Quality Control Inspections for Indonesian Seafood Imports

A buyer-side, inspection-ready playbook for Indonesian seafood metal detector verification. Exact test sizes, frequency, evidence, reject checks, and PO wording you can deploy today.

If you buy frozen seafood from Indonesia and rely on a metal detector check, verification will make or break your shipment. The good news. there’s a clear, buyer-friendly way to inspect and prove performance without derailing production. This is the exact playbook we use when we run pre-shipment checks for tuna, snapper, shrimp, and IQF portions.

Here’s the thing. you don’t need a broad plant audit. You need a scoped procedure that an inspector can run in under an hour and a QA team can document in minutes.

The 3 pillars of a verification-ready program

In our experience, consistent results come from three things. clear sensitivity targets, disciplined challenge tests with evidence, and a functioning reject system that cannot be bypassed.

1) Sensitivity and test piece sizes that match the product and aperture

Start with realistic acceptance criteria. For frozen seafood on conveyor detectors, these are the most commonly achievable baseline sizes when the aperture height is 80–120 mm and product is well-frozen.

Fe 2.0 mm
Non-Fe 3.0 mm
SS 3.5 mm (type 316 test sphere preferred)

When to tighten or loosen.

Small IQF portions and fillets like Grouper Fillet (IQF) or Mahi Mahi Portion (IQF). SS 3.0 mm is often achievable with an 80–100 mm aperture.
Thick or dense packs like Yellowfin Saku (Sushi Grade) blocks or tuna steaks. SS may need to be 4.0 mm, especially with a 150–200 mm aperture.
Shrimp packs like Frozen Shrimp (Black Tiger, Vannamei & Wild Caught). Many buyers hold to Fe 2.0 mm and SS 3.0–3.5 mm. If the pack thickness is under 40 mm and aperture is tight, SS 3.0 mm is a practical target.

What matters most. match the mm target to the detector’s aperture height and the product effect. A quick rule. larger apertures reduce sensitivity. Ask the factory for the current setpoint in mm shown on the detector screen, not just a percentage or number. Then verify that with real test spheres.

2) Disciplined challenge tests with frequency that survives audits

A metal detection challenge test should be run.

At start of each shift and at end of the run.
At least every 60 minutes during production.
At product changeover and after downtime, maintenance, or parameter changes.

Use certified test pieces. Fe, Non-Fe, and SS 316 spheres embedded in test cards. Time-stamped labels on the cards are a plus. Place test cards in three belt positions. left, center, right. And three positions relative to the pack. leading edge, middle, trailing edge. This catches edge effects and orientation issues.

Logs must tie to traceability. Every pass or fail should map to the lot number, shift, operator, and the master carton printing line. We link detector logs to the actual carton ID shown in photos. No orphan log entries.

3) A reject system that works and is tamper-proof

For conveyor detectors, verify the reject device and bin.

Functional test for reject flap or pusher. A metalized pack triggers the alarm, the pack is ejected, the red beacon sounds, and the line counter records the reject.
Reject confirmation. Sensor confirms the reject occurred. Many buyers require the belt to stop if a reject is not confirmed.
Locked reject bin. Lid locked and latched. Only QA holds the key. Do a reject bin lock check. try to open the bin without a key during inspection.
Full-bin interlock. If the bin is full, the line should stop, or an alarm should trigger. Test this with simulated rejects if possible.

Takeaway. if any fail-safe is bypassed or not working, you do not have a reliable CCP.

Your inspection scope at pre-shipment

Use this when you or your third-party inspector arrive after packing but before loading. It also works for remote validation on live video.

Confirm detector setup on the actual line for your product.

Photograph the detector nameplate and serial number.
Photograph the screen showing sensitivity setting in mm, product profile number, aperture size, and product effect compensation.
Note conveyor speed and pack orientation.

Run a full challenge test set.

Fe 2.0 mm, Non-Fe 3.0 mm, SS 3.5 mm. Adjust sizes to match your PO if tighter.
Three positions across the belt and three positions along the pack.
Record pass/fail for each orientation.

Verify reject and alarm functionality.

Video of a seeded pack going through. Capture the ejection, the beacon, the audible alarm, and the reject confirmation on screen.
Try to open the locked bin. Record the locked status and who holds the key.

Traceability link.

Photograph the line’s metal detection log for that hour and the full run.
Photograph a master carton label that shows lot, line, date, and time. If your cartons for Goldband Snapper Portion or Pinjalo Fillet (IQF) have QR codes, scan and save.

Documents to collect.

Calibration certificate Indonesia. issued within the last 12 months, covering Fe, Non-Fe, SS 316, with the detector serial number, aperture size, and traceability to standards. Preferably issued by a KAN-accredited provider.
HACCP CCP metal detector procedure and the last three months of monitoring records.
Test piece certificates for Fe, Non-Fe, SS spheres. Include sphere sizes and expiry dates.
Maintenance and verification records, especially any parameter changes during the lot.

What evidence proves the detector is working?

Inspections live and die on evidence. We ask for this minimum set.

Photo of the detector screen with sensitivity in mm and product code.
Photo of the test spheres/cards showing sizes and material types.
Video of each test piece traveling through and being rejected, including the alarm and the reject confirmation.
Photo of the locked reject bin closed and then opened with a key.
Photo of the metal detection log sheet with clear timestamps, operator signature, and mapping to lot/carton IDs.
Photo of the calibration certificate header showing date, due date, serial number, and signature or stamp.

Remote only. add a wide shot showing the detector relative to the packing line. That reduces the risk of staging.

Common questions we get

What size stainless steel test pieces should I require for frozen shrimp inspections?

Most buyers specify SS 3.0–3.5 mm depending on pack thickness and aperture. If the pack is thin and the aperture is under 100 mm, SS 3.0 mm is realistic. Keep Fe at 2.0 mm. Validate on the actual line, not on an empty belt.

How often should a metal detector challenge test be run?

Start and end of shift, hourly during production, at changeover, and after any downtime or parameter change. If a test fails, isolate and recheck all product since the last pass.

How do I verify the reject mechanism and locked bin on a conveyor detector?

Run a seeded pack. Watch for the reject device to actuate, the beacon to flash, the alarm to sound, and the reject confirmation on screen. Then perform a reject bin lock check and try to open without a key. Finally, simulate a full bin and confirm the line alarm or stop.

Can I validate metal detection remotely by video?

Yes. Request five shots. a wide shot of the line with the detector, a close-up of the screen with mm sensitivity, video of Fe, Non-Fe, and SS tests rejecting, a shot of the locked bin check, and a pan to the log sheet and master carton label with matching timestamps.

Should I accept a lot if the detector fails one challenge test but passes after adjustment?

Only if the factory isolates all product produced since the last documented pass and re-screens it at equal or tighter sensitivity. You need a rework log, a root-cause note, and a fresh pass at end of run. If any of that is missing, don’t accept.

Which documents prove calibration and CCP monitoring in Indonesian plants?

You want a current calibration certificate referencing the specific machine, traceable test piece certificates, a written HACCP CCP procedure, and complete hourly monitoring logs. A KAN-accredited calibration vendor is preferred, and the certificate should be less than 12 months old.

The mistakes we still see and how to avoid them

Vague PO language. “Metal detector required” is not enough. Specify Fe, Non-Fe, SS sizes in mm, frequency, reject and lock checks, evidence list, and acceptance criteria.
Testing only one position. Edge-of-belt failures are common. Run left, center, right and leading, middle, trailing.
No link to cartons. Logs with no lot mapping are audit risks. Photograph log sheets with a master carton label in the same frame.
Ignoring repack steps. If glazing, IVP, or labeling occurs after detection, require a second pass. We see this with value-added portions like Grouper Bites (Portion Cut).
Over-tight specs for big apertures. Asking for SS 2.5 mm on a 200 mm aperture tuna line leads to endless false rejects. Match sensitivity to the physics and manufacturer spec.

Target false rejects. Agree a cap such as under 0.1% of units per hour. Higher rates should trigger investigation and parameter tuning.

PO clause you can copy and use today

Here is buyer-side wording we recommend.

Metal detection CCP. Conveyor metal detector with aperture sized to product. Sensitivity verified on product at Fe 2.0 mm, Non-Fe 3.0 mm, SS 3.5 mm unless otherwise approved in writing.
Challenge tests. At start and end of shift, hourly, at changeover, and after downtime or parameter changes. Test cards run left, center, right and at leading, middle, trailing positions.
Reject and lock. Functional test for reject device, alarm, and reject confirmation. Locked reject bin with QA-only key and full-bin interlock tested.
Evidence required at pre-shipment. Photos of detector screen with mm setting, test card sizes, locked bin check, metal detector logs mapped to lot and carton IDs, current calibration certificate, and test piece certificates.
Non-conformance. Any failed test requires isolation and 100% re-screening of affected product with documented rework at equal or tighter sensitivity.

Need a tailored clause for specific products like Kingfish Fillet (Portion Cut / IQF) or Yellowfin Steak? If you want our editable template and a video shot list, Contact us on whatsapp.

What’s new that buyers should know

We’re seeing more retailers asking for SS 316 at 3.0 mm on thin IQF packs, and more remote validations by live video. Indonesian plants are also moving to digital detector logs. Ask for exported CSVs that include timestamp, profile, and pass/fail. And for thick cuts where SS 3.5–4.0 mm is borderline, some buyers are layering x-ray for bones and non-metal hazards while keeping the detector as the CCP. The reality is that a tuned detector still catches most metal efficiently and at lower cost.

We recommend you embed this playbook in every pre-shipment inspection for Indonesian seafood. It gives you verifiable performance on the line that packed your cartons. If you want to see how we apply it across our range, including tuna, snapper, shrimp and IQF fillets, View our products.

Practical takeaway. set realistic mm targets based on aperture and product. run disciplined hourly challenges with proper evidence. and never ship unless the reject system is proven and logs tie to your cartons. Do that, and your Indonesian seafood metal detector verification will stand up to any customer audit.