“The cycle of parts breaking down, being thrown away and then having to be replaced is not just wasteful, it is also unsustainable long term. In many instances, the machinery on a line represents millions in capital expenditure and often has potentially decades of useful life in it," says Fortress founder Steve Gidman.

The longevity of an inspection system is heavily influenced by build quality. Some of the earliest analogue Fortress metal detectors installed nearly 30 years ago continue to operate today, but with efficient digital features, Fortress says. At the time of commissioning, these features were yet to be invented.

Following a similar principle, another global food processor was able to introduce a digital feature to record every signal generated by each product bag passing through the aperture of their metal detectors. Fortress supplied modular communication adapters, enabling automatic data extraction to a central database. In addition to delivering the requested functionality, this upgrade strengthened reporting capabilities and overall quality assurance.

Adaptable and upgradeable

Scalability and simplicity are at the forefront of Fortress inspection system designs. Each machine allows upgrades with minimal disruption, downtime, and investment. “Rolling out upgrades requires far less time, capital, and business interruption compared to commissioning an entirely new build and installation,” says Gidman.

Fortress Technology search heads, electronic boards, and other parts can be replaced with the latest revisions, while software can be upgraded to the newest iteration. This modular design model means that components can be added or reconfigured to deliver customized inspection systems.

Adaptations of this scale are only feasible if the metal detector has a stable hardware platform, Gidman says.  

Interchangeable components simplify maintenance, allowing site engineers to quickly troubleshoot, replace parts, and restore functionality with minimal downtime, the company notes. Optional expandable I/O hardware further increases connectivity, such as adding extra communication between upstream and downstream systems or enhancing integration with PLCs, reject devices, and monitoring equipment.   

Sustainability in food production does not always mean radical reinvention, Gidman says. “In the case of inspection equipment, it means designing machines to be simple, upgradeable, and built to last.” 

Technology designed for adaptability offers more than convenience; it bridges the gap between legacy systems and today’s digitally connected production lines, the company adds. The Fortress "Never Obsolete" commitment embodies this philosophy, ensuring its customers can upgrade existing metal detection without purchasing a whole new system, Fortress notes.

Related: Fortress Technology launches easy-clean conveyor range