Metal Separator Used in Milk Powder and Flour Processing

Industry: Food Processing (Dairy & Grain) | Location:Malaysia

Customer Challenge

A leading milk powder and flour manufacturer in Kuala Lumpur needed to ensure product safety for export to EU and Middle East markets. They were facing three critical issues:

1. Metal contamination in raw materials — small metal fragments from harvesting equipment, transport containers and processing machinery were entering the production flow
2. Regulatory compliance requirements — EU buyers required HACCP and BRC certification, which mandated effective metal detection at critical control points
3. High product loss with existing detection — their previous detector had high false reject rates, causing significant waste of expensive milk powder and flour

The factory required a solution that could:
• Handle high-volume free-fall powder processing (up to 5 tons/hour)
• Detect all metal types including Fe, Non-Fe and SUS stainless steel
• Minimize false rejects and product waste
• Integrate with their existing pneumatic conveying system
• Provide audit-ready data logging for compliance inspections

DORIA Solution

DORIA supplied a high-sensitivity free-fall metal separator with custom chute design, installed directly above the packaging line. The system features:

• Multi-coil detection technology for maximum sensitivity in powder products
• Automatic rejection diverter valve (fast-acting pneumatic cylinder)
• Product effect compensation to minimize false rejects
• IP65 waterproof rating with food-grade 304 stainless steel construction
• Real-time detection data logging with USB export
• Quick-release clamps for tool-free cleaning and maintenance
• Custom chute angle optimized for powder flow characteristics

The system was calibrated specifically for milk powder and flour products, with separate product presets for each production line.

Results & Benefits

After 12 months of operation, the manufacturer reported:

• Zero product recalls due to metal contamination
• Achieved HACCP and BRC Level 2 certification
• Expanded export market to 5 new European countries
• Reduced false reject rate from 8% to less than 0.5%
• Saved approximately $15,000/month in wasted product
• Passed all customer audits with zero metal detection findings
• Processing speed maintained at 5 tons/hour with no bottleneck
• Payback period: approximately 4 months

Customer Feedback

"The DORIA metal separator was the key to getting our BRC certification. The sensitivity is excellent and false rejects are almost zero — which is critical when you're dealing with expensive milk powder. The data logging feature makes audits so much easier. We've already ordered a second unit for our new production line."

— Production Manager, Dairy & Grain Processing Plant, Kuala Lumpur Malaysia

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