Metal Detectors & X‑Ray Inspection In Food Production Risk Assessment
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Risk Assessments
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Risk
Initial Risk
Controlled Risk
Action
Accessibility and Accommodation for Disabilities (Healthcare)
12
4
Adverse Weather Conditions (Traffic Management)
12
4
Anesthetic Gases
12
4
Asbestos Exposure
20
5
Battery Acids (Lead-acid Batteries) Exposure
12
4
Biological Hazards
12
4
Cargo Theft
16
8
Cement Dust Exposure
16
4
Chemical Exposure
16
4
Chemical Exposure
12
4
Cold Stress
12
4
Compliance with Transportation Regulations
16
8
Confidentiality Breaches
12
4
Confined Spaces
15
5
Cross-border Transportation Challenges
12
8
Cybersecurity Threats in Fleet Management Systems
20
10
Digging near underground pipes, cables and equipment
10
10
Driver Fatigue Among Subcontracted Drivers
20
5
Driver Licensing and Certification Risks
16
8
Dust/Fume Inhalation
15
5
Economic and Market Volatility
16
8
Electrical Hazards
15
5
Electrical Hazards (Traffic Management)
15
5
Electrical Safety
15
5
Electrical Safety (Healthcare)
2
2
Emergency Vehicle Access (Traffic Management)
15
10
Environment Spillages/Use of Hazardous Substances, Use of Concrete
12
4
Environmental Conditions and Natural Disasters
12
8
Equipment Failure
12
4
Ergonomic Injuries
12
3
Excavation Work/Collapse of Excavation
15
5
Exposure to Infectious Diseases
20
20
Extreme Weather Conditions
12
4
Falling Objects
20
10
Fire
15
5
Fuel (Diesel and Petrol) Exposure
15
5
Fuel Price Fluctuation and Management
12
6
General Site Working, Access to the Work
15
5
HAVS
12
4
Health and Safety Risks in Warehousing and Material Handling
16
8
Health Crises and Pandemics
20
10
Heat Stress
12
4
HGV Overloading
12
4
Improper Waste Disposal (Healthcare)
12
4
Inadequate Infection Control
20
5
Inadequate Traffic Control Measures
20
10
Inadequate Vehicle Servicing and Maintenance
16
4
Inadequate Worker Training and Supervision
16
4
Incorrect Cargo Loading
16
8
Insufficient Site Security
12
4
Insurance and Liability Issues with Subcontracted Drivers
15
5
Isocyanates Exposure
16
4
Lack of Emergency Preparedness
15
5
Lack of Emergency Preparedness (Healthcare)
15
5
Lack of Training (Traffic Management)
16
8
Lack of Training and Familiarisation for Subcontracted Drivers
16
4
Laser Hazards (Healthcare)
12
4
Lead-Based Paint Exposure
15
5
Legal and Regulatory Changes
12
4
Manual Handling
12
4
Manual Handling (Traffic Management)
12
4
Mechanical Failures Leading to Road Incidents
15
5
Medical Equipment Malfunction
12
4
Mental Health and Stress
16
8
Mercury Exposure
15
5
Miscommunication Among Team Members
16
8
Miscommunication and Coordination Failures in Management
12
3
Mobile Phone Use on Site
15
5
Mould Exposure
12
3
Moving/Use of Plant and Machinery, Re-fuelling of Plant
15
5
Needlestick Injuries
12
4
Night Work (Roadworks)
16
8
Night Work and Reduced Visibility
16
8
Noise Exposure
12
4
Noise Exposure (Roadworks)
12
6
Noise Pollution
12
3
Non-Compliance with LGV Regulations
20
5
Patient Allergies and Specific Needs
15
5
Patient Elopement
12
4
Patient Handling
16
8
Personal Protective Equipment (PPE) Non-Compliance
16
4
Pharmaceutical Errors
15
5
Plant and Machinery Operation
12
4
Polychlorinated Biphenyls (PCBs) Exposure
15
5
Poor Lighting
12
3
Psychological Stress from High-Risk Environment
12
8
Psychosocial Risks
12
4
Public Interference
12
4
Radiation Exposure
10
5
Radiation Exposure (Healthcare)
12
4
Refrigerants (Freon, Ammonia) Exposure
12
4
Scaffolding Collapse
15
5
Silica Dust Exposure
20
5
Slips, Trips and Falls, Poor Housekeeping
16
4
Slips, Trips, and Falls (Healthcare)
9
3
Slips, Trips, and Falls (Traffic Management)
12
4
Solvent Exposure
12
4
Stress and Mental Health Issues
12
4
Struck by Moving Equipment
12
4
Structural Collapse
15
5
Subcontractor Compliance and Safety Standards
12
4
Supply Chain Disruptions
16
8
Sustainability and Environmental Impact (Fleet & Logistics)
12
4
Talent Acquisition and Retention
12
4
Tool Misuse and Malfunction
16
4
Traffic Accidents
20
5
Traffic Delays and Public Frustration
12
8
Traffic Management (Roadworks)
16
8
Use of Electric Leads/Power Tools
15
5
Use of Hand Tools
9
3
Use of Sthil Saw/Abrasive Wheels
15
5
Vehicle Accidents Due to Driver Fatigue
20
10
Vehicle Collisions (Roadworks)
20
10
Vehicle Collisions (Traffic Management)
20
10
Vehicle Defects Leading to Accidents
15
5
Vehicle Incursions into Work Zones
20
10
Water and Flooding
12
8
Water Hazards
12
4
Worker Fatigue
9
3
Working at Height
15
5
Working on National Highways
15
5
Working on National Highways under adverse weather conditions
10
10
Workplace Violence (Healthcare)
12
4
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This risk assessment template is designed for food manufacturers, line operators and maintenance engineers who use metal detection and X‑ray inspection equipment on production lines. It covers the hazards associated with locating and removing foreign metal objects, ensuring radiation safety for X‑ray units, and maintaining electrical and mechanical integrity of the equipment. The template is suitable for a range of food products – from dry cereals and confectionery to packaged meats and ready‑meals – where strict contamination control is required to meet the Food Safety Act 1990, the Food Hygiene (England) Regulations 2013 and relevant HACCP principles.
Use this document to identify task‑specific risks, assign appropriate control measures and demonstrate compliance with UK food safety legislation, the Provision and Use of Work Equipment Regulations 1998 (PUWER), the Control of Substances Hazardous to Health Regulations 2002 (COSHH) for cleaning chemicals, and the Radiation (Emergency Preparedness and Civil Defence) Regulations 2001 for X‑ray safety. Each hazard includes a hierarchy‑of‑controls approach, with engineering solutions preferred over administrative actions and personal protective equipment (PPE) used only where residual risk remains.
Installation and commissioning of conveyor‑mounted metal detectors.
Routine X‑ray scanning of packaged foods for dense contaminants.
Preventive maintenance and calibration of detection systems.
Cleaning and sanitising of detector housings and surrounding areas.
Use this template for:
Assessing risks associated with metal detector installation and operation.
Evaluating radiation safety for X‑ray inspection units.
Developing maintenance and calibration procedures for detection equipment.
Ensuring compliance with food safety and HSE regulations.
By completing this risk assessment you can provide clear guidance to workers, support audit trails for food safety inspections and reduce the likelihood of product recalls caused by undetected metal fragments. The document is fully editable and shareable for customisation.
