FlexXray: Emerging Technologies for Improving Foreign Material Detection

Kye Luker serves as the Chief Product Officer at FlexXray, where he leads development of the company's innovative X-ray inspection process and technology. With more than two decades of experience in the service, consumer packaged goods (CPG), and food and beverage industries, Kye brings a wealth of knowledge in continuous improvement, quality assurance, and formulations to his role. In this episode of Food Safety Matters, we speak with Kye [1:34] about: How foreign material (FM) contamination continues to challenge food manufacturers as it remains one of the leading causes of food recalls each year Why certain contaminants are difficult to detect with traditional metal detectors and inline X-ray systems How many FM control strategies remain reactive, with detection systems acting primarily as signaling devices rather than preventing contamination upstream The role of third-party inspection partners in helping manufacturers investigate FM incidents, narrow hold windows, and support data-driven product release decisions Key limitations of re-inspecting product in-house using the same inline equipment, speeds, and sensitivity settings that originally failed to detect FM How computed tomography (CT) inspection can analyze products in three dimensions, allowing inspectors to identify FM hidden by layering effects in complex food products The benefits of a multi-pronged FM control strategy that combines upstream detection technologies with advanced downstream inspection Advanced technologies utilized by FlexXray to enhance detection sensitivity and precision, including photon-counting X-ray systems and machine learning algorithms. Resources 2025 Foreign Material in Food Benchmark Report Sponsored by: FlexXray