Remarkably, the vast majority of food processing
facilities around Australia still rely on human beings to do the track
and trace inspections
It is a critical aspect of quality assurance and food safety
to identify a product at its origin and track and trace the forward
movement through the entire process of the food supply chain, including
food processing, filling, closure and packaging. To retrospectively
identify where and when a problem may have occurred, and to date and
time stamp the event, is a prerequisite.
The ability to
automatically recognise defects up and down the supply chain has become
an integral part of quality control in the food industry business and is
a legal requirement in many processes.
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The problem is that human beings cannot, for the most
part, keep pace with industry requirements for increased production
speeds and increased product quality. Operators get tired, lose focus
and make mistakes. This loss of concentration could result in them
failing to detect potentially defective products; the criteria that they
apply during inspections are inevitably subjective.
Machine vision (MV) is the technology to replace or
complement manual inspections and measurements with digital cameras and
image processing. The technology is used in a variety of different
industries to automate the production processes, increase production
speed and yield, and to improve product quality.
Typical applications of machine vision in the Australian market:
- Code validation - confirming that all the codes on the product are readable.
- Label inspection - ascertaining that the labels are placed correctly.
- Label validation - validating that the correct label is affixed to the product.
- Packaging integrity - ensuring that any recycled packaging material is adequate.
- Filling monitoring - validating that the correct product and correct amount is filled.
- Closure inspection - ensuring that lids and caps are positioned and tightened correctly.
- Sealing validation - ensuring that foil covers and anti-tamper seals are present and correctly applied.
Code validation
Machine vision solutions for code inspection are used
to verify code presence, position, formation and readability, and
sometimes to also provide code reading and matching. Such systems can
automatically identify and reject containers or packages with missing,
incorrect or unreadable codes to ensure only properly coded items are
produced.
Codes that can be validated are date codes, batch
codes, barcodes and 2D data matrix codes, all ensuring that
non-compliance can be traced and acted on.
Label inspection
High-speed labelling of products, of all types, shapes
and sizes, can result in a wide variety of possible defects. These
defects can lead to labelling errors that can be harmful to a brand or
even present liability issues for a brand owner. Labels can be inspected
for label presence, wrinkles, tears, skewed labels, double labels,
flagged or missing labels, as well as incorrect label pairs (back and
front) on containers and packages.
Overwrap alignment is another form of label inspection
in which wraparound labels are checked for straightness and proper
position. With appropriate MV system design, a 360° inspection on round
bottles can be performed.
Label validation
The importance of correct labelling on a food product
grows each day as scientists and doctors discover more food properties
that need to be identified and displayed: peanut allergies, gluten-free,
salt content - the list is extensive.
Machine vision technology for label inspection can be
set up to help ensure correct labelling, and packages and containers
with incorrect or defective labelling can then be automatically rejected
in the production line.
Incorrect product labelling on the supermarket shelves could result in costly litigation, or worse.
Packaging integrity
Inspection of recycled packaging equipment can be easily achieved using MV technologies.
In beer bottling lines it is common practice that the
beer crates are checked for wholeness, and if the crate has any damages,
such as a hole in the bottom, it can be rejected before a bottle is
inserted and falls through.
A further application has been implemented by a leading
confectionery company in Melbourne that uses MV to check that the
confectionery trays are clean for re-use before reintroduction into the
manufacturing process of the next batch.
Filling monitoring
Ensuring that the correct product is filled into the
correct container, and that the correct amount is filled, can be
achieved using MV together with the code validation technologies.
This application is used by a global pet-food producer
with process plants in Australia. Here the importance of correct filling
is even higher due to the fact that much of the production is exported
to Asian markets where brand reputation is paramount. Product recall, in
this instance, can be very costly, both in terms of product waste and
brand damage.
Closure validation
Obviously the integrity of closures and seals on
bottles and other containers is important for the quality of the product
and the safety of the consumer. MV systems can be used to visually
check the closures and seals for integrity.
A simple application, albeit in a related industry, is
using MV technology to check that the correct colour cap is placed on
the correct home brand bleach bottle at a Queensland-based contract
bottle filling company. And, more importantly, that the sealing is
perfect - leaking bleach in the boot of a car could have some unpleasant
consequences.
Checking the closure’s colour and dimensions verifies
that the right closure has been applied to the container, while visually
checking liner formation and placement ensures the product is properly
sealed and protected from contamination and leakage. In the same way,
tamper seals can be checked to make sure they are not broken.
Sealing inspection
There are many other applications where the integrity
of the sealing process is paramount. The sealing of all wet food needs
to be checked - any small flaw in the seal will result in the product
possibly leaking contents, and the definite likelihood of the product
spoiling. Additionally, tamper-proof seals can be checked for correct
application prior to packaging and a photographic record kept of every
product inspected.
We have reviewed a small selection of applications for
the use of MV technology. Further applications of machine vision in
other markets include:
- Checking product quality - bruises, cuts, damage to fruit and vegetables, cracked eggs.
- Sorting fresh produce by size, colour and type - nuts, oranges, eggs, coffee.
- Checking for defective bottles and hygiene inspection in the bottle-washing process.
- Additional checks on bottle crates - logo inspection (correct crate for specified product), edge inspection to avoid sharp edges causing injury.
- Fish filleting using MV in conjunction with robots.
MV technology is developing as a rapid rate, providing
faster, smarter and more accurate measurements. This evolution ensures
that the food industry can apply the technology to more complex track
and trace applications thereby assuring an even higher degree of quality
assurance and food safety.
As the food and beverage authorities tighten the regulations, MV solutions are the best way to ensure compliance.
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