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Total Inspection Provider

Total Inspection ProviderTotal Inspection Provider

Testrods.com is just one facet of the Regal Packaging Services company as your total inspection provider.  It all starts with metal detector sales and service.  We represent the Fortress Technology brand of metal detectors and checkweighers.  In addition, we offer audits on all brands of metal detectors and x-ray inspection systems.  Now  (March 2024), we’re happy to announce that metal detector rentals is a part of what we offer.  And finally, what you see here on Testrods.com is our own line of metal detection and x-ray inspection verification test pieces.

So actually, we’re approaching what we do as total inspection providers from six different angles:

  1. Fortress Technology metal detector sales, what we believe to be the best in the world. And you can put that claim to the test. Our sales area covers Illinois, Wisconsin, Indiana, and Iowa. With Fortress, you get: Simple Operation, Exceptional Performance, Outstanding Reliability and a Never Obsolete Commitment.  Visit Regalpack.com, call 630-942-8461 or email us @regalpack@regalpack.com
  2. Service on Fortress Technology metal detectors. We don’t simply sell a machine and then walk away. We can provide service at all levels, assist with startup, and provide training.  And while others may take weeks to show up, we’ll be there when you need us.  If you have a Fortress brand metal detector an are in our sales area (above) call 866-869-4130.
  3. Sales and service of Fortress checkweighers, a great companion product to Fortress metal detectors.
  4. Metal Detector and X-ray Inspection system audits, whether on an annual, semi-annual, or quarterly basis. We can get you ready for that visit from the auditor. We audit all makes and models of metal detectors and x-ray systems. It’s another reason you can trust us to help meet the needs of the industry.  Visit DetectorAudits.com call 800-976-2390 or email inquiries@detectoraudits.com
  5. Metal Detector rentals to get you through those moments when your system is down or you need to do a re-work.  Visit detectorrentals.com or call 866-982-4442 or email inquiries@detectorrentals.com.
  6. Worldwide sales of certified test pieces (purchased here or call 866-691-8560 or email testrods@testrods.com) will ensure that your systems are in working order. You will meet the demands of your HACCP plan, and test pieces come with free certificates that never expire. The Regal Packaging Team.
    1. We offer 16 different contaminant types for metal detection and x-ray inspection verification.
    2. Our product line includes 8 different standard type test pieces.
    3. We can manufacture nearly any custom piece you can imagine.

A total inspection provider is an absolute necessity, and it’s what you’ll get from Regal Packaging Services.  Our goal isn’t to make profit by simply by selling equipment and services.  Of course, we have to be concerned about the proverbial “bottom line,” just as every company does.  But we realize that in order to that, we have to help you achieve the food safety criteria in your packaging, processing or manufacturing plant.  When your customer in the marketplace safely enjoys your food product, we know we’re part of that picture, and we take that very seriously.

Started in 1998, Regal has over 100 years of combined experience in the food industry.  Our commitment to excellence and customer service is the highest caliber in the industry.  We don’t work on a “one-size-fits-all” model, and we’ll help you determine what works best for your particular application.  We’re well versed in nearly every product you may be running on your production line.  Whether it’s packaged gummies or 40lb blocks of cheese, we can design a system that will meet the challenge.  And remember, we won’t walk out on you once your system is up and running.

We’re here to help keep that system running and audited so you can pass any inspection you’re facing.  Having Regal in your “hip pocket” is never anything less than an advantage in securing your position as a safe, quality food source.  When you unleash our services you gain a source of deep knowledge, intelligence and experience.

So before you purchase a metal detector, checkweigher, audit services or test pieces, give us a call at the numbers above.  Not only will you not regret it, but you’ll be happy you did.

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Floatable Thermoform Test Cards

Some applications involve large tubs, vats, or some other type of product travel where it would be nice to have a test piece that floats. Once again, our thermoform cards provide the simplest solution. We simply insert some type of structure that forces the thermoform card to retain air, which, of course, is what makes it float. We have also manufactured floating rods, which are more difficult because there is less space to close in enough air to make the rod float but is doable.

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We took an ordinary plastic “chip clip” as defined by the customer and embedded the contaminant into the clip. The clip can be attached to the product on the line without damaging or opening the product for testing purposes.

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Bone is a difficult contaminant to find because it can vary widely based on the size, age, and calcium content (as well as feed used) of the animal. After working with several customers, Regal Packaging Services offers Pork, Beef and Chicken Bone Simulate. We have a small range of sizes at a variety of depths to simulate whatever you might expect to find in the product. Our recommendation (assuming your x-ray has visual display) is always to start with a multi-card. Using a multi-card gives you an easy way to test several sizes and depths to determine what matches the bone you’re using. Once you’ve made a comparison, testing the card against the bone you’re looking for, you can purchase a card with a single contaminant for regular testing.

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This small pill shaped test piece is used in a system with a vacuum tube that shoots the test piece through the aperture and returns it to the “home” base. Your system may never be like it, but the point is that we can make a customized solution no matter how unusual or impossible it might seem.

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As you may have seen in some of the other thermoform card descriptions, we can put nearly as many seeds as you can imagine on a single card. Pictured here you will find a wide variety of configurations and contaminants. Just let us know your specs: size of the card (up to 8” x 8”) along with size and type contaminant(s) and we’ll get you a quote as quickly as possible. Working with a multi-card is especially helpful when you are looking for multiple types of contaminants or when you want to determine what size of the same contaminant you are able to detect. In that event, once the size is chosen, you can order individual card(s) for regular, standard inspection and detection.

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There are a wide range of applications that require a test piece much longer than our standard 5” or 6” Testrods. We can make up to 3/8” x 34” or 1/2” x 34” rigid test pieces which can then be extended well beyond that length with a “handle” made of acetal cylinder larger than the 3/8” or 1/2” extension. In the photos, we used a 1” x 24” cylinder handle with a 3/8” x 24” inch extension.

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Test pieces can be made in a variety of sizes and given a pointed end in applications that require the contaminant (metal) to be inserted into a food package such as sugar or some other soft packaged food product. This allows the metal to reach the center of the aperture.

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Double-End Test Whips are also available, with metal in both ends. One consideration is to make certain that the whip is long enough to keep the metal on the non-testing side of the whip outside the metal free zone of your detector. If you insert, for instance one end of a whip with 2.0mm and 3.0mm Ferrous, you need to make certain that the 2.0mm metal doesn’t affect the detection of the 3.0mm metal (and vice versa). If the 3.0mm metal is inside the metal free zone, then the detector will be reacting to the 2.0 as well as the 3.0 as if they were combined.

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Multi-seed laminate test cards are designed for seeds 4.0mm or less. Multi-cards are useful in x-ray inspection to determine what sizes and types of contaminants your system can achieve. They can be especially useful in temperate environments and applications. If your application is rugged or wet, or your standards are larger, we recommend our thermoform multi-cards.

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We can simulate a variety of packaging in an application where you need the test piece to mimic what is traveling down the production line. In this case, we manufactured a clear “package” with the seed inside. With this method, the customer is able to reject the container appropriately, and, in the event the package is not rejected, it is easily seen by the line worker for manual removal.

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There are two types of “candy bars” pictured here – one similar to a flat candy bar and the other in a custom, near perfect copy of a candy bar. Since we’re now able to produce many variations using colored material, the copy was made in red (Fe), green (NFe) and blue (SS 316). We have the equipment to accomplish nearly anything you can imagine, and these kinds of designs are proof positive.

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Need a test piece that looks and handles like chicken nugget? We can do it. Interestingly enough, in this situation, our first version for the customer left too much “void” in the hole where the metal was placed. Given the sensitivity the customer system was using, the void had the effect of causing false positives. We were able to minimize that hole and supply the test piece with almost no void. It’s an example of how we can work with you before, during and after manufacturing to ensure all the specifications were met.

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Our standard acetal card is 2 1/4"x3 3/8,” but if needed, we can cut that size down to as small as 1 1/4” x 1 1/4” (with limited engraving). If a larger card or a card with multiple seeds is needed, see our Custom Shape-Size Blocks and Tablets.

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This distinctive test piece was created to mimic an actual hamburger patty. The customer supplied photos of the raw product, which we were able to reproduce and then we placed blue glove contaminant. Using this configuration, the customer was able to determine what size piece the vision scanning system could detect with the raw burger as the background. Had they simply used a blank card with the glove, the system could easily have achieved contaminant rejection, but they needed to be sure the system could “see” the blue against the product itself.

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A card with 100 seeds in a 10x10 configuration is used to place beneath whole chickens on a production line. This gives the x-ray system operator the ability not just to see IF the equipment can detect the metal in the card, but also WHERE the equipment can detect it. If there is a problem, the operator (or company) can make any changes necessary to achieve the end goal – safe chicken in this case. This card really highlights another valuable facet of our thermoform cards.

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In this scenario, a company processing sugar needed to have a “bag” simulated with the same weight in order to accurately fall through the reject mechanism. A lighter test piece had the risk of passing over the reject mechanism.

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Our standard cubes are 1” and 1.5,” but we can also manufacture other sizes if needed. The cubes shown here are 1/2" in dimensions. Cubes can be helpful in applications where a ball or cylinder may bounce or roll away during testing, making their retrieval difficult, or, in some cases, present a hazard to the product or production equipment.

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This is a test piece that is dropped into a bottle. It’s designed so that the metal appears in the center of the aperture when testing the metal detector. In addition, the round stop makes the test piece easily removable after testing.

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Hexagonal Shaped test pieces can be very useful in places where a cylinder or ball might roll or bounce around a production floor whether dropped by a line worker or ejection from a reject mechanism. Hexagons are similar in weight to the 1inch cylinders without having the smooth, rounded cylinder edge.

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Our customer in this plant needed a test piece with a thickness less than 5.0mm. Because we have the capacity to customize sizes and shapes, we were able to mill down a product that met their specifications. That’s always our goal, meeting the specs you need for your product, testing environment and contaminants.