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Client Background
This case features a professional rubber toy manufacturer whose products are exported to European and American markets, requiring strict quality and safety standards. During production, rubber toys may be contaminated with metal foreign objects (such as machine wear debris or raw material impurities). If these metal fragments enter the market, they could pose safety risks to children, lead to product recalls, and damage brand reputation. Therefore, the client urgently needed an efficient and reliable metal detection solution.
Challenges
● Complex Product Characteristics: The rubber material has a high product effect (meaning the material itself can interfere with metal detection), causing traditional equipment to frequently generate false rejects or miss contaminants.
● High Detection Accuracy Requirements: Needed to detect tiny ferrous (Fe), non-ferrous (Non-Fe), and stainless steel (304 SUS) metal contaminants, with sensitivity meeting industry standards.
● Production Line Integration: The detection equipment needed to fit the existing production line speed and support customized rejection methods to avoid disrupting production flow.
● Environmental Interference: The production environment contained electromagnetic interference and vibration, demanding highly stable and reliable equipment performance.
Solution
Guangdong Yiwan Detection Technology recommended its New Generation Digital Metal Detector and provided a customized configuration tailored to the rubber toy characteristics:
● Aperture Dimensions: Customized aperture height of 150mm (adjustable range 100-200mm) and standard width of 400mm to ensure smooth passage of toys.
● Sensitivity Settings: Utilized the equipment's "100 Product Parameter Memory Function" to store detection parameters for rubber toys, setting sensitivity to:
○ Ferrous (Fe) Metals: ≥1.0 mm
○ Non-Ferrous (Non-Fe) Metals: ≥1.8 mm
○ 304 Stainless Steel: ≥2.0 mm
Meeting the client's requirement for detecting minute metal contaminants.
● Conveying Speed: Adjusted to 25 m/min, matching the client's production line speed for efficient inspection.
● Rejection Method: Customized "Pusher Rejection Mechanism" to accurately separate products containing metal contaminants without stopping the line.
● Environmental Adaptability: The detector features a sealed search coil and anti-interference design, effectively countering environmental disturbances on the production floor.
Implementation & Results
● Rapid Setup: Using the "One-Button Automatic Setup" and "Automatic Product Effect Learning" functions, the client completed parameter calibration quickly, minimizing setup time.
● Detection Performance: During testing, the detector successfully identified φ1.0mm Fe, φ1.8mm Non-Fe, and φ2.0mm 304 SUS test pieces hidden within rubber toys, with a false reject rate of less than 1%.
● Production Efficiency: Operating synchronized with the production line, the system inspects over 10,000 pieces daily with a rejection accuracy rate exceeding 99.5%, increasing the client's production efficiency by approximately 20%.
● Long-Term Value: The capability to store 100 product parameters allows quick switching between different rubber toy types, reducing operational costs.
Product Highlights
● High Detection Accuracy: Employs advanced digital technology and imported chips. The filled-and-sealed search coil ensures high detection sensitivity, stable performance, and strong resistance to external interference, even with the high product effect of rubber toys.
● Intelligent Features: Automatic Product Effect Learning effectively filters out material interference. The reverse detection function (requires customization) can check for missing metal accessories or desiccants.
● Customization Service: Offers tailored aperture sizes, rejection methods, and sensitivity settings to meet diverse production line needs.
● Compliance with Standards: The machine design meets European and American mechanical safety standards, suitable for food and toy industries, assisting clients in passing international certifications.
Client Testimonial
"Our toys are for children, so safety is an absolute red line. This metal detector acts like a guardian angel on our production line, ensuring every product that leaves our facility is worthy of that trust. It safeguards not only children's safety but also our brand's reputation. Choosing Yiwan means choosing peace of mind."
— Client Quality Director
