers want transparent granulate, which can be used to make a much larger range of products.

The composition of packaging is also important. Beverage packaging made of composite materials takes more work to recycle. It can consist of several layers of different types of plastic, as well as layers of paper or filler, such as chalk.

Recycling – a question of profitability

When manufacturers decide whether to use recyclate or new plastic made from mineral oil, they consider both quality and cost. Recyclers therefore have to depend on modern technology to produce recyclate profitably, so that they can sell it at competitive prices. The recyclate has to be able to compete with new materials on both quality and price.

The profitability of the recyclate depends on numerous variables. Firstly, the quality of the incoming material must be as high as possible. The better the material, the more economical the sorting procedure, reducing process costs and increasing profitability.

The recycling process has several stages. First a shredder cuts the refuse into small pieces, then a strong blast of air removes everything that is not needed, such as film, polystyrene or textile waste. The remaining plastic is ground, washed and sorted by density before being dried and melted.

Recyclers must know from the outset the quantities of waste they have to process so that they can optimally plan their systems – and calculate which modules they require to sort, wash and shred refuse – or decide whether it is worth investing in an extrusion system. To produce high-quality, competitive recyclate and ensure that the manufacturing process remains profitable, all the modules must be coordinated

Flexible process technology in recycling

Only in theory do recyclers have a stable quantity of input material of consistent quality. If that theory translated into practice, then they would be able to buy the appropriate systems, and would always be working at capacity. In reality, the type and quantity of the used plastic they receive varies considerably. That is why it is important that companies use flexible technology in their systems. They must be able to identify a wide range of materials, including existing and future plastic packaging and product designs.

However, sorting processes also have to be flexible so that they can react to fluctuations in the quality and quantity of the incoming material. Well-considered, coordinated implementation and combination of sorting systems raises both the quality and output quantity of the respective plastic, increasing profitability.

Higher recycling rates thanks to intelligent technology

The industry depends on innovation to further improve the recycling rate and make processing more profitable. According to the plastic recycling trade association bvse-Fachverband Kunststoffrecycling, just 12.3% of new plastic products are made from recyclate. That low figure is due more to uncertainty rather than a lack of will on the part of manufacturers, who often have insufficient knowledge about recyclates and the plastics they contain. Materials melt at different temperatures and have different strengths. As a result, many manufacturers stick to tried-and-tested raw materials made from mineral oil, even though consumer and public pressure is driving a trend towards recyclate.  

Intelligent technology may soon be able to solve this problem. In the future, sensors may be able to analyse the quality of processed plastics as they are produced. Software could be used to assess that data and make it available to the industry via a digital platform.

More recycling, less refuse – a win for the environment

Recyclers’ calculations also take indirect account of consumers’ wishes. Buyers are becoming more environmentally conscious and are increasingly demanding products made with high proportions of recycled material. That trend could also raise demand for recyclate, which would increase prices and profitability.

Well-considered recycling benefits companies and the environment alike – and not just because plastic waste pollutes land and seas around the world. The manufacture and incineration of plastic generates emissions of the greenhouse gas CO2, which is partly responsible for global warming. The reuse of plastics in a circular economy therefore benefits not only the recycling industry and consumers, but also the environment, and helps lay the foundations for a sustainable economy.

About Sesotec

As a partner to the plastics industry, Sesotec provides a variety of solutions designed to meet the needs of recyclers, plastics manufacturers and plastics processors. Sesotec helps ensure product purity through sensor-based material analysis systems, sorting systems, metal separators and services. The result? Guaranteed efficiency and profitability for the preparation, production and processing of plastics.

eBook: Driving Impact - Closing the plastic cycle

Closing the plastic cycle is the cleanest solution for humans and the environment. That is something politics have come to realise. Still, the industry also needs to lead by example. In our eBook we show you, amongst others, which challenges plastic recyclers, manufacturers and processors are faced with in the context of the circular economy.

<![CDATA[Sesotec presents a virtual interpack exhibition stand]]> 2020-03-26 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-presents-a-virtual-interpack-exhibition-stand https://www.sesotec.com/emea/en/resources/blog/sesotec-presents-a-virtual-interpack-exhibition-stand Food Safety

In light of the developing coronavirus situation, the 2020 interpack trade fair in Düsseldorf has been rescheduled for February 25 to March 3, 2021. Sesotec GmbH welcomes this postponement as a necessary measure to protect the health and safety of all interpack presenters and visitors.

In the meantime, in order to keep Sesotec customers up-to-date on company news, the manufacturer of contaminant detection and material sorting technologies is launching a virtual trade show experience.  Starting May 7, 2020, interested parties can visit http://www.sesotec.com/en/interpack to learn about the exciting product developments Sesotec would have presented at the exhibition.

Under the slogan “Driving Impact – Safe food and saving food,“ Sesotec will present on a number of issues concerning food safety and the fight against food waste. The virtual exhibition will cover some of the most pressing challenges facing the food processing and manufacturing industries, from conserving resources, to production efficiency, to increasing profitability, to environmental protection.

Highlight: Metal Detection with Artificial Intelligence

The virtual trade show exhibit will also feature the debut of Sesotec’s latest innovation: “THiNK,” an AI-software for metal detection equipment. Other topics include food safety compliance and a lifetime warranty package for x-ray inspection systems.

“The interpack may have been rescheduled for next year,” says Uli Hurzlmeier, Product Manager for Food at Sesotec, “but we will still take this opportunity to present our latest products and service innovations to our customers.  We look forward to welcoming many visitors to our virtual exhibition stand.”
<![CDATA[High-quality PET recyclate for the plastics processing industry]]> 2020-03-25 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/high-quality-pet-recyclate-for-the-plastics-processing-industry https://www.sesotec.com/emea/en/resources/blog/high-quality-pet-recyclate-for-the-plastics-processing-industry Case Studies

With the rise in consumption of raw materials, plastic processors are facing higher political and social demands to use a greater proportion of recycled materials. Companies such as MultiPet GmbH, a recycling company which processes used PET materials into flakes, make this transition possible. Along with their sister company Multiport, which specialises in making HDPE compounds from packaging waste, they are considered important suppliers of secondary raw materials for the plastics processing industry.

MultiPet GmbH is part of Veolia, a globally active environmental service provider. Multi-Pet processes discarded PET bottles and trays into high-quality recycled PET flakes that are pure enough to be used by plastic processors to create new products and containers.

How does the PET recycling process work?

MultiPet receives pressed bales of pre-sorted PET waste. After the bales are broken up, plastics are first checked for impurities, then ground into flakes and intensively washed.

The FLAKE PURIFIER+ multi-sensor sorting systems from Sesotec come into play directly after the ground material has undergone a two-stage density separation process involving two rounds of hot washing. At this stage, the sorting systems separate discoloured materials, foreign plastics and metals from the flakes.

Sesotec FLAKE PURIFIER+ units are designed especially for use in plastic flake processing and are characterized above all by ease of operation and heightened throughput capacities.

At MultiPet, the FLAKE PURIFIER+ systems are equipped with multiple sensors for colour and material recognition. This enables MultiPet to produce PET flakes in batches of different colours and qualities for use as raw materials in the plastics processing industry. By using recyclates produced by MultiPet, plastic processors are reducing their CO2 footprint, contributing to climate protection and conserving resources.

“Sesotec’s processing technology enables us to keep the loss of good material to a minimum”, says Herbert Snell, Managing Director of MultiPet GmbH. “This makes our sorting processes even more efficient.“ Sesotec‘s scope of delivery was complemented by a turn-key material handling setup which included steel work platforms and material conveyance systems, simplifying integration into the overall system.

Download Case Study

 High-quality PET recyclate for the plastics processing industry

<![CDATA[Next Generation Metal Detection with Artificial Intelligence]]> 2020-03-23 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/next-generation-metal-detection-with-artificial-intelligence https://www.sesotec.com/emea/en/resources/blog/next-generation-metal-detection-with-artificial-intelligence Food

Would you like to learn more about this topic? We would be pleased to advise you. Contact us!

The food processing and manufacturing sector is confronted with a monumental undertaking: a rapidly growing number of people must be fed, the supply chain is becoming increasingly complex, consumer tastes are becoming increasingly specific, and the standards for food safety and quality have never been higher.  

Challenging requirements...

The future of global food security depends on an increase in productivity on the one hand, and a reduction of food waste on the other. A food industry partner for nearly 50 years, Sesotec offers intelligent technologies that make it possible for processing and manufacturing businesses to comply with stringent food safety requirements in a productive and resource-efficient manner. 

…met with innovative solutions

“THiNK,” the latest innovation from the Sesotec headquarters, is an AI-software for metal detection equipment. Using machine learning algorithms exponentially more powerful than if/then conditions, the metal detection system is able to independently assess and draw conclusions from large data sets.  

While the field of metal detection has seen tremendous technological advancements, certain practical challenges persist. For example, some food products have a high degree of “product effect” and can lead to a high rate of false rejections. AI technology provides a solution for such a difficult-to-solve problem. In comparison to common industrial metal detector systems, THiNK detects physical contaminants with greater precision and proves to significantly reduce the frequency of false rejects.

This innovative metal detection software from Sesotec is especially advantageous for facilities that process food products with high levels of product effect. Meat, poultry, fish, and dairy products, as well as baked, pickled, or ready-made foods, can all be reliably inspected while virtually eliminating false rejects. Compared with the evaluation algorithms of conventional metal detectors, this intelligent technology proves to be especially beneficial for products with metallized packaging. Additionally, the software in earlier Sesotec metal detector models can be easily upgraded to operate with AI.  

Ensure success

Metal detection with THiNK makes it easier for food producers to comply with even the strictest international food safety regulations. At the same time, this program diminishes the rate of false rejects, thereby dramatically reducing industrial food waste. This solves both an economical as well as ethical problem.  

Act as a Game Changer

THiNK AI is the tool of choice for food processors and manufacturers who are looking to equip their facilities for the future. Sesotec supports food industry customers in their efforts to make products safer, processes simpler, and production more profitable. Our experts are well-versed in the challenges of the food industry and can offer valuable guidance on complex topics such as validation and food safety certification.

Save the date

Starting May 7, 2020, you can visit our virtual exhibition stand and explore the latest product highlights and company news from Sesotec. Visit www.sesotec.com/en/interpack for more information.

<![CDATA[eBook: Driving Impact – Safe food and saving food]]> 2020-03-22 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/ebook-driving-impact-safe-food-and-saving-food https://www.sesotec.com/emea/en/resources/blog/ebook-driving-impact-safe-food-and-saving-food White Paper

Download E-Book

The world population stood at 7.71 billion in 2019. That figure is set to reach 9.74 billion in 2050, according to United Nations predictions. Making sure each and every person has access to food is a mammoth task. It is estimated that the world population will need 70 % more food in 2050. In order to secure the global supply of food in the future, waste must be reduced and productivity increased.  

High demands of consumers and retail chains increase pressure on food producers and processors.

Retailers and consumers don’t just expect safe and high-quality food, they are legally entitled to it. In addition to compliance with legal regulations, most retail chains also require special certifications from their suppliers.

In our e-book we show you, amongst others, what challenges the development of the world's population and especially food safety pose for manufacturers and processors and how they can still be mastered.

Find out in our eBook:

  • what influence the development of the world population has on the food industry
  • why the pressure on manufacturers and processors continues to rise
  • what food manufacturers and processors need to cope with this

Download E-Book

<![CDATA[Statement from Sesotec on the Corona situation]]> 2020-03-19 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/statement-from-sesotec-on-the-corona-situation https://www.sesotec.com/emea/en/resources/blog/statement-from-sesotec-on-the-corona-situation Company

Marc Setzen, CEO Sesotec

Dear customers and partners,  

The current situation regarding the spread of the Corona virus affects us all. In extraordinary situations such as these, one pillar of our corporate strategy emerges as particularly important: collaboration. At a time when much remains uncertain, at least this much is clear: we can only survive this crisis if we work together and mutually support one another. Now is the time for solidarity and responsibility.

Many of our customers and partners work in system-critical spheres. Their continued operation is crucial in order to provide the public with basic goods and services in times of crisis. With this knowledge, Sesotec is committed to doing its part to ensure their uninterrupted operation.  

Risk minimisation is the top priority

Right now, the world has a common goal: reduce the spread of the virus. As such, Sesotec is committed to minimising the risk of infection for our employees and the people around them. At the same time, we take seriously our responsibility to our customers who rely on our support in order to serve the public. We have taken extensive measures to ensure that we can stand by our customers during these trying times:

  • To date, there are no major restrictions affecting either the production or delivery of our physical contaminant detection systems. With fully stocked warehouses and stable supply chains, we can continue to uphold this guarantee.
  • Our employees are alternating between working from home and working out of the office; our representatives will continue to have full availability to attend to urgent customer requests.
  • Although travel, especially abroad, has been significantly reduced, we remain available to provide system servicing. Innovative technologies like Remote Service make it possible for us to solve many technical issues for our customers without an on-site visit.
  • We are doing everything in our power to ensure that our employees are well-informed and abiding by all official regulations in regard to health and safety.

With the cancellation or postponement of numerous trade shows, such as interpack, due to the Corona virus, we have sought alternative means of keeping our customers informed about exciting developments in our product portfolio. Explore the highlights digitally on our website: www.sesotec.com/en/interpack  

Please do not hesitate to contact us if you have any questions. We thank you for your continuing solidarity and look forward to seeing you all again soon. Until that time, please remain in good health.


With kind regards,

Marc Setzen, CEO


P.S. Save the Date: Starting May 7, 2020, you can visit our virtual exhibition stand and explore the latest product highlights and company news from Sesotec. Visit www.sesotec.com/en/interpack for more information.

<![CDATA[New Metal Separator: Sesotec presents RAPID PRO-SENSE 6]]> 2020-03-05 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/new-metal-separator-sesotec-presents-rapid-pro-sense-6 https://www.sesotec.com/emea/en/resources/blog/new-metal-separator-sesotec-presents-rapid-pro-sense-6 Plastics

Sesotec extends its range of free-fall metal separators with the RAPID PRO-SENSE 6. This system is optimised for applications in the plastics industry, especially for granulate and compound producers. Used for quality assurance it, among other things, also is suitable for applications involving abrasive material. The model features a high detection accuracy and thus provides protection against complaints caused by metal particles, and the logbook function allows full traceability. Constant high product quality is thus guaranteed.

Sesotec metal separators for plastic applications every day prove their worth in many business divisions: Incoming goods, production, outgoing goods. RAPID PRO SENSE 6 is characterised by an aperture size ranging from 50 to 250 millimetres that can be individually adapted to customer requirements, and features a wear-resistant design because, for example, it does not contain any product-contacting seals that might come loose.

RAPID PRO-SENSE 6 also contributes to a higher process reliability because it allows tool-free cleaning also in case of complex installation situations. The metal separator therefore is optimally suited for compound producers who need frequent colour changes and/or short cleaning intervals. Another outstanding feature worth mentioning here are the optional washing nozzles that allow water cleaning of the interior. The short cleaning times increase up-time, reduce personnel expenses, increase line availability, and all things considered make the lines more efficient.

RAPID PRO-SENSE 6 furthermore is equipped with an Ethernet interface and thus is "IoT-ready". The metal separator can be easily integrated in the customer's software world and, for example, coupled with OPC UA to optimise production processes.

<![CDATA[How the growing world population will shape the future of the food industry]]> 2020-02-20 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/how-the-growing-world-population-will-shape-the-future-of-the-food-industry https://www.sesotec.com/emea/en/resources/blog/how-the-growing-world-population-will-shape-the-future-of-the-food-industry Food Safety

In as little as three decades time, the United Nations estimates that 9.7 billion people will inhabit the planet. This rapid expansion of the global population will change many aspects of life around the world, particularly the ways we live, work, and eat.

The Food and Agricultural Organisation of the United Nations forecasts that worldwide food production will need to increase by at least 70 per cent in order to adequately feed the projected global population of 2050. A great challenge to achieving the industrial output necessary to feed 9.7 billion is the question of how to balance the shrinking availability of resources with heightened consumer expectations.

If food products are to remain safe, nutritious, affordable, and plentiful in the face of massive population growth, the global food industry must continue to adopt innovative solutions.

Food production and population growth: the past, present, and future

Over the course of the last century, the market for industrial food production has expanded alongside the growing world population and climbing global prosperity. As household incomes and standards of living have risen the world over, food manufacturers, aided by technological innovations, have been able to supply the rapidly increasing demand for a wide assortment of high-quality foods.

Huge strides in food manufacturing technology have made it possible to produce higher volumes of safe and nutritious food, even as the amount of land available for agricultural and industrial development has declined.

The sheer diversity of food products available today, as well as the ‘round-the-clock nature of their availability, is unprecedented in human history. This is especially true in industrial nations. In Germany, for instance, the average customer can choose between more than 170,000 different food products each day (BVE, “Germany – Partner of the World 2018”, pg. 28).

But with formidable demographic and environmental changes on the horizon, the present state of industrial food manufacturing will be insufficient to maintain current levels of diversity, quality, and availability in food products by 2050. Furthermore, rapid population growth will place tremendous stress on the natural resources needed for bountiful food production. In turn, the technology that has driven productivity growth in the food industry up until this point must continue to evolve and rise to these new challenges.

Increasing food production in the face of limited resources

In diverse sectors of the global food supply chain, automation is already helping to make great improvements in terms of efficiency and sustainability. From agriculture to processing to packaging, smart systems are processing huge volumes of data in real time in order to make better use of available resources and achieve ideal results.

Within the food manufacturing sector, ramping up output requires tightening controls on food safety and product quality. Automated inspection technology is making it possible to increase global food production without compromising on the safety or quality of food products. Computerised food inspection machines, ranging from optical sensors to metal detectors to x-rays, can be programmed with information about product characteristics and processing conditions in order to perform with incredible accuracy.

By implementing a sophisticated network of automated inspection equipment at key junctures in the production process, contaminants and defects can be identified and removed immediately and reliably. Automated inspection technology also makes it possible to detect contaminants early, thus reducing the food waste caused by product recalls and cross-contamination.

Population growth and heightened stakes for food safety

Globalised trade is only forecasted to increase alongside the world population. This means that any defective food products entering the market can have widespread and disastrous consequences for public health and corporate trust.

In the coming decades, food manufacturers will need to practise extreme diligence to ensure that their upstream and downstream partners are operating with integrity and complying with food safety protocol.

Robust inspection technology is key in this endeavour, as it can help manufacturers and international regulatory bodies trace contaminants directly to their source. In this way, advanced food safety equipment will have a crucial role to play in promoting transparency in the food industry and keeping the public informed about threats of contamination.


Consumer culture in a world of 9.7 billion

Technological advancements such as these are necessary in the pursuit to feed the world population of 2050. But beyond simply supplying the world with enough calories, food industry productivity will need to improve even further if products are to adequately address changing consumer expectations. The world of 2050 will not only be more multicultural than ever before, it will also be more concerned with issues of health, ethics, and sustainability.

Mass migration and demographic change are causing urban areas to grow and become increasingly diverse. As cities around the globe become more multi-ethnic with each passing year, new markets emerge alongside new challenges. In order to meet the needs of growing populations with varied dietary preferences and restrictions, food industry companies will need to tailor their manufacturing practices and expand their product portfolios to suit diverse tastes and religious affiliations, even in formerly homogenous markets.

Furthermore, living in a world populated with 9.7 billion others will inevitably lead to shifts in the way that everyday people think about resources, health, and the products they consume. Dramatic changes in consumer attitudes are already apparent and influencing the market in meaningful ways. A 2019 survey of consumers in Europe, Asia, and North America revealed that 49 and 37 per cent of those surveyed cited health and environmental impact, respectively, as major considerations when making purchases.


The growing world population will have an indelible impact on global supply chains, international economies, and cultural dimensions of societies worldwide – all of which will shape the future of the food industry. In order to produce enough food to both feed the world in 2050 and address an evolving consumer culture, the global food industry will need to adopt innovative technologies and controls across all sectors. Such advancements are crucial to achieving the necessary output without compromising on public health, environmental impact, or consumer demands.

About Sesotec

For more than 40 years, Sesotec has been a market leader in the field of contaminant removal and sorting technology. We develop both standardised and customised food safety solutions for food and beverage manufacturers around the world.

White Paper - Five tips to optimise metal detector performance

Metal detectors are an important component of a functioning food safety concept. You already have a metal detector in use? Then read our 5 tips to ensure the optimum performance of your metal detector over the long term.

get free White Paper

<![CDATA[Circular economy – it needs to be profitable]]> 2020-02-19 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/circular-economy-it-needs-to-be-profitable https://www.sesotec.com/emea/en/resources/blog/circular-economy-it-needs-to-be-profitable Circular Economy

In 2015, the EU Commission adopted an action plan for the circular economy encompassing 54 measures. In March of 2019, it delivered a positive summary of the progress to date: “The principles of the circular economy have found their way into production, consumption, water management, the food industry, the management of specific waste streams and especially in plastics,” explained Frans Timmermanns, First Vice President of the EU Commission. The numbers back it up. In 2016 alone, EUR 147 billion of added value was generated from circular economy activities such as repairs, re-use or recycling, with investments totalling EUR 17.5 billion. One element of the circular economy in Europe is the EU Plastics Strategy. Among other things, it envisages that all plastic packaging in the EU market will be recyclable by 2030.

Challenges for recyclers

However, there is still plenty to do before this becomes a reality and the cycle is closed. For example, prices for recycled and new materials are currently fluctuating. This represents a challenge for recyclers, because if the price for recycled materials is higher than the price for new materials, demand for them will fall.

At the same time, the price for recycled materials depends on a number of factors. First of all, there is the amount of available material, which in turn is linked to collection and disposal systems. It is also measured against the respective cost of the sorting and treatment process, as the degree of purity required of the plastic varies depending on its target application. In some cases, significant quantities of water and energy need to be consumed in the cleaning and sorting process. If its profitability is called into question at this point in the cycle, the entire circular economy will start to falter.

Hurdles for plastics manufacturers and processors

Plastics manufacturers and processors face a similar situation. Their profitability is also dependent on the available quantity, quality and price of the recycled material. Manufacturers and processors need planning reliability with regard to all three components. Without a sufficient quantity, for example, they face the threat of loss of production, and if the raw material is of poor quality, they risk an inferior end product. The material used is often contaminated with pieces of metal, which results in costly damage to machinery, process disruptions and stoppages. Not least, their profits will be squeezed if purchase prices are too high.

Lots of potential

Calculation scenarios of “Der Grüne Punkt” (The Green Dot), Germany’s market leader for dual systems, have shown that there is considerable value added potential for recycled materials based solely on a more extensive use of the current leading technology without any substantial technological developments. For example, the market volume for recycled plastics in Germany could increase by up to 119 percent, from EUR 189 million in 2014 to EUR 414 million in 2030. If the framework conditions and demand trends improve, a market volume of as much as EUR 1.04 billion may be possible for 2030.

A further point that confirms this potential is that global demand for plastic is rising. At the same time, increasing demand may result in a difficult supply situation with long delivery times for new materials. In this case, secondary raw materials may supplement the primary materials and form a supply market which is largely independent of the volatilities of new materials in respect of supply and price.

From “nice to have” to competitive advantage

Politicians can also have a positive impact on the potentials inherent in recycling by enacting measures which concern packaging laws and set fixed recycling rates, for example. Ambitious targets have already been set with the EU Plastics Strategy mentioned at the start of this article.

The attitude of companies concerning the use of recycled material also plays an important role. A lot of companies have started to rethink their approach. The CO2 footprint – the total carbon dioxide emissions generated directly or indirectly in the manufacturing process or whole life cycle of products – is attracting increasing attention. A positive CO2 balance is becoming part of a sustainable product strategy and in some cases a competitive advantage. The recyclability of materials can be taken into account in the product and packaging development stage. If this is communicated clearly to the consumer, it will in turn increase the acceptance and demand for products made from recycled materials – in part, because they are doing their part to protect the environment.

For the sake of the environment

The environment benefits greatly from a high recycling potential and a closed plastics cycle. The reason being that production of plastics products currently mainly makes use of primary plastics made out of crude oil. According to the German Association for Secondary Raw Materials and Waste (bvse), plastics recycling reduces the demand for crude oil in two ways – through saving new plastics on the one hand, and saving energy on the other. In plastics recycling, only 33 to 50 percent of the energy needed to manufacture new materials is consumed. Furthermore, the CO2 saving is considerable. According to the association, every tonne of recycled plastic used instead of comparable new materials, prevents between 1.45 and 3.22 tonnes of climate-relevant greenhouse gases.

Investment in recycling can therefore be of a great advantage for all parties involved. In view of the huge potential, investing time and money into technologies and structures which serve to make recycling profitable appears to be a promising approach. Landfilling and disposal in the environment should quickly give way to recycling, because the only way to preserve limited resources and close the plastics cycle is through the recycling of plastic waste, ideally in higher-quality products.

About Sesotec

As a partner to the plastics industry, Sesotec provides a variety of solutions designed to meet the needs of recyclers, plastics manufacturers and plastics processors. Sesotec helps ensure product purity through sensor-based material analysis systems, sorting systems, metal separators and services. The result? Guaranteed efficiency and profitability for the preparation, production and processing of plastics.

eBook: Driving Impact - Closing the plastic cycle

Closing the plastic cycle is the cleanest solution for humans and the environment. That is something politics have come to realise. Still, the industry also needs to lead by example. In our eBook we show you, amongst others, which challenges plastic recyclers, manufacturers and processors are faced with in the context of the circular economy.

<![CDATA[Reliable X-ray inspection of metallised packaging]]> 2020-02-18 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/reliable-x-ray-inspection-of-metallised-packaging https://www.sesotec.com/emea/en/resources/blog/reliable-x-ray-inspection-of-metallised-packaging Case Studies

The problem: Inspect cassava chips in metallized packaging for foreign bodies

On an international market that is becoming ever more competitive, an exporter of fried cassava chips, decided to distance itself from its competitors by installing cutting-edge technology for quality assurance. The challenge was the metallised packaging of the products.

The solution: The product inspection system RAYCON provides highly accurate inline detection of metals, glass, ceramics and stones

The customer provided the chips in metallised 200 g bags for the tests. Sesotec demonstrated that the X-ray inspection system RAYCON met the quality requirements without any problems. RAYCON easily detects the smallest physical contaminants, in any type of packaging, and meets all common food industry guidelines.

The outcome: The company has GMP, HACCP certificate, ISO 22000: 2005, Halal certificate and registration number of BPOM (Indonesian Health Department)

The development of a quality assurance program with the X-ray inspection system from Sesotec contributed significantly to allowing the customer to obtain national and international quality certificates such as HACCP and GMP.

An additional reason why this customer chose Sesotec from a number of renowned providers was that RAYCON operates with the highest economic efficiency. Besides Sesotec has service centres all over the world which ensure an excellent service offer at any time.

The objective of Sesotec is not only to support its customers to achieve quality standards but to promote the value added of the food industry in general. This happens by guaranteeing the purity of every individual product to meet the expectations of the end customers and the requirements of the industry.

Download Case Study

 Reliable X-ray inspection of metallised packaging

<![CDATA[What is Food Safety?]]> 2020-01-29 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/what-is-food-safety https://www.sesotec.com/emea/en/resources/blog/what-is-food-safety Food Safety

As a scientific discipline, food safety draws from a wide range of academic fields, including chemistry, microbiology and engineering. These diverse schools of thought converge to ensure that food processing safety is carried out wherever food products are sourced, manufactured, prepared, stored, or sold. In this sense, food safety is a systemic approach to hygiene and accountability that concerns every aspect of the global food industry.

The following article defines food safety in manufacturing and explains the importance of food safety for the global food chain. Following a brief overview of the different regulatory bodies tasked with evaluating food safety around the world, the article outlines the key principles of effective food safety regulation, the history of food safety and the consequences of unsafe food handling practices and procedures for companies and consumers.

Food safety regulations in a globalised world

Food products are among the most-traded commodities in the world. As markets become increasingly globalised with each passing year, and as the world’s population continues to grow, the global food supply chain will only continue to increase in scale and complexity. Precisely because of these megatrends influencing the mass production and distribution of food, food safety compliance has never been more important.

Every country has different regulatory bodies that preside over the definition and enforcement of domestic food safety standards. In order to sell or manufacture food products in any given country, domestic and international businesses alike are subject to the food safety legislation and enforcement measures of that nation. In the European Union, for example, food safety legislation is detailed in Regulation (EC) 852. In the United States, the Food Safety Modernization Act outlines the legal requirements for food safety.

Around the world, the majority of laws about food safety are based on two concepts: HACCP and GMP.

HACCPHazard Analysis and Critical Control Points is a systemic, risk-based approach to preventing the biological, chemical and physical contamination of food in production, packaging and distribution environments. The HACCP concept is designed to counter health hazards by identifying potential food safety problems before they happen, rather than inspect food products for hazards after the fact. The HACCP concept entails controlling for contaminants at a number of key junctures in the food production process and strict adherence to hygiene practices throughout.

GMPGood Manufacturing Practices are internationally recognised quality assurance guidelines for the production of food, beverages, cosmetics, pharmaceuticals, dietary supplements and medical devices. These guidelines lay out the protocols which manufacturers must implement to assure that their products are consistently high-quality from batch to batch and safe for human use, including mandatory product inspection at critical control points.

There are also several privately-owned international organisations that provide comprehensive guidelines for auditing food manufacturers on the basis of food safety and hygiene. These international standards facilitate the global food trade by helping food industry players from different countries to ensure that food quality and safety standards are met in a way that transcends borders.

In addition to complying with the food safety laws of the countries in which they are active, global market leaders in the food industry often pursue certification with a number of private food regulators. They may furthermore demand that the upstream and downstream suppliers they work with provide proof of the same certifications.

Internationally recognised food safety organisations and certification programs include:

IFS Food 6.1 – The IFS Food Standard is part of the Global Food Safety Initiative and is an international standard for performing audits of food manufacturing processes. Their compliance audits concern both the factory floor and administrative duties, with regulations on topics ranging from the installation of food defence and inspection equipment to thorough bookkeeping.   

BRCGS – The British Retail Consortium Global Standards (formerly BRC) are a set of international consumer protection certifications that provide safety criteria for global food retailers, food manufacturers, packaging manufacturers and food service organisations. Their certification for food manufacturers includes an assessment of the equipment used to detect and remove physical contaminants.  

SQF – The Safe Quality Food Institute provides detailed safety programs tailored to the specific concerns of different food industry players. The various SQF codes are segmented to address the unique conditions of each stage of the food production life cycle, from agriculture to packaging, from manufacturing to retail. Each SQF program is internationally recognised.


Each of these private food safety organisations have built their certification programs around ISO 22000, an international norm for food safety management systems:

ISO 22000 – The International Organisation for Standardisation details a proactive management plan for food safety relevant for any organisation along the food supply chain. ISO 22000 includes an interactive communication strategy between upstream and downstream industry players and a comprehensive system for management. Furthermore, the norm encompasses a model for how to implement a customised HACCP concept depending on the industry, product and facilities. For instance, should a risk of metal contamination be identified, ISO 22000 may recommend the installation of a metal detector with a rejection mechanism to manage the hazard.

Who is responsible for enforcing food safety standards?

While the international regulatory bodies listed above provide guidance, certification and auditing services for global food manufacturers, they are not responsible for the active enforcement of food safety laws.

Every nation defines and establishes its own laws and enforcement practices for food safety regulation and these regulations may vary from country to country, and domestically from region to region. Bringing a food product to a foreign market requires compliance with the food safety and consumer protection laws of that nation and its regional governmental authorities.

Generally speaking, international food safety standards are designed to facilitate compliance with food safety laws in major markets, simplifying the process of receiving approval from foreign governmental regulators.  

The history of food safety

Foodborne illness has threatened human health since the dawn of time. In fact, many food preparation methods we still use today, such as cooking, canning, smoking and fermentation, can be understood as primitive food safety measures, developed as a means of keeping people from getting sick.

Today, we benefit from centuries of scientific and technological progress that have made an abundance of safe food and drink products something that many of us take for granted. But the concept of food safety as we know it today, and the rigor with which it is enforced, is a relatively new development in human history that is intimately tied to changes in the way we live and eat.

In 1905, American author Upton Sinclair published his novel The Jungle, which featured horrific depictions of Chicago’s meatpacking industry. The ensuing public outrage led the U.S. government to pass the Meat Inspection Act the following year, establishing the first sanitary standards for slaughtering and butchering. This law marked the first time that food processing facilities were subject to regular audits and inspections by governmental authorities and some of the very first laws for food safety in manufacturing.

Across Europe and North America, the industrial revolution ushered in the establishment of many regulatory bodies and foundational laws concerning food safety and inspection. As food production became increasingly mechanised and profit incentives climbed, laws were passed to prevent the intentional sale of food products that were misbranded, contaminated, or otherwise tampered with. It was during this era that ingredients and additives became subject to regulation.

In the decades following World War II, electric refrigerators entered middle class homes across Europe and North America, changing the way that everyday people purchased and stored food. The era of home refrigeration sparked the rapid expansion of industrial food production, as well as a growing need for stricter food regulations. It was in this changing food landscape that Mars Incorporated became the first major food manufacturer to install metal detectors in their facilities in 1947.

The shift from reactive to proactive food safety principles began when HACCP was born in 1959. Recognising that testing finished products was not an effective means of ensuring food quality and safety, scientists at NASA collaborated with the Pillsbury Company, an American manufacturer of baked goods and baking mixes, to create a risk-based system that identified “critical failure areas” in production that posed health risks. With Pillsbury leading the way, this system of hazard analysis and control was adopted by a number of leading food manufacturers in the United States.

By the mid-1980s, scientists around the world agreed that the proactive nature of HACCP provided a more effective means of controlling for food safety hazards than traditional inspection methods. The following decades saw the establishment of international regulatory bodies and third-party audit firms designed to implement and enforce preventative compliance in an increasingly globalised food industry. It is upon this groundwork that modern food safety regulations and practices are built.

The seven principles of a safe food supply chain

While HACCP lays out the steps necessary to proactively ensure food quality safety in individual food production environments, a healthy supply chain also demands action on a collective level. The European Union identifies seven overarching food safety principles necessary for the entire food supply chain to operate for the public good.


  1. Corporate responsibility – Every company involved in the food supply chain is required to do their due diligence to ensure the quality and safety of a food product within the bounds of their responsibility. This includes implementing in-house controls according to HACCP. In addition, corporations assume liability for any damages their products may cause.

  2. Traceability – All food business operators in the EU are responsible for documenting where their materials are sourced and where they are sent. This documentation helps regulatory bodies quickly identify the source of contamination should a recall become necessary.

  3. Official food controls – Governmental authorities within the federal states are responsible for enforcing EU food law requirements through risk-oriented reviews, targeted sample collection and regular inspections.

  4. The precautionary principle – Competent authorities are permitted to take precautionary measures if they believe the effect will minimise food safety risks. These precautionary measures will be reviewed on an ongoing basis as scientific data becomes available.

  5. Independent scientific risk assessment – A governmental institution that operates independently of political, social and economic influences is responsible for scientifically investigating and assessing the risks that food products may pose to human health. In the EU, this institution is known as the European Food Safety Authority.

  6. Separation of risk assessment and risk management – Due to possible conflicts of interest, a clear distinction is made between those responsible for scientific risk assessment and those responsible for risk management.

  7. Transparent risk communication – The public must be promptly informed of imminent and potential food safety hazards. Circulating information about food safety problems is only possible if scientists, policymakers and food business operators communicate transparently.


The importance of food safety and the consequences of non-compliance

Food safety is highly important both financially and ethically. The consequences of failing to comply with food safety standards are manifold. In addition to being incredibly costly for companies who must recall their products, overhaul their processes and manage the public relations crisis, inadequate food safety in manufacturing carries a significant human cost.

The cost of food recalls for companies

Failing to implement an effective food safety protocol can lead to contaminated products entering the food chain. Once the defective product has been discovered, food businesses are subject to dramatic disruptions in their operations as they manage and assume the cost for product recalls.

Food recalls cost companies an average of $10 million USD in direct, immediately measurable costs alone. But the long-term effect that a product recall can have on consumer trust is perhaps even more costly. Some 21 percent of consumers say they would never again purchase anything from manufacturer who had to recall one of their food products. 

The human cost of unsafe food

The importance of food safety to modern human life would be difficult to understate. Food safety problems are a leading cause of more than 200 preventable diseases worldwide. Each year, one in ten people will suffer from foodborne illness or injury. An estimated 420,000 people die every year as a result of eating contaminated food and more than a quarter of these victims are small children.

In addition to the immediate human cost, inadequate food safety comes with a greater ripple effect that impedes socioeconomic progress, especially in the developing world. The World Health Organisation states that food safety, nutrition and food security are inextricably linked. A lack of safe food creates a “vicious cycle of disease and malnutrition” which overburdens public health services, disrupts social and economic progress and detracts from the quality of life.


About Sesotec

For more than 40 years, Sesotec has been a market leader in the field of contaminant removal and sorting technology. We develop both standardised and customised food safety solutions for food and beverage manufacturers around the world.

White Paper - Five tips to optimise metal detector performance

Metal detectors are an important component of a functioning food safety concept. You already have a metal detector in use? Then read our 5 tips to ensure the optimum performance of your metal detector over the long term.

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<![CDATA[Circular economy – how it will change our lives]]> 2020-01-28 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/circular-economy-how-it-will-change-our-lives https://www.sesotec.com/emea/en/resources/blog/circular-economy-how-it-will-change-our-lives Circular Economy

What does the circular economy refer to?

Every year, Germany generates more than 50 million tons of domestic waste. Much of this is valuable raw materials. Alongside metals, plastics are also a highly significant share. Almost every product contains plastic – a material created from crude oil. Cars are one-quarter plastic. But even furniture, cosmetics, electronic devices and in particular a great deal of packaging are made from plastic. When they reach the end of their lives, these products often end up in waste incineration or landfill facilities. Only some of them are recycled. This is quite a waste of resources.

The circular economy aims to make intensive use of all materials obtained at some point from the natural environment and to subsequently return them to the manufacturing process as raw materials. For example, in a functioning circular economy, a plastic bottle would be refilled as often as possible before being shredded – and then used again as a raw material for new bottles or other products. Eight recyclable PET bottles is all it takes to manufacture one football shirt.

Many countries are tightening their waste laws to create closed systems. They are doing this to preserve natural resources and protect the environment. The European Parliament estimates that a circular economy would cut greenhouse gas emissions by 2%–4% annually. There are also cost effects: this system could save around €600 billion, which is equal to 8% of the annual revenue of EU companies.

What does a “linear economy” mean?

A linear economy is best described as a throwaway culture – the opposite of a circular economy. This wasteful way of behaving is rooted in the industrialisation process that took place over 150 years ago. That is when people began to process raw materials on a massive scale. The resulting products were sold and then simply disposed of later on. There was hardly any recycling. This has led to the loss of huge quantities of valuable materials up to the present day. Since plastic spread into all areas of life following the Second World War and harmed the environment, the downsides of this linear economy have become clear. There is 150 million tons of waste floating in our oceans alone, and three quarters of it is made up of plastics.

History of the circular economy

The idea of a circular economy is not a new one. Rather, it was the basis of how humans worked for millennia and can still be found in many developing economies. Everything from straw to kitchen waste and excrement to the work performed by animals is part of the same system. Industrialisation and the urbanisation that followed suppressed this sustainable economic system.

British economist David W. Pearce introduced the modern concept of the circular economy in the 1990s, which originated in the concept of industrial ecology. This involves minimising the use of resources and strengthening clean technologies. The German government adopted the Circular Economy Act back in 1994 with the intention of encouraging waste recycling. The “cradle to cradle” principle is an update of this idea, developed by German chemist Michael Braungart and US architect William McDonough.

What kinds of circular economy are there?

Seamless recycling is still impossible today. For example, only 14% of all plastic packaging is recyclable.

As of now, it is indeed the case that many used materials can be reformed and recycled, but these often lead to low-quality products. This works until the remaining components are no longer reusable – which can be the case after just a few re-uses.

Our waste cycle is an open loop, as materials leave the loop during the process and end up being disposed of as waste.

However, the trend is moving in another direction. Researchers are working at full speed on new types of plastics that can be used for a long time and as often as possible. Their work will help to close the loop.

Open and closed loops – what are the differences?

In an open loop, materials are also sorted and recycled. In general, however, they are not enhanced. In other words, the materials degrade every time they are recycled. Plastic becomes more and more opaque and brittle until it leaves the loop. So the open loop leads once more to the creation of new waste that cannot be recycled, only now that happens at a point in time farther into the future. This means natural resources are used for a longer time but the actual problem remains.

The idea circular economy, in contrast, is sustainable in the long term. The aim is to recycle used material indefinitely without losing quality. That is already possible today with aluminium cans. Almost all of the material disposed of can feed back into the manufacture of new drinks cans. There are still limits to the closed-loop circular economy, because dirt and toxins build up in many recyclable materials and make recycling more difficult.

Cradle to grave

The “cradle to grave” concept outlines an economic system that has predominated in most states to date: raw materials are extracted from the earth and processed. These often become low-quality products with a short lifespan that quickly end up in incinerators or landfill. The “cradle to cradle” principle, in contrast, describes a very different way of behaving.

Cradle to cradle

The concept is linked to the idea that every material is the source material for another product, creating an eternal loop. Anything extracted from the natural environment remains part of this system – without any loss of quality. If the principle works perfectly, no more waste is generated. To realise the idea, however, a number of basic principles have to be fulfilled:

all products have to be manufactured in a way that does not harm humans or the environment. In other words, you can divide them into materials that can be recycled and those that are biodegradable. It only permits waste that is also a nutrient.

So if it were properly sorted in a technical loop, the steel used in a car would become a new vehicle body. The plastic built into the cockpit would be created in such a way that it could also be used to make new products. In contrast, tyres and worn seat covers would enter a biological loop. The materials made from natural rubber or ecologically produced cotton would rot and could serve as fertiliser for new plants. Of course, these biodegradable materials would also be recycled as often as possible in the technical loop.

Another precondition is the use of renewable energy, such as wind and solar power, because emissions such as greenhouse gases or nitric oxides are also a form of waste. Of course, solar installations and wind turbines must also be manufactured on the basis of the “cradle to cradle” principle. In other words, their components should either be properly sorted and recycled at the end of their lifespans or rot in a biologically clean manner.

Diversity is a key aspect of “cradle to cradle”, because uniformity leads to vulnerability – and this is particularly true of natural systems. Monocultures in agriculture that encourage pest infestations are one example of this. That is why “cradle to cradle” requires people to be creative and use biological and cultural diversity in a rational way. Every product should contribute to maintaining this diversity. This could mean using locally available materials and material flows. The use of regional plants in their place of origin can make a lot of sense. If they have to be transported halfway around the globe as a raw material first, then this is no longer the case.

Spiral economy

The circular economy concept is a pioneering one, but it has a weakness: it assumes that material flows are clear and traceable. In reality, however, this is rarely the case, as the economy is a dynamic and highly complex system. That is why a pure circular economy will remain a dream.

A more plausible alternative is the spiral economy concept, which is based much more firmly on real-world conditions. The basic idea is that materials or products from individual sectors can also be re-used in totally different circumstances. One example is used packaging, which can in various ways serve as a raw material for new pullovers and jackets.

In the spiral economy, used products are not part of an isolated cycle, but form a platform that generates an endless number of possible uses. As that would make it much easier to maintain balance in the system, there are many reasons to favour the spiral economy as an idea with good chances of prevailing in future.

About Sesotec

As a partner to the plastics industry, Sesotec provides a variety of solutions designed to meet the needs of recyclers, plastics manufacturers and plastics processors. Sesotec helps ensure product purity through sensor-based material analysis systems, sorting systems, metal separators and services. The result? Guaranteed efficiency and profitability for the preparation, production and processing of plastics.

eBook: Driving Impact - Closing the plastic cycle

Closing the plastic cycle is the cleanest solution for humans and the environment. That is something politics have come to realise. Still, the industry also needs to lead by example. In our eBook we show you, amongst others, which challenges plastic recyclers, manufacturers and processors are faced with in the context of the circular economy.

<![CDATA[Sesotec Receives DIN EN ISO 9001:2015 Quality Seal]]> 2020-01-10 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-receives-din-en-iso-9001-2015-quality-seal https://www.sesotec.com/emea/en/resources/blog/sesotec-receives-din-en-iso-9001-2015-quality-seal Company

We've made it! Dieter Sprenzinger (left) and Christina Lenz (right) are pleased to receive the certification document from Jutta Deinbeck (center), manager of the Bavaria Certification certification body.

For almost a year we intensively dealt with the requirements of DIN EN ISO 9001:2015 certification and particularly with our processes, and since 26 November 2019 it is an official fact: Sesotec received the DIN EN ISO 9001:2015 quality seal. We expressly thank all our employees for their support and for the work performed so far by every individual. Successful certification would not have been possible without this. 

After certification is before certification

The DIN EN ISO 9001:2015 certificate is valid for three years starting from the time it is issued (with annual monitoring audits). After three years a re-certification audit is necessary to renew the certificate.

<![CDATA[The new website of our partner Unirob in Poland is now online]]> 2020-01-09 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/the-new-website-of-our-partner-unirob-in-poland-is-now-online https://www.sesotec.com/emea/en/resources/blog/the-new-website-of-our-partner-unirob-in-poland-is-now-online Company

Unirob, Sesotec sales partner for more than two decades and in Poland servicing customers in the food and plastics industries, now has a new website https://www.unirob.com.pl/.

With a new design, completely revised contents, and a clearer structure the website presents Sesotec metal detectors, X-ray inspection systems and magnet systems in a user-friendly way. Having changed to responsive technology web design the Unirob website now also can be visited with the smartphone.

<![CDATA[Sesotec India wins "Spice Icon of the Year" award]]> 2019-12-03 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-india-wins-spice-icon-of-the-year-award https://www.sesotec.com/emea/en/resources/blog/sesotec-india-wins-spice-icon-of-the-year-award Food

Mahashay Dharampal (sitting), chairman of the renowned" MAHASHIAN DI HATTI (MDH)" organisation, presented the award to the managing director of Sesotec India, Makarand Mandke (left of Mahashay Dharampal)

Spices like cardamom, pepper, nutmeg, curcuma, ginger, coriander, aniseed and cumin all come from India, and especially for Christmas baking such spices are absolutely essential ingredients. To ensure that these spices that give cookies and gingerbread their taste are free of metallic contaminations, many spice producers and processors in India use product inspection systems. 

Sesotec is one of the leading suppliers of machines and systems for contaminant detection and material sorting, and for the Sesotec subsidiary in India it was a highlight in 2019 to receive the  "Spice Icon of the Year" award at the "Global Spice Summit and Excellence Award" event. Sesotec India was granted this award in recognition of its innovative solutions that make it possible for spice producers and processors to comply with international quality standards, and in appreciation of the training courses they provide for the nationwide spice industry. 

The managing director of Sesotec India, Makarand Mandke, received the award from the patron of the event, Mahashay Dharampal, a businessman highly decorated by the government of India and owner of "MAHASHIAN DI HATTI (MDH)", one of the most renowned spice companies in India. It was a great honour for Makarand Mandke to receive the award from his hands. 

Building of extensive know-how

For many years Makarand Mandke and his employees have visited lots of plants of spice producers and processors in India and in neighbouring countries, and in all their visits they could see that these customers have a great demand for quality assurance solutions. Many of them were looking for good contaminant inspection systems that would allow them to guarantee the purity of their products, prevent contaminations, and observe quality standards throughout the complete production process. Reliable customer service is another important criterion for spice producers and processors.  

With detailed tests at customer plants, tests in the technical laboratory, and analyses Sesotec India continuously has made great efforts to meet all the requirements. By interacting with all the persons involved in spice production and processing, and with the support of the technical team at the Sesotec headquarters in Germany/Bavaria, they managed to provide innovative solutions for the spice industry that feature top-class technology and highest cost efficiency. Many of the leading customers and exporters now benefit from customised Sesotec solutions.

<![CDATA[X-ray inspection system helps to accomplish SQF certification]]> 2019-11-20 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/x-ray-inspection-system-helps-to-accomplish-sqf-certification https://www.sesotec.com/emea/en/resources/blog/x-ray-inspection-system-helps-to-accomplish-sqf-certification Case Studies This family business began making good-quality sausages about 20 years ago in a local area butcher shop. After determining that the small butcher shop was not well-suited to producing the volume of sausage products demanded by its customers, the president and co-owner sold
the shop and acquired a nearby bakery. Already in compliance with the provincial food safety standards, the facility was modified and equipped with some newly-purchased sausagemaking equipment to fulfill his vision of making gourmet-quality sausage products.

Processing roughly 350,000 kilograms of sausages annually, still a small company, compared to some of the big national processors who produce some 200,000 kilograms of sausages per week.

The Problem: SQF certification requires technologies to remove or detect foreign objects

The high-aiming company is keen on becoming a true market leader, with national distribution to match, in a very competitive meat industry segment with high demands regarding ingredients and product purity.

In order to be competitive and to be able to win larger customers, a food safety certification is inevitable. Therefore, the company strived to accomplish the SQF (Safe Quality Food Institute) certification initiative. And an important requirement of SQF are “technologies to
remove or detect foreign matter“.

The solution: X-ray inspection system for foreign body detection

They purchased a RAYCON X-ray inspection system manufactured from Sesotec. Featuring a large 300x150 mm inspection window, the highspeed RAYCON can inspect packaged goods at rates of up to 300 pieces per minute, depending on the object´s length, detecting and rejecting all magnetic and nonmagnetic metals and materials such as glass, ceramic, stone, bone, PVC etc., even when contained within metallic or metal-coated foil.

Along with performing its primary task of detecting foreign particles in the product flow, the RAYCON can also provide visual detection of misshaped products, as well as check for incorrect product weight. The RAYCON can inspect different size and shape products on the same production line by utilizing its unique multilane and multiproduct software.

The RAYCON X-ray system can learn specific packaged product shapes, thereby allowing for different products to be handled on the same production line without triggering false positives and optimizing detection performance. The real time operating system with touchscreen provides the operator with a clear view of each packaged sausage being inspected.

The outcome: Effective food safety system and successful SQF certification

After the installation of the X-ray inspection system the company accomplished the SQF certification initiative. The president has already realized how beneficial the RAYCON system has been to the company: „The RAYCON model X-ray product inspection system from Sesotec is an essential part of our food safety system and I continue to be impressed by the level of service provided us by Sesotec.“

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 X-ray inspection system helps to accomplish SQF certification

<![CDATA[eBook: Driving Impact - Closing the plastic cycle]]> 2019-11-20 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/ebook-driving-impact-closing-the-plastic-cycle https://www.sesotec.com/emea/en/resources/blog/ebook-driving-impact-closing-the-plastic-cycle Circular Economy

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In a time when most discussions concerning plastic seem to centre on waste, the positive properties of this synthetic substance are often overlooked. Few other materials have such a good track record when it comes to factors such as food hygiene and shelf life.  

Too little plastic waste is recycled

Only 30% of plastic waste was recycled in Europe in 2017. In China, that figure stood at 25 %, and was just 9 % in the United States. That is a lot of wasted potential. Much of the world’s plastic waste ends up in landfills or is incinerated, posing a risk to groundwater and the air.  

The solution – a circular economy

Closing the plastic cycle is the cleanest solution for humans and the environment. That is something politics have come to realise. Still, the industry also needs to lead by example. In our eBook we show you, amongst others, which challenges plastic recyclers, manufacturers and processors are faced with in the context of the circular economy.


Find out in our eBook:

  • Why plastic is an extremely valuable and important material of todays society
  • What problems arise from plastic waste if it is not recycled
  • What are the requirements for a circular economy to really work
  • Which challenges plastic recyclers, manufacturers and processors are faced with in the context of the circular economy

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<![CDATA[Five tips to optimise metal detector performance ]]> 2019-11-14 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/five-tips-to-optimise-metal-detector-performance https://www.sesotec.com/emea/en/resources/blog/five-tips-to-optimise-metal-detector-performance White Paper

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Metal detectors are used in the food industry for quality control purposes and to protect products from contamination. The devices are set up to provide maximum performance as a default. However, a metal detector’s performance can drop off over subsequent weeks and months of operation due to factors such as changes in the device settings or changes in products.

Achieving the best results is not just about using the best available technology: optimum set-up is just as important. Aspects such as product centring, the distance between the products, the metal-free zone, the position and shape of the product during teach-in and the settings for different products have to be taken into account.

In our white paper, we lay out the issues in detail and provide you with five useful tips on how to achieve an optimum set-up on your metal detectors to ensure you are getting the best possible performance and guaranteeing the purity of your products

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<![CDATA[Sesotec under the Banner of "Circular Plastics Economy"]]> 2019-11-07 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-under-the-banner-of-circular-plastics-economy https://www.sesotec.com/emea/en/resources/blog/sesotec-under-the-banner-of-circular-plastics-economy Circular Economy

From 16 to 23 October Sesotec GmbH was present as an exhibitor at the K trade fair in Düsseldorf and now looks back on a fully positive trade fair appearance. The key topic of "Circular Plastics Economy" attracted many customers, partners and interested visitors to the trade fair stand where Sesotec provided a summary of the subject and presented customised solutions which at decisive points in the plastics cycle - production, processing and recycling - contribute to the conservation of resources and to increased production efficiency. 

Valuable insights into the challenges of the plastics industry

"The K trade fair is held every three years and is an optimal opportunity to learn about current topics in the industry and to exchange information about these topics.   We are more than satisfied with the results of the trade fair", says Marc Setzen, CEO of Sesotec GmbH, and concerning the focal topic of the K trade fair continues: "Circular Economy not only is a technical challenge but also requires a change of the way people think. The attitude that plastics are throwaway products must be abandoned, and people must become aware of the fact that plastics are valuable reusable materials. Our machines and systems only are one component in the material cycle, but they nevertheless make an essential contribution because they ensure the high quality of secondary raw materials made from recyclate and guarantee that the cycle really works." Michael Perl, Group Director Sales Division Sorting Recycling, adds: "The immense interest in our new FLAKE SCAN plastic flake analysis system both among plastics producers and processors as well as recycling companies indicates that the subject of "Circular Plastics Economy" has become a 'Hot Topic' in the industry."

Video series, topic page and Circular Economy blog

After the K trade fair Sesotec continues to further extend the competences concerning the "Circular Plastics Economy" topic. Already in the middle of the year Sesotec published a video series titled "Plastics: Part of the problem ... Part of the solution" which shows the problems with plastic waste and also presents solutions for a functioning circular economy.

Sesotec created a topic page at www.sesotec.com/en/circular-economy, and as of late the Sesotec website also contains a special Circular Economy blog that in the future will feature articles, white papers and e-books on the subject. In addition to basic information on Circular Economy, trends and topics will be discussed there that are of practical interest for plastics recyclers, producers and processors. For 2020 Sesotec plans several blog articles and additional formats.

The blog www.sesotec.com/en/circular-economy-blog has a central position in the communication of the "Circular Economy" topic because it provides all the information in concentrated form.

<![CDATA[Plastic: part of the problem...part of the solution - Part 4: Efficient use of recyclates]]> 2019-10-10 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-4-using-recyclates-closes-the-recycling-loop https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-4-using-recyclates-closes-the-recycling-loop Circular Economy

The plastics industry is facing a great many challenges. Harvesting recyclates from waste is only worthwhile if the plastic has been properly sorted and does not contain any metal, and if the products made from the secondary raw material are similar in quality to those made from new plastic.

Manufacturing recyclates from plastic waste is the first step. But in order to fully close the plastic cycle, more recyclates need to be used in the manufacturing of new products. This is a lucrative business for plastics processors, as recyclates are cheaper than new materials.

With material costs in the plastics industry accounting for 40% to 80% of total expense, depending on the segment, using recycled materials can significantly increase profitability. In addition, the secondary raw material in its ultra-pure state has practically the same characteristics as new plastic.

Yet there are still a number reservations in the industry when it comes to recyclates. The quality of the input material is particularly important in this regard. Recyclates must be free from any contamination to protect processes and machines from damage and ensure that the final products meet high standards of quality. 

BY PLASTICS PROCESSORS IN EUROPE (IK Survey – Nov. 2017, excerpt)

  • Lack of quality and security of supply are the key challenges facing plastics processors at the moment
  • Price is the main incentive for companies to switch to using recyclates.
  • The attitude of processing companies’ customers regarding the use of recyclates needs to be improved
  • The introduction of quality standards for recycling could lead to companies using more recycled plastics.
  • Despite the numerous obstacles, the vast majority of European plastics processors already use recyclates – for cost reasons.
  • Increase volumes and quality in the recyclate market.
  • Increase demand and improve the acceptance of recycled plastics.
  • Increase innovation to find additional processing technologies.

Metal particles among the most common forms of contamination affecting the quality of recyclates. These particles must be removed prior to processing to prevent faulty plastic parts from being produced and to prevent machinery from standing idle. Defective plasticising screws, blocked hot runners and under-injected plastic parts are all issues caused by metal contamination.

Idle machinery, machinery downtime and recalls are costly and can damage a company’s image. Furthermore, they all lead to valuable material being wasted.

The solution to this problem is to use metal detectors and separators. Compound manufacturer Sitraplas, for example, has used metal separators since 2006 to detect and sort out metal contaminants. Installed directly before the conveyor pipe, they detect the finest metal particles in a fraction of a second and remove them using a reject mechanism.
Metal separators therefore help enhance the quality of recyclates, allowing them to be used without risk, and make a sustainable contribution to a properly functioning circular economy.

Missed any other parts of this series? You can find them here:

Part 1: A global problem

Part 2: The European Union's solution

Part 3: Sorting technology

<![CDATA[Sesotec makes the circular economy efficient when it comes to plastics]]> 2019-09-23 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-makes-the-circular-economy-efficient-when-it-comes-to-plastics https://www.sesotec.com/emea/en/resources/blog/sesotec-makes-the-circular-economy-efficient-when-it-comes-to-plastics Circular Economy

Sesotec GmbH, a leading manufacturer of metal detectors and sorting systems for the plastics industry, will be showcasing its contribution to a circular economy at K 2019 (hall 10, stand E60). The company will present tailored solutions that help to conserve resources and increase production efficiency at the most critical points in the plastic cycle: manufacturing, processing and recycling. Sesotec plans to unveil its RAPID PRO SENSE 6 metal detector and the FLAKE SCAN plastic material analysis system to industry visitors. Information about the company’s wide range of services will also be available at the stand. 

The circular economy presents manufacturers, processors and recyclers of plastic with a wide range of challenges as well as numerous opportunities. Virtually everyone knows that the raw materials to make new products are available in limited quantities. Yet plastic is still a valuable commodity at the end of its life cycle. The key is to make the circular economy a success by involving all stakeholders so that everyone benefits. 

Andreas Reckziegel, Group Director Sales Division Product Inspection, says: “Plastics manufacturers and processors are going to use more and more recyclates – first because they have to, second because the products are designed to be recyclable, and third because it is more appealing to do so from a price perspective. So manufacturers and processors need to make sure that the quality of the material they’re processing is very high. Quality assurance is tremendously important.” 

The economic side of using recyclates

As Andreas Reckziegel says, lower costs and the political and social pressure to increase the proportion of recycled material are the reasons why plastics manufacturers and processors are looking to use more recyclates. Often, an adequate amount of sufficiently high-quality recycled material is not available, forcing plastics manufacturers and processors to use lower-quality constituents. This compromise is associated with substantial risk, since it can negatively impact process efficiency due to unscheduled machine downtime or lower quality of finished products, or because recyclates may simply be unsuited for use. The result is a loss of efficiency and price advantages. 

To create a plastic cycle in line with the aim of achieving a circular economy, recyclers need to receive material of sufficient quality and process it with the utmost efficiency. 

How do Sesotec devices and systems contribute to the circular economy?

At its K 2019 stand, Sesotec will showcase metal detectors from its GF, PROTECTOR and RAPID PRO SENSE 6 series. The detectors can be used in a variety of material infeed applications and ensure high plant availability for processing machinery and equipment by preventing unscheduled machine downtime due to metal particles, thereby avoiding the repair costs associated with breaks in production and potential recalls. Metal detectors play an essential role in ensuring high plant availability and avoiding damage, especially when processing recyclates. 

The RAPID PRO SENSE 6 metal detector, which will be unveiled at K 2019, is equipped with a newly developed reject mechanism designed for compound manufacturers that have frequent colour changes or that manufacture or process abrasive materials.

K 2019 will also see the premiere of the FLAKE SCAN plastic flake analysis system, which is designed to be the perfect size for laboratory use. Companies looking to turn recyclates into new granulate can use the FLAKE SCAN material analysis system to inspect incoming goods. In recycling, the device can be used by quality laboratories to inspect outgoing goods. So far, both branches of the industry have employed manual analytical procedures that take a lot of time and produce results that cannot be duplicated. But thanks to FLAKE SCAN, a few minutes is all it takes to get reports on the composition of various plastics and on off-colour components in consistently high quality and with reproducible results. 

Another new attraction is the ASM QUASAR optical sorting system, which can be used in granulate quality assurance in plastics manufacturing to ensure that granules with black spots, for example, are removed. Along with colour, further parameters – such as surface, shape and size – can also be analysed, making the system very accurate in deciding what to keep or reject. 

Sesotec sorting systems for plastics recycling can be equipped with sensors that are capable of sorting bottles, flakes or regrind according to different criteria, such as colour, shape, material or metal content. The various sensors can also be combined depending on the application. The FLAKE PURIFIER+ multi-sensor sorting system, on display at Sesotec’s stand, features high-precision contaminant separation and reduced loss of good material. The special material infeed system, extra-fine valve grid and optional integrated resort track on the FLAKE PURIFIER+ increase efficiency during the recycling process, especially when dealing with highly contaminated input material. 

Service rounds off the circular economy

At K 2019, Sesotec is set to showcase not only proven and new devices and systems alike, but also its wide range of service offerings. From expert advice and commissioning to maintenance packages and digital services such as predictive maintenance, Sesotec offers a full range of support to help customers ensure maximum machine availability and optimum performance. Using the new VISUDESK visualization program, all Sesotec devices in a plant can be monitored and controlled. The basis for this is an OPC UA machine communication model that is implemented on the devices. 

Michael Perl, Group Director Sales Division Sorting Recycling: “K 2019 is proof positive that a circular economy is no easy task and that our metal detectors, material analysis systems, sorting systems and services offer benefits for everyone involved in the plastic cycle: manufacturers, processors and recyclers. All that makes this year’s K event more exciting than ever for us.”

Click here for more information about Sesotec at K 2019.

<![CDATA[Sesotec systems in Ireland’s most advanced glass recycling facility]]> 2019-09-20 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-systems-in-irelands-most-advanced-glass-recycling-facility https://www.sesotec.com/emea/en/resources/blog/sesotec-systems-in-irelands-most-advanced-glass-recycling-facility Case Studies

Glass is a material that can be endlessly recycled without any loss in quality. Compared to the production of new glass, using recycled glass offers the advantage of a clearly reduced energy input and at the same time helps save raw materials such as quartz sand, soda and lime.

The Problem: Non-transparent glass is a special challenge for the recycling process

In the production of new glass products the purity of the cullet is the decisive factor for glass factories. Cullet from waste glass collections, however, frequently contains unwanted materials such as ceramics, stones, and porcelain (CSP) that have to be removed. In bottle production such contaminants may lead to defects and inclusions. Because of their optical similarity glass types that could be recycled often are separated together with such CSP contaminations.

Glass of dark to black colour, which preferably is used for packing sensitive and easily perishable food such as salad oil or cream liqueur, generally protects the contents against light and especially against solar radiation and therefore against early perishing. After its disposal such dark, non-transparent glass is a special challenge for the recycling process because CSP contaminations and dark glass so far could not be differentiated. Such cullet of dark colour was sorted out together with CSP contaminations and thus ended up in landfills.

The Solution: Innovative sorting technology detects dark glass

Glassco Recycling Ltd. is Ireland‘s biggest collector and recycler of waste glass and cans. In cooperation with Sesotec GmbH and their partner KRS Recycling Systems GmbH the company, based on Sesotec‘s revised „FLASH C-C Technology“, has now found a possibility to recycle dark, non-transparent waste glass and supply it back to the glass production industry in adequate quality, thereby completing the recycling circuit. In this facility alone this means that every year more than 10,000 tons of waste glass that otherwise would have ended up in landfills can now be recycled. According to Glassco Recycling this facility is the first of its kind.

Sesotec‘s K9 FLASH C-C multi-sensor sorting systems operate with high-precision highspeed cameras that allow a scan rate of more than 20,000 scans per second and thus a detection of up to 100,000 glass particles per minute. Combined with state-of-the-art LED light technology these cameras provide highly accurate optical measurements of every single piece of broken glass. With a new evaluation process that among others employs artificial intelligence approaches this state-of-the-art system is able to differentiate between dark glass and ceramic, stone and porcelain (CSP) parts.

The Outcome: Reduced glass loss in the sorting process

Zeki Mustafa, Managing Director of Glassco Recycling, is convinced of the performance of these K9 FLASH sorting systems: „With this new technology we are now able to reduce the amount of glass loss in the sorting process because dark, non-transparent glass now remains in the glass flow and can be recycled.“

Download Case Study

 Sesotec systems in Ireland’s most advanced glass recycling facility

<![CDATA[New Research Project IRVE for Innovative Recycling of E-Waste]]> 2019-09-17 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/new-research-project-irve-for-innovative-recycling-of-e-waste https://www.sesotec.com/emea/en/resources/blog/new-research-project-irve-for-innovative-recycling-of-e-waste Recycling

E-waste contains many recyclable materials that should be recovered for recycling. These include high-quality metals such as gold, copper, tantalum and rare earth elements, but also high-quality plastics. While some metals such as gold and copper, for example, can already be recovered efficiently, many valuable materials and around half of the low-concentration metals contained in e-waste are still lost in conventional recycling processes. A consortium consisting of the Technische Universität Aschaffenburg, the Fraunhofer Research Institution for Materials Recycling and Resource Strategies IWKS and the industrial partners Sesotec and Mairec has now set itself the goal within the framework of the project "IRVE - Innovative Recycling Processes for Electronic Waste" of finding new processes for the efficient recovery of components containing valuable materials from electronic waste.

Up to now, coarse shredders are mianly used in existing recycling processes to shred the electronic waste with subsequent energy-intensive melting processes. Since the various components of electronic waste are often soldered, welded or glued together, the disadvantage of shredding is that although the e-waste is shredded into many parts, the various material components are still connected. In addition, further valuable materials such as plastic fractions are lost in the melting process.

The IRVE project starts here in order to optimize the recycling of e-waste. Two different approaches are being investigated: In the first process, the electronic waste is detected with the aid of sensors. The data will be used for search algorithms that identify components containing valuable materials. These components are then dismantled. In the second process, the e-waste is broken down by means of so-called electrohydraulic fragmentation. The process is based on shock waves generated by pulsed spark discharges which are transmitted to the material via a liquid carrier medium. These short but violent mechanical shocks target weak points in the material. The separation takes place at macroscopic joints (soldered, welded, clamped, glued, screwed) or at microscopic interfaces (grain or phase boundaries). In the second step, the components are separated into individual material fractions by automated sorting. Both processes are examined and compared not only with regard to the effectiveness of the concentration of the valuable materials, but also with regard to their economic efficiency. It will be determined which process is economically feasable for which material flow.

The results of the project will then be used directly in plants and processes of the participating industrial partners to optimise the recycling processes. Thus, the project will contribute to securing raw materials in Bavaria and beyond and conserve valuable primary resources.

The IRVE project was launched as part of the project network for more resource efficiency in the Bavarian economy, in particular for SMEs and craft trades - ForCYCLE II and is part of the 7-point plan of the Bavarian State Government of 31.07.2018, which was prepared as a measure of the current Environmental Pact Agreement between the State Government and the Bavarian economy by the StMUV.

Reference: Fraunhofer IWKS

<![CDATA[Sesotec is member of the “SAVE FOOD” organization]]> 2019-09-04 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-is-member-of-the-save-food-organization https://www.sesotec.com/emea/en/resources/blog/sesotec-is-member-of-the-save-food-organization Company

The company Sesotec GmbH is contributing innovative solutions to reduce food waste. In the picture from left to right: CEO Marc Setzen, Group Director Sales Division Product Inspection Andreas Reckziegel, Group Director Marketing Christian Stadler.

Sesotec is now participating as member of the "SAVE FOOD" organization, and thus actively contributes to reducing the waste and loss of food. "SAVE FOOD" is a joint initiative of the Food and Agriculture Organization FAO, the environmental program of the United Nations, UNEP, Düsseldorf Trade Fair, and "interpack", the international trade fair for packaging machines and processes. Through a wide range of projects, fairs and conferences, the companies taking part in this initiative want to raise awareness among decision-makers in politics, the economy and industry as well as among consumers, and dedicated themselves to counteract food waste.   

Sustainable management and conservation of resources are cornerstones of Sesotec Group's corporate philosophy. For that reason, the manufacturer of machines and systems for contaminant detection and material sorting decided to become a member of the "SAVE FOOD" initiative. Objective is to provide customers from the food industry with solutions that contribute to the minimisation of food waste and at the same time increase productivity and product quality. 

Andreas Reckziegel, Group Director Sales Division Product Inspection explains: "The availability of sufficient and safe food is one of our driving challenges. Within food production, our highly sensitive contaminant detectors and material sorting systems allow the accurate removal of unwanted parts such as contaminants or faulty products from the material flow, with a minimum loss of good material." 

"With our more than 40 years of experience and our innovative machines and systems we make our contribution to ensure that no contaminated food reaches the customer. Product recalls, for example due to contaminants that were found in a product, not only damage the image of a company, they also involve immense waste because all the products of a recalled batch must be destroyed", says Reckziegel explaining the commitment of Sesotec.

Marc Setzen, CEO of Sesotec, adds: " Being a member of "SAVE FOOD" is very important for Sesotec, because food wastage is not only an ethical, but also an economic problem. The EU accounts for about 88 million tons of food waste each year, estimated to cost € 143 billion. About 13 percent arise during food processing, thereof three to five percent by false reject. By working in partnership with food industry companies, we help to prevent this waste."

<![CDATA[Booklet about X-ray Inspection Systems]]> 2019-08-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/booklet-about-x-ray-inspection-systems https://www.sesotec.com/emea/en/resources/blog/booklet-about-x-ray-inspection-systems White Paper

Download Booklet

Product inspection has become an indispensable element of responsible food production, an inherent part of any HACCP concept, and an absolute prerequisite for the observance of international food standards.

In particular, X-ray systems are increasingly becoming the focus of attention. With our booklet about X-ray inspection of food products we give you an overview of x-ray inspection in general, important food standards and Sesotec's solutions.

This awaits you in our  X-ray Booklet:

  • Your product – Our solution
  • The functioning of an X-ray system and its decisive advantage
  • Food safety and food standards
  • X-ray systems for packaged products
  • Altes Gewürzamt counts on Sesotec
  • RAYCON being tested
  • Facts about radiation protection
  • Do Product – Think Service

Click here to download our free booklet:

Download Booklet

<![CDATA[Plastic: part of the problem… part of the solution - Part 3: Sorting technology]]> 2019-07-25 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-3-sorting-technology https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-3-sorting-technology Circular Economy

Each year, Europeans generate 25 million tonnes of plastic waste. At a global level, 78 million tonnes of plastic waste is created annually. The world has to respond to this global problem together, as recycling rates everywhere have been at a low level so far: 30% in Europe, 25% in China, and just 9% in the USA (Plastikmüll-Statistik 2017). A large portion of the supposed waste is still incinerated, or ends up in landfills and the environment, which harbours risks for our water, air, and food chain. 

To achieve a circular economy, it’s important that all players contribute to this task: from product design and manufacture on the part of the plastics industry, along with conscious use and avoidance of plastics as well as waste separation on the part of consumers, followed by proper recycling and sorting by the waste and recycling sector, all the way up to conversion into high-quality secondary raw materials and their use in the manufacture of new products.

How does a circular economy work?

In order to be able to use the plastic waste or used plastic as a secondary raw material and thereby create recyclates of the right quality for new products, the source material has to be as pure as possible. Given the developments that have taken place, materials sorting technologies and contaminant detection systems are becoming increasingly important for the waste sector.

And this is exactly where Sesotec’s expertise is called for. Technology that can sort waste with great precision and thereby supply pure source materials has been around for a long time.

Sesotec’s sorting systems sort the collected plastics (bottles, flakes, and ground material) based on a range of criteria, such as colour, shape or type of material. They are equipped with sensors that can be combined to suit the particular application scenario. Infrared technology enables the systems to recognise different materials. Camera systems allow the material flows to be sorted by colour and shape. Special metal sensors can also be built into the systems.

Sesotec has taken on the industry’s challenge, and more than 600 of its sorting systems for plastics recycling are in use worldwide. In many application scenarios, purity levels of more than 99.9% have been achieved. Only high-quality sorted materials can facilitate high-quality material recycling. The challenges that arise in sorting are caused primarily by material composites, plastics with additives, labels, and dirty plastics.

One textbook example of how a circular economy can work – and one that is already in existence today – is PET. When it comes to PET recycling, Sesotec is already playing a leading role and is a key partner. Solutions are developed to separate contaminants from PET material flows or to divide these material flows into pure groupings.

Depending on the degree of contamination, multi-level sorting processes can achieve purity levels of almost 100%. These sorting steps are what makes bottle-to-bottle recycling – turning used bottles into new ones – possible in the first place.

PET as a model

Polyethylene terephthalate – better known as PET – is a highly reusable material as it does not lose its properties when recycled, making it 100% recyclable.
German consumers return 99% of the PET bottles that require a mandatory deposit. 93.5% of these bottles are sorted and recycled, either into new PET bottles (34%), films (27%), textile fibres (23%) or strapping and cleaning product bottles (16%).

In a nutshell, not only must the supply of plastic recyclates be increased – the demand and willingness to use it must rise too.

This is the only way to close the loop. The circular economy is a global project that requires everyone in society to pitch in.

In political terms, there is currently no global consensus – and that is why the industry has to take on a key role.

Read the other parts of this series here:

Part 1: A global problem

Part 2: The European Union’s solution

Part 4: Efficient use of recyclates

<![CDATA[Safe inline metal detection for fresh and processed meat]]> 2019-07-24 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/safe-inline-metal-detection-for-fresh-and-processed-meat https://www.sesotec.com/emea/en/resources/blog/safe-inline-metal-detection-for-fresh-and-processed-meat Case Studies

One of Singapore‘s most technologically advanced meat processing plants produce a large variety of fresh and processed products from chicken, beef and lamb in traditional HALAL quality. The processing of meat has to meet high quality standards. Therefore, this reference customer observes carefully every production step in his more than 11,000 m² sized production plant, where a fourth of the demand for fresh poultry in Singapore is processed.

KSB Distribution Pte.Ltd. obtained the ISO 9001, HACCP and HALAL certifications in recognition of its food safety, manufacturing and quality management systems and is also a Food Safety Partner of the Agri-Food and Veterinary Authority of Singapore.

The production line for HALAL sausages is the line with the highest quality requirements. Starting with best Australian meat, products on this line are produced in accordance with all HACCP rules until they find their way to supermarkets, renowned restaurants and hotels.

One of the requirements of the HACCP standard is the installation of metal detectors at different critical points of the production process. KSB already had various control points in the meat processing and was looking for a solution for the end-of-line inspection after packaging.

Sesotec attracted the interest of this company with its wide product range for almost all demands. The GLS GENIUS+ tunnel detector has established itself as one of the most widely used detectors in the food industry because it can be optimally combined with conveyor belts for the inspection of packed products. Its closed, rectangular design ensures high accuracy, reliable metal detection and is available in more than 200 sizes.

This mature technology and the services Sesotec provides before and after a purchase decisively influenced the customer in his purchase decision.

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 Safe inline metal detection for fresh and processed meat

<![CDATA[Sesotec sorting systems for globally leading e-scrap recycler]]> 2019-07-22 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-sorting-systems-for-globally-leading-e-scrap-recycler https://www.sesotec.com/emea/en/resources/blog/sesotec-sorting-systems-for-globally-leading-e-scrap-recycler Case Studies

Established about 100 years ago as a small recycling company by Albert G. Sims in Sydney, Australia, “Sims Metal Management“ (SMM) has developed into a leading metal recycling enterprise with numerous locations all over the world. As part of the complete SMM group, “Sims Recycling Solutions“ (SRS) is responsible for the environmentally compatible separation and utilisation of electrical and electronic scrap and mixed metals. The company is one of the world‘s biggest e-scrap utilisation and recycling enterprises.

SRS relies on Sesotec

At its plants in the UK, in the Netherlands, in Germany and in Austria SRS has already been using Sesotec‘s VARISORT sorting systems for many years. Integrated in the recycling processes these sorters are flexible solutions for the processing of electrical and electronic scrap. At its location in Eindhoven, Netherlands, SRS has expanded its capacities and now runs one of the region‘s biggest e-scrap recycling plants there. The expansions include their own metal and plastics recycling lines, which are equipped with Sesotec sorting systems for the separation of metals and plastics. SRS further processes the separated materials as secondary raw materials, which allows their renewed addition into the recycling cycle.

The cycle only works with pure secondary raw materials

The recycling processes at the Eindhoven plant are exemplary for the complexity of the sorting requirements in the field of electrical and electronic scrap recycling. It is of particular importance here that shredded material is separated into pure material flows so that these can be fed into the raw material cycle again. Electrical and electronic scrap among other things contains metals (steel, aluminium, copper), plastics, and printed circuit boards.

Sesotec‘s VARISORT WEEE multi-sensor sorting systems reliably separate plastics from printed circuit boards and metals. For performing the sorting tasks at the SRS plant Sesotec uses a combination of inductive metal detection and optical object recognition in their VARISORT WEEE sorting systems.

“The continuous improvement of processes has top priority if secondary raw materials should be provided in high quality on a global scale. Sesotec‘s multi-sensor sorting systems allow a flexible adaptation to new and also more complex sorting requirements that result from more complex products on the market“, says Marc Afüpper, director of SRS, EMEA.

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 Sesotec sorting systems for globally leading e-scrap recycler

More information about Sims Recycling Solutions: www.SimsRecycling.com

<![CDATA[Plastic: part of the problem…part of the solution - Part 2: the European Union’s solution]]> 2019-07-10 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-2-the-european-unions-solution https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-2-the-european-unions-solution Circular Economy

China is no longer taking on the world’s plastic waste, and our oceans could soon be home to more pieces of plastic than fish. The time to act is now.

There are many ways to reduce plastic waste. Banning their use is one of them. A great deal of plastic packaging is, in fact, unnecessary. Yet it also offers benefits in certain areas, such a hygiene and shelf life, making a complete ban rather unrealistic.

Another approach is to avoid plastic in many situations and to practise “plastic fasting”. Still, even that will not work everywhere, especially in the industrial sector. It is therefore essential to find an alternative solution – one that is also reflected in the EU’s plastics strategy: a circular economy.

The European Union’s plastics strategy

The European Union presented its plastics strategy on 16 January 2018. Under the strategy, all plastic packaging must be either reusable or recyclable at low cost by 2030. One of the EU’s goals in its plastics strategy is to stop marine litter. The long-term goal must be to avoid marine plastic waste entirely. However, creating a circular economy and recognising the value of a material that is widely considered to be refuse will be essential to achieving this aim.

The overall EU strategy is based specifically on four basic tenets:

  • manufacturing recyclable products
  • optimising the separation and collection of plastic waste
  • increasing recycling capacities
  • reusing recyclates in production

In doing so, the EU is voicing a commitment – an absolute necessity given the waste and recycling figures.

Unused potential

Every year, the people of Europe produce 25 million tonnes of plastic waste. 
The world produces 78 million tonnes of plastic waste a year.
The world as a whole needs to respond to this global problem. So far, recycling rates have been low around the globe,
ranging from 30% in Europe and 25% in China
to just 9% in the US (plastic waste statistics for 2017).
Much of that waste ends up in landfills or is incinerated, posing a risk to our groundwater and the air.

Projects such as Pacific Garbage Screening are currently trying to develop technologies and methods for collecting waste. The massive quantities of refuse destined for the world’s oceans could be separated using appropriate sorting systems and reused efficiently if it were possible to fish them out of the water at the mouths of rivers – something that would also be in line with the EU’s plastics strategy.

The circular economy in the real world

So how does a circular economy work? Recyclability must be taken into account when designing packaging. That is because the material itself has to be as pure as possible in order to actually be able to use plastic waste or used plastic as a secondary raw material and convert it into recyclates with the quality necessary to manufacture new products, no matter where in the world this process takes place.

Read the other parts of this series here:

Part 1: A global problem

Part 3: Sorting technology

Part 4: Efficient use of recyclates

<![CDATA[Plastic: part of the problem…part of the solution - </br>Part 1: a global problem]]> 2019-06-26 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-1-a-global-problem https://www.sesotec.com/emea/en/resources/blog/plastic-part-of-the-problem-part-of-the-solution-part-1-a-global-problem Circular Economy

The production of plastic has increased dramatically around the world in recent decades and currently stands at 200 times the amount manufactured by factories back in 1950. Europe is responsible for one-quarter of the world’s plastic consumption, mainly due to packaging that lands in the rubbish bin after being used for only a short time. Plastic is also used in construction (20%), vehicles (8.6%) and electronics (5.7%).

China and the EU up the pressure

Even today, used plastic is often considered to be refuse and is seen as a problem that can be taken care of by simply throwing it away. In recent years, a large amount of used plastic has been shipped to China, destined for what many believed was a solution. Roughly 51% of the world’s plastic waste, or 7.5 million tonnes, ended up in China in 2017. At the time, China was the world’s largest importer of plastic waste. Transporting waste there by ship, and then loading the ships with new consumer goods for the journey back to their home countries, was long seen as a profitable business model. However, this cycle has since been made more difficult by China’s National Sword initiative. What is the idea behind it?

In January 2018, the Chinese government stopped the import of low-quality plastic waste as part of its National Sword programme. Only plastic waste with a purity level of 99.5% or more is still allowed into the country. China no longer wants to act as a dumping grounds for other countries. The Asian countries that subsequently stepped in at short notice to take on the waste have been overwhelmed and will eventually issue their own bans on imports. As a result, they are not a solution to the current problem, presenting the waste management and recycling industry with a number of challenges. Finding alternatives is an absolute must.  

The EU has also acknowledged the problem. In early 2018, it adopted a plastics strategy, stating that all plastic packaging must be either reusable or recyclable at low cost by 2030.

The strategy poses another challenge for the waste management and recycling industry that ultimately places it in the same position as China’s National Sword initiative: ensuring the utmost purity of plastic waste prior to its recycling and reuse – an essential part of its ability to be employed as a secondary raw material.

Plastic – and no end in sight

The first plastic product hit the market in 1950. At the time, the world
produced around 1.5 million tonnes of plastic every year. In 2017, that figure
stood at roughly 350 million tonnes annually. A total of 8.3 billion tonnes of
plastic were manufactured between 1950 and 2017. 
China is the largest producer of plastic (26%), followed by Europe (20%) and North America (19%). According to estimates from Plastics Europe, plastic production is set
to increase to 1,124 million tonnes.

A floating problem

The world’s oceans are already home to 150 million tonnes of waste. Three-quarters of it is plastic waste, and 1 million tonnes is added to that amount every year. Many living creatures die a painful death as a result. So far, little research has been performed on the effects that plastics in the world’s oceans can have on the health of humans, who are exposed to it through the food chain. But what has been proved is that plastics take 350 to 400 years to decompose.

Packaging material disposed of along the shoreline, residues from rivers and fishing waste, such as leftover nets or ropes, are the main causes of marine pollution and the suffering of many marine organisms.

The long-term goal must be to avoid marine plastic waste entirely. However, creating a circular economy and recognising the value of material that is widely considered to be refuse will be essential to achieving this aim.

Tracking down marine debris

Plastic waste is mainly concentrated in five regions: in the north
Pacific, Indian Ocean, south Pacific, north Atlantic and south Atlantic. In
each region, the waste gathers close to the equator, where various water
currents and temperatures converge. 

The largest patch of floating debris is the Great Pacific Garbage Patch
in the northern Pacific Ocean, with an area of roughly 1.6 million square
kilometres and an estimated 1.8 trillion pieces of plastic.

Purity matters

With plastic consumption and waste constantly on the rise, fast and efficient methods of recycling and reuse at the locations where waste is generated are of the essence. 

A new way of thinking and a new approach are also necessary from a sustainability perspective.

Plastic waste can no longer be seen as rubbish. In times of dwindling fossil resources, it is a valuable commodity. Top-quality recycling material is the key to top-quality reuse.

Read the other parts of this series here:

Part 2: The European Union’s solution

Part 3: Sorting technology

Part 4: Efficient use of recyclates

<![CDATA[Detectors protect frozen fish products from metal contamination]]> 2019-06-19 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/detectors-protect-frozen-fish-products-from-metal-contamination https://www.sesotec.com/emea/en/resources/blog/detectors-protect-frozen-fish-products-from-metal-contamination Case Studies The Danish company Fisker Skanderborg A/S, a supplier of packaging equipment, has sold two Sesotec Metal Detection Systems of the type VARICON COMPACT to P. Taabbel & Co. A/S in North Jutland.

Taabbel processes all types of fish and shellfish into products for caterers at home and abroad. Taabbel‘s mission and goal is to produce food constantly at a high quality standard that complies with applicable food safety regulations, especially the requirements based on HACCP principles. The metal detection system VARICON COMPACT from Sesotec consists of a tunnel metal detector, a conveyor belt and a control unit. In the case of metal detection, the separation takes place by means of a belt stop.

VARICON COMPACT can be easily integrated into existing production lines. It detects various metallic foreign bodies in products and thanks to its high detection performance, it is ideally suited for applications in the food industry.

Effective protection for consumers, machines and image

Sesotec‘s metal detection systems, used to inspect piece goods after packaging, weighing or labelling, protect the products of manufacturers and processors in the food industry from unwanted metal contaminants. The tunnel metal detector detects metal particles contained in products quickly and efficiently. Thus, consumers, machines and the reputation of the company are well protected.

The solution for Taabbel in the fish industry

The two VARICON COMPACT metal detection systems were sold by Fisker Skanderborg A/S to P. Taabbel & Co. A/S in North Jutland. „The solution is extremely hygienic and meets the high demands of the food industry“, was the argument from Fisker´s Sales Manager Flemming Foldager to convince his customer.

For Per Toft, Technical Director of Taabbel, the quality and price of metal detection systems were the most important points. That‘s why he chooses the solution from Sesotec. „All of our frozen fish pro­ducts have passed through Sesotec‘s metal detectors. The operation of the VARICON COMPACT devices is very logical and therefore easy to learn. They fully live up to our expectations“, says Per Toft.

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 Detectors protect frozen fish products from metal contamination

<![CDATA[Metal contamination in plastics processing – causes and countermeasures]]> 2019-06-19 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-contamination-in-plastics-processing-causes-and-countermeasures https://www.sesotec.com/emea/en/resources/blog/metal-contamination-in-plastics-processing-causes-and-countermeasures White Paper

Download free White Paper now

Metal contamination is a major issue in the plastics processing industry. Not only do metal contaminants pose issues to quality and compliance, but they can also damage plastics processing equipment.

The key to metal-free production is enacting the right combination of a variety of countermeasures. Through a balance of in-process inspection, a robust program for total preventative maintenance, and end-of-line metal detection, plastics manufacturers can reap the rewards of high system availability, low rejection rates and happy customers.

How metals end up in plastics

Metal contamination has a variety of different causes. Metal contaminants are often introduced during the production process, such as through general wear and tear from machinery or tools. Other times, metal may be present in the intake materials or introduced through employee handling.

Effective countermeasures for metal contamination in plastics.

In our white paper, we provide a detailed outline of the issues, their causes and the necessary countermeasures for eliminating metal contamination in the plastics processing industry.

This awaits you in our white paper:

  • Problems caused by metal contamination
  • Causes of metal contamination: where is all this metal coming from?
  • Measures to reduce metal contamination in plastics processing

<![CDATA[Metal Detector for the Quality Inspection of Rubber Mats]]> 2019-06-04 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-detector-for-the-quality-inspection-of-rubber-mats https://www.sesotec.com/emea/en/resources/blog/metal-detector-for-the-quality-inspection-of-rubber-mats Case Studies

CY Handee Rubber Mouldings in the north of Malaysia produces rubber mats for a renowned international furniture company and is market leader in Malaysia. To meet the quality requirements that are demanded by the furniture company, CY Handee Rubber Mouldings decided to install a metal detector, and for this purpose they compared and evaluated Sesotec and another supplier.

For final quality inspection CY Handee Rubber Mouldings wanted to inspect large boxes filled with rubber mats before they leave the company. The objective was to ensure that the boxes exclusively contain rubber mats without any metal inclusions. Since the boxes are very big, the performance of the metal detector with respect to scanning sensitivity was of greatest importance because the sensitivity decreases with increasing size of the detector.

Sesotec‘s GLS tunnel metal detector is installed in a conveyor belt and provides highest sensitivity and maximum interference immunity. The GLS tunnel metal detector is used in many industry sectors. It detects all magnetic and non-magnetic metals and due to its extremely short metal-free zone can be easily integrated in every existing conveyor belt.

In addition to the technical reliability of the metal detector it was an advantage for Sesotec that they provided a demonstration system. This demonstration system convinced CY Handee Rubber Mouldings both with its easy installation and its ease of use and operation. The facts that the high scanning sensitivity requirements were fulfilled and that excellent detection results were achieved then resulted in a purchase decision in favour of Sesotec‘s GLS tunnel metal detector.

Technical features surely are important for the choice of a supplier, but a long-term partnership only can be based on excellent additional services, and for CY Handee Rubber Mouldings these were the crucial factors for their decision in favour of Sesotec.

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 Metal Detector for the Quality Inspection of Rubber Mats

<![CDATA[What the Meat Industry Expects from Product Inspection Systems]]> 2019-05-23 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/what-the-meat-industry-expects-from-product-inspection-systems https://www.sesotec.com/emea/en/resources/blog/what-the-meat-industry-expects-from-product-inspection-systems Company

For Sesotec GmbH, one of the leading manufacturers of product inspection and sorting systems for the food industry, the IFFA 2019 trade fair appearance was centered on two important subjects: X-ray technology and services.  

For Sesotec, close cooperation with customers, who are important drivers of innovation and partners on the same level, is the key to the success of X-ray systems. At their trade fair stand Sesotec therefore presented an "X-ray inspection for the future" design study where users had the chance to discuss the requirements, e.g. with respect to construction and design, that an X-ray inspection system in their opinion should meet. Customers who talked with the Sesotec team at the trade fair stand provided feedback from their practical experience and described the features they would like to see or even expect in X-ray systems of the future.  

With respect to innovative services Sesotec at the IFFA presented the new "Lifetime Warranty" service package for X-ray systems. This service package includes a lifetime warranty extension for X-ray tube and detector as well as predictive maintenance. The advantage for users of Sesotec X-ray systems with "Lifetime Warranty" service is that production can be run throughout the complete lifetime of the system with maximum value added and with full cost control. 

The supporting program of the IFFA this year again included the "IFFA Forum" that in technical lectures focused on important industry trends. "Food Safety" was one of the top subjects. Uli Hurzlmeier, X-ray Product Manager of Sesotec, in this context gave a lecture on the subject of "Detection of plastics with dual-energy technology". The resonance of the audience was positive throughout, which clearly indicates that in the meat industry the subject of "Detection of plastics" is gaining more and more importance and that solutions are actively searched.

<![CDATA[Detection of Plastics with X-Ray Systems in the Food Industry]]> 2019-05-22 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/detection-of-plastics-with-x-ray-systems-in-the-food-industry https://www.sesotec.com/emea/en/resources/blog/detection-of-plastics-with-x-ray-systems-in-the-food-industry Food
The supporting program of the IFFA this year again included the "IFFA Forum" that in technical lectures focuses on important industry trends. "Food Safety" was one of the top subjects. Uli Hurzlmeier, X-ray Product Manager of Sesotec GmbH, one of the leading manufacturers of product inspection and sorting systems, in this context gave a lecture on the subject of "Detection of plastics with Dual-Energy technology".

It is a fact that food products more and more often have to be recalled because they are contaminated with foreign particles - among others with plastics. To protect consumers against negative consequences, complete batches of products often must be withdrawn from the market. As an innovative solution approach for the detection of contaminants, especially of plastics, Uli Hurzlmeier presented the possibilities of X-ray inspection with Dual-Energy technology.

Conventional X-ray systems are able to detect contaminants such as metal particles and stones. Plastic and rubber contaminations due to their low density often are not detected. For the detection of plastic contaminations the Dual-Energy method offers an alternative solution.

If you are interested in the subject of "Detection of plastics with dual-energy technology" a video recording of Uli Hurzlmeier's lecture and the presentation charts are available here:

Download Lecture presentation

 "Detection of plastics & other low dense foreign bodies within meat industry"

<![CDATA[Metal detection for the safety and purity of meat products]]> 2019-05-09 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-detection-for-the-safety-and-purity-of-meat-products https://www.sesotec.com/emea/en/resources/blog/metal-detection-for-the-safety-and-purity-of-meat-products Case Studies

The Fleischmanufaktur Haspel e.K. with over 25 years of experience in purchasing, processing and selling meat, relies on quality and innovative technology. At the company headquarters in Dombühl, the company employs more than 200 people and give great importance to compliance with national and international quality standards such as the QS seal and IFS. In addition, individual customer requirements are met. Haspel is not only driven about achieving quality standards but also by the good conscience that the goods are free from contaminants.

A wide range of fresh and frozen pork and beef meat as well as meat preparations in various packaging variants from 200 grams to six kilograms and very high product effects require metal detection with top technology. An outgoing goods inspection of up to 130 tons of meat and meat preparations processed every day is necessary.

The conveyor belt system UNICON+ from Sesotec with integrated metal detector INTUITY ensures stability and hygiene in combination with maximum metal detection performance and easy operation. The multi-simultaneous-frequency technology allows Haspel to inspect products from three different packaging lines with the same metal detector. „Fast changing of different programs via external control our own management system represents a very important and useful function for us due to the already mentioned three packaging lines" says Florian Stadelmann, Production Manager of the Haspel Fleischmanufaktur.

In multi-simultaneous-frequency technology, two frequencies between 0 and 900 Kilohertz work in parallel. The selection of the two frequencies that best suit the product takes place during the learning process. Afterwards, INTUITY will simultaneously use these two frequencies to achieve the best metal detection results.

The customer‘s goal is to be able to inspect the most diverse meat products and packaging sizes with the best possible sensitivities. Although Sesotec units are already known, tests were made with devices from different manufacturers to compare the performance of the new multi-simultaneous-frequency technology. INTUITY from Sesotec convinced with highest detection performance and very simple operation. In addition to this come a impeccable and stable operation without rejection faults and the best sensitivity to stainless steel, which lead to the full satisfaction of the customer. The cooperation between Haspel and Sesotec is once again confirmed.

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 Metal detection for the safety and purity of meat products

<![CDATA[Advantages and benefits of OPC UA in the plastics industry]]> 2019-05-07 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/advantages-and-benefits-of-opc-ua-in-the-plastics-industry https://www.sesotec.com/emea/en/resources/blog/advantages-and-benefits-of-opc-ua-in-the-plastics-industry Plastics For years now, the world has been talking about “Industry 4.0”. The exchange of data in production plays an important role in making the introduction of Industry 4.0 a success. The open communication protocol OPC Unified Architecture, or OPC UA, is increasingly gaining popularity as a way of promoting data sharing. But what advantages and benefits does using OPC UA offer the plastics industry, for example? 

In the plastics industry, the OPC UA machine communication standard helps to optimise processes from production to service while minimising the loss of time, resources and products (rejects), thereby ensuring top quality and maximum value creation. 

An example of OPC UA communication: metal separator “talks” to mixing and dosing unit

A plastics company that produces caps and lids for the cosmetics industry, for example, may have multiple injection moulding machines in use on the shop floor. To increase plant availability, the company might use metal separators that are located directly between the mixing and dosing unit for the granulate and the material feed of the machine.  

Under certain circumstances, the granulate could contain a small, metallic contaminant that makes its way through the mixing and dosing unit and into the machine by way of the conveyor pipe. The metal separator would detect the tiny metal part and expel it safely, preventing any disruptions to the production process. Because a small amount of the desired material is also expelled during separation, the volume of granulate actually reaching the injection moulding machine may fall short of the expected quantity. 

The OPC UA link allows the metal separator to notify the mixing and dosing unit that a certain amount of material has been expelled. At the same time, it provides information as to the volume that needs to be added back into the system to maintain correct calculation. The result is a smooth manufacturing process that produces perfect caps and lids. 

Without standardised communication thanks to OPC UA, even the slightest deviations in the quality and flow of granulate could lead to the production of faulty parts, such as weak, under-injected lids. Such defective products often remain unnoticed at first and are later packaged for shipment to the customer without further inspection, virtually ensuring complaints. 

Advantages and benefits of OPC UA: optimised plant availability and product quality

By intelligently connecting all of the components involved in production and processing, OPC UA ensures smooth communication in the plastics industry. The exchange of data between metal separators and dosing units, for example, is the key to increasing plant availability and product quality while preventing complaints. 

Bartosch Jauernik, an OPC UA expert at Sesotec, says: “We are confronting the challenges of Industry 4.0 head-on and are actively working on the development of OPC UA standards for our devices. Sesotec is one of the first providers of intelligent metal separators for the plastics industry. Our devices can communicate with each other and with other machines, exchange data and optimise themselves.” 

Bartosch Jauernik is available to answer questions related to OPC UA and provide practical tips on implementation and processes.

Bartosch Jauernik
Product Manager
Tel. +49 (0) 8554 308-2370
<![CDATA[Sesotec Honours Stol Inspection Systems with "Regional Dealer Award 2018"]]> 2019-05-06 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-honours-stol-inspection-systems-with-regional-dealer-award-2018 https://www.sesotec.com/emea/en/resources/blog/sesotec-honours-stol-inspection-systems-with-regional-dealer-award-2018 Company

Sesotec's sales team was pleased to present the "Regional Dealer Award 2018" to Stol inspection systems bv.. Left to right in the picture: Andreas Reckziegel, Oliver Uhrmann, Udo Stol, Peter Dries and Simone Thijs  

During a visit in March 2019, Sesotec GmbH honoured its sales partner Stol inspection systems bv from the Netherlands with the "Regional Dealer Award 2018". Of all the sales partners in the EMEA sales region (Germany excepted) Stol inspection systems bv sold most Sesotec metal detection, X-ray, and magnet systems. CEO Udo Stol and Sales Director Simone Thijs accepted the award certificate. 

On behalf of Sesotec, Group Director Sales Division Product Inspection Andreas Reckziegel, Director Sales Division Product Inspection EMEA Oliver Uhrmann, and Regional Sales Manager Peter Dries expressed their thanks to Stol inspection systems for their outstanding performance. Sesotec also highly appreciates their continuous contribution to the development and improvement of product portfolio and proactive service. 

Stol inspection systems bv has been a sales partner of Sesotec for ten years and specialises in the sales and after sales services of inspection systems for the food, chemical, and pharmaceutical industries. Sesotec's metal detection, X-ray, and magnet systems are available for almost all applications both in standardised and in customer-specifically adapted versions. Consulting services with respect to the observance of HACCP, IFS, BRC and ISO 22000 for the avoidance of foreign matter contamination complete the portfolio of Stol inspection systems bv.

<![CDATA[Recycling of Electrical and Electronic Waste at Hennemann Umweltservice]]> 2019-04-30 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/recycling-of-electrical-and-electronic-waste-at-hennemann-umweltservice https://www.sesotec.com/emea/en/resources/blog/recycling-of-electrical-and-electronic-waste-at-hennemann-umweltservice Case Studies

Hennemann Umweltservice Elektronik GmbH is headquartered in Espelkamp in North Rhine-Westphalia. The company‘s scope of services comprises the collection, transport, disassembly, and recycling of waste electrical and electronic equipment including all the necessary project planning, organization and documentation tasks. 

Since the beginning of 2015 the company has been a member of the Drekopf-Group, a family-run medium-sized business that has been operating in the field of proper waste disposal for more than 75 years. With the incorporation of Hennemann Umweltservice GmbH the Drekopf-Group was able to expand its scope of services by WEEE recycling. 

Hennemann Umweltservice Elektronik GmbH processes up to 50,000 tons of electrical and electronic products per year. Its customers come from trade, commerce, municipalities, industry, administration, and the private sector. The company‘s services also include the certified destruction of data media. Material is correspondingly processed in the company’s own recycling lines. „And this is where Sesotec recycling sorting systems are used“, says Eugen Wiebe, branch manager in Espelkamp. 

The WEEE recycling process

First of all, waste electrical and electronic equipment is broken down into individual components in manual disassembly stations, shredders, and by means of manual sorting. This allows the separation of valuable and reusable materials. The use of Sesotec‘s automatic VARISORT WEEE sorting systems made it possible to achieve even higher precision in separation and simultaneously reach higher throughput rates.

The VARISORT WEEE recycling sorting systems are used for the re-sorting of shredded small waste electrical and electronic devices. The objective of the sorting process is to separate the mixture of metals that is contained in the material. In addition to this mixture of metals the shredded small WEEE material also contains about 80% plastics which, after metal removal, can be supplied to the recycling loop. The VARISORT WEEE systems transport the material by means of a conveyor belt to the detection unit, which at Hennemann is equipped with sensors for color and shape recognition as well as for metal detection, alternatively also for stainless steel detection. 

Inverse sorting

For this application Sesotec uses inverse sorting, which allows the reliable separation of about 90% of the plastic parts contained in the electronic waste fraction. Inverse sorting means that objects that do not provide a metal signal are sorted out. In this fraction, a purity of >99% is achieved. This application furthermore has the advantage of reduced compressed-air consumption. Since most of the objects that must be sorted out are flat and of light weight, an air pressure of 3-4 bar is sufficient. With this type of sorting, rolling or heavy metal parts (e.g. screws and bolts) that have a small contact surface also are correctly sorted into the metal fraction. 

Separation of aluminium and printed circuit boards

Another sorting task at Hennemann is solved by means of colour/shape detection. The input material in this case is a mixture of aluminium, copper, and PCBs. This mixture is the result of separation in an eddy-current separator, where the resulting aluminium fraction also contains PCBs and copper. By means of re-sorting with the VARISORT WEEE recycling sorting system these PCB and copper parts can be reliably separated from the aluminium parts. This results in two pure fractions that can be sold separately. 

Flexible sorting system

With the VARISORT WEEE systems Hennemann, if required, is also able to perform cable sorting based on combined metal/shape sorting – a typical application for the WEEE sector.  

The Hennemann team received individual training at Sesotec for the various applications of the VARISORT WEEE systems so that operators are able to adapt corresponding system settings for new sorting tasks themselves. Eugen Wiebe is convinced of the advantages offered by Sesotec‘s solution: „With the possibility of combining various sensors, and with individual program adaptations that can be performed by our employees for sorting tasks with different input materials, we can use these systems with greatest flexibility. For this purpose, Sesotec provided intensive training for our employees, and in this field also offers special training courses at Sesotec‘s location or directly at the customer‘s place.“

Download Case Study

 Recycling of Electrical and Electronic Waste

<![CDATA[Metal detector protects Wanner granulators from damage]]> 2019-04-25 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-detector-protects-wanner-granulators-from-damage https://www.sesotec.com/emea/en/resources/blog/metal-detector-protects-wanner-granulators-from-damage Case Studies Wanner´s granulators are used in plastic recycling to granulate sprues and defective parts coming from the production of injection molded, blow molded or extruded thermoplastic products.

The machines from the Xtra series have hardened cutting tools made of high quality steel. This guarantees a long service life even when processing abrasive plastic materials. Metal impurities in sprues can nevertheless cause damage to the cutting chamber. In order to reduce impurities and thereby costs, Wanner was looking for a metal detection solution for the inhouse recycling of plastic sprues. The metal detector should be especially suitable for the Xtra series and easy to sell for Wanner´s sales network.

Cutting unit safe protected

Wanner opted for the plate type metal detector ELCON 250 from Sesotec GmbH, since a successful cooperation between the two companies existes already for a long time. With this metal detector are the cutting tools of the granulator safely protected against damage because ELCON detects all magnetic and non-magnetic metal impurities before even touching the cutting chamber. The used half-wave technique stops the crushing tool when metal detection occur and thus prevents the introduction of metallic impurities into the further manufacturing process. In addition, false rejects caused by vibrations in the crushing of brittle plastic materials and hard sprues are minimised.

Carsten Weidel, Regional Sales Manager at Wanner: „What we particularly appreciate about Sesotec is their support on site and the precise implementation of our specifications from Sesotec´s development department. Our customers who use Xtra granulators benefit from the metal detection solution by reducing costs related to machine repair or production stops.“

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 Metal detector protects Wanner granulators from damage

<![CDATA[Sesotec Canada’s move provides base for further growth]]> 2019-04-24 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-canadas-move-provides-base-for-further-growth https://www.sesotec.com/emea/en/resources/blog/sesotec-canadas-move-provides-base-for-further-growth Company

Sesotec Canada Ltd. is a subsidiary of Sesotec GmbH, a manufacturer of metal detectors, x-ray inspection systems and sorting systems based in Germany. For over four years, Sesotec Canada was based in Cambridge, some 90 km west of Toronto. As of 1 April, it moved from Cambridge to Guelph.

Sesotec Canada is expanding rapidly and the premises available in Cambridge became too small to cope. For this reason the company made the decision to move to Guelph, some 75 km south-west of Toronto. Situated only one hour’s drive from Canada’s largest airport in Toronto, the new location at 275 Hanlon Creek Boulevard Unit 3 provides enough space for offices, a meeting room and a showroom with demo equipment. Metal detection, x-ray inspection, and checkweighing systems will be available for product testing and customer training. In addition, the new location also houses on-site spare parts storage, making it possible to quickly support customers with a range of services.

Doug Pedersen, Director of Sales Sesotec Canada, said: “Sesotec Canada aims to better meet the needs of the food, plastics and recycling industries. We possess the technological and application-specific expertise to detect foreign materials and help companies produce safe products that are free of contaminants. This ensures that both consumers and the brand image are safely protected. Sesotec has thousands of systems for contaminant detection and sorting installed around the world, making it one of the leading manufacturers and the only one to offer such a broad and flexible range of products.” 

For over 40 years, Sesotec has been working in close cooperation with customers from very different industries and using innovative and reliable technologies to develop practical, cost-efficient solutions for product inspection, metal detection and materials sorting in the food, plastics and recycling industries.

Sesotec Canada’s new location at 275 Hanlon Creek Blvd Unit 3 in Guelph, Ontario offers potential for further growth.

<![CDATA[IFFA 2019: Helping shape the future of X-ray inspection]]> 2019-04-16 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/iffa-2019-helping-shape-the-future-of-x-ray-inspection https://www.sesotec.com/emea/en/resources/blog/iffa-2019-helping-shape-the-future-of-x-ray-inspection Company

At IFFA 2019, Uli Hurzlmeier, product manager for X-rays at Sesotec, will present a design study on the RAYCON D+ X-ray scanner to encourage discussion of the features and functions that an ideal device should offer in the future. (Photo: Sesotec GmbH)

At IFFA 2019 in Frankfurt (Hall 9.1, Stand C58), Sesotec GmbH will present a design study on the RAYCON D+ product inspection system. To promote co-creation, Sesotec plans to talk to visitors to its stand about the future demands facing X-ray machines for unpackaged meat products. The showcased design study, “X-ray inspection for the future”, is a transparent prototype that can be used in detailed discussions of how ideal solutions will need to be engineered in the future, which features they should have and where untapped potential still lies.

Listening to the customer: the demands facing X-ray inspection in the future

Using the showcased design study, “X-ray inspection for the future”, visitors to the Sesotec stand will be able to discuss various aspects that are relevant for the meat industry and provide feedback on trends, giving them a practical opportunity to help shape the next generation of X-ray scanners. Uli Hurzlmeier, product manager for X-rays at Sesotec, will be on hand to answer questions such as: How do X-ray scanners support compliance with food guidelines such as IFS, HACCP and BRC? How versatile is the device in use? Does the device meet hygienic design standards and EHEDG guidelines? How economical is the system? What if the use of conventional X-ray inspection is not enough? How does the dual-energy method work? What alternatives are available for parts that come into contact with products, such as anti-radiation curtains?

Sesotec IFFA special: Lifetime Warranty service package for X-ray machines

At its stand, Sesotec will be placing a special focus on service offerings for X-ray machines. Service life in 24/7 use is a major issue, especially when it comes to core components such as X-ray tubes and detectors. Sesotec is providing support and a solution by presenting its Lifetime Warranty service package.


All information about Sesotec at IFFA is available at https://www.sesotec.com/en/iffa-2019

Sesotec at the IFFA Forum 2019!

"Detection of plastics with dual-energy technology"
Expert lecture by Uli Hurzlmeier, Product Manager X-ray, Sesotec GmbH

Tuesday, May 7, 2019, 3:40 pm - 4:00 pm
IFFA Forum (Hall 11.1 C40 )


<![CDATA[Nampak Inspection & Coding Systems new Partner of Sesotec in South Africa]]> 2019-04-08 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/nampak-inspection-und-coding-systems-new-partner-of-sesotec-in-south-africa https://www.sesotec.com/emea/en/resources/blog/nampak-inspection-und-coding-systems-new-partner-of-sesotec-in-south-africa Company

Simon Euler, Account Manager Division Product Inspection of Sesotec GmbH (fourth from left) was present at the ProPak Africa trade fair stand of Nampak Inspection & Coding Systems.

Since 1 June 2018 Sesotec GmbH has a new partner in South Africa with Nampak Inspection & Coding Systems. The partnership relates to the "Inspection Division" and primarily concentrates on the food sector, but it is also planned to utilise the existing potential in the plastics industry and to conquer regional markets with active campaigns.  

At the ProPak Africa trade fair that was held in Johannesburg from 12 to 15 March 2019 Sesotec presented the VARICON+W metal detection system with INTUITY metal detection coil, and the RAYCON EX1 X-ray scanner at the Nampak trade fair stand. Potential customers were impressed by the performance and ease of use of these systems. In the opinion of both Sesotec and Nampak the trade fair appearance was a great success.

In addition to sales and distribution, service is another strong point of Nampak, which is why Nampak also will perform local service for Sesotec metal detection and X-ray systems.


<![CDATA[Important factors when buying a metal detector for plastics processing machines]]> 2019-04-03 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/important-factors-when-buying-a-metal-detector-for-plastics-processing-machines https://www.sesotec.com/emea/en/resources/blog/important-factors-when-buying-a-metal-detector-for-plastics-processing-machines White Paper

Download White Paper

As a plastics processor, you know how important the utilisation and uptime of expensive equipment such as injection moulding machines, extruders and blow moulders can be for your company. Avoiding unscheduled downtime due to issues such as metal contamination in granulates is an absolute must. That is why metal detectors are an important part of production lines in the plastics industry today. They help prevent damage and increase the service life of machinery. What is more, greater machine uptime also increases the productivity of the entire line.

The decision to purchase specific metal detectors for moulding machines, extruders and blow moulders is usually based on criteria such as detection accuracy and price, both of which should indeed be taken into consideration. However, two other factors usually do not receive enough attention in the decision-making process: how easy is it to install the metal detector in the production line – and how easy is it for your staff to operate the device?

In our white paper, we will take a closer look at these two factors and show you why you should take them into account when making your decisions. We will also provide you with a checklist that you can use to check whether a metal detector is both easy to install and easy to operate.

Download our free white paper here:

Download White Paper

<![CDATA[Lifetime warranty extension for Sesotec X-ray machines]]> 2019-04-02 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/lifetime-warranty-extension-for-sesotec-x-ray-machines https://www.sesotec.com/emea/en/resources/blog/lifetime-warranty-extension-for-sesotec-x-ray-machines Company

Sesotec GmbH, a provider of machines and systems for contaminant detection and material sorting for the food, plastics and recycling industries, is constantly expanding its range of services. At IFFA 2019 in Frankfurt (Hall 9.1, Stand C58), Sesotec will present its new Lifetime Warranty service package for X-ray machines.  

This service package features a lifetime warranty extension on X-ray tubes and detectors, as well as predictive maintenance. For users of Sesotec X-ray devices, the Lifetime Warranty service ensures that production is possible over the entire lifetime of the machine, with maximum value creation and full cost control.

Markus Grimm, Group Director Service at Sesotec, looks forward to presenting the Lifetime Warranty service package in detail at the company’s IFFA stand: “Thanks to our lifetime warranty extension for X-ray tubes and detectors, we are supporting our customers’ ability to produce top-quality products at all times by using our RAYCON D+ and RAYCON EX1 X-ray scanners. Unscheduled machine downtime and breakdown, inventory hold and subsequent inspection costs are a thing of the past.”  

Standard service packages

To fulfil the requirements for successful audits and ensure maximum productivity, manufacturers and processors of food products must inspect the relevant components of their systems at regular intervals. Sesotec offers three standard service packages – Compact, Pro and Ultimate – for metal and contaminant detection systems, depending on the customer’s service needs.

Click here to find more information about Sesotec at IFFA 


<![CDATA[IFFA 2019: Meat and sausage products, free of contaminants – guaranteed]]> 2019-03-26 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/iffa-2019-meat-and-sausage-products-free-of-contaminants-guaranteed https://www.sesotec.com/emea/en/resources/blog/iffa-2019-meat-and-sausage-products-free-of-contaminants-guaranteed Company At IFFA 2019 in Frankfurt (Hall 9.1, Stand C58), Sesotec GmbH will present technologically sophisticated solutions for detecting metals and contaminants in packaged and unpackaged meat and sausage products. A design study on the RAYCON D+ product inspection system and the VARICON+ metal detection system, featuring the INTUITY metal detector, will be showcased at the trade fair. In addition, Sesotec will present the new Lifetime Warranty service package for X-ray machines at its stand at IFFA.

Customer co-creation

Product inspection systems which work with X-ray technology are already widely used in the meat industry. For Sesotec, the key to the success of X-ray systems is close cooperation with customers, who are important drivers of innovation and equal partners. Sesotec will therefore be exhibiting a design study entitled “X-ray inspection for the future” at its stand, where users can discuss what they expect from an X-ray inspection device in terms of its construction and other factors. 

Uli Hurzlmeier, product manager for X-rays at Sesotec: “The most important thing is to understand customers and offer them the services they need. With X-rays, that means not only the accuracy of detection, but also the kind of contaminant the user is looking for and the construction of the devices.” Findings of plastic contamination in meat products have therefore led Sesotec to develop the Dual Energy technological solution in cooperation with its customers.  

At IFFA, Sesotec will present the VARICON+ metal detection system, which is equipped with the INTUITY detection coil and achieves up to 50% higher scanning sensitivity than other systems on the market thanks to multi-simultaneous frequency technology. If used to help inspect outgoing goods, it can ensure that packaged meat and sausage products are free of metal contaminants.

Lifetime Warranty service package for X-ray devices

Sesotec will also present the new Lifetime Warranty service package for X-ray systems at IFFA. This service package features a lifetime warranty extension on X-ray tubes and detectors, as well as predictive maintenance. For users of Sesotec X-ray devices, Lifetime Warranty service ensures that production is possible over the entire lifetime of the machine with maximum value creation and full cost control.


Click here for further information about Sesotec at IFFA 2019.

<![CDATA[X-ray system inspects tuna fillets]]> 2019-02-12 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/indonesian-processor-of-tuna-fillets-uses-sesotec-x-ray-system-raycon-for-ensuring-product-purity https://www.sesotec.com/emea/en/resources/blog/indonesian-processor-of-tuna-fillets-uses-sesotec-x-ray-system-raycon-for-ensuring-product-purity Case Studies The company is convinced that the key to success is a balance in the chain of supplier, producer and consumer. Therefore, their mission is to grow step by step together with their suppliers and to achieve the satisfaction of their customers for whom health and
food safety have priority. Sesotec with its RAYCON X-Ray inspection system contributes to the improvement of food purity.

In this case the concrete detection requirements were particularly high and at the same time it was not allowed to change the dimensions of the inspected tuna blocks. This could be met thanks to the flexible configuration of the X-Ray inspection system in a version with 80 KV X-ray source. The customer can now inspect his standard blocks and benefits from highest detection accuracy – no matter whether the contaminants are metals, stones, glass or plastics whose specific density differs from the density of tuna.

“Our requirements for the detection of contaminations were very high but the constant reliability that the RAYCON system demonstrated in the tests compared to competitor systems made the decision easy for us,“ says the Production Manager.

<![CDATA[Sesotec sorting systems at New Zealand’s first PET recycling plant]]> 2019-02-11 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-sorting-systems-at-new-zealands-first-pet-recycling-plant https://www.sesotec.com/emea/en/resources/blog/sesotec-sorting-systems-at-new-zealands-first-pet-recycling-plant Case Studies Multi-sensor sorting line with two Sesotec VARISORT bottle sorters

20,000 tons of virgin PET is imported to New Zealand annually. New Zealand government’s Waste Minimization Fund supports the project to reduce that environmental harm. A grant enables the parent company Flight Group Ltd. to open New Zealand’s first PET recycling plant in Wellington and spend NZ$ 12 million (US$ 8.8 million) on a full upgrade at its facility including a wash plant for PET bottles.

Flight Group was established in 1907 and initially made leather luggage. It is still privately held by members of the original Osborne family owners. Flight moved into plastic production in the 1970s. It also has PET product manufacturing plants in Adelaide, Australia, and Romsey, England.

Keith Smith, CEO of Flight Plastics Ltd in Wellington said the wash plant and other work at the facility enables Flight Plastic to produce thermoformed packaging from recycled PET bottles. The company installed extrusion equipment to use recycled PET flakes starting in 2014, using imported flake to prove the process and establish a customer base.

They had very encouraging results, so the next step was to install their own wash plant. Flight Plastic has the capacity to recycle 6,000 metric tons of PET a year. It gets feedstock from curbside collections around the nation, which collect about 8,000 tons annually.

Sorting bottles and flakes

As a part of the investment in a wash plant, Flight Plastics installed a multi-sensor sorting line including two bottle sorters and a flake sorter. These three systems secure the outputquality as well as a continuous supply of PET flakes to the production line.

After the upstream process steps such as bale breaking the bottles are feed to Sesotec‘s VARISORT MN multi-sensor sorting system. This system was installed for the separation of PET bottles from other polymers (near infrared sensor N) as well as metals (metal sensor M). Flight Plastics also decided to install a further VARISORT CN. This second VARISORT is equipped with colour sensors C and near infrared sensor N for material identification and sorts as well as cleans the PET bottles into a transparent clear and a coloured fraction.

Those sorted bottles are feed into a cutting mill where they are cut to the desired flake size and passed through a washing and drying process. In the next step Sesotec‘s FLAKE PURIFIER multi-sensor-sorting-system is used for a final cleaning of the PET flakes. Here the remaining off-colours, wrong polymers and small sized metal pieces will be removed. This multi-sensor configuration equipped with a high resolution out-blast system allows highest possible sorting efficiency combined with lowest possible material loss rates. Depending on the application the three sensors can be used individually or in combination.

Sesotec‘s FLAKE PURIFIER multi-sensor-sorting-system used for a final cleaning of PET flakes

Flight Plastics director Derek Lander said in a statement: „The opening of the wash and sorting line was a milestone for Flight and its customers. Five years ago, we assessed the economic and environmental costs and benefits of introducing such a plant in New Zealand. The business case was predicated on the wash and sorting line being part of an integrated solution to use recycled PET flake in onsite production. CEO Keith Smith added: “Offshore recycling options are getting fewer, meaning countries need to find solutions for their own waste.“ In regards to the cooperation and the performance of the Sesotec machines Smith emphasized: “We are finding the Sesotec machines to be very reliable and user-friendly. In particular we have been impressed with the quality of service and support from the Singapore-based team.”

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  Sesotec sorting systems at New Zealand’s first PET recycling plant

<![CDATA[Maximum productivity of an injection moulding machine without downtime]]> 2019-01-30 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/maximum-productivity-of-an-injection-moulding-machine-without-downtime https://www.sesotec.com/emea/en/resources/blog/maximum-productivity-of-an-injection-moulding-machine-without-downtime Case Studies

X-PACK is a Tunisian company which has developed more than 100 references of plastic packaging for the last 10 years. One major business is the processing of high-density polyethylene (HDPE) to produce reliable closures for the packaging industry.

With a big investment in two new injection moulding machines for 150 tons and a material consumption of 18 kg/hr, X-PACK was looking to grow in the market. To be able to do that, the machines have to run at their maximum production last and any production stop affects the productivity and causes huge loss.

Mohamed Amine ABID, Director of X-PACK, says: „We had some production breakdown in the past due to a metal contamination and we did not know where it came from, apparently was mixed in the raw material. After that we decided to protect the hot runner system to avoid a major disaster“.

Two PROTECTOR 40 PRIMUS+, to direct installation as Last Chance Control were the solution for this customer´s problem.

Small metal particles in the plastic melting process often result in costly breakdowns of injection moulders, extruders and blow moulders. The quantity of such metal contaminants increases throughout the processing of regranulates and grinding stock. As a result, clogged nozzles, filters and hot channel systems can lead to production downtime.

The metal separator PROTECTOR is installed directly over the feeder of an injection moulder, an extruder or a blow moulder. It detects all magnetic and non-magnetic metal contaminants (steel, stainless steel, aluminium, etc.) – even when they are enclosed in the product. Metal contaminants are rejected via the “Quick-Valve” separation unit. Metal separators protect the processing machines, prevent malfunctions and thus increase the running time.

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  Metal separator protects injection moulding machine from impurities in the raw material.

<![CDATA[X-Ray Technology for inspection of coffee in metalized packs]]> 2019-01-09 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/x-ray-technology-for-inspection-of-coffee-in-metalized-packs https://www.sesotec.com/emea/en/resources/blog/x-ray-technology-for-inspection-of-coffee-in-metalized-packs Case Studies

The business of Sesotec´s reference customer Khao Shong Group Co.,Ltd. is the coffee blending. Over the years, developed Khao Shong the perfect manufacture process to ensure the optimal flavour of the coffee.

Committed to nature and to the efficient use of resources this customer also strives to achieve highest quality. He thus was able to establish himself on the market and to win the confidence of various OEM customers for whom he produces today.

In the production of coffee mix 3in1 (instant coffee, milk powder and sugar) broken metal particles from processing machines might contaminate the product. And if this coffee mix – as is the case with this customer – is packed in metallized packs it is difficult to detect such metal particles with conventional methods. Therefore, this company was looking for alternative methods for contaminant detection.

The RAYCON X-Ray inspection system from Sesotec is able to detect even smallest metal particles in metallized packs and to sort out contaminated products. Faulty activations are systematically avoided. It is quite easy to make such statements, but Sesotec in an extensive test run at the customer's plant also provided proof of the system's performance.

Says Chana Chiralerspong, Managing Director from Khao Shong Group Co.,Ltd.: "Sesotec's X-Ray technology at present is the best technology to meet the high demands of our quality management. And the experience we have in the meantime made with Sesotec's customer service further confirmed our decision for the RAYCON system."

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 X-Ray Technology for inspection of coffee in metalized packs

<![CDATA[High scanning sensitivity for all metals at the noodle filling]]> 2018-10-30 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/high-scanning-sensitivity-for-all-metals-at-the-noodle-filling https://www.sesotec.com/emea/en/resources/blog/high-scanning-sensitivity-for-all-metals-at-the-noodle-filling Case Studies

The beginnings of our reference customer can be traced back to the early 17th century. After a rapid rise in the thirtie s the company was completely destroyed in the years of war, what however, could not keep our customer from pursuing his dream.

What has once started as a small bakery has until today grown into a medium-size family owned company that produces noodles in various forms, sauces and several ready-made products.

In this big industrial company on an area of more than 20.000 sq m about 150 employees are producing products of perfect quality under highest technical and hygienic standards. This company just outside Munich required a metal detector with a focus primarily in detection. In the inquiry from Bernbacher, quality assurance was the most important factor. According to the customer´s description a system should be used to help with noodle filling at the end of a production line. Furthermore, the desired sensitivities that should be reached already were defined and were the incentive for the upcoming test series in the company.

The tests were performed with pasta noodles in free fall, using a P-SCAN RS 170 metal detector. For this application the closed metal detector with round aperture of the P-SCAN Series was exactly the right solution. This system can be perfectly matched to customer specific requirements and can be easily integrated in almost all types of standard pipelines. Only a few tests were necessary because right from the start the results were quite clear. The customer´s requirements concerning the desired scanning sensitivities could be exceeded by far and the reference customer also was highly satisfied with clear and hygienic design.

In addition to all the technical criteria and the positive results, the excellent service and the perfect project handling also were decisive for the decision for a continuing cooperation with Sesotec.

<![CDATA[Metal Separators Optimise the Production of Blood Tubes and Syringes]]> 2018-10-05 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-separators-optimise-the-production-of-blood-tubes-and-syringes https://www.sesotec.com/emea/en/resources/blog/metal-separators-optimise-the-production-of-blood-tubes-and-syringes Case Studies

One of the world's leading medical technology companies produces and sells an extensive range of medical supplies, laboratory and diagnostic equipment for health care facilities, life science institutes, and clinical laboratories. In the fi eld of injection and infusion technology the company is regarded as an innovation leader.

The company attaches particular importance to highest quality. Development, production, and delivery of products and services are subject to a continuous process of improvement. For this purpose processes are analysed to determine where and how effi ciency and effectiveness can be increased.

Task: Protection of injection moulding tools and quality assurance of plastic products

For the production of plastic parts by way of injection moulding the medical technology company uses both new granulate and regrind, which may both be contaminated with foreign bodies such as metal particles. In the past this often complicated the injection moulding process because such metal particles resulted in clogging of individual cavities in injection moulding tools, and tools frequently had to be cleaned. This caused expensive production downtimes of injection moulding machines, quality defects of plastic products, and a reduced output.

Looking for a solution for these production problems the company came across Sesotec metal separators. Using metal separators is the most reliable method for the removal of metallic particles and thus for the protection of injection moulding machines and for quality assurance of plastic products.

Solution: PROTECTOR reliably removes metallic contaminants from the processing material

After thorough tests the medical technology company now uses Sesotec PROTECTOR metal separators for the inspection and cleaning of granulate (new material and regrind). Metal separators of the PROTECTOR series are installed directly above the material inlet of injection moulding machines, where they reliably remove metallic contaminations from the slowly descending material column. Apart from outstanding properties such as high sensitivity and space-saving, compact design, the metal separators of the PROTECTOR series especially are characterised by the "Quick-Valve" reject unit. When a metal particle is detected a pneumatically controlled piston in this reject unit moves into its reject position, and the rejected material is completely sucked off into a collecting container by means of a Venturi nozzle. The piston then moves back to its pass-through position again. Only a minimum of good material is lost in this process, and clogging is impossible.

The medical technology company is highly satisfied with the Sesotec PROTECTOR metal separators: "Since the installation of these metal separators the operating time of our injection moulding machines has considerably improved, because disturbing metal contaminations are no longer an issue in the production process.“

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  Metal Separators Optimise the Production of Blood Tubes and Syringes

<![CDATA[Intelligent Machine and System Communication in the Plastics Industry]]> 2018-09-10 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/intelligent-machine-and-system-communication-in-the-plastics-industry https://www.sesotec.com/emea/en/resources/blog/intelligent-machine-and-system-communication-in-the-plastics-industry Plastics

At the Fakuma 2018 trade fair in Friedrichshafen from 16 to 20 October, Sesotec GmbH in hall B1, stand 1302, especially for the target groups of injection moulding companies and system integrators focuses on metal separators that can be networked in the production environment. The OPC UA (Open Platform Communications Unified Architecture) machine communication standard contributes to the optimisation of processes in the plastics industry, from production through to service, and to the minimisation of time and product losses, and it thus guarantees highest quality and maximum value creation.


What is OPC UA?

Industrial communication through OPC UA provides the required network mechanisms for data exchange between machine components. In the production process this ensures communication that guarantees a smooth production flow and initiates countermeasures in case of errors. Efficient industrial networks and properly functioning automation only can be realised on the basis of communication standards such as OPC UA, because such standards ensure a high level of openness and flexibility. 

What is the benefit of OPC UA for injection moulding companies and system integrators?

If in the processes of the plastics industry processing machines such as e.g. injection moulding machines are networked with peripheral machines, e.g. dosing units and metal separators, it can be ensured that the dosing unit feeds sufficient material if the metal detector detects a metal contamination and triggers a reject process. The benefit of OPC UA for injection moulding companies and system integrators is that product quality can be guaranteed because underinjection of produced plastic parts is avoided. OPC UA furthermore improves and simplifies service, e.g. maintenance measures. Machine parameters can be evaluated on cloud basis and are thus available for service engineers in real time.

At the Fakuma 2018 Sesotec also presents proven metal separators for the plastics industry which prevent metal contaminations from reaching plastics processing machines and thus protect tools against clogging and damage. Furthermore, Sesotec also presents the new service packages that ensure best possible preparation in case of malfunctions. 

At the trade fair stand experts of the Sorting Recycling Division shall be pleased to answer any questions concerning the latest technologies for plastics sorting.

More information about Sesotec at the Fakuma can be found here.

<![CDATA[Advanced Functions and Capabilities of X-Ray Technology]]> 2018-09-04 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/advanced-functions-and-capabilities-of-x-ray-technology https://www.sesotec.com/emea/en/resources/blog/advanced-functions-and-capabilities-of-x-ray-technology White Paper Quality inspection is an indispensable element of responsible manufacturing and packaging of food products. It is imperative to maintain high quality and ensure consumer safety with food and health products.

X-Ray inspection systems have become more common for such applications in the food and pharmaceutical industries in the past years. They offer an advantage over conventional metal detectors because X-Rays can detect not only a wide variety of foreign dense materials but also can-do with a much higher detection resolution.

In this White Paper we show you the key benefits and diverse application possibilities of x-ray technology and how these systems help you to ensure your product quality.

Download our free white paper here:

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<![CDATA[Use of food metal detectors as a competitive advantage]]> 2018-08-08 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/use-of-food-metal-detectors-as-a-competitive-advantage https://www.sesotec.com/emea/en/resources/blog/use-of-food-metal-detectors-as-a-competitive-advantage Case Studies

Often on his drive into the office, Huer CEO Ryan Storey asks himself a simple question: "How do I know the innovative products we will make today are being produced and packaged as safely as possible?"

  Our large national customers expect us to have the highest safety standards, so do regulators, so do the children and adults who enjoy the products we process,“ Ryan says. “And no one expects more from us than we do of ourselves.“ Ryan, a former lawyer, clearly understands the potential risks to both consumers and Huer Foods if products are contaminated.

As one of Canada‘s leading confectionery packagers and distributors, Huer Foods has been at the forefront since 1986 with its commitment to identifying and using the latest in proven technologies designed to keep manufactured and packaged products like theirs as safe as possible.

It’s no small task. Subject to random audits and some tough regulatory demands, Huer delivers its own products and packages those of others in all significant channels including grocery, drug, convenience, discount and specialty shops. With offices near Montreal and Vancouver, its reach is nationwide. Certainly, its wide array of products were already safe. But that wasn’t enough for Ryan and his colleagues. “They had to be even safer, and we wanted to find the most advanced tools available to achieve that goal.”

Raising the Safety Bar

Improving safety is the right thing to do. It’s also good for business. Ryan recognized the duality here that eluded his competitors. “We wanted to have a competitive advantage,” he recalls. “I don’t believe all of my competitors use metal detectors.” Leveraging the technology would be a strong selling point in the crowded marketplace. “We saw that it would provide more confidence to our customers and could set us apart from the rest of the pack.”

As part of Huer’s continuous improvement process, Ryan helped to launch a search committee. It began to hit the most important trade shows to kick the tires on some products – and put sales representatives through their paces with tough questions and their ideas on how to solve real-world scenarios. After making the rounds at several packaging shows, Ryan and the search team were struck by the sheer number of companies that said they were in the food production metal detection business. “I was overwhelmed,” he remembers. “There were lots to choose from.” Of course, having too many choices is a nice problem to have. Still, the sheer data to pore over and claims to vet can be a little daunting.

A Thorough Search

As part of Huer’s continuous improvement process, Ryan helped to launch a search committee. It began to hit the most important trade shows to kick the tires on some products – and put sales representatives through their paces with tough questions and their ideas on how to solve real-world scenarios. After making the rounds at several packaging shows, Ryan and the search team were struck by the sheer number of companies that said they were in the food production metal detection business. “I was overwhelmed,” he remembers. “There were lots to choose from.” Of course, having too many choices is a nice problem to have. Still, the sheer data to pore over and claims to vet can be a little daunting.

The Huer team knew the kind of solution they wanted; they just weren’t sure they could find it. “We were after something that was of demonstrably high quality, that was easy to learn and use, and boasted cutting-edge technology,” he says. After an extensive search, the Huer team found several firms that fell within the same price range – but Sesotec’s products stood out in terms of quality.

What did Huer see in Sesotec he didn’t find elsewhere?

“It was a clean looking machine,” he explained. It had good visual appeal but its German construction also showed it was very robust. The “heart and soul” of the product is made in Germany, with the conveyor system designed and manufactured in the United States.

Frankly, another selling point was that the product was made by a company whose focus was metal and x-ray detection and nothing else. As Ryan said Sesotec knows their business exceptionally well. Huer selected Sesotec’s C-Scan GHF. This leading edge metal detector boasts high performance detection of magnetic and non-magnetic metal contaminants, an intuitive touch screen set up, USB capability, and as standard HML multi-frequency technology.

Simple Implementation

Setting up the Sesotec equipment was easy. “We got it in the morning, and had it up and running about two hours later,” he explains. Because some of its products – including licorice and gummy candies – require different sensitivity settings Huer‘s production manager went through a spate of synchronicity tests and running products through the system at least eight times to make sure the product adjustments were correct. A small piece of test metal is run through the system every day.„And every day the Sesotec system catches it“, Ryan said with every bit of confidence. A Sesotec tech also helped set up the system. Subsequent training requirements were minimal. In addition, the machine is largely insensitive to vibration and, because it has no dirt-collecting edges, easy to clean.

An Immediate Safety Benefit

When the C-Scan GHF detects metal, a signal is sent to a rejection unit, an alarm or to a process controller to initiate a remedial action. Huer’s salespeople also appreciate Sesotec. “We always focus on it during a presentation,” Ryan says. “We’re in a business, when it is not always easy to differentiate yourself from the others in an obvious way. This is one effective way to do just that.”

A Look Ahead: The Power of Confidence

The partnership with Sesotec is, in part, one of the factors giving Huer the confidence to continue to build private label opportunities with partners and further expand their own brand. “Our retail customers like to partner with Huer because they want to partner with a company that is committed to making the necessary investments in equipment and food safety certification to ensure their brand investment is secure; therefore we must continue to produce everything in a safe and effective manner to grow our partnerships,” Ryan stresses.


Doing the Right Thing

At Huer, safety isn‘t an option it‘s a required investment as Ryan points out. No business wants a recall, so an ounce of prevention is clearly worth it. It is about developing long-term relationships and giving partners – new and old – an even stronger sense of confidence when they work with Huer.

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<![CDATA[Glass Sorting with Sesotec Sorting Systems at Schirmbeck Glasrecycling GmbH]]> 2018-08-07 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/glass-sorting-with-sesotec-sorting-systems-at-schirmbeck-glasrecycling-gmbh https://www.sesotec.com/emea/en/resources/blog/glass-sorting-with-sesotec-sorting-systems-at-schirmbeck-glasrecycling-gmbh Case Studies

In November 1996 a new combined recycling line for hollow and flat glass cullet was put into operation, processing hollow and flat glass from the regions of South Germany and Switzerland. Already one year later another recycling plant started operations in Kraubath an der Mur (Austria). In March 2007 the plants in Schierling and Kraubath were extended with two additional lines for hollow glass processing.

The branch in Immendingen (Baden Württemberg) that was started in August 2009 is used for the more efficient handling of transport volumes from nearby areas and from Switzerland.

Today the company operates three glass recycling plants in Schierling, Kraubath, and Immendingen. With more than 200 employees and a fleet of approx. 85 commercial vehicles the company every year recycles approx. 400,000 tons of glass (flat glass and hollow glass).

For many years Schirmbeck has been using machines and systems made by Sesotec (formerly S+S) in the plant that was planned by KRS Recycling Systems GmbH. At the Schierling plant glass sorting initially was performed with Sesotec SPEKTRUM systems.

At the IFAT 2014 trade fair the new K9 glass sorting system was presented for the first time, and today Schirmbeck Glasrecycling GmbH uses the K9 Basic and K9 Flash system versions for the sorting of waste glass in the hollow glass line.

The K9 systems are used for the colour separation of cullet starting from a grain size of five millimetres. They improve the quality in the recycling of fine, hollow, and flat glass and allow high throughput capacities.

At the Schierling plant the waste glass from the hollow glass line is sorted with three K9 glass sorting systems. One K9 FLASH system and two K9 BASIC systems are installed in a cascaded arrangement. K9 FLASH separates CSP (ceramics, stones, porcelain), and in the second stage one K9 Basic also performs CSP separation. In the last stage the second K9 Basic is used for colour separation.

The finished material is supplied to the glass-producing industry again. Material that has been sorted out is properly disposed of by external waste disposal companies.

<![CDATA[MultiPet uses Sesotec sorting systems in PET flake recycling]]> 2018-06-28 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/multipet-uses-sesotec-sorting-systems-in-pet-flake-recycling https://www.sesotec.com/emea/en/resources/blog/multipet-uses-sesotec-sorting-systems-in-pet-flake-recycling Case Studies

MultiPet GmbH was founded in the year 2001 and started production with a new PET recycling plant. Today the company processes up to 35,000 tons of PET waste every year. The Multiport GmbH sister company also is located in Bernburg. Multiport processes up to 38,500 tons of HDPE and PP waste and produces customerspecific regranulates. The two plants in Bernburg thus have a total capacity of more than 70,000 tons per year. The two companies in Bernburg presently have more than 150 employees.

Right from the start recycling sorting systems of Sesotec were used to separate colours and metals from PET flake flows in the PET recycling plant. With a volume of Euro 1.2 million MultiPet GmbH specifically invested in the optimisation of existing plant components with new recycling sorting systems. The existing sorting stage was supplemented with an additional stage, which in addition to colours and metals also allows the reliable separation of unwanted plastics.

For this purpose Sesotec supplied two FLAKE PURIFIER multi-sensor sorting systems together with suitable installation and material conveying components. Equipped with multi-spectral sensors for the separation of foreign polymers and true-colour sensors for the removal of wrong colours, the sorting systems provide highest qualities in the end product with a minimum loss of good material. These positive quality changes with respect to the specifications for recycled flakes perfectly match the increased quality demands of the customers
of MultiPet GmbH.

<![CDATA[Production security through machine protection]]> 2018-06-25 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/production-security-through-machine-protection https://www.sesotec.com/emea/en/resources/blog/production-security-through-machine-protection Case Studies

Mah Sing Plastics Industries Sdn Bhd (MSPI), one of the largest high-tech plastic manufacturers in Malaysia, has a major local market share and is recognized for its trustworthiness and reliability. They supply local and international businesses with a wide range of plastic products such as plastic pallets and plastic containers. MSPI wanted to inspect raw materials such as Polyethylene (PE) or Polypropylene (PP) before entering the manufacturing process to assure product security. Therefore, MSPI was commisioning JS Analytical to offer a system for separating any metal contamination from those raw materials. 

JS Analytical, part of the Osnab Group from Malaysia, is a solution provider of metrology, analytical and detection equipment serving various industries. They are representing Sesotec metal detectors and separators in Malaysia. Through outstanding personalized professional customer service, they propagate the benefits of these technologies and provide the needed equipment to satisfy their customers. During a visit, a technician from JS Analytical set-up a RAPID VARIO-FS metal separator from Sesotec and gave a live testing showcase on how the unit could improve MSPI’s raw materials´ quality without causing any production stop.

Sometimes there are cases where small metallic impurities enter the production process and may end up damaging the processing machine. To repare the machine, the factory will have to shut-down their work operation for reparation which means a huge loss in production especially if their line operates 24 hours a day.  

The RAPID VARIO-FS from Sesotec is a metal separator for free fall applications. It detects all magnetic and non magnetic metal contaminations (steel, stainless steel, aluminium) – even when enclosed in the product. Metal contaminations are rejected through the “Quick Flap” reject unit, with minimum loss of good material. 

In the test made for MSPI, the RAPID VARIO-FS showed a 100% result detecting and separating metallic parts mixed into the inspected plastic resins.

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Mah Sing Plastics: Production security through machine protection  

<![CDATA[IFAT 2018 Presentation Platform for Sesotec Smart Sorting Solutions]]> 2018-06-22 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/ifat-2018-presentation-platform-for-sesotec-smart-sorting-solutions https://www.sesotec.com/emea/en/resources/blog/ifat-2018-presentation-platform-for-sesotec-smart-sorting-solutions Recycling For Sesotec GmbH and their partner company KRS Recycling Systems GmbH, two manufacturers of machines and systems for material sorting, the IFAT 2018 was highly successful. Trade visitors to a large extent came from the intended target group and showed great interest in the machines presented at the trade fair, the FLAKE PURIFIER+ multi-sensor sorting system for plastics recycling, and the new SPEKTRUM SCOPE glass sorting system.

Sesotec and KRS used the IFAT trade fair to meet many of their customers and to provide information about product innovations, and also in 2018 were able to again welcome many visitors from at home and abroad at the trade fair stand. The further development of the FLAKE PURIFIER+ multi-sensor sorting system as well as the new SPEKTRUM SCOPE glass sorter obviously were well received by customers.

Says Michael Perl, head of BU Sorting Recycling at Sesotec, summarizing the IFAT: "The fact that plastics recyclers showed such great interest at our trade fair stand also may be due to the current situation that it is no longer allowed to export unsorted plastic waste to China, and to the statements of the European Commission concerning plastics and their disposal and recycling. Our partner company KRS Recycling Systems GmbH, which for the first time presented the new SPEKTRUM SCOPE glass sorting system to trade visitors at our Sesotec stand, also gave a highly positive feedback. The machines and systems we presented at the fair, and the sorting concept solutions of our team, resulted in interesting and promising talks that reflect an overall positive atmosphere with respect to the business situation and positive future prospects for the year 2019."  

Sesotec is a regular exhibitor at the IFAT in Munich because the IFAT trade fair is a very important communication platform for the dialog with customers. For Sesotec the trade fair furthermore is an important cornerstone for brand communication under the slogan "Purity matters".

<![CDATA[PET Flakes in Highest Quality]]> 2018-06-19 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/recycling-sorting-system-for-pet-flakes-in-highest-quality https://www.sesotec.com/emea/en/resources/blog/recycling-sorting-system-for-pet-flakes-in-highest-quality Case Studies undefined

The Mexican company organises the collection of plastic bottles through its own national network of collection centres.  Pressed into bales the plastic bottles arrive at the GREEN Mind plant, where they are first singularised, and in the next step the labels are removed. After pre-washing the plastic bottles then are separated into unmixed fractions, and this stage in the recycling process is where Sesotec's VARISORT multi-sensor sorting systems are used. These systems are equipped with sensors for colour and shape detection, and with sensors for the differentiation of plastic types.

Subsequent shredding of these sorted PET bottles then is followed by washing, drying, and screening processes. The PET flakes then undergo fine sorting with the help of Sesotec FLAKE PURIFIER sorting systems. The FLAKE PURIFIER systems at this stage separate coloured flakes, metals, and foreign plastic parts from the transparent PET flakes.

Contact between Sesotec USA and GREEN Mind was established through the Mexican distribution partner Innovateck®. GREEN Mind has been using Sesotec sorting systems since 2012. The Mexican company first invested in a flake processing line with a total of four recycling sorting systems. The excellent quality of the end products and the continuously increasing recycling rates in the year 2015 then were the reasons for GREEN Mind to build an additional sorting line and to integrate another five Sesotec recycling sorting systems in this line. For the purpose of machine protection GREEN Mind also uses seven Sesotec metal detectors. All this demonstrates how Sesotec's product portfolio ideally supports the complete recycling process.

Confirms plant manager Saúl Solaeche: "We are convinced by the quality of the sorting results, and we are highly satisfied with the maintenance and service of our Sesotec systems. We shall recommend Sesotec in every respect."

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<![CDATA[New Sesotec Website]]> 2018-06-06 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/new-sesotec-website https://www.sesotec.com/emea/en/resources/blog/new-sesotec-website Company

For Sesotec, one of the leading manufacturers of machines and systems for contaminant detection and material sorting, the ambition to achieve more customer and market orientation is a main driving force in corporate strategy decisions and in branding. In this context the corporate website is the most important information, communication and interaction instrument, and was therefore created completely anew with respect to design, structure and content. 

New structure in a new design

For the uniformity of content and brand design a new structure was developed that is based on the interests and usage behaviour of customers. "Attractive pictures should immediately fascinate website visitors, because a user only remains on the website if the first impression really fits", explains Benjamin Manzenberger, Senior Online Marketing Manager at Sesotec's  corporate headquarters in Schönberg and responsible for the relaunch. On the homepage the visitor can directly reach the "Industries" and "Products" pages, and can use a "Burger" navigation that allows quick orientation and leads to various sub-items. The new Sesotec website features Responsive Design, which means its flexibility ensures the same user friendliness on the computer desktop, tablet and smartphone, and the full content is quickly available for the visitor.

Informative content attractively presented

"The new website contains both short informative texts and also detailed articles. For example, we explain to our visitors where Sesotec systems can be used in their industries", explains Manzenberger. Many pictures and graphics are used to illustrate and supplement the texts. Links are used to inform the visitor about contents that also may be interesting for him.  

High-quality contents in multimedia formats, especially in the form of videos, whitepapers and case studies, with practical orientation make it possible for the customer to experience Sesotec competence in the complete value creation chain as a reference for his specific project and as a basis for his individual solution.

"Instead of only reading theoretical contents on the website, customers can really experience how contaminant management actually works in real operational practice", says Manzenberger. Case studies demonstrate which product inspection systems are available and where these can be used. Visitors furthermore have many possibilities to contact Sesotec, e.g. to reach the Service Center, or to arrange a visit date.

<![CDATA[Sesotec's positive review of Anuga FoodTec 2018]]> 2018-04-25 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotecs-positive-review-of-anuga-foodtec-2018 https://www.sesotec.com/emea/en/resources/blog/sesotecs-positive-review-of-anuga-foodtec-2018 Food

At the Anuga FoodTec, the world's leading trade fair for the food and beverage industry in Cologne, Sesotec GmbH presented intelligent, long-lived and robust contaminant inspection and sorting systems for the industry. 

As trade fair highlight Sesotec GmbH presented the completely new developed RAYCON D+
X-ray inspection system to trade visitors. With the intelligent power management software of the RAYCON D+ system Sesotec sets new standards not only with respect to detection accuracy, application flexibility, and ease of operation, but also with respect to the long service life of the X-ray tube. The automatic adaptation of the X-ray power to the product, and the Edge Filter that automatically detects the edge e.g. of packagings, both minimise the frequency of false rejects and of wasted products.   

In addition to the RAYCON D+ Sesotec at the Anuga FoodTec 2018 also presented the INTUITY metal detector that is excellently suited for use in the food industry, and the attractively priced RAYCON EX1 entry-level X-ray inspection system. The new QUASAR optical sorting system that was developed especially for the requirements in the quality inspection of bulk materials also was shown at the trade fair. 

"We really are pleased that our intelligent and long-lived contaminant inspection systems and sorting systems that contribute to the optimisation of value creation by minimising losses of time and products made such an excellent impression on trade visitors at the Anuga FoodTec", summarises Sesotec EMEA sales manager Oliver Uhrmann.

<![CDATA[Smart Sorting Systems Made By Sesotec ]]> 2018-04-24 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/smart-sorting-systems-made-by-sesotec https://www.sesotec.com/emea/en/resources/blog/smart-sorting-systems-made-by-sesotec Recycling

At the IFAT 2018 trade fair that will be held in Munich from 14 to 18 May, Sesotec GmbH in hall B5, stand 415/514, will present the FLAKE PURIFIER+ multi-sensor sorting system that now as standard is equipped with a 3.2mm nozzle and valve grid, allows a higher throughput capacity, and is easy to operate with the "SesoDesk" operating software. As co-exhibitor Sesotec's partner company KRS Recycling Systems GmbH will be present at the IFAT trade fair stand with the new SPEKTRUM SCOPE glass sorting system. The SPEKTRUM SCOPE among others features a new NIR (near infrared) sensor unit.

The modified FLAKE PURIFIER+ multi-sensor sorting system in addition to optimised material infeeding now also features a valve unit with doubled number of nozzles, which ensures higher precision in contaminant separation and a reduced loss of good material. Furthermore, the dust-proof design and the resort track that can be integrated in the FLAKE PURIFIER+ also increase efficiency in the recycling process, especially in cases with highly contaminated input material.  

Michael Perl, head of BU Sorting Recycling at Sesotec, says about the FLAKE PURIFIER+: "For the modification of the FLAKE PURIFIER multi-sensor sorting system into the new-generation FLAKE PURIFIER+ the wishes of our customers for increased throughput capacities with minimised loss of good material, and thus an overall increase of value creation, were the decisive factors."

Together with KRS Recycling Systems, Sesotec for the first time present the SPEKTRUM SCOPE glass sorter that is equipped with the new Sesotec NIR sensor unit. With this sensor unit, for example, transparent plastics of the same colour can be differentiated in a flow of white cullet.   Special glass types, among others borosilicate glass, also can be reliably detected. To allow even higher throughput capacities and more flexible plant planning, the working width of the SPEKTRUM series is extended to 1563 mm with the SPEKTRUM SCOPE.

For information about the systems presented at Sesotec's IFAT stand please visit www.sesotec.com/en/ifat2018.

<![CDATA[Nutradried Creations uses Sesotec X-ray Inspection System]]> 2018-04-04 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/x-ray-inspection-system-for-food-used-by-nutradried-creations https://www.sesotec.com/emea/en/resources/blog/x-ray-inspection-system-for-food-used-by-nutradried-creations Case Studies

Nutradried Creations is a Blaine, Washington-based leader that uses state-of-the-art technology to create shelf stable, healthy snacks derived from natural, whole foods. As a company, it boasts a track record that demonstrates it is about more than turning a profit.

 Nutradried Creations has a compelling, simple mission statement: Nutradried Creations’ purpose and mission is to create a Triple Bottom Line – impacting people’s lives and bringing profit to shareholders – through social business by selling environmentally and socially responsible products that will ensure that the customer receives the best nutritional products possible, through the innovative use of our patented process and strategic relationships.

For example, it partners with organizations like Agros International, a Seattle-based nonprofit that assists poor, rural farmers in purchasing their own land through low-interest or interest-free loans. This helps these farmers break out of their generational poverty cycle. By only purchasing ethical ingredients that are fairly traded, Nutradried also partners with its customer to provide a fair wage for a beautiful product. This helps to enable farmers to provide food, clothing, shelter, and an education for their children. The achievements are impressive. With Agros, Nutradried Creations helped develop 42 villages, aiding 24,000 farmers and fostering generational change. It is now doing similar work in Ethiopia by supporting dairies that feed orphanages and provide economic opportunity for their local communities. To help achieve these and other goals, the company needs vendors it can trust to help it on the operation and processing side.


In addition to new customer expectations, Nutradried Creations must also comply with a higher compliance bar raised by the Food and Drug Administration (FDA) in the past several years. Perhaps the most significant are the much tougher Hazard Analysis and Critical Control Points (HACCP) requirements. When an inspector comes calling at your food processing facility, they expect to find strong evidence that you have completed a hazard analysis, and have a plan that includes, identified critical control points (CCPs), and the limits for each CCP; as well as introduced CCP monitoring processes, procedures and corrective actions, ensuring your HACCP system functions as intended. 

Of these, FDA warning letters have tended to most often focus on corrective actions. The final rule requires a plant‘s HACCP plan to identify the corrective actions to be taken if a critical limit is not met. Corrective actions are intended to ensure that no product leaves the facility that has been adulterated or is dangerous to human health. 

Sesotec’s solution is HACCP, BRC, and IFS compliant.


“We needed to provide our customers with the absolute security that the products we make for them are safe with no foreign contaminants“ says Nutradried Creations Plant Manager Phil Fraley. That‘s especially important for a company with a higher calling to help the economically disadvantaged. 

Working with Sesotec also gives Nutradried Creations more confidence when preparing for a customer audit. “We want to be ready,“ Phil said. “We want our customers to have confidence in doing business with us.“


Phil‘s team evaluated nine different X-ray suppliers. “We spent about twelve hours going through the capabilities for each,“ he adds. Ultimately, many things set Sesotec apart from the pack, but Phil cites one example: A commitment to quality training. 

“Sesotec included quality training in their fees and provided us with a great machine,“ Phil said. Competitors wanted to charge up to $5,000 to provide training, he added. He spent about four hours putting together spreadsheets and presented the Nutradried Creations‘ owners with the recommendation to go with Sesotec RAYCON Technology.


In addition to metal, RAYCON product inspection systems can complete more advanced product analysis to detect contaminants, other systems might miss. Glass, ceramic, stone and bone in food can be problematic for an inadequate system. The RAYCON will detect high density plastics such as PVC and natural rubber, as well as identify other product defects including cracks, missing components and underweight products.

In addition, packaging components such as aluminum clips on sausage chubs or aluminum pie plates can be masked out as needed. RAYCON’s unique edge filter technology will analyze dense packaging edges in metal cans or carton walls, compensate for them; but still find foreign material at these edges. So 100% package inspection is always taking place with the RAYCON. Users like Nutradried Creations can operate with confidence with this kind of support.

RAYCON‘s innovative software also delivers a number of advantages. The use of real-time, solid-state flash memory, means no longer having to account for error-prone spinning hard drives. A Linux operating system - known the world over as a very robust industrial platform - allows for the full processing horsepower of a dedicated image analysis computer to find the smallest foreign material in food products. Finally, the electronic design is modular and rugged; no UPS is required for system protection, and access is easy, for lower cost of ownership.


Because of its partnership with Sesotec, Phil says the company will now be able to pursue larger partners, including private labels. “This represents a potentially big growth opportunity for Nutradried Creations,“ Phil stressed. “We benefit from working with partners who share our commitment to doing things well and doing them right.“ 

Phil and the team at Nutradried Creations remain committed to providing high-quality products that benefit people all over the globe. Working with a partner like Sesotec, they are confident they‘ll achieve their worthy goals. 

Nutradried Creations is a company full of dedicated, visionary professionals who firmly believe that getting also means giving. It‘s understandably proud of all that it has achieved by providing quality food inextricably linked with fair treatment of farmers and others in the production and delivery chain, but now it‘s hungry for more. At Nutradried Creations, the future is now.

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<![CDATA[Waste reduction with Sesotec Sorting Systems]]> 2018-04-03 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/waste-reduction-with-sesotec-sorting-systems-for-plastics-pet-flake-recycling https://www.sesotec.com/emea/en/resources/blog/waste-reduction-with-sesotec-sorting-systems-for-plastics-pet-flake-recycling Case Studies

BTB PET-Recycling GmbH & Co. KG, established in the year 2006, and headquartered in Bad Salzuflen (Germany) processes approx. 20,000 tons of PET bottles per year. The owner-managed company with about 30 employees primarily produces PET granulate both for bottle-to-bottle and for foil manufacturers. 

The PET bottles to be processed undergo a preparation process of several steps before they as PET flakes pass through the newly installed Sesotec flake sorting system. This system comprises a new chute machine of type FLAKE PURIFIER CM 1536 and an already existing belt machine from the year 2011,  which after modification could be integrated in the new installation. 

In accordance with the idea of BTB PET-Recycling GmbH & Co. KG, Sesotec in addition to the optical sorters also supplied the steel construction, the pneumatic conveying technology, and the control technology. The objective of this was to better coordinate the work that had to be performed, and to shorten the down-time of the complete plant in the construction phase. 

"Because of continuously falling prices for low-grade PET material on the Asian market we had to develop new economic solutions for PET waste, and our strategy was to reduce the waste volume", says plant manager Mr. Zajontz. "With the new installation of the Sesotec sorting system we have reached this objective. There is no question regarding the profitability of the system." He furthermore adds: "The integration of remote access makes it possible to monitor the sorting system through the network. Sesotec service engineers also can use remote diagnostics for short-term error remedying or for software updates, which makes processes in everyday operations much easier. Cooperation with Sesotec was smooth right from the start."

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<![CDATA[USA and the Food Safety Modernization Act]]> 2018-04-02 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/usa-and-the-food-safety-modernization-act https://www.sesotec.com/emea/en/resources/blog/usa-and-the-food-safety-modernization-act Food

In an article from the year 2013 the Food Sentry company that watches the origin of food on a global level writes that this standard is violated especially in India and China. The ASEAN region in Southeast Asia, on the other hand, with respect to safety regulations clearly stands out from these two countries and is also considered a true power producer of food – with an export total of approximately US dollar 53 billion in 2011 in the agricultural sector.

The unlimited flow of food within this market is hindered by several safety regulations: Before food in the ASEAN region can be marketed in Southeast Asia, it is checked for certified production and in some countries first registered in order to guard against and counteract possible risks. Anyone who cannot prove certified production of his product will not be allowed to import or export in these nations.

In the United States there are clearly defined regulations for the observance of food safety standards for a long time. Currently the Foreign Supplier Verification Program (FSVP), which entered into force on 30 May 2017 within the scope of the Food Safety Modernization Act (FSMA), should ensure that the safety and quality of all the food imported into the United States are guaranteed helping to protect the consumer. Originating from the U.S. Food & Drug Administration (FDA) the FSMA was signed already in the year 2011, but it only took effect in September 2016. Food producers who export into the United States therefore must be aware now that food purity and quality should no longer only be seen as competitive advantages, but rather as an obligation and an established standard.  


What is the FSMA?

The Food Safety Modernization Act is a resolution originating from the FDA (Food & Drug Administration) that aims to ensure the fulfilling of safety and quality requirements in the US food industry. With the now effective FSMA the FDA now have a wider scope of action with respect to measurements and inspections at food producers in order to avoid possible risks for consumers, which for example may result from contaminations.

What does the resolution mean for trade?

Food producers who export to the USA must ensure that their products comply with FSMA regulations. This means that food should be produced in certified production processes – which for example includes the fulfilling of necessary hygiene requirements, the inspection of products with inspection systems, and the documentation of potential risks.

In detail

  • ƒCompanies that import into the USA according to the FSMA must demand from their sub-suppliers that they perform these inspection measures with their products.
  • ƒThe FSMA authorises the FDA to refuse the acceptance of imported food if the foreign-country establishment refuses to be inspected by the FDA.
  • ƒThe resolution furthermore allows the FDA to request a compliant certificate from food producers that ensures that imported food complies with the US food regulations.

When does the FSMA take effect?

According to the FDA, the obligations to comply with FSMA regulations have been in force since March 2018.

Contaminant inspection systems are important components for FSMA compliance

The objective of the FSMA is to guarantee food safety. A first important step for proper preparation is the so-called Hazard Analysis and Critical Control Points concept (HACCP): The identification of critical control points. Critical control points are those stages in the production process that allow inspections which lead to a reduction of hazards for food purity. It may be decisive here, for example, whether the product should be inspected in packed or unpacked condition, when goods are received or at the end-of-line. Another decisive factor is the type of inspection. Here the type of contaminant must be determined, or whether product-related quality differences should be detected. The FSMA also includes the so-called HARPC concept (Hazard Analysis and Risk-Based Preventive Controls) which specifies preventive measures against possible risks with the aim of implementing inspections and verifying the success of such inspections. A good inspection system features sophisticated and reliable technology, high-quality workmanship, and user-friendly innovative operation. Users who choose magnet systems, detection systems, X-ray systems, and optical sorting systems made by Sesotec can be sure that all the above-mentioned criteria are fulfilled.

Sesotec offers a wide product portfolio that covers almost all applications. Customers from all over the world can be supplied with systems for all process stages, products, and conveying types. Sesotec systems are produced at the main factory in Germany and comply with highest safety requirements and with hygienic design that is required for the world market. Control unit and software design are developed to ensure that they comply with the requirements of HACCP and all the current food standards.

Result: The benefit of FSMA is higher than the efforts

Apart from the expenditure in money and time due to the installation of inspection systems, the Food Safety Modernization Act also offers many benefits. The resolution not only can be seen as a chance to guarantee food safety, but also as a safeguard against damage to a company‘s brand image that may result from recall campaigns.

<![CDATA[SABIC chooses Sesotec metal separator]]> 2018-03-23 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sabic-chooses-sesotec-metal-separator-for-inspecting-plastics-compounds https://www.sesotec.com/emea/en/resources/blog/sabic-chooses-sesotec-metal-separator-for-inspecting-plastics-compounds Case Studies About Sabic

SABIC Innovative Plastics strategic business unit is a wholly owned subsidiary of Saudi Basic Industries Corporation (SABIC) and was founded in September 2007. Innovative Plastics is employing over 9,000 people worldwide, manufacturing high-end thermoplastic materials in more than 35 countries. SABIC is working on the principles of Six Sigma. The highly disciplined Six Sigma process helps them to focus on developing and delivering near-perfect products and services. It encompasses design, production, and distribution. The product quality improvements behind SABIC Innovative Plastics‘ materials can help enhance the quality and marketability of customers‘ end products.


In Bergen op Zoom SABIC is producing plastics compounds PC, PC blends and Noryl. Quality and Product Purity is extremely important for SABIC. So they were looking for a machine for their outgoing quality control. Highest scanning sensitivity for ferrous metals, but also stainless steel and other non-ferrous metals was required. They requested for the best sensitivity in combination with reliability, aftersales and a supplier who has experience in plastics.


PME is one of the leading suppliers of peripheral equipment for the plastic processing industry in the Netherlands. They not only represent foreign and domestic producers but also provide service, maintenance, engineering and project management for all the peripherals for injection moulding machines, extruders, blow moulding machines and other machines producing plastics, plastic semi-manufactured products, and final products.

As a long term partner of Sesotec in the Netherlands PME offered RAPID PRO-SENSE metal separators to SABIC. Using innovative HRF technology (High Resolution Frequency), RAPID PRO-SENSE, a system for free-fall applications, features extremely high sensitivity to all metals. The metal separator is specifically designed to meet the requirements of plastics and compound producers and features a genuinely innovative modular design. The reject unit can be chosen to match the conveyed material or to meet specific customer needs. 

As SABIC’s material inspection of the end product happens before packaging with special requirement that the unit must be cleanable with water inside. So water tightness of equipment is necessary. In part, the material is also abrasive. Wear-down protection of equipment is an important point. Last but not least there is a need of customized fitting to local installation requirements with special flanges.

SABIC decided to use RAPID PRO-SENSE metal detectors of Sesotec because of its outstanding features especially regarding the scanning sensitivity which is on highest level compared to other existing metal detectors. Another convincing feature is the reject mechanism where material cannot deposit which is important in case of material changes. Also the self-cleaning feature of the reject mechanism of RAPID PRO-SENSE is unique. The surface of parts in contact with material has been specially treated so that it is more resistant against wear-down.

Result and customer statement

The long experience with plastics handling and the aftersales in the Netherlands by PME is one more reason why Sabic bought RAPID PRO-SENSE metal detectors. Ronald van der Wal and Rob Willems from Sabic confirm: “The first units of RAPID PRO-SENSE are running in production very well. We are very satisfied with the results.”

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<![CDATA[Sesotec sorting technology replaces manual sorting]]> 2018-03-07 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-sorting-technology-replaces-manual-sorting-of-pet-flakes https://www.sesotec.com/emea/en/resources/blog/sesotec-sorting-technology-replaces-manual-sorting-of-pet-flakes Case Studies

PT. Rejeki Adigraha is a well-known plastics recycling company in Indonesia primarily specialising in the recycling of PET and PVC materials. PT. Rejeki Adigraha is headquartered in Jababeka Industrial Area – the largest industrial area in Southeast Asia. With about 150 employees the company reaches a recycling capacity of approximately 1000 tons of PET and PVC per month. 

PT. Rejeki Adigraha already was established in the year 1986 under the name of UD Rejeki Adigraha. At the beginning of its corporate history the company operated as a small trading company for PVC pipeline component brands and later also established itself as a manufacturer of rigid PVC granulate especially for pipeline components. At that time PT. Rejeki Adigraha was the first company in Indonesia that produced recycled PVC granulate for the pipeline component market.  In addition to granulate the company also produces PET flakes that are used as starting material for the polyester industry. PET products at present mainly are exported to China. 

Sesotec Asia, one of Sesotec's eight subsidiaries, based in Singapore, established the contact with PT. Rejeki Adigraha. 

PT. Rejeki Adigraha has replaced the manual sorting of PET and PVC flakes with automated sorting technology of Sesotec. "With the  FLAKE PURIFIER multi-sorting-system we have achieved a clear increase in efficiency. The quality of recycled plastics is guaranteed at highest levels and without any quality fluctuations," confirms Mr. Dede Indrapurna of PT Rejeki Adigraha. 

The recycling process of the Indonesian company starts with plastic materials from residual waste and plastic flakes containing 70 percent PVC and 30 percent other plastics, mainly PET. The material first is shredded to obtain parts of approximately the same size, and then passes through washing and drying processes. In the next plastics processing step Sesotec's FLAKE PURIFIER multi-sorting-system is used for the separation of PVC. The FLAKE PURIFIER sorting system was specifically developed for applications in the plastics recycling industry. The especially adapted small conveyor ensures that the plastic flakes are optimally singularised. In addition to the sensors for metal and colour separation Sesotec also provides a high-performance module for the detection of contaminations, which also include different types of plastics. Depending on the application these sensors are used individually or in combination. 

PT Rejeki Adigraha today can look back on more than 20 years of experience in plastics recycling. By using state-of-the-art recycling technologies the company has expanded its PET flake and PVC granulate production and thus is able to provide its customers with materials of highest quality.

<![CDATA[Snack Producer selects Sesotec food metal detector]]> 2018-03-02 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/snack-producer-selects-sesotec-metal-detector-for-food https://www.sesotec.com/emea/en/resources/blog/snack-producer-selects-sesotec-metal-detector-for-food Case Studies

180 Degrees is a rapidly growing Auckland company producing a range of baked biscuits, snacks and crackers. With export markets really taking off, 180 Degrees have begun a major investment programme to expand production capacity and improve the efficiency of their plant.

Quality is the big driver behind 180 Degrees investment programme, so it was a priority for company director Nigel Cranston to make sure 180 Degrees had the best available metal detection technology in place.

After looking at all the options 180 Degrees selected a Sesotec Varicon+ metal detector supplied by Reynolds Group, featuring a C-SCAN GHF multi-frequency detector tunnel. This provided the best possible level of detection for all metal types across the full range of products, and extremely easy set-up and operation.  

The VARICON+ metal detection system detects all metal contaminants (ferrous, non-ferrous and stainless steel) – even when enclosed in the product. Designed for a wide range of packaged and unpackaged products. 

The VARICON+D series is designed for dry areas, the VARICON+W series for more hostile environments. VARICON+ systems are equipped with the GENIUS+ Control Unit and either a GLS or a C-SCAN GHF search head.


  • Space efficient metal detector individual and packaged goods up to 50 kg
  • Enhanced easy clean hygienic design
  • Available with a wide range of detector heads
  • High stability, precision inline metal detection with very short metal-free zone (MFZ)
  • Compliant with BRC, IFS and HACCP standards
  • Dry and wet environment versions

Nigel noted, “We have worked with Reynolds Group for our coding requirements for many years, and knowing that our new quality control systems are supported by such a great partner is reassuring.”

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<![CDATA[Sesotec Plastics Sorting – Fast, Reliable, Pure]]> 2018-02-07 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/plastics-recycling-with-sesotec-sorting-systems https://www.sesotec.com/emea/en/resources/blog/plastics-recycling-with-sesotec-sorting-systems Case Studies

All over the world waste plastics are a highly complex recycling subject. Nowhere else is there such a large number of different materials that need to be sorted. The pure sorting of waste plastics and their returning into the raw material cycle is particularly relevant both from an ecological and economical point of view. The correct sorting technology is of outstanding importance here. 

In the sorting of plastic bottles into pure plastic fractions the Taiwanese recycling company Tong Yi is serviced by Sesotec Pte.Ltd., Singapore, together with the distribution partner Uniplast Corporation. Tong Yi automates plastic bottle sorting with the Sesotec VARISORT N recycling sorting system.

Tong Yi specified the sorting requirements that have to be met. Test material from Tong Yi was sorted in the technical laboratory at the Sesotec headquarters in Germany. The customer thus had the opportunity to convince himself of the results and capabilities of the recycling sorting systems.

Optimal sorting solution for individual recycling requirements

Tong Yi uses the VARISORT N recycling sorting system – based on multispectral analysis – for the reliable sorting of plastic bottles, and thus gets two high-quality plastic fractions, PE and PET. 

A special challenge at Tong Yi is that the bottles to be sorted are transported on the conveyor belt in unpressed form. This leads to additional rotation of the bottles, which is countered by a special belt design. The conveyor belt with a length of five metres furthermore is used to singularize the whole bottles that should be sorted, which further increases the reject accuracy in the separation process.

The VARISORT version that is installed at Tong Yi features a three-shaft design, which means that three fractions can be separated in one sorting process. Fraction 1 contains PE, fraction 2 PET, and fraction 3 the other plastics and materials.

Depending on future sorting requirements and materials the customer can retrofit his existing system with additional sensors. This combination of different sensor types apart from plastics separation also allows applications in the fields of colour sorting and metal separation.

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<![CDATA[MB-Sort – Recycling of Metal Waste and Plastics with VARISORT COMPACT]]> 2018-02-06 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/mb-sort-recycling-of-metal-waste-and-plastics-with-varisort-compact https://www.sesotec.com/emea/en/resources/blog/mb-sort-recycling-of-metal-waste-and-plastics-with-varisort-compact Case Studies

MB-Sort is headquartered in Schönberg in the heart of the Bavarian Forest. Established in August 2016 the company presents itself as a specialist for material recycling on a market with great potential and offers professional contract sorting of all kinds of complex and technically problematic materials. The objective is to recover secondary raw materials from different kinds of mixed fractions, for example from electric and electronic waste, metal waste, and plastics.


Every month MB-Sort recycles up to 200 tons of various mixed fractions. Its customers include recycling companies and companies from the manufacturing industry. "In our own sorting line the material must be sorted into different material groups or cleaned. Sesotec's VARISORT COMPACT system is optimally suited for this task", says Markus Burghart.


The material to be inspected is fed into the VARISORT COMPACT system by means of specifically adapted vibration feeders that ensure a homogeneous material transfer onto the full width of the high-speed belt conveyor. The combination of infeed slide and belt conveyor eliminates form, weight, and friction influences of the material that is fed in. At the end of the belt conveyor the material is classified by means of corresponding sensors. After evaluation of the relevant information, highspeed valves are activated with a corresponding delay time for material discharge. Particles that must be separated are deflected from their original trajectory by exactly targeted compressed-air blasts and thus fall into a separate shaft.

Fields of application

The VARISORT COMPACT CM+ recycling sorting system among others is used for the sorting of shredded small electric/electronic devices. The purpose of sorting here is to separate printed circuit boards, copper, aluminium, stainless steel, and to generally remove metals from electronic waste plastics.

In multi-sensor operation the C and M+ sensors are combined. The C sensor unit provides information about form and colour, and the M+ sensor is responsible for metal detection. With this combination a high metal purity can be achieved and a usable plastic fraction can be obtained as a result.

In metal recycling the objective is to achieve correct sorting of the metal mixture consisting of aluminium, zinc, copper, brass, and stainless steel. Sesotec's VARISORT COMPACT CM+ system ensures reliable recycling with purities of more than 98%.

For plastics-processing companies different production waste or regrind materials must be separated by colour. Once recycled, these materials can be fed back into the production cycle again. With the C colour detection sensor the VARISORT COMPACT system is optimally suited for this task.


At MB-Sort the VARISORT COMPACT system made by Sesotec allows high-precision sorting of different material mixtures with high throughput rates.

Conclusion: VARISORT COMPACT is a flexible sorting system

With the VARISORT CM+ recycling sorting system MB-Sort is able to perform many tasks of its customers with highest flexibility.

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<![CDATA[Almi: Food metal detectors inspect flavourings and spices]]> 2018-02-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/food-metal-detectors-inspect-flavourings-and-spices https://www.sesotec.com/emea/en/resources/blog/food-metal-detectors-inspect-flavourings-and-spices Case Studies

The company continues to expand both home and abroad and in 2006 built a completely new production facility. This advanced factory extends over 18,000 square metres and incorporates all the latest equipment to enhance product quality and increase customer satisfaction. The company meets  all IFS, ISO 9001 and HACCP standards and holds many certificates and awards for consistently high product quality.

The new plant utilizes the latest in bulk material handling technology designed, supplied and installed by engineering company Johann Daxner GmbH who specializes in providing integrated plant and machinery projects particularly for bulk material processes.

Sesotec, in partnership with Daxner, supplied IFS and HACCP compliant food metal detectors for product inspection on milling, mixing, filling, bagging and small component lines. Food metal detectors from the Sesotec RAPID 5000 range were installed at the large bag filling station.

IFS Conformity

For Almi it was particularly important to choose metal detection systems that fulfilled all the requirements of HACCP and IFS in the food industry. RAPID 5000 metal detectors detect and remove magnetic and non-magnetic metal contaminants from free-falling bulk materials.

The contaminants are removed by means of a fast-reacting reject flap (“Quick Flap System”) with minimal loss of good material. The modular design concept means that the machines can be easily adapted for different drop heights by removing or adding intermediary pieces.

One of the main reasons for installing Sesotec machines was their “Hygienic Design”; specifically designed and constructed to meet the exacting hygiene standards of the food industry. The circular design of the reject mechanism eliminates sharp edges and crevices, preventing product build-up and blockages, even with non free-flowing flavourings, avoiding product build up over time and the resulting mould formation.

The „Easy Clean“ construction of the reject device means it is straightforward to access for cleaning and maintenance. The RAPID 5000 metal detection systems are also certified for ATEX Zone 20 because flammable dust is created during the filling/bagging process.

E R P and Metal Detection at Almi

A particular challenge of this application was varying product effect of individual flavouring product which can cause false triggering and material loss. To obtain optimum performance machine parameters for each product must be easily set up for each of the different product mixes.. Through the integral Ethernet interface attached to each metal detector the higher-level ESAweight production control system uploads  system parameters for each product batch.

Another feature that distinguishes the Sesotec machines is their high level of detection accuracy. The GENIUS controller and operating unit utilizes digital signal processing technology and ensures that the detector head is finely tuned to operate at optimum efficiency. Even particularly difficult, highly conductive spices and flavourings can be tuned out and optimum scanning sensitivities achieved.

The time and data of every event is recorded via the integrated logbook function. The GENIUS controller communicates all  relevant data for recording and traceability to the ESAweight control system, for subsequent processing batch by batch in the  central database. Analysis of the rejected material provides important information on the source of contamination and Almi have set up an additional station specifically to examine rejected material.


Robert Leeb, Production Manager at Almi is delighted with the results, “Sesotec RAPID 5000 metal detectors meet all our exacting standards and play a vital part in our complex quality management system.”

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Food metal detectors inspect flavourings and spices  

<![CDATA[Marangoni installs Sesotec Metal Detectors]]> 2018-02-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/marangoni-installs-sesotec-metal-detectors https://www.sesotec.com/emea/en/resources/blog/marangoni-installs-sesotec-metal-detectors Case Studies

Marangoni Meccanica S.p.A, located in the Italian town Rovereto near Trento, is a globally leading company in the development and production of tyre machinery both for the production of new tyres (with the Marangoni Tyre Machinery brand) and retread tyres (TRM brand). Machines for the production of large and extra-large radial tyres, so-called OTR (Off The Road) tyres, are a specialty of Marangoni Meccanica S.p.A. Such extra-large tyres are needed for agricultural vehicles, earth-moving machines, and dump trucks.

In the course of the last ten years Marangoni Meccanica S.p.A has revolutionised the engineering approach for large Farm and OTR tyre machinery and has built production lines that are perfectly matched to customer demands. Marangoni Meccanica S.p.A very often installs Sesotec tunnel metal detectors of type GLS and plate-type metal detectors of type ELS in its production lines, which, at tyre producers’ sites, are running with high capacity utilisation and a high level of automation.

Marangoni Meccanica S.p.A installs these metal detectors in optimal size above or below the feed conveyor belts. With state-of-the-art detection technology Sesotec metal detectors provide maximum scanning sensitivity for all types of metals, both ferrous metals and stainless steel or non-ferrous metals such as aluminium, copper or brass – no matter whether magnetic or non-magnetic, coated, painted, loose, or enclosed in the material. For tyre producers who operate a production line made by Marangoni Meccanica S.p.A with integrated Sesotec metal detectors, machine downtimes or damage cases that often involve high repair costs and reduced productivity, are reliably excluded.

Edoardo Salaorni (Marangoni Meccanica’s Commercial Director) emphasises the importance of Sesotec metal detectors: "Marangoni Meccanica S.p.A wants to provide its customers with production lines that grant optimal running times and allow the production of highest quality tyres. Metal detectors made by Sesotec are an important component for us and help us guarantee that our tyre production lines are among the best of the world."

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Marangoni installs Sesotec Metal Detectors  

<![CDATA[ The influence of intuitive operation on the total cost of ownership of a metal detector]]> 2018-02-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/the-influence-of-intuitive-operation-on-the-total-cost-of-ownership https://www.sesotec.com/emea/en/resources/blog/the-influence-of-intuitive-operation-on-the-total-cost-of-ownership White Paper

Investments in machines and systems for the protection against contaminants and for metal detection in the food industry for many years have an influence on a factory's internal processes and on its productivity.

In addition to the detection accuracy of such machines, their ease of operation, their usability, also plays an important role. This factor has a significant influence on the total cost of ownership.

Our "Time is Money" White Paper informs you about the criteria that need to be considered when you choose machines and systems for the protection against contaminants and for metal detection.

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<![CDATA[Metaldetector allows economic processing of regenerated material]]> 2018-02-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-detectors-allow-economic-processing-of-regenerated-plastics https://www.sesotec.com/emea/en/resources/blog/metal-detectors-allow-economic-processing-of-regenerated-plastics Case Studies

In the production of plastic parts for industrial electronics and automotive components, whether in small series with less than 500 parts per year or with annual production volumes of several million parts, the requirement for maximum process reliability has top priority. Environmental as well as economic considerations result in the use of industry-grade granulate (regenerated material, regrind) for plastic parts that in the end often are not visible, because a slight loss of optical properties is not important here.

The processing of regenerated material and regrind, however, is complicated by possible contaminations with foreign substances such as metal particles. Depending on the production system this may cause unwanted machine downtimes due to damage or clogging. The apparent economic advantage thus is quickly lost if downtimes caused by contaminations cannot be avoided. Using metal separators is the most reliable method for removing metal particles.

Sesotec provides metals separators for the inspection and purification of plastic granulate (new material and industry-grade material). The metal separator of type GF, for example, is especially suited for installation in vacuum and pressure conveyor pipes. Once installed it ensures undisturbed production. Only the use of metal separators allows an economic processing of granulate mixed with regenerated material or regrind.

The GF metal separator removes metallic contaminations (steel, stainless steel, aluminium, etc.) from the pneumatically conveyed regenerated material. Installed directly in the vacuum conveying pipe of the material conveyor for the injection moulding machine, it reliably separates metallic contaminations, even such contaminations that are embedded in a granulate grain. With the "Easy Mount System" the metal separator can be installed in already existing vacuum conveying pipes without any problems. Parts in contact with the product are made of stainless steel (1.4301). The outwardly sealed reject unit prevents any impairment of the function of the material conveyors due to outside air.

Product effects of the bulk material that are caused by moisture, colour pigments, or carbons, are automatically compensated, which guarantees a constant scanning sensitivity. With default settings the systems provide outstanding ease of operation. One advantage of the fast-acting "Quick-Flap-System" is the minimum loss of good material. Contaminated material is collected in a collection container and is thus available for detailed analyses.

Says Gerhard Kerschhackl, area sales manager of Sesotec Business Unit Plastics: "Sesotec metal separators are absolutely state-of-the-art, of outstanding quality, and they operate with highest reliability. Sesotec systems provide a rapid return on investment because they prevent the causes of downtimes and expensive repair work and guarantee optimal machine running times and product quality. Customers from the plastics-processing industry who have once acquired a metal separator to protect their machines later in most cases also purchase additional systems."

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Metaldetector allows economic processing of regenerated material  

<![CDATA[Metal Detection Steps Up]]> 2018-02-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-detection-steps-up https://www.sesotec.com/emea/en/resources/blog/metal-detection-steps-up White Paper

Significant innovations in metal detection came in the early 1980s with crystalcontrolled oscillators and automatic balance circuits. By the late 1980s, the first microprocessor-based metal detectors enabled automatic product learning and delivered digital information on the metal signals. Since then, there have been incremental improvements in detection performance.

Our White Paper describes the development of technologies in contaminant detection in the food industry and shows the progress metal detectors have made in terms of usability and detection accuracy in recent years.

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<![CDATA[Optical Sorting is the Core of the Recycling Cycle]]> 2018-02-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/optical-sorting-of-plastics-thermoplast-relies-on-sesotec-recycling-systems https://www.sesotec.com/emea/en/resources/blog/optical-sorting-of-plastics-thermoplast-relies-on-sesotec-recycling-systems Case Studies

Thermoplastkreislauf GmbH is headquartered in the Lower Austrian town of  Traiskirchen near Vienna. As a specialist in the field of thermoplast refining the company in its "Production" business unit produces individual plastic granulates by means of sophisticated compounding processes. The recycling of high-quality thermoplasts is the company's second business unit. The objective of this business unit is to process production waste into high-quality regrinds or regranulates.

All the products – new material, regrind, regranulate, and recyclate – undergo stringent quality inspection, and it is also of great importance here that products are of pure colour and correct form, and metal-free.

Sesotec sorting station with integrated multi-sensor sorting system

In its recycling business unit Thermoplastkreislauf GmbH installed a sorting station designed by Sesotec. Sesotec supplied a customised station with suitable steel construction, conveyor technology, and multi-sensor sorting system. The scope of delivery also included feeding hoppers, conveyor belts, steel construction for screens and working platform, and a suitable  SIEMENS control unit. For easy cleaning of the conveyor belts in case of material changes, mobile folding conveyors were integrated in the sorting station.

The core component of the sorting station is the VARISORT COMPACT multi-sensor sorting system that is equipped with sensors for colour and shape detection and with an all-metal sensor. The sorting station furthermore includes various screens that remove oversized and undersized particles before the material is transferred into the sorting system. The VARISORT COMPACT multi-sensor sorting system separates unwanted colours, shapes, and metals from the plastic flow and thus guarantees a constant high quality of the plastic recyclate. The unmixed products in additional steps are processed into granulate or are returned to the customer for further processing.

Says Christian Wind, managing director of Thermoplastkreislauf GmbH: "The project was perfectly planned and smoothly executed by Sesotec. We greatly benefit from the experience and flexibility of Sesotec in the field of sorting technology, because we can now guarantee that our products meet highest quality demands."

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<![CDATA[Aptar Relies On Sesotec Metal Separators]]> 2018-02-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/aptar-relies-on-sesotec-metal-separators-for-machine-protection https://www.sesotec.com/emea/en/resources/blog/aptar-relies-on-sesotec-metal-separators-for-machine-protection Case Studies About Aptar

The AptarGroup is a global market leader for dosing systems with more than 50 years of experience in a constantly changing world of packaging.  The most important corporate objective of the AptarGroup is to provide safe products for the business segments beauty+home and pharma. This objective is reached by using state-of-the-art technology. For the complete development, procurement and production processes the AptarGroup has set highest standards for itself.

In the business unit for fragrances, skin care, and cosmetics Aptar provides innovative, reliable, and flexible solutions. Packaging systems for beauty products must combine perfect function with attractive aesthetics. For demanding customers from the cosmetics industry Aptar is a partner for the providing of ideal beauty product packings. The product portfolio includes pump dispensers, caps and valves for skin care products, as well as spray pumps. Aptar also develops and produces complete packings and customer-specific solutions. At the Neubourg production plant in France Aptar Beauty+Home among others is certified acc. to ISO 14001:2004 for the development and production of spray and dosing systems as well as small packings.

Soufflet provides a test system

At Aptar in Neubourg the components for perfume sprayers are produced with injection-moulding machines. For the observance of quality standards the use of Sesotec metal separators is of decisive importance there. To convince Aptar of the high performance of such machines, the French Soufflet company provided a PROTECTOR system for testing for a period of six months. The advantages and improvements that this PROTECTOR system provided were quite obvious: A higher output of products of perfect quality, and reduced down-times of injection-moulding machines. The resulting rapid return on investment and the excellent cost/performance ratio in the end were the decisive purchasing arguments for Aptar.

Metals in plastic granulate may clog hot runner nozzles

Long before the use of metal separators, magnet grids were inserted in the material feeders of Aptar production lines that predominantly comprise injection-moulding machines. These magnet grids, however, were not efficient enough to remove all metal particles from the hot plastic material. Furthermore, magnets only attract ferrous metals.

Metal separators as the perfect solution for Aptar

For more than five years Aptar therefore has been using Sesotec metal separators of the PROTECTOR type for the protection of its processing machines. These metal separators are installed directly above the material inlet of injection-moulding machines. They detect all magnetic and non-magnetic metal contaminants (steel, stainless steel, aluminium, …) even if such contaminants are enclosed in the product. Metal particles are removed by means of a "Quick Valve" reject unit. The PROTECTOR metal separators are perfectly adapted to Aptar's requirements.  

Detection accuracy convincing for Aptar

Both Aptar's plant maintenance engineer and production manager consider  Sesotec metal separators as an important component in quality assurance: "We are particularly convinced by the detection accuracy of these systems. The daily performance tests demonstrate that the systems operate reliably, that fewer metal particles reach the injection-moulding machines, and that these machines therefore are reliably protected against functional disturbances. To this day we have installed more than 20 PROTECTOR in our production lines."

PROTECTOR protects in many applications

In its application possibilities the PROTECTOR offers highest flexibility. For example the metal separator is ideally suited for application in the packing industry in the production of caps for beverages and other liquids, or in the production of plastic articles for medical technology. Metal separators prevent malfunctions and thus increase the productivity of plastics processing machines.

<![CDATA[Contaminant Detection in the Meat Industry]]> 2018-01-23 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/contaminant-detection-in-the-meat-industry https://www.sesotec.com/emea/en/resources/blog/contaminant-detection-in-the-meat-industry White Paper

The Fish, Poultry and Meat (Protein) Industries present a series of challenges when it comes to foreign material, it can be said based on current knowledge that one of the highest risk food groups in terms of foreign material inclusions and the most demanding in terms of the operational environment.

Our White Paper describes some of the challenges that exist in the meat industry with respect to product purity and safety, and explains the available technologies for contaminant detection.


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<![CDATA[Sesotec With New CEO]]> 2018-01-22 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-with-new-ceo https://www.sesotec.com/emea/en/resources/blog/sesotec-with-new-ceo Company

Marc Setzen (on the right) is CEO successor of Xaver Auer who will leave Sesotec at his own request.

Sesotec, developer and manufacturer of contaminant detectors and sorting systems, reports a change in its corporate management team. Xaver Auer, who joined Sesotec in 2011 in the course of a change of ownership and as CEO is in charge of strategy, sales, and subsidiaries, will leave the company at his own request at the end of February. As his successor Marc Setzen could be won. 

Marc Setzen was born in Aachen and is 48 years old. He studied chemical process engineering at the Aachen University of Applied Sciences (Dipl.-Ing. / graduated engineer) and holds an Executive Master in Business Administration (EMBA) of the ESSEC-Mannheim Business School (Paris/Mannheim). He last worked as Chief Engineering Officer in the corporate management of the Klöckner Pentaplast Group. 

"Xaver Auer has developed Sesotec into an innovative and highly dynamic company. I sincerely thank him for this optimal basis and I greatly look forward to having the chance of taking part in shaping the success story of the company in the future", says Marc Setzen. "My objective in the medium term is to turn Sesotec into a premium provider in our focus industries. The term premium for me includes a high quality demand in our products, services, and processes." 

"With Marc Setzen we were able to recruit an experienced manager," says Xaver Auer, previous  CEO of Sesotec. "My successor has comprehensive competences and skills. Best preconditions for keeping Sesotec on its above-average profitability course and for further increasing the company's attractiveness for customers, partners and employees. I wish Marc Setzen and all the Sesotec colleagues every success."

<![CDATA[Metal-free granulate for SUZUKI motorcycle parts]]> 2018-01-18 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-detector-inspects-granulate-for-suzuki-motorcycle-plastics-parts https://www.sesotec.com/emea/en/resources/blog/metal-detector-inspects-granulate-for-suzuki-motorcycle-plastics-parts Case Studies


SUZUKI MOTORCYCLES INDIA PVT. LTD. is a subsidiary of Suzuki Motor Corporation, Japan, and in the Indian town of Gurgaon (Haryana) operates a plant with 1.700 employees and an annual capacity of 750.000 motorcycles and scooters. 

The core of Suzuki's philosophy always has been to provide bikes that are optimal in form and function. Their products are based on the effort to implement customer wishes and demands in development. 

Quality inspection is of outstanding importance for SUZUKI All the components of a bike undergo thorough inspection and quality testing. To ensure that material and aesthetic demands of the product are met, individual parts undergo performance testing before they are released for assembly. For efficient testing SUZUKI. has installed state-of-the-art inspection and testing machinery, which includes metal separators of the Protector range of Sesotec.


Plastic parts for motorcycles are produced in injection-moulding machines and are then painted. For the production of plastic parts for these 1.500 vehicles per day, SUZUKI. uses both new granulate and recycled material. The processing of recycled material and regrind, however, is complicated by contamination with  metal particles. This may cause unwanted downtime of the expensive injection-moulding machines and Hot Runner Systems of the mould due to damage or clogging.


Using metal separators to remove metal particles is the most reliable method to prevent machine downtime and quality defects. The Protector metal separator is installed directly above the material inlet of an injection-moulding machine, extruder, or blow-moulding machine. It detects all magnetic and non-magnetic metal contamination (steel, stainless steel, aluminium, ...) even if they are embedded in the product. Metal contamination is removed by the reject unit ("Quick-Valve").

At SUZUKI. a height of only 350 millimetres was available for installing the metal separators on the injection-moulding machines. With its slim and sturdy design the Protector is a perfect fit. The high-temperature version the Protector ensures perfect processing of the 90°C to 110°C hot granulate. External interference is compensated by the  Auto-learn function. Preset operating parameters ensure outstanding ease of operation.

Customer statement

Vipul Vikas, Project Manager at SUZUKI., is highly satisfied with the Sesotec Protector metal separators: "We were actively searching for a solution to solve the problem of metal contamination, and we found Sesotec through the manufacturer of our injection-moulding machines. Our Sesotec metal separators operate successfully, productivity has increased by five percent."

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<![CDATA[ For decades Brückner has been relying on Sesotec metal separators ]]> 2018-01-02 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/metal-detector-for-plastics-use-of-ground-material https://www.sesotec.com/emea/en/resources/blog/metal-detector-for-plastics-use-of-ground-material Case Studies

About Brückner Maschinenbau

Founded in 1960, Brückner Maschinenbau GmbH & Co. KG, Siegsdorf, today is the globally leading supplier of production lines for the manufacture of high-quality mono- and biaxially stretched film as well as extruded and smoothed flat film. Brückner Maschinenbau also provides complete turnkey plants as well as laboratory and pilot plants.

Brückner Maschinenbau is world market leader in the field of film stretching technology. Brückner's lines guarantee film manufacturers an efficient, flexible and reliable production of a wide range of film types that are used as high-quality packaging materials and in technical applications (e.g. capacitor film and high-tech screen film).

Today, approximately 600 Brückner film production lines are in operation all over the world. The customer list includes all the large and renowned international film producers. For many years Sesotec, Schönberg, has maintained a customer and supplier relationship with Brückner. For decades Brückner has acquired metal separators from Sesotec for the inspection and purification of film raw materials (film shreds, ground material, and new material).


In the production of films the edges, which due to the production method are somewhat thicker, are cut off, creating long strips that are recycled in the company. For this purpose the film strips are ground in a mill, and the ground material is added to the starting material again.

To guarantee the reliable removal of possibly included metal particles which, for example, might get into the material during the grinding process, the film flakes pass through metal separators before they are processed. Film stretching machines and extruders thus are reliably protected against damage caused by metal particles.


Brückner uses Sesotec metal separators of type RAPID DUAL at central positions. This separator type is excellently suited for the inspection of non-free-flowing bulk materials such as film shreds and of high-volume material flows in free-fall conveyor pipes. The separator detects all magnetic and non-magnetic metal contaminations (steel, stainless steel, aluminium, ...), even if such contaminations are embedded in the product.

Metal contaminations are ejected by a double flap ("Quick Flap System"). This eject system keeps the loss of good material at an absolute minimum. Using Jacob standard pipe connections the metal separator can be easily installed in existing pipes with minimum effort and in no time at all. Product-contacting components are made of stainless steel.


  • Detects and separates magnetic and non-magnetic metal contamination, even when enclosed in product
  • Reduces expensive machinery failure and minimises production downtime
  • Ensures product quality
  • Prevents customer complaints
  • Break even within a very short period of time


"In matters of metal separation, Brückner and Sesotec have been cooperating on partnership basis for decades. Brückner is satisfied with Sesotec because our metal separators are state-of-the-art in their technology and are of highest quality in their construction. Our systems operate reliably, reproducibly, and they amortise in a very short time because they prevent the causes of downtimes and expensive repair work and thus guarantee optimal machine operating times and product quality", says Erwin Reitberger, Sesotec Branch Manager - Plastics Industry.

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For decades Brückner has been relying on Sesotec metal separators  

<![CDATA[Andritz: High-quality plastics from waste electrical equipment]]> 2018-01-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/andritz-high-quality-plastics-from-waste-electrical-equipment https://www.sesotec.com/emea/en/resources/blog/andritz-high-quality-plastics-from-waste-electrical-equipment Case Studies

Throughout Europe, electrical and electronic scrap is the highest growing waste stream and  since electronic equipment contains a wide variety of materials, the recycling of such waste makes significant demands on any separation and sorting processes. The German plant builder, ANDRITZ MeWa, has built and commissioned a state of the art WEEE plant in the UK for a major waste management company incorporating a number of Sesotec sorters.  Designed to process recycled refrigerators, computers, hifi systems and other types of electronic and electrical waste the plant operates with two separate lines.

Sesotec has supplied through ANDRITZ MeWa three WEEE-SORT N near infra-red sorting systems for the identification and recovery of  high-quality plastics such as ABS , polycarbonate and the recycling of printed circuit boards. "The decision to use Sesotec systems was based on the high output quality of  WEEE-SORT systems. Only the most pure fractions can be sold at the best price ", explains Michael Perl, business manager - sorting at Sesotec.

Innovative technology for outstanding value creation

WEEE-SORT N polymer sorters are based on near-infrared technology. At the ANDRITZ MeWa facility these systems operating fully automatically separate different types of plastic pre-crushed electrical waste. The material stream to be inspected reaches the infra-red detector spread across a  fast-running conveyor belt and at this point the position and type of plastic is identified. Then depending on which types of plastic have been selected for separation but the user unwanted types are accurately and precisely removed by a precision air blast ejection system mounted at the end of the conveyor belt.

One of the three WEEE-SORT systems has a colour sensor combined the infra-red unit which provides a combined sorting process based on both colour and polymer type.

Recycling materials is  cost effective and environmentally friendly

Sesotec WEEE-SORT N polymer separators operate with high throughput  capacities and the sorting belt runs at up to  3m/sec. Air-blast valves,  specifically developed for this application, keep the loss of good material to an absolute minimum. For WEEE  recycling WEEE-SORT systems are a cost effective solution for the reclaiming of high-quality plastic and pcb fractions. The resulting pure plastics can be profitably returned to the production cycle , and valuable  metals can subsequently be reclaimed from the separated printed circuit boards.

Flexible and future-proof solutions provided by Sesotec

Says Michael Perl, business manager - sorting technology at Sesotec: "Recycling companies that produce clean, economically-priced material have a tremendous competitive advantage. The outstanding flexibility of WEEE-SORT systems makes them ideal for the sorting of electrical waste.

The markets for recycled materials are rapidly changing especially in the field of electrical waste, and since quality requirements for recycled materials are high, and recycled material has to compete with the price of new materials, the WEEE-SORT sorting system with its flexibility is a future-proof investment: the technologies employed and the techniques used are highly sophisticated and  provide high-purity material fractions."

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High-quality plastics from waste electrical equipment  

<![CDATA[Food Metal Detectors for Kalustyan]]> 2018-01-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/food-metal-detectors-ensure-quality-at-kalustyan https://www.sesotec.com/emea/en/resources/blog/food-metal-detectors-ensure-quality-at-kalustyan Case Studies Customers and federal regulators expect more and more from suppliers in today’s increasingly competitive and federally-monitored marketplace. New tools and technologies offer effective ways to meet those needs with easy implementation, reasonable costs, and immediate benefits. 

In this case study, sweets and spices purveyor Kalustyan, a long-time customer, reports on its experience with Sesotec, including how Sesotec’s array of product solutions is fueling growth.

For Kalustyan, a spice and herbs processing company located in New Jersey, the new and revised federal regulations posed significant new compliance challenges. In addition, its largest customers were demanding assurance that Kalustyan’s products were up to the mark. “Our quality system is based on Global Food Safety Initiatives (GFSI) and is the backbone of our organization,” said Abdul Basit Gaba, director, quality/food safety.

“We have a systematic assessment of each step of our production processes through our HACCP plan and a proactive and preventative control of all raw materials, processing activities, and our processing environment.” To meet its customers’ growing needs, Kalustyan knew it needed to find new solutions.

“Our customers appreciated the fact that we were tackling the new regulatory requirements head on,” said Fernando Porras, Kalustyan’s VP of operations. But Kalustyan also knew it needed more than a technically superior solution. It had to demand a solution that was easy to understand and operate, known for reliability, and offered at a reasonable price. “We believe that our success depends on the supply of safe quality products that meet or exceed our customers’ expectations,” said CEO Errol Karakash.


Kalustyan has been in the business of sourcing spices and herbs globally since its founding in 1977. It has a long history of sourcing from places including Armenia, Australia, Bangladesh, Belgium, Bulgaria, China, Egypt, England, France, Germany, Greece, Guatemala, Holland, Indonesia, Iran, Israel, Italy, Japan, Jordan, Lebanon, Malaysia, Morocco, Pakistan, Philippines, Romania, Spain, South Africa, South America, Saudi Arabia, Sri Lanka, Syria, Thailand, Tunisia, Turkey, Vietnam, West Indies, Yugoslavia and many others. The products are characteristically more challenging when it comes to procuring and producing adulteration-free products while also meeting Good Manufacturing Processes (GMP).

Achieving a BRC rating of “A” for the last three years, along with Customs Trade Partnership Against Terrorism (CTPAT) certification, Kalustyan has also deployed a long-standing, positive control-based, quality assurance approach to prevent adulteration and provide safe product to many of the leading manufacturers in the world. “Over time, we have refined our programs to further guarantee the quality and safety of our products,” Abdul added. Kalustyan has manufacturing operations in three countries so far, and the company takes its commitments to quality work in each location very seriously, Abdul stressed.


For Kalustyan, the search was relatively easy. After trying out a number of competing solutions, it made a lot of sense to stick with Sesotec. “From a cost perspective, they were about in the middle of the pack, but from a dependability and performance perspective, Sesotec was at the head of the class,” Abdul reported. “Sesotec delivered the most effective and effi cient method to assure the absence of economic adulterants and contaminants in the product.”

Another critical factor: Kalustyan is already operating more than a dozen Sesotec metal detectors and x-ray products. “Because some of our products are packaged in foil, we need more than a basic metal detector. We require the extra comfort of x-ray inspection,” Abdul added. “Sesotec meets or exceeds our requirements every day.”


Kalustyan leverages three Sesotec solutions: RAYCON X-ray Inspection System, and two designs of gravity free-fall metal detectors, the RAPID 4000 and the RAPID 5000.

The RAYCON X-ray Inspection System is very easy to operate and is notable for several unique performance capabilities. These include a full product inspection window without blind corners that assures 100 percent product inspection regardless of product height or placement on the belt, precision-matched x-ray source/detector, combined with Sesotec’s unique methodologies for x-ray analysis to provide the highest level of detection of dense foreign materials such as metal, stones, bone, HD plastics and glass. A real-time operating system performs at up to 600ppm with simultaneous inspection of up to four lanes running in different products in parallel.

The RAPID 4000 is used for the inspection of spice and grain materials to detect and reject magnetic and nonmagnetic metal contamination, even when enclosed in the product. It also ensures product quality, prevents customer complaints, and provides a quick return on investment when used to protect against expensive processing machinery failures thus maximizing production uptime efficiency.

The RAPID 5000 operates as an effective metal detector for the inspection of powdery and fine-grained bulk materials. It detects and rejects magnetic and nonmagnetic metal contaminants, with a unique elliptical stainless steel reject flap diverter. The leading hygienic design does not have any corners or niches that can be harborage areas for pathogen growth, making it suitable in applications where high sanitary standards are required.

Finally, all Sesotec solutions are BRC, IFS and HACCP compliant.


Implementation of the system upgrade began in June 2014. It was a smooth process, eased by Sesotec’s simple operation and easy to understand communications. “We knew it would work,” Abdul said. “Our track record with Sesotec made us confi dent of that.” Kalustyan had already installed a new Sesotec X-ray detection device in 2013 and Abdul reported “we are very happy with it and look forward to growing the relationship.”


Working with Sesotec, the NJ-based operation continues to import and manufacture products from all corners of the globe in order to meet the specifi cations of its customers. “It feels good to work with a vendor partner who understands our mission and is helping us to achieve it,” Abdul adds. Kalustyan has plans to purchase more equipment from Sesotec. “It’s been nothing but a positive experience for us, and we’d like to build on that success,” Abdul says. For a spice maker with a historic legacy, the future looks nothing but bright — with a touch of distinctive flavor.

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Food Metal Detectors for Kalustyan 

<![CDATA[Machinery protection at Starlinger]]> 2018-01-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/machinery-protection-plastics-industry-with-metal-detectors https://www.sesotec.com/emea/en/resources/blog/machinery-protection-plastics-industry-with-metal-detectors Case Studies

About Starlinger & Co. Gesellschaft m. b H.

Austrian company Starlinger GmbH is a  global market leaders in the field of machinery and process technology for woven plastic sacks.

Since 1987 the company has manufactured and supplied recycling lines for plastics, and in 2002 established the  "recycling technology" division. This division includes innovative machine solutions for the efficient recycling of a wide range of plastics including PE, PP, PA, PS, PET, and others.

Starlinger employs new recycling technologies and a well proven and established machinery concept and since the beginning this concept has included metal detectors from Sesotec.


Plastic shredding is the first step in the recycling process and at this stage since metal contamination can cause damage to  downstream modules reliable metal detection is therefore indispensable. Consistent metal separation prior to shredding reduces malfunctions and increases the profitability of the recycling lines and for this purpose Sesotec C-SCAN DLS type detectors are used and are mounted over the conveyor system prior to the shredder.


C-SCAN DLS detectors will detect magnetic and non-magnetic contaminants even if they are embedded in the product and by removing contamination prior to the process reduce costs due to machine damage and production downtime, guarantee product quality, and protect against customer complaints. C-SCAN DLS metal detectors can offer a rapid return on investment.

Customer Benefit

C-SCAN DLS metal detectors offer many advantages: They prevent metals from reaching cutting machines and thus avoid wear and broken cutting tools. They reduce downtimes and maintenance costs, they improve the quality and value of the cut material, they reduce malfunctions and off-times in downstream processing machines, and they minimise quality defects and reject rates in recycled plastic materials.


Andreas Pechhacker, technical manager of Starlinger "recycling technology" is very satisfied with the result: "Starlinger has used Sesotec metal detectors for several years. The systems are highly robust, offer flexible installation capability, and operate with outstanding reliability. Return on investment is ensured in a very short time because the blades of the agglomerator or single shaft cutter and downstream extruder screws are protected. Expensive repairs are a thing of the past. Sesotec metal detectors help us reach our objective of ecological and economic efficiency and sustainability – from the raw material to the woven sack, and back to the recycled material again."

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Machinery protection at Starlinger  

<![CDATA[Sesotec convince manufacturer of pharmaceutical packaging]]> 2018-01-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-metal-detectors-convince-manufacturer-of-pharmaceutical-packaging https://www.sesotec.com/emea/en/resources/blog/sesotec-metal-detectors-convince-manufacturer-of-pharmaceutical-packaging Case Studies

A leading manufacturer of pharmaceutical packaging, e.g. nasal spray containers, operates according to its conviction that its devices have an influence on the health of their users. Quality therefore is extremely important in this field, and this is considered in all phases of the production processes – from product design to production sequences and through to 100 % inline testing. The high quality of the products thus is the result of sophisticated processes and efficient systems.

The significant reduction of customer complaints is the most important indicator for how the company values the observance of quality standards.  Other criteria also are considered with the objective of remedying defects, reducing the number of deviations, and finally increasing customer satisfaction.

Protection of injection moulds and quality assurance of products

One of the packaging manufacturer's plants almost exclusively produces articles for the pharmaceutical industry. About 25 different products are made with a variety of hot runner moulds, with quantities of almost one million per year. Each of these products in turn can comprise up to 27 individual parts that are all injected in the same plant. Some of the large moulds have 48 cavities. All the injection-moulding machines operate in hygienically closed halls.  

Since 2011 the company has equipped its injection-moulding machines with Sesotec metal detectors of type Protector Primus to remove metal contaminations from the plastic granulate. The Protectors make an important contribution to the observance of the company's high quality demands.

With respect to quality standards there were three reasons for the purchasing of metal detectors:

    1. That they avoid machine damage caused by metal particles which e.g. choke cavities and thus lead to expensive repair work.
    2. That there no longer are production losses due to machine downtimes.

    3. That there are no more customer complaints due to contaminated or underinjected products.

How the Protector metal detector works

Metal detectors of the PROTECTOR series are installed directly above the material inlet of injection moulding machines, where they reliably remove metallic contaminations from the slowly descending material column. Apart from outstanding properties such as high sensitivity and space-saving, compact design, the metal detectors of the PROTECTOR series especially are characterised by the "Quick-Valve" reject unit.

When a metal particle is detected a pneumatically controlled piston in this reject unit moves into its reject position, and the rejected material is completely sucked off into a collecting container by means of a Venturi nozzle. The piston then moves back to its pass-through position. Only a minimum of good material is lost in this process, and clogging is impossible.


The project manager of the pharmaceutical packaging manufacturer is highly satisfied with the Sesotec Protector metal detectors: "We are particularly convinced by the high detection accuracy and the high reliability of the systems, and by the ease of operation provided by the Primus control unit."

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Sesotec convince manufacturer of pharmaceutical packaging  

<![CDATA[Food producer uses Sesotec x-ray inspection systems]]> 2018-01-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/food-producer-uses-x-ray-inspection-systems-to-increase-value-creation-in-production https://www.sesotec.com/emea/en/resources/blog/food-producer-uses-x-ray-inspection-systems-to-increase-value-creation-in-production Case Studies

A big international food group in addition to high quality demands also has committed itself to the fight against food wastage. Following the principle "What men eat must be pure!" they want to ensure perfect product quality so that complete batches of food that may contain contaminations no longer have to be returned and destroyed ("save food!"). Such product recalls are expensive and – what is much more important – damaging to a company's image. In addition to comprehensive inspection procedures in every production stage the measures also include the installation of product inspection systems in the packing lines prior to dispatch.

The systems are used to inspect drink powders and spice blends that are packed in metallised film. They especially search for metal particles but also detect other contaminations. Because of the conductive properties of metallised film inspection cannot be performed with standard metal detectors. To still be able to meet quality demands and prevent food waste the producer decided to use X-ray scanners of the RAYCON range from Sesotec for contaminant inspection. Sesotec is able to meet the high demand specifications with respect to sensitivity and to guarantee swift installation.

Sesotec RAYCON product inspection systems feature sophisticated and reliable X-ray technology and fully meet the quality requirements of the food and packaging industries. The combination with modular conveyor belts allows a customised adaptation to different products and local conditions.

RAYCON product inspection systems provide high-precision inline detection of many contaminants, e.g. magnetic and non-magnetic metals, glass, ceramics, stones, raw bones, and some types of plastics. This also is possible with the type of aluminium packing that is used here. Weight deviations (overweight and underweight) also can be detected. With the "Autolearn" function a new product can be learned in no time at all.

With the "Retrain Region" function the operator for example no longer has to manually make sensitivity settings in order to prevent incorrect separations e.g. due to spice clumps. Due to these and other automated functions machine operators no longer need any expert knowledge, and standstill times for calibration or retooling are reduced.

RAYCON X-ray systems are absolute state-of-the-art with respect to detection possibilities, radiation protection, and system safety. When properly used the X-ray scanner is non-hazardous for operators and products. Radiation levels are many times below the statutory limits. EU directive 1999/2/EC expressly allows X-ray systems for contaminant inspection even for organic food. Innovative X-ray technology offers comprehensive additional benefits for users, which puts the additional costs of purchase and operation into perspective  

Uli Hurzlmeier, Product Manager of Business Unit Food at Sesotec, says: "We were able to demonstrate to our customer a high level of know-how in the field of X-ray inspection, and we were able to prove that we can meet special design and documentation requirements in a very short time. Our expertise and our technical support are unique. And RAYCON also could convince with its price."

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Food producer uses Sesotec x-ray inspection systems  

<![CDATA[Networked Sesotec Solutions in Friedrichshafen]]> 2017-11-15 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/networked-sesotec-solutions-in-friedrichshafen https://www.sesotec.com/emea/en/resources/blog/networked-sesotec-solutions-in-friedrichshafen Plastics

A well-attended FAKUMA 2017 is over, and also this year Sesotec convinced trade visitors with the metal separators presented at the trade fair. At the FAKUMA Sesotec not only maintained existing business relations with customers and partners but also was able to establish many new national and international contacts.  The trade fair presence with the new "Purity matters" corporate claim was a complete success. 

At the FAKUMA 2017 Sesotec presented metal separators of the PROTECTOR, RAPID PRO SENSE and GF series. These systems reliably detect and separate magnetic and non-magnetic metal particles even if they are enclosed in the granulate, and they thus ensure the quality of plastic products. Injection moulding machines, extruders, and blow moulding machines are protected against damage and clogging, the output is increased, and the amount of rejects is reduced. Metal separators contribute to the optimisation of processes, to the minimisation of time losses, and to cost savings.  

At this year's FAKUMA trade fair Sesotec for the first time presented OPC UA (Open Platform Communications Unified Architecture) which meets all the requirements concerning Industry 4.0 communications. OPC UA is increasingly being established as a standard. Additional advantages: The criteria of easy operation have been considered, intuitive user interfaces prevent user errors and thus increase process stability. The sequence of operation is safe and follows logical steps. Data and documentation in the system can be quickly accessed.

<![CDATA[Sesotec at the interpack 2017 with Focus on Product Purity]]> 2017-09-22 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-at-the-interpack-2017-with-focus-on-product-purity https://www.sesotec.com/emea/en/resources/blog/sesotec-at-the-interpack-2017-with-focus-on-product-purity Food

With respect to the number of visitors and their quality the interpack trade fair, held from 4 to 10 May in Düsseldorf, showed excellent results for Sesotec GmbH. Never before has Sesotec presented so many new and innovative products than at this year's interpack trade fair. RAYCON EX1 X-ray scanner, INTUITY metal detector, and CAPTURA FLOW sorting system demonstrated Sesotec's technology strong points in the competence fields of product inspection and food sorting. Sesotec thus presented itself as a reliable partner for product purity for customers from the food and packaging industry. 

With the new RAYCON EX1 Sesotec provides and easy-to-use entry-level system for the X-ray inspection of packed products, a product segment for which Sesotec before had no systems in its portfolio. Sesotec customers now can have a full-fledged X-ray system in German industry quality at a really fair price. 

The INTUITY metal detector is Sesotec's new flagship in metal detection. It simultaneously inspects food materials with several frequencies and thus reaches extremely high scanning sensitivities, and at the same time offers improved ease of operation with the new INTUITY Control operating panel. 

With its variable use of sensors the CAPTURA FLOW food sorting system offers the advantage of outstanding flexibility. Depending on the type of food that should be sorted the CAPTURA FLOW multi-sensor system can be adapted to the respective sorting requirements. The modular design allows sensor upgrades at any time, which for the customer means that the system is a safe investment for the future.


Premiere for slogan and key visual

Sesotec's new Corporate Design also was presented for the first time at the interpack. The new claim "Purity matters" and the key visual of the green diamonds demonstrate Sesotec's brand promises: Perfect purity, reliable quality, long-term partnership, inspiring products, and high sense of responsibility. With this new appearance Sesotec emphasises the company's further development towards a global specialist for solutions in contaminant detection and material sorting. 

Says Oliver Uhrmann, Head of Sales EMEA at Sesotec: "Our strong point is our large product portfolio that allows us to cover all the process steps. From incoming goods inspection through to production and up to packing and outgoing goods inspection, Sesotec provides reliable technologies for all these fields. Our objective is to ensure that our customers achieve highest product purity and quality. Because as our new slogan says: Purity matters."


<![CDATA[Reliable Sesotec sorting systems convince the Swiss]]> 2017-08-29 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/pet-recycling-sorting-of-pet-flakes-with-sorting-systems https://www.sesotec.com/emea/en/resources/blog/pet-recycling-sorting-of-pet-flakes-with-sorting-systems Case Studies About RecyPET

RecyPET AG, established in 1998 has operated Europe’s first bottle-to-bottle PET recycling plant in Fraunfeld, Switzerland, since September 2000. The plant operates with the URRC technology developed by the United Resource Recovery Corporation in the USA  together with Coca-Cola and has an input capacity of approx. 18,000 tonnes per year. A total of five plants in Europe now use this technology.

In Switzerland used beverage bottles are sorted, after collection, in five primary sorting plants by colour and quality, compressed into  bales and delivered to RecyPET AG, and other recycling operators, for processing. RecyPET’s goal is closed loop recycling for  PET beverage bottles. The recyclate produced is used to make a number of products including new PET bottles, food packaging films and other film.


Sesotec supplied a PETMAG metal separator to RecyPET in 2001to separate metal contaminants from PET flakes. As colour sorting was also required, Sesotec, working closely with RecyPET, developed a colour sorter for PET flakes based on a unit originally used in the glass recycling industry. The result was the SPECTRUM range of colour sorters which with double-sided inspection can also separate flakes contaminated with glue residues.


During 2010 the PETMAG , which had proved a reliable and effective metal separator with minimal maintenance costs, was replaced with  the latest generation VARISORT COMPACT combining metal and colour sensors in the same unit.

Product Advantages

The vibratory feeder and fast inspection belt systems of the VARISORT COMPACT combine the  advantages of chutes and belt systems. For the  first time, for example, rubber pieces can be removed from the material stream which is not the case with chute technology due to friction variation. VARISORT COMPACT with its open construction has the additional benefits over channelled chute systems of being easy to clean and much less prone to blockages caused by larger flakes and irregular shaped product

Even for irregular product or materials which have differing  friction coefficients, the belt feeding system facilitates  pinpoint ejection in free fall at the end of the  feed belt, immediately after inspection. Following inspection, high-speed, precisely timed valves are activated to eject unwanted material from the main product flow into a separate zone for subsequent handling.

VARISORT COMPACT, as the name implies is  characterised by its small footprint  requiring minimum line space. Retrofitting to existing plants and the utilisation of existing chutes and handling systems is easily possible. Using high-resolution sensors and state-of-the-art signal processing technologies allows high detection accuracy and the analysis of up to 500,000 parts per second.  Ejecting product in freefall is precise and repeatable even with high percentages of impurities and individually controlled, closely spaced valves, operating at 500 switching cycles per second ensure effective and efficient operation.

Customer Feedback

For Kornel Büsser, production manager at RecyPET AG, the long-standing cooperation with Sesotec has proven its value: “The reliability and ease of maintenance of the Sesotec units convinced us, together with their performance, particularly in the separation of difficult contaminants.”

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<![CDATA[Sesotec Service Acceptance with new Address]]> 2017-08-20 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-service-acceptance-with-new-address https://www.sesotec.com/emea/en/resources/blog/sesotec-service-acceptance-with-new-address Company

Sesotec GmbH, a manufacturer of machines and systems for contaminant detection and material sorting for the food, plastics, and recycling industries, is growing in all segments, which correspondingly need more room. Early in July 2017 service acceptance at the company headquarters in Schönberg therefore was relocated from Regener Straße 130 to Industriestraße 5. The new location lies close to the company headquarters and combines repairs department, spare parts storage, training rooms, technical support, and – now new – service acceptance. The Sesotec Service Center is well prepared for future growth. 

All over the world Sesotec has twelve service locations in total. The spare parts storages are logistically optimally supplied from Schönberg. With its global service network Sesotec is able to ensure support for its customers all over the world within a very short time.  

Markus Grimm, Head of Service at Sesotec, is pleased that all the service sectors are now combined at one place: "It is a particular advantage for our customers that with the newly created service center with spare parts storage we are now able to deliver faster and react more flexibly to inquiries from our global customers and locations."  


Sesotec ist weltweit nah an den Kunden mit Tochtergesellschaften, Servicestandorten, Testzentren, Produktionen und Vertriebspartnern.

Unsere neue Adresse für Reparaturen und Rücksendungen: 

Sesotec GmbH Service Center
Industriestraße 5
94513 Schönberg


Hotline Produkt Inspection: +49 (0) 8554 / 308 173

Hotline Sorting Recycling: +49 (0) 8554 / 308 129

Hotline Sorting Food: +49 (0) 8554 / 308 2203

<![CDATA[Sesotec With New Managing Director in Italy]]> 2017-08-07 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-with-new-managing-director-in-italy https://www.sesotec.com/emea/en/resources/blog/sesotec-with-new-managing-director-in-italy Company

With Andrea Festelli the Sesotec group with effect from 1 April 2017 has recruited a new managing director for the two Italian subsidiaries. The born Genoese studied electrical engineering at the university of Genoa. Before he changed to Sesotec, Festelli for seven years had worked for the Italian subsidiary of the GEA group, where he last held the position of managing director, and before that also was head of the service department. In the course of his professional career he held positions in international sales, marketing, and R&D departments.

One of the major tasks of Andrea Festelli (47) will be to merge the two Italian companies  Sesotec Italy, business segment product inspection, and ASM, business segment food sorting. Says the new managing director about his objectives: "Sesotec successfully develops top technology for contaminant detection and material sorting and is globally present on all the important markets. In the last years Sesotec has achieved remarkable growth, and I am really happy to now be part of this growth. What is particularly interesting for me is the possibility to develop the potential of ASM optical sorters in the product portfolio of the Sesotec group, because with respect to quality and functionality this definitely is a unique offer for our customers. And vice versa we now also can provide ASM customers in Italy with Sesotec product inspection technologies combined with excellent service. A unique opportunity from which both we and our customers will benefit."

Xaver Auer (46), CEO of the Sesotec group: "We really are pleased to now have Andrea Festelli in our group. He has both industry expertise and relevant management experience. The complete merging and integration of our Italian subsidiaries will result in synergies, and the combination of product inspection and material sorting systems offers many advantages for our customers. For us this means that we will move forward even faster on our already successful course in Italy."

<![CDATA[PET Flake Sorting Station Completely Provided by Sesotec]]> 2017-08-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/pet-flake-sorting-station-completely-provided-by-sesotec https://www.sesotec.com/emea/en/resources/blog/pet-flake-sorting-station-completely-provided-by-sesotec Recycling At the Drinktec 2017 trade fair that will be held in Munich from 11 to 15 September 2017, Sesotec GmbH in hall A4, stand 306, for the first time presents itself as a supplier of complete sorting stations for  PET flake recycling. Target customers are recycling companies that are looking for a profitable solution for PET flake recycling and wish to have all the components - from air separator through to sorting machine - from one source. The revised FLAKE PURIFIER+ multi-sensor sorting system will be the trade fair highlight.

Sesotec has more than 20 years of experience in the development and production of sorting machines for PET flake recycling, and based on many corresponding inquiries from customers Sesotec now also offers complete PET flake sorting stations. A complete PET flake sorting line from Sesotec offers many advantages, for example less interfaces and contact persons, and uniform operation of all the line components. Mechanical sorting is perfectly matched to sensor sorting, and both ensure optimal performance.

The FLAKE PURIFIER+ multi-sensor sorting system presented at the trade fair was comprehensively modified and features optimised material infeeding for a more evenly distributed material flow and increased material throughput.  It also allows easier maintenance and integration.  The system's dust-proof design and integrated dust and label extraction connections provide increased efficiency in the recycling process. All Sesotec multi-sensor sorting systems - and of course also the new FLAKE PURIFIER+ - are available with all sensor combinations and in various working widths.

Says Michael Perl, Head of BU Sorting Recycling at Sesotec, about the complete station concept and the new FLAKE PURIFIER+: "Since we received more and more inquiries from customers who wanted to know whether Sesotec also provides complete sorting stations, we decided to satisfy this customer wish. The advantages for customers are obvious: The amount of time and money needed for the coordination of a project is considerably reduced, and the PET flake sorting station operates with maximum profitability. In the modification of the FLAKE PURIFIER multi-sensor sorting system into the new-generation FLAKE PURIFIER+ the wishes of our customers for easier operation and higher material throughput were the decisive factors."

<![CDATA[Sesotec Innovations Benefiting Customers]]> 2017-08-01 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/sesotec-innovations-benefiting-customers https://www.sesotec.com/emea/en/resources/blog/sesotec-innovations-benefiting-customers Company With machines and systems for contaminant detection and material sorting Sesotec GmbH in Schönberg has made it and ranks among the most innovative companies in Germany. In Essen, on 23 June 2017,  Ranga Yogeshwar awarded the TOP 100 seal* to Sesotec.  

What is Sesotec's drive for innovation? First and foremost the customers from the food industry, plastics industry, and recycling industry, who are under a continuously growing pressure to produce their products in highest quality with maximum output and to avoid any waste of resources.  For more than 40 years Sesotec has been developing innovative solutions that contribute to the fulfilling of such requirements.  The company's management actively promotes an innovation-friendly environment: "We listen to our customers, our employees exchange ideas with them on partnership basis, and in the end the result often is a new product idea", says COO Axel Vornhagen. 

In addition to this customer focus, Sesotec also has always been open for new ideas. And this results in innovative products (X-ray systems, metal detectors, metal separators, magnets, and sorting systems) that are characterised by highest detection accuracy and outstanding ease of operation, operate reliably for many years, and are easy to clean and maintain. 

"Our systematic innovation management, from the idea to its practice-relevant checking through to its implementation, is a decisive competitive factor for us", explains Axel Vornhagen. "We invest a lot of time and money in the development of innovations, and we combine the input coming from various sides, from customers and markets as well as from politics and science, with the competence of our employees. We are highly pleased to receive this Top 100 award in recognition of our work."

<![CDATA[Food-PET or Non-Food-PET, that is the Question]]> 2017-02-28 00:00:00 UTC https://www.sesotec.com/emea/en/resources/blog/food-pet-or-non-food-pet-that-is-the-question https://www.sesotec.com/emea/en/resources/blog/food-pet-or-non-food-pet-that-is-the-question Recycling
The Polymark sorting machine made by Sesotec with Polymark detector unit for the detection of UV fluorescence markers on PET bottles.

The "Final Consortium Meeting" of the Polymark project was held at Sesotec GmbH in Schönberg on 7th and 8th February 2017. Polymark was a three-year research project funded by the European Commission that focused on a new technology for the identification and sorting of plastics, particularly PET. The correct detection of plastics and the generation of high-quality secondary raw materials should be further improved. The project involved participants from the complete PET value creation chain. 

The objective of the Polymark project was to increase the level of food-contact-approved recyclate from the PET recycling process by differentiating between PET bottles that were used for food (food bottles) and bottles that did not contain food (non-food bottles). On the one hand marker substances were developed for this purpose that make it possible in the recycling process to efficiently differentiate food-PET bottles from non-food PET bottles. These marker substances are used to encode information about the properties and structure of the PET bottles. 

On the other hand the Polymark project also developed a sensor-based identification system that detects the markers and decodes the information. In a next step the plastic packings are separated in a mechanical sorting process. Sensor technology and mechanical components are integrated in a sorting machine. 

How does a marker substance work?

For the differentiation between food-PET and non-food-PET a bottle type is coated with an invisible UV fluorescence marker. This marking substance is applied to the outside of the bottle or is printed onto the label or the envelope and fluoresces when it is excited by UV light. 

How does sorting work?

In an industrial PET recycling process the bottles usually pass through automated sorting machines that separate the PET flow by colour and plastic type. In the Polymark project this approach was used for the development of a prototype sorting machine that is able to sort food and non-food bottles using a UV fluorescence sensor. Sesotec played a leading role in the development of this sorting system.  

"Our research partners have successfully developed a complete technology package", explains Patrick Peuch of Petcore Europa. "The sorting technology was developed in parallel to the marking technology, and test runs have demonstrated that the markers can be detected by the sorting machine and that the respective bottles can be separated. Economically efficient and profitable high-speed sorting with the result of pure food-PET for bottle-to-bottle recycling thus has become possible." 

The list of Polymark partners includes: Petcore Europa, European Federation of Bottled Waters (EFBW), European Association of Plastics Recycling and Recovery Organisations (EPRO), Plastics Recyclers Europe, UK Health and Environmental Research Institute (HERI), Fraunhofer Institut für Photonische Mikrosysteme (IPMS), Sesotec GmbH, 4PET Recycling BV, Mikrolin Hungary Kft.  and Colormatrix Europe Ltd .