A beef slaughter plant microbial contamination early warning system

Abstract

The application provides a beef slaughter plant microbial contamination early warning system, comprising the following steps: a contamination early warning module: collecting relevant early warning data in the contamination early warning system to generate a pre-warning index; an alarm response time evaluation module: when triggering a hierarchical early warning, forcibly pausing the production line and collecting response time data to generate a response time index; a cleaning quality closed-loop evaluation module: collecting quality characteristic data to generate a closed-loop quality index; and a plant credit supervision module: counting the number of days from the last pathogenic bacteria positive event, the number of repeated alarms at the same point within a preset statistical period, and the total number of alarms in the plant, and generating a plant credit comprehensive index together with the response time index and the closed-loop quality index. The application can improve food safety, reduce recall losses, eliminate management blind spots, and form a continuous improvement closed-loop control mechanism by pre-warning, quantifying response time and cleaning quality, and driving operation permissions and supervision linkage with credit scores.

Description

Technical Field

[0001] This invention relates to the field of microbial contamination detection technology, specifically to a microbial contamination early warning system for beef slaughterhouses. Background Technology

[0002] Beef slaughtering and processing is one of the most concentrated stages in the meat production chain in terms of microbial contamination risk. From bleeding, skinning, eviscerating, splitting, to cooling and aging, each step can introduce or spread microbial contamination. Major sources of contamination include bacteria carried on animal skins, leakage of digestive tract contents, cross-contamination of equipment contact surfaces, airborne bacteria in the workshop, and improper operation by personnel. Once pathogenic bacteria contamination occurs, it can trigger serious food safety incidents, causing significant damage to public health and business operations. A microbial contamination early warning system can be constructed that integrates ATP time-series trend prediction, response timeliness and quality quantitative evaluation, and credit-driven closed-loop management. This system can achieve a paradigm shift from post-inspection to process control, ensuring the microbial safety of beef products, thereby improving food safety levels, reducing recall losses, and eliminating management blind spots.

[0003] Existing technology, publication number CN120028297B, discloses a rapid detection method and system for microbial contamination based on ATP fluorescence detection. This technology includes: determining optimal reaction conditions for different types of microbial samples; mixing the sample to be tested with an ATP fluorescence detection reagent to generate a reaction mixture with maximum ATP release efficiency; automatically adjusting the gain level based on preliminary measured fluorescence signal intensity; measuring the fluorescence signal intensity value of the reaction mixture to generate an optimized fluorescence signal intensity value; comparing the optimized fluorescence signal intensity value with a preset microbial ATP content standard curve to generate a preliminary prediction of the degree of microbial contamination; evaluating the reliability of the detection results; and sending the detection results to a remote monitoring platform to achieve real-time monitoring and early warning of microbial contamination. The technical solution provided in this application improves the accuracy and response speed of microbial contamination detection.

[0004] However, existing microbial contamination early warning systems generally employ an ATP single-point threshold alarm mechanism, triggering an alarm only when the detected value exceeds the limit. This fails to identify early trends of accelerated contamination growth, leading to delayed warnings and a narrow response window. The monitoring system operates independently from the workshop's industrial control system, meaning alarm signals cannot be automatically converted into mandatory production line shutdowns, relying on manual intervention. Furthermore, existing technologies lack quantitative evaluation methods for alarm response timeliness and cleaning quality, making it difficult to effectively address issues such as delayed responses and incomplete cleaning. In addition, microbial control performance is not yet linked to workshop operating permissions and monitoring platforms, resulting in a lack of a long-term constraint mechanism.

[0005] The information disclosed in the background section is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide a microbial contamination early warning system for beef slaughterhouses to address the problems mentioned in the background section. This invention captures early signals of the logarithmic growth phase of microorganisms through the acceleration trend term of ATP time-series data, shifting the early warning window more than two hours earlier than the threshold alarm. The response timeliness index quantifies the handling speed into a comparable indicator and links it to the alarm level, eliminating response delays. The closed-loop quality index integrates ATP retesting and culture results, allowing for traceability and zeroing when pathogens are detected. The workshop credit comprehensive index links management performance with resumption authority and the regulatory platform, forming a closed-loop process management system driven by prediction, response, verification, and credit.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] A microbial contamination early warning system for beef slaughterhouses includes the following steps:

[0009] Pollution early warning module: Collects relevant early warning data from the pollution early warning system, including the current ATP detection value, the ATP value of the previous detection cycle, the ATP value of the detection cycle before that, and the ATP safety limit; weights and fuses the relevant early warning data to generate an early warning index, identifies early signals of accelerated microbial growth, and triggers a graded early warning when the ATP value does not exceed the limit;

[0010] Alarm Response Timeliness Assessment Module: When a graded warning is triggered, response time data is collected, including the alarm trigger time, the time when the responsible person confirms the alarm, the time when the alarm is unlocked after passing the re-inspection, and the alarm level coefficient. The response time data is combined with the total handling time and the standard time to generate a response timeliness index, which is used to quantify the alarm response and handling speed. The response timeliness index is adjusted in conjunction with the pre-alarm index. The higher the warning level, the smaller the alarm level coefficient value.

[0011] Cleaning quality closed-loop evaluation module: Collects quality characteristic data, including post-cleaning retest ATP value, ATP safety limit, and pathogen detection results by culture method; uses the ratio of retest ATP value to ATP safety limit as a cleaning evaluation item, and the culture method detection result as a traceability correction item, multiplying them to generate a closed-loop quality index; when pathogens are detected, the index is forcibly reset to zero and historical records are traced and corrected; when the pre-alarm index reaches a high-risk level, the retest pass standard is temporarily raised;

[0012] Workshop credit supervision module: It counts the number of days since the last positive pathogenic bacteria event, the number of repeated alarms at the same location within the preset statistical period, and the total number of alarms in the workshop, and generates a comprehensive workshop credit index by combining the response timeliness index and the closed-loop quality index; when the comprehensive workshop credit index is lower than the credit threshold, the autonomous resumption of production is restricted, and when it continues to decline, a collaborative report is automatically pushed to the regulatory authorities.

[0013] Furthermore, the early warning index is calculated using the following formula:

[0014]

[0015] in: This is the early warning index;

[0016] This represents the current ATP detection value.

[0017] This refers to the ATP value from the previous testing cycle;

[0018] The ATP value for the previous testing cycle;

[0019] For ATP safety limits;

[0020] As the current pollutant, As an accelerating trend factor; The weighting coefficient of the current pollutant represents the degree of contribution of the current pollutant to the PRI. The weighting coefficient of the accelerating trend factor represents the degree to which the accelerating trend factor contributes to PRI.

[0021] Furthermore, the acceleration trend factor is used to identify the acceleration inflection point characteristics of microorganisms entering the logarithmic growth phase from the lag phase, enabling the system to capture early signals of contamination spread before the ATP detection value exceeds the safety limit; the pre-alarm index determines the risk level based on the preset interval to which the calculated value belongs, triggers the corresponding level alarm signal and generates an electronic disposal work order when the warning level threshold is reached, and further outputs a forced production line suspension command to the industrial control system when the high-risk level threshold is reached; in addition, the pre-alarm index actively outputs linkage correction parameters when the warning level is reached, adjusting the alarm level coefficient in the subsequent response time index and the re-inspection qualification threshold in the closed-loop quality index.

[0022] Furthermore, the response timeliness index is calculated using the following formula:

[0023]

[0024] in: For response timeliness index;

[0025] The alarm trigger time;

[0026] Confirm the alarm time with the responsible person;

[0027] The unlocking time is when the re-inspection is passed;

[0028] Standard confirmation duration;

[0029] Total standard processing time;

[0030] Alarm level coefficient;

[0031] To confirm the speed factor, which represents the speed at which the responsible person responds to an alarm, This refers to the actual confirmation time. The handling speed factor represents the overall handling speed from alarm triggering to cleaning verification completion; This represents the total actual time from the alarm being triggered to the re-inspection passing.

[0032] Furthermore, the alarm level coefficient is preset to a value based on the severity of the alarm event and is subject to linkage correction by the pre-alarm index: the higher the warning level, the smaller the value of the alarm level coefficient, resulting in a lower response time index under the same confirmation and handling speed, thereby forcing a shorter response time to high-risk alarms in order to maintain the timeliness score.

[0033] Furthermore, the calculated value of the response timeliness index is compared with a preset multi-level evaluation threshold range. When the response timeliness index is higher than the first threshold, the response timeliness is judged to be excellent, indicating that the alarm confirmation speed and overall handling efficiency of the responsible person are significantly better than the preset standard. When the response timeliness index is between the first threshold and the second threshold, it is judged to be good, indicating that the overall response and handling meet or slightly exceed the standard requirements. When the response timeliness index is between the second threshold and the third threshold, it is judged to be qualified, indicating that although there is a certain delay, it is still within an acceptable range. When the response timeliness index is lower than the third threshold, it is judged to be unqualified, indicating that the response is seriously delayed, and the system generates management early warning information accordingly.

[0034] Furthermore, the closed-loop quality index is calculated using the following formula:

[0035]

[0036] in: The ATP value was retested after cleaning;

[0037] For ATP safety limits;

[0038] The results for pathogen detection by culture method are as follows: zero for no pathogens detected, and one for detected pathogens.

[0039] This is a cleanliness factor used to evaluate the surface hygiene quality after cleaning and disinfection. To facilitate retrospective corrections, microbiological culture results are introduced as the final quality criterion. When pathogenic bacteria are detected by culture, the retrospective correction is zero, and the closed-loop quality index is forced to zero, regardless of how low the ATP retest value is.

[0040] Furthermore, when the closed-loop quality index is between the first and second quality thresholds, it is judged as a qualified level, indicating that the cleaning effect meets the basic hygiene requirements; when the closed-loop quality index is between the second and third quality thresholds, it is judged as a level requiring improvement, and the system automatically generates a secondary cleaning work order and requires re-treatment; when the closed-loop quality index is lower than or equal to the third quality threshold, including situations where the re-inspection ATP value exceeds the ATP safety limit causing the cleaning evaluation item to be less than or equal to zero, and the culture method pathogen detection result is positive causing the traceability correction item to be zero, it is judged as a treatment failure level, and the system forcibly locks the production line reset permission and triggers the management upgrade process; in addition, when the pre-alarm index reaches the high-risk level, the ATP safety limit is temporarily lowered, so that the re-inspection qualification standard is correspondingly increased.

[0041] Furthermore, the comprehensive credit index of the workshop is calculated using the following formula:

[0042]

[0043] in: The comprehensive credit index of the workshop;

[0044] This refers to the number of times an alarm is triggered repeatedly at the same location.

[0045] Total number of alarms in the workshop;

[0046] This refers to the number of days since the last positive event for the pathogenic bacteria;

[0047] This refers to the preset safety period reference number of days;

[0048] The overall performance score for handling a single alarm; As a trend control factor, it is used to penalize the repeated occurrence of the same problem and to evaluate the workshop's continuous improvement capability; It is a safety cycle factor used to impose a long-term penalty that gradually diminishes on microbial safety incidents.

[0049] Furthermore, when the workshop's comprehensive credit index is higher than the first credit threshold, the workshop enjoys full autonomy to resume production, and the production line can be reset without external approval. When the index is between the first and second thresholds, the platform pushes a credit attention reminder to the management, but the operating permissions remain unchanged. When the index is between the second and third thresholds, the workshop enters a restricted state, and the resumption order must be remotely approved by the group's quality center before it can be executed. When the index continues to fall below the third credit threshold, the system determines that the workshop has entered a credit alert state, automatically generates a collaborative report including credit score, recent alarm handling records, and repeated alarm statistics, and pushes it to the food safety supervision platform of the regulatory department through a preset communication interface.

[0050] Compared with existing technologies, the beneficial effects of this invention are as follows: By constructing a pre-alarm index based on the time-series data of three consecutive ATP detection values, the system can trigger graded early warnings before the absolute value of ATP exceeds the safety limit; by using a response timeliness index to quantify the confirmation speed and total handling time into comparable timeliness evaluation indicators, and linking it with the alarm level coefficient to achieve strict assessment for high-risk cases, effectively preventing handling delays; by using a closed-loop quality index to integrate ATP retest values ​​and pathogen detection results from culture methods, the inherent defect of rapid detection methods in distinguishing pathogen types is compensated for, and the index is reset to zero when pathogens are detected, and historical records are traced and corrected; by using a workshop credit comprehensive index to accumulate the performance of a single handling into a credit score, and deeply linking it with autonomous resumption of production authority, superior approval, and regulatory platforms, a complete closed loop from prediction, response, verification to credit-driven management is formed, upgrading microbial contamination control from discrete event response to continuous process control. Attached Figure Description

[0051] Figure 1 A system block diagram of a microbial contamination early warning system for a beef slaughterhouse;

[0052] Figure 2 This is a schematic diagram of the process of a microbial contamination early warning system for a beef slaughterhouse according to the present invention. Detailed Implementation

[0053] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0054] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0055] Example:

[0056] Please see Figures 1-2 The present invention provides a technical solution:

[0057] A microbial contamination early warning system for beef slaughterhouses includes the following steps:

[0058] Pollution Early Warning Module: This module collects relevant early warning data from the pollution early warning system. This data includes: the current ATP detection value, collected in real-time by fixed ATP fluorescence detectors deployed at preset key control points in the slaughterhouse according to a preset sampling cycle, and uploaded via Z-Wave-based wireless networking technology using mobile telecommunications services provided by the new generation mobile communication core network and access network; historical ATP detection values ​​recorded in the previous detection cycle adjacent to the current time, stored in the system database and recorded as the ATP value of the previous detection cycle; historical ATP detection values ​​stored in the system database two detection cycles prior to the current time, recorded as the ATP value of the previous-previous detection cycle; and ATP safety limits preset according to workshop hygiene control standards and stored in the system configuration module. The current ATP detection value, the previous ATP value, and the previous-previous ATP value together constitute ATP time-series detection data for three consecutive sampling times.

[0059] The relevant early warning data are weighted and fused to generate an early warning index, which is calculated using the following formula:

[0060]

[0061] in: This is the early warning index;

[0062] This represents the current ATP detection value.

[0063] This refers to the ATP value from the previous testing cycle;

[0064] The ATP value for the previous testing cycle;

[0065] For ATP safety limits;

[0066] For the current contaminant, the current ATP detection value is normalized to the ratio relative to the safety limit, reflecting the absolute contamination level at this moment. During normal operation, the value range is usually [0,1]. The closer the value is to 1, the closer the microbial contamination on the equipment surface is to the safety boundary. When the ATP value exceeds the limit, this item is greater than 1, and PRI will inevitably enter the high-risk range. To accelerate the trend factor, the first-order difference ratio of three consecutive ATP detection values ​​was used to determine whether the growth rate of microbial contamination was accelerating. This represents the absolute increase in ATP levels during the most recent testing period. This represents the absolute increase in ATP levels during the previous testing period. The weighting coefficient of the current pollutant represents the degree of contribution of the current pollutant to the PRI. The weighting coefficient of the accelerating trend factor represents the degree to which the accelerating trend factor contributes to PRI.

[0067] The acceleration trend factor captures the rate of change of ATP growth over three consecutive sampling times by calculating the first-order difference ratio of the current ATP detection value, the ATP value of the previous detection cycle, and the ATP value of the detection cycle before that. When the first-order difference ratio is greater than a preset threshold, it indicates that the pollution growth in the most recent detection cycle exceeds the growth in the previous detection cycle, meaning that the pollution growth shows a positive acceleration. This positive acceleration time series characteristic highly corresponds to the kinetic inflection point of the microbial community ending its lag phase and entering the logarithmic growth phase. Therefore, the acceleration trend factor can identify early signals of accelerated microbial proliferation before the absolute value of the current ATP detection exceeds the ATP safety limit, providing an advance time window for subsequent early warning responses.

[0068] After the pre-alarm index is calculated, the system compares its value with a preset multi-level threshold range to determine the current risk level. When the pre-alarm index reaches the early warning threshold, the system automatically triggers the corresponding level alarm signal and generates an electronic handling work order through the data interface, pushing it to the responsible person's terminal, requiring cleaning operations to be performed within a limited time. When the pre-alarm index further climbs to the high-risk threshold, the system, while triggering the alarm signal, simultaneously outputs a forced production line stop command to the workshop industrial control system through the communication interface, physically interrupting the operation of the production equipment associated with the alarm point until it passes the cleaning re-inspection and can be unlocked and reset.

[0069] Alarm Response Timeliness Assessment Module: In response to a pre-alarm index reaching a preset threshold and triggering a tiered early warning, the system records response time data, including the precise moment the tiered early warning is triggered, recorded as the alarm trigger moment, and uses this moment as the starting reference point for response timing. During alarm handling, the system further collects timeliness data related to the response behavior. This timeliness data includes: the moment the responsible person confirms the alarm, generated when the responsible person performs a confirmation operation on the alarm signal through a mobile terminal application interface or mobile voice service and mobile data communication service, and uploaded to the system for recording via a wireless network link; and a successful re-inspection. At the unlocking time, after the cleaning and disinfection work is completed and the alarm point is re-inspected by a portable ATP detector, and the re-inspection result meets the current applicable qualification standard, the system sends a production line unlocking and reset command to the industrial control system. The industrial control system executes the unlocking action and returns a status confirmation signal to the system. The system records the time of receiving this signal as the unlocking time of the re-inspection qualification. The alarm level coefficient is a weight parameter pre-configured according to the warning level corresponding to the current alarm event. It is stored in the system configuration module and is used to apply differentiated timeliness assessment benchmarks to alarm events of different severity levels in the subsequent response timeliness index calculation process.

[0070] The response time data is combined with the total processing time and the standard processing time to generate a response timeliness index, which is calculated using the following formula:

[0071]

[0072] in: For response timeliness index;

[0073] The alarm trigger time;

[0074] Confirm the alarm time with the responsible person;

[0075] The unlocking time is when the re-inspection is passed;

[0076] Standard confirmation duration;

[0077] Total standard processing time;

[0078] Alarm level coefficient;

[0079] To confirm the speed factor, which represents the speed at which the responsible person responds to an alarm, This factor represents the actual confirmation time. If the actual confirmation time is faster than the standard confirmation time, this factor is greater than 1, increasing the RRI; if the confirmation is delayed, this factor is less than 1, decreasing the RRI. The handling speed factor represents the overall handling speed from alarm triggering to cleaning verification completion; This factor represents the actual total time from alarm triggering to successful re-inspection, evaluating the overall handling speed from alarm activation to cleaning validation completion. If the handling is faster than the standard, this factor is greater than 1; if the handling is slower than the standard, this factor is less than 1.

[0080] The alarm level coefficient is a pre-configured weighted parameter based on the severity level of the alarm event. Its preset value is negatively correlated with the warning level; that is, the higher the risk level of the alarm event, the smaller the initial value of the corresponding alarm level coefficient. In addition, the alarm level coefficient further receives linkage correction from the pre-alarm index: when the pre-alarm index reaches the preset warning level or high-risk level threshold, the system outputs a linkage correction command to apply a multiplication correction of less than one preset ratio to the alarm level coefficient, so that the alarm level coefficient participating in the calculation of the response timeliness index is further reduced. Since the response timeliness index is generated by multiplying the actual duration ratio with this coefficient, under the same confirmation time and handling time conditions, the corrected coefficient will lead to a corresponding decrease in the calculated response timeliness index value. Therefore, if the workshop wants to maintain its response timeliness evaluation results without deterioration, it must invest less confirmation and handling time in high-level warning events to compensate for the score loss caused by the reduction of the coefficient.

[0081] After the response timeliness index is calculated using the aforementioned formula, the system is configured to automatically compare the calculated value of the response timeliness index with a preset multi-level evaluation threshold range to output the corresponding timeliness level judgment result. The multi-level evaluation threshold range includes a first threshold, a second threshold, and a third threshold set sequentially from high to low. The specific values ​​of each threshold are pre-calibrated and stored in the system configuration module based on the statistical distribution of historical response data in the workshop and management objectives.

[0082] When the calculated value of the response timeliness index is higher than the first threshold, the system determines that the response timeliness of this alarm handling is excellent. This determination result indicates that the responsible person's confirmation of the alarm signal is extremely rapid, and the overall handling process from alarm triggering to successful cleaning re-inspection and unlocking is significantly shorter than the preset standard time, reflecting that the workshop has a highly sensitive emergency response capability in microbial risk events;

[0083] When the response timeliness index is between the first threshold and the second threshold, the system determines the response timeliness to be at a good level. This determination result indicates that the responsible person's confirmation speed and overall handling efficiency meet or slightly exceed the system's preset standard requirements, and the workshop's response to alarm events is at a robust and controllable level.

[0084] When the response timeliness index is between the second threshold and the third threshold, the system determines that the response timeliness is qualified. This determination result indicates that although there is a certain degree of delay in the confirmation or handling process, the overall time consumption is still within an acceptable range and has not had a substantial adverse impact on the pollution prevention and control effect. However, it is still necessary to remind the relevant responsible persons to pay attention to the room for improvement in response timeliness.

[0085] When the response timeliness index falls below the third threshold, the system determines the response timeliness to be substandard. This determination indicates a significant delay in the responsible party's confirmation of the alarm signal or execution of cleaning procedures, potentially leading to an expansion of the contamination area or an escalation of product safety risks. In response to this determination, the system is configured to automatically generate management warning information, push this warning information to the workshop management and quality management department terminals, and mark it in the alarm event handling record.

[0086] Cleaning quality closed-loop evaluation module: Collects quality characteristic data for evaluating the effectiveness of cleaning treatment. The quality characteristic data includes: ATP value after cleaning retest, which is obtained by the operator resampling and measuring the same test surface using a portable ATP fluorescence detector after completing the deep cleaning and disinfection operation of the alarm point, and is used to characterize the residual level of organic matter on the surface after the cleaning operation is completed; ATP safety limit; and pathogen detection results by culture method. This result is a qualitative judgment issued by the laboratory regarding whether the specified pathogen has been detected after culturing environmental swab samples collected from the alarm point or its associated area for a preset time according to the microbial testing methods specified in the national food safety standards. The value is negative or positive.

[0087] The ratio of the retested ATP value to the ATP safety limit is used as a cleanliness evaluation item, and the result detected by the culture method is used as a traceability correction item. The two are multiplied to generate a closed-loop quality index. The closed-loop quality index is calculated using the following formula:

[0088]

[0089] in: The ATP value was retested after cleaning;

[0090] For ATP safety limits;

[0091] The results for pathogen detection by culture method are as follows: zero for no pathogens detected, and one for pathogens detected.

[0092] The ATP (Acidity Factor) is used to evaluate the surface hygiene quality after cleaning and disinfection. The lower the ATP value of the retest is to the safety limit, the closer this item is to 1, indicating that the cleaning is more thorough. If the retest value reaches or exceeds the limit, this item is less than or equal to zero, and the system determines that the treatment is unqualified. To facilitate retrospective corrections, microbiological culture results are introduced as the final quality criterion. When pathogenic bacteria are detected by culture, the retrospective correction is zero, and the closed-loop quality index is forced to zero, regardless of how low the ATP retest value is.

[0093] After the closed-loop quality index is calculated and generated, the system compares and determines it with a preset multi-level quality threshold range, which includes a first quality threshold, a second quality threshold, and a third quality threshold set sequentially from high to low.

[0094] When the closed-loop quality index is between the first quality threshold and the second quality threshold, it is judged as qualified, indicating that the ATP value after cleaning is significantly lower than the safety limit, meets the basic hygiene requirements, and the production line reset authority is released normally.

[0095] When the closed-loop quality index is between the second and third quality thresholds, it is determined to be at the level of needing improvement, indicating that there is room for improvement in the thoroughness of cleaning. The system automatically generates a secondary cleaning electronic work order and pushes it to the responsible person's terminal, requiring re-processing.

[0096] When the closed-loop quality index is lower than or equal to the third quality threshold, it is determined to be a disposal failure level. Triggering scenarios include: the ATP value upon retesting reaches or exceeds the safety limit, causing the cleanliness evaluation item to be less than or equal to zero; or a positive result for pathogenic bacteria detected by culture, causing the traceability correction item to be zero. Based on this, the system forcibly locks the production line reset permission and triggers a management escalation process.

[0097] In addition, when the early warning index reaches a high-risk level, the system outputs linkage correction parameters to temporarily lower the ATP safety limit, thereby raising the re-inspection qualification standard accordingly, so as to impose more stringent cleaning acceptance criteria on high-risk early warning events.

[0098] Workshop Credit Supervision Module: The system statistically analyzes the following historical operating parameters: the cumulative number of safe operating days since the most recent positive event for pathogenic bacteria detected by culture method, recorded as the number of days since the last positive event; the cumulative number of times an alarm is triggered at the same monitoring point due to the pre-alarm index exceeding the threshold within a preset statistical period, recorded as the number of repeated alarms at the same point; and the total number of times alarms are triggered at all monitoring points in the workshop within the same preset statistical period, recorded as the total number of alarms in the workshop.

[0099] The above parameters are automatically maintained and periodically updated by the system timer and alarm event counter, respectively, and are combined with the response timeliness index and closed-loop quality index to generate the workshop credit comprehensive index. The workshop credit comprehensive index is calculated using the following formula:

[0100]

[0101] in: The comprehensive credit index of the workshop;

[0102] This refers to the number of times an alarm is triggered repeatedly at the same location.

[0103] Total number of alarms in the workshop;

[0104] This refers to the number of days since the last positive event for the pathogenic bacteria;

[0105] This refers to the preset safety period reference number of days;

[0106] The overall performance score for handling a single alarm; As a trend control factor, it is used to punish the repeated occurrence of the same problem and evaluate the workshop's continuous improvement capability. The higher the percentage of repeated alarms, the lower this item is, forcing the workshop to solve the problem at its root. As a safety cycle factor, it is used to impose a long-term penalty on microbial safety incidents with continuous decay. The closer to the last pathogenic bacteria positive event, the lower this factor is. It recovers linearly with the increase of safe operating days, incentivizing the workshop to maintain a long-term good record.

[0107] After the workshop credit comprehensive index is calculated and generated, the system is configured to compare its value with the preset first credit threshold, second credit threshold and third credit threshold in a hierarchical manner, and automatically execute differentiated management and control strategies based on the comparison results.

[0108] When the workshop's comprehensive credit index is higher than the first credit threshold, it indicates that the workshop's microbial contamination control level is in an excellent state. The system grants the workshop full autonomous resumption of production authority. That is, after the red alarm event is handled and the re-inspection is qualified, the production line reset operation can be directly performed by the workshop's quality inspectors without remote approval from the superior management department. When the workshop's comprehensive credit index is between the first credit threshold and the second credit threshold, it indicates that the workshop's control level has slightly declined. The system pushes credit attention reminder information to the workshop management and the group's quality center through the industrial internet platform, but the current operation permission configuration remains unchanged, and the workshop still enjoys autonomous resumption of production authority.

[0109] When the workshop's comprehensive credit index falls between the second and third credit thresholds, it indicates a significant decline in the workshop's control level, and the system determines that the workshop has entered a restricted state. In this state, after a red alarm event is handled and passes re-inspection, the production line reset command must be remotely approved by the group's quality center before it can be issued and executed; the workshop no longer has the authority to reset autonomously. When the workshop's comprehensive credit index continues to decline below the third credit threshold, the system determines that the workshop has entered a credit alert state. In response to this determination, the system automatically generates a collaborative report containing the current credit score, alarm handling records within a preset statistical period, statistics on repeated alarms at the same location, and a closed-loop quality index trend curve. This collaborative report is then pushed to the food safety supervision platform of the regulatory department through a preset communication interface to support the regulatory department in implementing key supervision and inspection.

[0110] The above formulas are all dimensionless calculations. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters in the formulas are set by those skilled in the art according to the actual situation.

[0111] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented in software, the above embodiments can be implemented, in whole or in part, as a computer program product. Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented by electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution.

[0112] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0113] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application.

Claims

1. A microbial contamination early warning system for beef slaughterhouses, characterized in that, Includes the following steps: Pollution early warning module: Collects relevant early warning data from the pollution early warning system, including the current ATP detection value, the ATP value of the previous detection cycle, the ATP value of the detection cycle before that, and the ATP safety limit; The relevant early warning data are weighted and integrated to generate an early warning index, which identifies early signals of accelerated microbial growth and triggers graded early warnings when the ATP value does not exceed the limit. Alarm response timeliness assessment module: When a graded warning is triggered, it collects response time data, including the alarm trigger time, the time when the person in charge confirms the alarm, the time when the alarm is unlocked after passing the re-inspection, and the alarm level coefficient; The response time data, total processing time, and standard processing time are used to generate a response timeliness index, which is used to quantify the alarm response and processing speed. The response timeliness index is linked to the pre-alarm index for correction; the higher the warning level, the smaller the alarm level coefficient value. Cleaning quality closed-loop evaluation module: Collects quality characteristic data, including post-cleaning retest ATP value, ATP safety limit, and pathogen detection results by culture method; uses the ratio of retest ATP value to ATP safety limit as a cleaning evaluation item, and the culture method detection result as a traceability correction item, multiplying them to generate a closed-loop quality index; when pathogens are detected, the index is forcibly reset to zero and historical records are traced and corrected; when the pre-alarm index reaches a high-risk level, the retest pass standard is temporarily raised; Workshop credit supervision module: It counts the number of days since the last positive pathogenic bacteria event, the number of repeated alarms at the same location within the preset statistical period, and the total number of alarms in the workshop, and generates a comprehensive workshop credit index by combining the response timeliness index and the closed-loop quality index; when the comprehensive workshop credit index is lower than the credit threshold, the autonomous resumption of production is restricted, and when it continues to decline, a collaborative report is automatically pushed to the regulatory authorities.

2. The early warning system for microbial contamination in a beef slaughterhouse according to claim 1, characterized in that: The early warning index is calculated using the following formula: ， in: This is the early warning index; This represents the current ATP detection value. This refers to the ATP value from the previous testing cycle; The ATP value for the previous testing cycle; For ATP safety limits; As the current pollutant, As an accelerating trend factor; The weighting coefficient of the current pollutant represents the degree of contribution of the current pollutant to the PRI. The weighting coefficient of the accelerating trend factor represents the degree to which the accelerating trend factor contributes to PRI.

3. The early warning system for microbial contamination in a beef slaughterhouse according to claim 2, characterized in that: The acceleration trend factor is used to identify the acceleration inflection point characteristics of microorganisms entering the logarithmic growth phase from the lag phase, enabling the system to capture early signals of contamination spread before the ATP detection value exceeds the safety limit. The pre-alarm index determines the risk level based on the preset interval to which the calculated value belongs. When the warning level threshold is reached, the corresponding level alarm signal is triggered and an electronic disposal work order is generated. When the high-risk level threshold is reached, a forced production line suspension command is further output to the industrial control system. In addition, when the pre-alarm index reaches the warning level, it actively outputs linkage correction parameters to adjust the alarm level coefficient in the subsequent response time index and the re-inspection qualification threshold in the closed-loop quality index.

4. The early warning system for microbial contamination in a beef slaughterhouse according to claim 1, characterized in that: The response timeliness index is calculated using the following formula: ， in: For response timeliness index; The alarm trigger time; Confirm the alarm time with the responsible person; The unlocking time is when the re-inspection is passed; Standard confirmation duration; Total standard processing time; Alarm level coefficient; To confirm the speed factor, which represents the speed at which the responsible person responds to an alarm, This refers to the actual confirmation time. The handling speed factor represents the overall handling speed from alarm triggering to cleaning verification completion; This represents the total actual time from the alarm being triggered to the re-inspection passing.

5. The early warning system for microbial contamination in a beef slaughterhouse according to claim 4, characterized in that: The alarm level coefficient is preset based on the severity of the alarm event and is subject to linkage correction by the pre-alarm index: the higher the warning level, the smaller the alarm level coefficient, resulting in a lower response time index under the same confirmation and handling speed, thereby forcing a shorter response time for high-risk alarms in order to maintain the timeliness score.

6. The early warning system for microbial contamination in a beef slaughterhouse according to claim 5, characterized in that: The calculated response timeliness index is compared with a preset multi-level evaluation threshold range. When the response timeliness index is higher than the first threshold, the response timeliness is judged to be excellent, indicating that the alarm confirmation speed and overall handling efficiency of the responsible person are significantly better than the preset standard. When the response timeliness index is between the first threshold and the second threshold, it is judged to be good, indicating that the overall response and handling meet or slightly exceed the standard requirements. When the response timeliness index is between the second threshold and the third threshold, it is judged to be qualified, indicating that although there is a certain delay, it is still within an acceptable range. When the response timeliness index is lower than the third threshold, it is judged to be unqualified, indicating that the response is seriously delayed, and the system generates management early warning information accordingly.

7. The early warning system for microbial contamination in a beef slaughterhouse according to claim 1, characterized in that: The closed-loop quality index is calculated using the following formula: ， in: The ATP value was retested after cleaning; For ATP safety limits; The results for pathogen detection by culture method are as follows: zero for no pathogens detected, and one for detected pathogens. This is a cleanliness factor used to evaluate the surface hygiene quality after cleaning and disinfection. To facilitate retrospective corrections, microbiological culture results are introduced as the final quality criterion. When pathogenic bacteria are detected by culture, the retrospective correction is zero, and the closed-loop quality index is forced to zero, regardless of how low the ATP retest value is.

8. The early warning system for microbial contamination in a beef slaughterhouse according to claim 7, characterized in that: When the closed-loop quality index is between the first and second quality thresholds, it is judged as qualified, indicating that the cleaning effect meets the basic hygiene requirements; when the closed-loop quality index is between the second and third quality thresholds, it is judged as needing improvement, and the system automatically generates a secondary cleaning work order and requires reprocessing; when the closed-loop quality index is lower than or equal to the third quality threshold, including situations where the retested ATP value exceeds the ATP safety limit, causing the cleaning evaluation item to be less than or equal to zero, and the culture method for pathogenic bacteria detection results are positive, causing the traceability correction item to be zero, it is judged as a failure, and the system forcibly locks the production line reset permission and triggers the management upgrade process; In addition, the ATP safety limit for the early warning index reaching the high-risk level was temporarily lowered, which correspondingly raised the standard for passing the re-inspection.

9. The early warning system for microbial contamination in a beef slaughterhouse according to claim 1, characterized in that: The comprehensive credit index of the workshop is calculated using the following formula: ， in: The comprehensive credit index for workshops; This refers to the number of times an alarm is triggered repeatedly at the same location. Total number of alarms in the workshop; This refers to the number of days since the last positive event for the pathogenic bacteria; This refers to the preset safety period reference number of days; The overall performance score for handling a single alarm; As a trend control factor, it is used to penalize the repeated occurrence of the same problem and to evaluate the workshop's continuous improvement capability; It is a safety cycle factor used to impose a long-term penalty that gradually diminishes on microbial safety incidents.

10. A microbial contamination early warning system for beef slaughterhouses according to claim 9, characterized in that: When the workshop's comprehensive credit index is higher than the first credit threshold, the workshop has full autonomy to resume production, and the production line can be reset without external approval; when the index is between the first and second thresholds, the platform pushes a credit attention reminder to the management, but the operating permissions remain unchanged. When the index is between the second and third thresholds, the workshop enters a restricted state, and the resumption of production order must be remotely approved by the group's quality center before it can be executed; when the index continues to fall below the third credit threshold, the system determines that the workshop has entered a credit alert state, automatically generates a collaborative report that includes credit score, recent alarm handling records and repeated alarm statistics, and pushes it to the food safety supervision platform of the regulatory department through a preset communication interface.

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