Foreign Material by the Numbers: What the 2026 Benchmark Report Reveals

# What this report measures

# How often events happen Responses show contamination is a recurring operational problem. 54.6% of respondents report a foreign material event monthly or more often. Nearly three-quarters experience events multiple times per year. The implication for operations: treat contamination as an ongoing operational reality and build practiced, rapid responses rather than assuming prevention alone will eliminate events.

# Where contamination starts and who detects it Two origin categories stand out. Equipment wear and failure are the single leading cause identified. When supplier-related sources are combined (supplier ingredients, natural inclusions, organic material), they form the largest category overall. Despite growing automation, employee reporting remains the most common first signal when an event surfaces. That means training and floor-level vigilance remain integral to any detection program.

# Contaminant profile: plastic on the rise For the first time in the report's three-year run, plastic is the most frequently cited contaminant at 37%, narrowly ahead of metal at 34%. That shift matters because many legacy detection strategies were optimized for metal. Metal detectors remain the most widely used technology, followed by sieves and screens, X-ray, and magnetic separation. Most facilities layer multiple technologies rather than relying on a single method.

# Technology strengths and blind spots

# Investment intent and confidence

# Response and decision-making When an event is confirmed, FSQA teams typically lead the decision on next steps. Internal remediation is the default path in about 63% of cases. Respondents weigh opportunity cost — the labor and downtime of tying up a line — heavily when deciding whether to release, rework, or hold product. The survey suggests operational trade-offs are central to remediation choices.

# Practical implications

• If plastic is rising in your contaminant profile, re-evaluate how your combination of detectors and separators performs against low-density, flexible materials.

• Plan detection investments with realistic expectations: many facilities lack full confidence in current systems, and spending intent has cooled in the near term.

# Bottom line Foreign material contamination remains frequent and varied. The shifting contaminant mix and persistent gaps in confidence mean periodic reassessment of detection strategies, supplier controls, and response processes will be necessary to manage risk effectively.