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Metal Detector Check Log Worksheet (Excel Export)

Metal detector and X-ray checks are a common control for physical hazards. This worksheet records test piece results per line and shift and calculates the reject rate so you can spot a drifting detector or a contamination source.

Download:

Date	Line	Shift	Ferrous test	Non-ferrous test	Stainless test	Units checked	Rejects	Reject rate	Initials
								0%
								0.1%
								0%
								0%

Total units checked

57,350

Total rejects

Overall reject rate

Record start-of-run, periodic and end-of-run test piece checks per your plan. Any failed test piece means product made since the last good check must be held and re-passed through a working detector. Use the test piece sizes in your own validated procedure.

Alert on failed checks from detector data

Optional review of connecting detector or line data to alerts and holds.

Optional. The tool and every export work without this. No spam.

How to use it

Add a row for each check event. Select pass or fail for the ferrous, non-ferrous and stainless test pieces, then enter units checked and rejects for the run. The reject rate calculates automatically, and the summary shows the combined rate for the sheet. If any test piece fails, record it, hold product from the last good check, and open a corrective action. Export to Excel for trending or to PDF for the HACCP file.

Test at start up, at intervals, after changeovers and at end of run
Pass the test piece through at the product position the plan specifies
Confirm the reject device actually removes the test piece
Never reset sensitivity to make a test pass

Reading the reject rate

Reject rate is rejects divided by units checked, multiplied by 100. A sudden jump on one line usually means a product effect, a sensitivity change or a real metal source upstream. A rate of exactly zero for months on a product with known signal effects may mean sensitivity is too low. Compare the rate across lines running the same product, and compare it by shift to see if a particular crew or maintenance event correlates.

Where it fits

Metal detection is treated as a critical control point in some plants and a prerequisite control in others, depending on the hazard analysis. Either way, schemes like SQF and BRCGS and many customer codes expect documented test piece verification and a defined response to failure. Keep the record with calibration data for the detector and the retention period your customer requires.

Frequently Asked Questions

How often should metal detectors be tested?

At start of production, at set intervals during the run, after any changeover or adjustment, and at the end. Many sites test hourly or every few hours, and customer codes may set a minimum. Follow your plan and customer requirements.

What if a test piece fails?

Stop the line, hold all product made since the last successful test, correct the problem, verify the detector with all test pieces, and re-inspect held product. Record the event in a corrective action.

Do I need ferrous, non-ferrous and stainless tests?

Most plants test all three because each has different detectability, and stainless is the hardest. Your validation and hazard analysis decide the exact test pieces and sizes.

Is X-ray different from a metal detector log?

The record structure is similar, with test pieces of metal, glass, stone or plastic depending on the unit. Use the same columns and adapt the test labels for your equipment.

If your detectors export event data, we can help bring it into a dashboard with alerts for failed checks and drifting reject rates.

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