Detecting foreign objects in food products remains a critical challenge for manufacturers, particularly when contaminants have properties that make them difficult to identify using conventional inspection systems. While metal detectors and X-ray machines are widely used to identify metallic and high-density contaminants, materials such as soft plastic, rubber and certain organic foreign objects can present additional inspection challenges. Swedish company Food Radar has developed a specialised microwave-based solution to address this gap, offering food manufacturers an additional layer of protection during processing.

Speaking at Gulfood Manufacturing 2026, Anton Alveflo, Application Engineer & Business Developer, Food Radar, explained how the company's technology detects and removes low-density foreign objects from production lines, helping manufacturers protect product integrity and minimise contamination risks.

The technology behind Food Radar dates back to 1999, when research began into detecting soft plastic in food products. Food Radar was founded in 2003 to further develop and commercialise the technology. Today, the systems are developed and assembled in Sweden, while the company reaches international markets through its distributor network.

"We are a very specialised company. X-ray machines and metal detectors are excellent at finding high-density foreign objects. However, there is no other company that can detect low-density foreign objects quite like Food Radar," Alveflo said.

Microwave technology for inline detection

Food Radar's solution uses microwave technology to identify foreign objects within flowing food products. Designed for inline installation, the system transmits microwaves through a pipe and monitors changes in the resulting signal. When a foreign object passes through the sensor, it creates a detectable difference, enabling the machine to identify material that does not belong in the product.

A key feature is its automatic product-learning capability. The machine learns the product within approximately four seconds and automatically adapts to the product signal. When manufacturers change recipes or switch to another product, the system can quickly relearn the new product. However, the appropriate sensitivity level is set for each recipe to achieve the desired balance between detection performance and process stability.

"The machine automatically learns the product in around four seconds. If you change the recipe or switch to another product, the system can quickly adapt to the new product signal. The sensitivity level is still set for each recipe, but the product-learning itself is automatic," Alveflo explained.

The system detects the presence of a foreign object rather than identifying its exact composition. Whether it is soft plastic, hard plastic, rubber, wood or a fruit stone, the machine recognises the deviation from the normal product signal and triggers rejection. According to Alveflo, the contaminated portion is removed along with approximately 500 grams of product.

Tackling contamination and protecting product quality

Food Radar's technology is particularly relevant to applications where soft plastic can inadvertently enter the production stream. Plastic materials are widely used across food manufacturing operations, including covering equipment and products during processing and packaging incoming ingredients. Small fragments can accidentally enter raw materials and subsequently reach finished products.

"One of the issues we frequently see in the food industry is the extensive use of soft plastic. There is a high risk that small pieces can enter the ingredients and eventually make their way into the final product. With Food Radar, manufacturers can address these quality issues," Alveflo said.

Fruit processing is another important application. Products such as jams and marmalades involve raw materials that may naturally contain stones. Removing every stone during processing can be difficult, particularly when handling large volumes of fruit. The technology offers manufacturers an additional inspection opportunity to identify and reject these contaminants before filling.

The implications extend beyond product quality. Foreign objects in finished food can pose choking hazards, expose manufacturers to legal liabilities and potentially lead to product recalls. Alveflo noted that customers can see significant value through reduced consumer complaints, lower recall risk and improved brand protection.

"From the end customer's perspective, we are helping manufacturers significantly reduce choking hazards. For our customers, the value lies in protecting consumers, reducing the risk of complaints and recalls, and safeguarding their brands," Alveflo said.

Revealing the extent of hidden contamination

An important insight from Food Radar's customer experience is that the actual incidence of foreign object contamination can be considerably higher than manufacturers initially realise. Customer complaints provide only a partial picture, as consumers do not always report finding a small foreign object in a food product. In many instances, they simply discard it.

The installation of Food Radar's equipment can therefore reveal contamination issues that may otherwise remain unnoticed.

"Many customers do not realise how many low-density foreign objects are present in their products until they install a Food Radar system. Customer complaints only reveal part of the picture. With continuous inline inspection, manufacturers gain a much clearer understanding of the actual level of foreign-object contamination in their production," Alveflo observed.

This increased visibility also allows manufacturers to investigate where foreign objects originate. If contamination can be traced back to incoming raw materials, the information can support discussions and quality improvements with suppliers. If the source is within the factory, manufacturers can instead use the findings to identify weaknesses in their own processes and take preventive action. 

Expanding across India and the Middle East

Food Radar's participation at Gulfood Manufacturing was aimed at connecting with regional food processors and strengthening its presence in the Middle East. The company is working with Safe Automations as its partner in both India and the Middle East. Having initially focused on the Indian market through this cooperation, it is now extending its reach across the Gulf region.

Alveflo sees considerable potential in the region, particularly among manufacturers of fruit and vegetable products, sauces, soups and baby food. Typical applications include jams, marmalades, fruit preparations, tomato-based products, dressings and other pumpable food products.

Alongside continued development of its technology, Food Radar is focused on expanding its international market presence through strong local partnerships.

"We are looking forward to continuing to build Food Radar's presence together with Safe Automations. Their support across several markets in the Middle East and India is an important part of our growth in the region," Alveflo said.

Demonstrating detection capabilities at the exhibition

A major objective of Food Radar's presence at Gulfood Manufacturing was to demonstrate its technology in operation. Alveflo said that despite growing interest in advanced inspection solutions, some manufacturers remain sceptical about the ability to detect soft plastic, given the limitations traditionally associated with conventional detection systems.

To address this perception, the company brought a demonstration unit to the exhibition. The system circulated water through the equipment, allowing different foreign objects to be introduced into the flow so visitors could observe the detection and rejection process.

"People find it difficult to believe that it works until they actually see it. That is why we brought the machine to the exhibition: to demonstrate that we can detect soft plastic," he explained.

Food Radar also offers pilot trials using customers' own products and relevant foreign objects, allowing manufacturers to evaluate the system's detection performance for their specific application before making an investment.

Inspection closer to the filling stage

Food Radar recommends installing its equipment as late as possible in the production process, immediately before filling. This positioning enables manufacturers to inspect the product closer to the final packaging stage and minimise the possibility of foreign objects entering the product after inspection.

For manufacturers looking to strengthen contamination control, the approach provides an additional inspection point without requiring a fundamental change to their existing production processes.

"In brief, Food Radar adds an important layer of protection by detecting and rejecting low-density foreign objects in pumpable food products. We generally install the machine as late as possible in the process, typically before the filling machine, so that detected foreign objects can be rejected close to the final packaging stage," Alveflo said.

With its specialised detection technology and expanding distributor partnerships, Food Radar is looking to build a stronger international presence. Its growing focus on India and the Middle East reflects the company's ambition to work with food processors seeking more effective ways to address low-density foreign object contamination and strengthen product quality.