How Antichi Sapori dell’Etna Achieves Quality and Efficiency with Metal Detection
Today, Antichi Sapori dell’Etna stands as a globally recognized expert in the processing and refinement of pistachios. Since its founding in 1999 in Bronte, at the foot of Mount Etna, the company has seamlessly blended traditional craftsmanship with modern techniques. Quality, origin, and artisanal expertise remain the cornerstone of our operations, continually evolving to meet the highest standards.
This commitment is reflected in our business model. Antichi Sapori dell’Etna thrives in the B2B sector with the brands Madero and Madero Quality, while also engaging directly with consumers through Pistì and Vincente. Our dual focus on both markets demands agile structures, efficient processes, and clearly defined quality standards.
A pivotal moment came in 2001 with the launch of our first pistachio spread, which significantly influenced our brand's evolution. In 2007, Antichi Sapori dell’Etna opened a new 4,000 m² production facility in Bronte to meet the growing demand from the food industry, particularly in the confectionery and bakery sectors. After surpassing the 50 million Euro revenue mark in 2021, the company became part of the Nutkao Group. By the end of 2024, revenue exceeded 129 million Euros with around 350 employees. Our success is built on local roots, artisanal expertise, and the strategic use of modern technologies.
The Challenge: Unmatched Product Safety Amid Growing Complexity
The dual focus on B2B and B2C markets significantly raises the bar for product safety and quality control. Antichi Sapori dell’Etna must comply with international standards like IFS, BRC, and FSSC 22000. These require reliable foreign body detection across multiple process stages, each with specific sensitivity demands.
The early production phases are particularly critical. Metallic foreign bodies must be reliably detected and removed to ensure product quality and protect downstream processing equipment from damage. At the same time, detection must not disrupt the production flow—a crucial aspect given high daily volumes.
Moreover, the product range is vast—from pistachios at various processing stages to liquid products like pistachio pesto and sophisticated baked goods like Colombe and Panettone. Each product category presents unique demands on detection technology, especially with varying moisture levels and different physical properties.
Antichi Sapori dell’Etna faced a central challenge: How to reliably combine maximum product safety, high efficiency, and artisanal quality in a scaling production environment?
The Solution: Tailor-Made Detection Systems by Sesotec
The company found its answer in partnering with Sesotec. The decision was driven by the exceptional sensitivity of their metal detection systems and the ability to create customized solutions that seamlessly integrate into existing production lines.
Several metal detection systems were installed at critical control points (CCPs):
In our pistachio processing lines, RAPID 4000 free-fall metal detection systems are deployed immediately after optical sorting. They ensure the nuts are completely metal-free before moving on to the next processing stages.
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For the pistachio pesto line, a LIQUISCAN PL metal detector has been integrated, specifically designed for liquid or pasty products. In the event of contamination, it is ejected along with a small amount of the pistachio mass, without disrupting the ongoing process.
Yeast pastries like Colombe and Panettone present a particular challenge. Their natural moisture content makes it difficult to reliably detect metallic foreign bodies. However, by using a VARICON+ INTUITY metal detection system, secure control can still be achieved: metallic contaminants are reliably detected and removed, ensuring both product safety and the protection of downstream equipment.
Our metal detection systems are integral to a comprehensive strategy combining cutting-edge technology, seamless collaboration with all project stakeholders, and on-site service to ensure rapid deployment and ongoing support.
Customer Benefits: Security, Efficiency, and Sustainable Growth
The impact of implementing metal detection systems is crystal clear. Antichi Sapori dell’Etna can now inspect over 70 tons of raw pistachios daily—swiftly, reliably, and without disrupting production flow. This achievement has sustainably and efficiently met a key quality management requirement.
In the production of pistachio pesto and pastries, two critical CCPs in the process have been fully secured. The result is consistently high product safety and quality, regardless of product type or process complexity.
Moreover, the company benefits from enhanced process security, reduced risk of machine downtime, and improved audit readiness for international certification bodies. These solutions not only bolster operational production but also strategically support the company's growth objectives.
The partnership with Sesotec is particularly valued: customized technology, high system availability, and expert service that acts swiftly and solution-oriented. For Antichi Sapori dell’Etna, this collaboration extends far beyond mere technology deployment—it is a cornerstone for long-term quality assurance and sustainable market success.
