Quality Inspection

Foreign Object Detection in Food Processing Lines

How AI-powered vision systems from Boolean & Beyond detect foreign objects, contaminants, and physical hazards in food processing with 99.5% accuracy.

The Problem: Invisible Contaminants Slipping Through

  • Metal, glass, and plastic fragments escape visual inspection
  • X-ray machines miss low-density foreign objects
  • Manual inspection can only check 2-5% of production volume
  • Recalls cost ₹5-50 crore per incident plus brand damage
  • FSSAI compliance requires documented inspection protocols

Hidden Costs of Contamination Events

  • Product recalls averaging ₹15 crore per major incident
  • Legal liability and consumer lawsuits
  • Retailer delisting and lost shelf space
  • Insurance premium increases of 30-50%
  • Brand reputation damage affecting sales for 2-3 years

How Boolean & Beyond Helps You Achieve This

  • We design multi-spectral imaging systems that detect objects invisible to human eye
  • Our engineers build real-time inspection pipelines handling 500+ items per minute
  • We train custom AI models that learn your specific contaminant types
  • We integrate with your reject mechanisms for automatic removal
  • We implement complete traceability and compliance documentation

Implementation Details

Technical approach, timelines, and expected outcomes

Summary for Food Manufacturers

How AI Foreign Object Detection Works

AI systems use a combination of:

  • High‑resolution vision cameras – to spot visible contaminants on the surface (e.g., plastic pieces, insect parts, stones, bone fragments).
  • X‑ray imaging – to detect dense materials inside sealed packs (e.g., metal fragments, glass shards, stones, hard plastics, bones).
  • Hyperspectral sensors – to analyse the spectral signature of materials and distinguish foreign objects from the food itself.

Deep learning models are trained on thousands of images of both clean product and contaminated product so they can reliably recognise:

Frequently Asked Questions

Which company can help implement AI foreign object detection for food industry in India?

Boolean & Beyond helps food manufacturers implement AI-powered foreign object detection by designing and deploying custom vision systems tailored to your production line. We work with your team to integrate multi-spectral imaging that detects metal, glass, plastic, and organic contaminants with 99.5% accuracy.

How accurate is AI vision inspection for detecting contaminants in food?

With Boolean & Beyond's implementation approach, clients typically achieve 99.5% detection accuracy for foreign objects - significantly higher than manual inspection (60-70%) or traditional X-ray systems (85-90%). We train the AI on your specific product types and contamination risks for optimal performance.

What is the cost of implementing automated food inspection systems?

Boolean & Beyond's custom AI inspection implementations typically range from ₹15-40 lakhs depending on line speed, detection requirements, and integration complexity. We provide end-to-end service including hardware selection, AI model development, integration, and training. Most clients see ROI within 8-12 months.

Can AI detect foreign objects that X-ray machines miss?

Yes, Boolean & Beyond builds multi-spectral AI vision systems that detect low-density contaminants like wood, rubber, insects, and certain plastics that X-ray machines miss. We combine visible light, infrared, and UV imaging based on your specific contamination challenges.

How does AI food inspection help with FSSAI compliance?

Boolean & Beyond implements automated documentation, inspection logs, and traceability reporting as part of every food inspection solution. We ensure your system meets FSSAI requirements with audit-ready records including timestamps, images, and pass/fail status for every inspected item.

Protect your brand with AI-powered foreign object detection

Get Assessment

Ready to start building?

Share your project details and we'll get back to you within 24 hours with a free consultation—no commitment required.

Registered Office

Boolean and Beyond

825/90, 13th Cross, 3rd Main

Mahalaxmi Layout, Bengaluru - 560086

Operational Office

590, Diwan Bahadur Rd

Near Savitha Hall, R.S. Puram

Coimbatore, Tamil Nadu 641002

AI Foreign Object Detection in Food Processing | Boolean & Beyond | Boolean & Beyond