Food inspection or fat analysis equipment, like an X-Ray machine, is a capital investment that requires thoughtful consideration. Total cost of ownership is a metric managers can use to determine if the investment is justifiable. Factors to consider include the production layout, number of daily shifts, processing environment, average or desired throughput, operator training and handling of maintenance.
Overview
What is total cost of ownership (TCO)?
The total cost of ownership includes the initial investment to purchase the machine and ongoing variable costs associated with operating the machine. Think spare parts, consumables (like X-Ray tubes and their safe disposal) and maintenance costs.
Understanding the total cost of ownership is important to understand the true cost of owning and operating an X-Ray inspection machine. The ultimate goal is to identify how long it will take before a system costs more than the value of the benefit it delivers.

How to use TCO and why it matters
Traditionally, it has been difficult for food processors to gain insight into the ongoing operating costs of equipment. Eagle has developed a total cost of ownership model for its equipment that considers the production realities like sanitation, plant environment, servicing costs, system lifetime and upgrades to provide a far more accurate total and true cost of ownership.
With this key figure, managers can compare competitor systems’ upfront costs and future costs to determine the overall impact on the business.
TCO for X-Ray and fat analysis machines includes factors such as:
- Estimated life of the machine
- Yearly running costs
- Machine availability/uptime
- Time to conduct a product changeover
- Sanitation cycle time
- Normal wear parts and consumable items
- Preventative maintenance frequency and service costs
- Anticipated spare parts usage and onsite inventory required
- Future machine hardware and software upgrades
- Periodic training and certification requirements.
Factors to consider for TCO
The first step when considering TCO is to calculate the cost to buy a unit, and how often components need to be replaced.
Purchase and setup costs
The first figure to ascertain is the initial purchase price of the machine, plus the costs of updating the processing line to install the new equipment. Include any initial staff training and machine calibration with the setup costs.
Operational costs
Operations costs consider everything that goes into keeping the machine running effectively. Questions to consider include:
- How long it takes to clean and how easy the sanitation process is
- How many annual preventative maintenance routines are required?
- Can preventative maintenance be done in-house or must it be done by the manufacturer?
- How long do the belts last?
- How many false rejects do you get?
- What is the skill level of the operators?
Understanding each of these variables can help managers to make a clear and informed decision about the investment. Let’s take a closer look at the operational costs of food processing equipment.
Daily running costs
Running costs can involve water, compressed air and electricity and are calculated based on power and time.
Maintenance and sanitation processes are also relevant, as meat and poultry processors often conduct cleaning regimes multiple times a day. Frequent wash-down and caustic cleaning solutions can lead to more downtime and a greater impact on the machine.
Machines that are designed for easy and rapid sanitation by one person that can be quickly returned to operation in a matter of minutes, like the Eagle X-Ray machine, provide a clear operational advantage.
X-Ray Inspection Case Study: Boulangerie St-Donat
Servicing costs
Regular preventive maintenance can extend the life of a machine. The machine supplier may provide a preventative maintenance service, visiting the operation site on a quarterly or bi-annually schedule to complete a full system test and identify parts for replacement now or in the near future.
This is an opportunity for new software updates to be installed, a review of safety systems and mechanical guards and refresher training for Operators and Maintenance personnel.
Servicing frequency will be determined by the operator’s standard operating procedures for maintenance, verification and calibration, as well as the application type and frequency of use.
Effective engineering for food safety
Microbial contamination is a primary concern for food processors, so it’s essential that machines are designed to promote food safety. X-Ray machines must be made from surfaces that resist bacteria collection and growth. Work areas should be positioned to allow easy drainage during cleaning, and components must be secure to survive long-term in the production environment.
A well-engineered machine will require less frequent parts replacement and faster turnaround in washdown and other cleaning routines, leading to a lower TCO.
Lifespan of the machine
Robust machines constructed with a particular processing application in mind, including handling wet or raw foods in meat or poultry plants, must meet industry guidelines and criteria. X-Ray machines require higher power for generators, so factoring in replacement costs of a generator along with the wear of the system’s parts is key for accurate TCO.
The lifespan of a well-maintained X-Ray or fat analysis machine is often more than a decade. Reinvesting in the system with preventative servicing and maintenance allows the machine to perform beyond full depreciation to provide ‘free’ years of operation.
Performance and technology
The technology of the investment is where the real returns are realised. Machine performance and accuracy, including the ability to adjust and update the software for new applications in production, enable one machine to provide many benefits.
For example, an X-Ray analysis machine may perform all of the following tasks:
- Check for contamination
- Count the number of products
- Measure the thickness of a product
- Identify if a product is missing
A system that interrogates an image for a number of parameters combines steps in the process to drive efficiency. Food processors can discover anomalies in the product, including contaminants as well as issues with mass and/or weight.
Identify foreign matter in food items to avoid expensive recalls
The dual-energy capability of Eagle’s X-Ray inspection systems discriminates between organic and inorganic materials (like steel or glass) using a high and low energy spectrum to identify the atomic number of the item under the beam. Inspection can be done at a high speed, such as 600 cans per minute or 200 ready meals a minute, to optimise running time and performance.
Traceback capability for peace of mind
Traceback capability adds another invaluable capability to machine performance. Built-in software includes a unique ID on each product, allowing the operator to access an actual image for a certain day, month, year or minute to review product integrity. This can potentially save the company from recalling complete batches and losing both money and product.
This capability also provides evidence that a product was contaminant-free when inspected, a real asset if potential false claims are raised against a processor or packager.
Ease of use
Choosing an X-Ray detection or fat analysis system that is easy to use enables operators to focus on other aspects of the operation, saving labour time. Consider touch-screen operated systems that allow intuitive interaction, faster changeovers and less downtime.
Likewise, simple machine disassembly and reassembly lead to shorter and easier maintenance. A machine designed for unobstructed sightlines gives operators the ability to clearly supervise, clean and maintain devices.
Minimising downtime risks
Besides the cost of product recall, downtime is the most costly risk in food manufacturing. When all pieces of equipment in a particular line work together in concert, shift after shift, according to their design specification, a processor is successful.
Changing software and machine parameters when changing over products or swapping parts all play into critical production minutes. Technically advanced machinery engineered with multiple sensors in place will help the operator to undertake quick operational fixes as needed, rather than requiring constant maintenance and intervention due to operational sensitivities.
A well-designed machine permits operators to easily troubleshoot and adjust the machine to continue production.
Footprint and integration
Making the most of every square metre and getting the highest productivity from each piece of capital equipment is key to a successful food processing operation. X-Ray technology’s complementary functions ensure products are safe and accurate throughout the further process and packing steps.
The idea is to maximise the data and efficiencies from the smallest footprint. Equipment that provides an array of data measures that enhance processing performance has greater value and a more favourable TCO.
Finally, future-proofing, while difficult, is important to stay competitive. Consider whether the speeds of the production line are likely to increase and whether the equipment and software will be able to keep up.
Total cost of ownership varies by use-case
Analysis of the total cost of ownership is specific to the processors’ or manufacturers’ operations. The type of product/s, whether raw, bulk, prepared or packaged, and frequency of use both play into the TCO. While an inefficient machine may bring unexpected costs and lower production, an efficient X-Ray or fat analysis machine will improve product integrity, quality and safety in a cost-effective and profitable way.
Work with a trusted partner to gain greater value from X-Ray inspection and fat analysis equipment
FPE works closely with our customers to ensure that the product inspection program you implement aligns with your unique food processing operational needs. Ultimately a system with the lowest cost of ownership will contribute the highest value.
Eagle’s well-designed X-Ray machines are engineered with meat and food processing applications in mind. Providing multiple data points, including foreign material detection, product size analysis and full traceability of images, these X-Ray machines can help reduce product recall while contributing to greater up-time in production.
To learn more about the total cost of ownership in your specific operation, contact our expert team at AU 1800 882 549 or NZ 0800 100 003.