Protecting and Moving the World Through Innovation
Protecting and Moving the World Through Innovation
MPI Magnet Audit Services
MPI understands the importance of magnetic separators working at peak performance. We have been conducting magnet certification audits since 1982 as a service to our customers to support them to develop and maintain an effective metal control program. Upon completion of the audit, MPI generates a comprehensive report that may also serve as support to corporate quality professionals or regulatory audits. In 2016 MPI launched our Certified Magnet Auditor Program to further standardize the quality and consistency of the reports, while also expanding our network of Certified Magnet Auditors to better support our customers.
MPI’s magnet certification audit report summarizes the various observations made during the recent magnetic separator audit at the facility. This report identifies areas found to be in satisfactory condition and includes magnet systems deemed to be candidates for improvement. Where magnet systems are found to be deficient, we identify possible recommendations to be considered for improvement.
All MPI Certified Magnet Auditors use NIST certified digital pull test scales, NIST certified gauss meters, and all test spheres are certified carbon steel ball bearings that have been welded to a stainless-steel ring and coated in zinc to prevent corrosion.
The Benefits of MPI Magnet Certification Audits
The benefits of MPI Magnet Audits:
- Easy to read audit results with photos of each magnetic separator and a color-coded rating system that helps you identify the separator and areas for improvement
- Exclusive rating system using four (4) criteria to ensure your separators are operating at peak performance
- Makes regulatory audits easier by confirming the high quality of your current metal control program or identifying areas for improvement
- Regular audits provide a comprehensive picture of a facility’s metal control system and proof of HACCP compliance with required documentation
- MPI’s Auditor Training Program ensures our trained and certified auditors provide consistent report formats and findings
- Our HACCP Certified MPI Regional Managers are familiar with the quality programs used by each customer
- MPI’s NIST certified Pull Test Kit replaces the need for a certified scale, as well as the time, resources and training need to conduct audits internally
MPI Rating System
Each magnet has been assessed based on four criteria. Each criterion is rated on a color scale from green to red based on the results found from the Certified Magnet Auditor. The criteria and color scales are:
|Correct Magnet: This rating is based on whether the separator is the correct type of separator as required by the application.|
|Green||Correct magnet, no action required|
|Yellow||Consideration for improvement as noted|
|Red||Replace separator as recommended|
|Magnet Strength: This ensures that the magnet has the required strength for the application.|
|Green||Magnet is testing at or above baseline values|
|Yellow||Magnet strength has decreased but within less than a 20% range|
|Red||Magnet is testing greater than 20% below baseline value|
|Tramp Metal: This rating is based on the amount of tramp metal saturation the separator has at the time it was tested.|
|White||Pre-cleaned, magnet was cleaned before the auditor inspected the magnet|
|Green||Separator had minimal tramp metal saturation|
|Yellow||Separator had moderate tramp metal saturation with some capacity remaining|
|Red||Separator was fully saturated with tramp metal and at maximum capacity|
|Maintenance: This rating is based on the separators requirement for maintenance.|
|Green||No maintenance required|
|Yellow||Maintenance required as noted|
|Red||Immediate action required as noted|
FSMA Compliance and Documentation: The Easy Way with MPI’s Magnet Audit
MPI has offered magnet audits to our customers and potential customers for years, but with the Food Safety Modernization Act (FSMA) taking effect, there has never been a better time to take advantage of this service. FSMA regulations are cumbersome, tedious, and time-consuming.
Here is a list of procedures required by FSMA, and how MPI’s magnet audit can help:
FSMA Sec 103 Hazard Analysis and Risk-Based Preventive Controls Procedure:
- Hazard Analysis
Prior to your audit, evaluate what metal hazards could potentially contaminate your product. These hazards are required to be documented by the FSMA. Supply a list of these hazards to MPI, and we will include them in your audit.
- Preventative Controls
During the audit, MPI will evaluate your process and review your preventative metal control equipment, including critical control points, and help you determine if your metal control equipment is sufficient to significantly minimize/prevent these hazards.
- Monitoring Effectiveness
The most effective way to monitor the effectiveness of your magnets is by conducting pull test to determine their strength. MPI will perform a pull test on every magnet in your facility.
MPI will verify your existing preventative controls are correct for the application in which they are installed. A trained magnet expert will ensure your magnets can effectively minimize/prevent the occurrence of your identified metal hazards.
The magnet systems audit report will serve as documentation to demonstrate your facility has identified potential hazards, implemented preventative controls for these hazards, and is monitoring the preventative controls to ensure they are effective. Your facility should maintain this document for no less than two (2) years.Many of our customers are ahead of the curve, and the documentation we provide with our audit serves as their proof. However, many customers would like a trained metal control expert to give them some direction. MPI will work with you to develop a plan to remedy any metal control systems that need improvement. All magnets identified as candidates for improvement will include recommended actions on our report.
Here’s how these recommendations can help you ensure compliance with the FSMA:
FSMA Sec. 102 Registration of Food Facilities:
(Sec. 102, Pg. 124, STAT. 3888, (3)) – “The secretary shall require the registrant to submit a corrective action plan to demonstrate how the registrant plans to correct the conditions found by the secretary.”If an inspector finds fault with any of your magnets, use MPI’s “Recommended Actions” to help determine your corrective action plan.
Metal Control Audit
To ensure metal detectors and x-ray equipment meet the standards and requirements of our industry and customer base, MPI offers metal control audits at customer facilities. Audits are conducted by MPI specialists who are specifically trained in the function and viability of electronic inspection equipment.
Prior to visiting the facility, MPI auditors will work with plant employees to develop an audit plan and determine priorities. During the audit, the specialist will physically inspect and validate each piece of electronic inspection equipment in the plant. The auditor will also identify and photograph the equipment. Shortly after the fieldwork is completed, a written report is presented to the customer. The report includes an overview of findings, an evaluation of equipment, and a detailed inspection report. Equipment photographs are used as reference points. The findings are presented formally to plant QA personnel to determine if actions are required.
To ensure magnetic separators meet the standards and requirements of our industry and customer base, MPI offers magnet audits and magnet certification at your facility.
Audits are conducted by MPI specialists who are specifically trained at appraisal, function and viability of magnetic equipment. MPI audits serve as HACCP documentation as well as meet plant requirements for QA standards.
Prior to visiting the facility, MPI auditors will work with plant employees to develop an audit plan and determine priorities. During the audit, the specialist will physically inspect and measure the effective strength of each magnetic separator in the plant. The auditor will also identify and photograph the equipment. Shortly after the fieldwork is completed, a written report is presented to the customer. The report includes an overview of findings, an evaluation of equipment, and a detailed inspection report. Equipment photographs are used as reference points. The findings are presented formally to plant QA personnel to determine if actions are required.
- Ensures equipment:
Meets application requirement
- Ensures magnets:
Have effective pull
Are in proper location
Are cleaned correctly
- Ensures tramp metal:
Is effectively trapped
- Ensures company:
Possesses HACCP documentation
Meets QA standards
Other magnet services include:
|3rd Party Auditing||Is your facility looking for a quick and easy way to validate and document the performance of your metal control systems? MPI certified magnet auditors are professionally trained on the proper procedures to monitor the effectiveness of your preventative controls by verifying their performance with testing. Methods of testing include pull testing and gauss testing when required.|
|Reporting and Documentation||The magnet systems audit report will serve as documentation to demonstrate your facility has identified potential hazards; implemented preventative controls for these hazards and is monitoring the preventative controls to ensure they are effective. Your facility should maintain this document on-site for no less than two years.|
||Welcoming new members to your team? Have an MPI magnet expert visit your facility to train your current and new employees on proper magnet cleaning and magnet safety.|
||Running out of time to complete that scheduled PM? Give MPI a call and we will send a technician to complete common preventative maintenance tasks such as replacing plastic strippers, bushings, gaskets, cylinders or bearings. On-site rebuilds can also be completed reducing the time it takes your equipment to be back in production.|
|Quality Program Development
||Let MPI Certified Magnet Auditors assist you in developing a quality assurance program that documents your magnet cleaning/testing schedule and reporting procedures that supports your established HACCP plan.|
|On-site Emergency Response Visit||Have peace of mind that in the event that your facility has a metal contamination issue, Hi-S members can have a metal control expert on-site within as little as the same or one day's time.|
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