Controlled batch distribution

Abstract

A method for generating batches of food items, comprising: • transfer food items to a weight determination medium where the weight of the food items is obtained for individual food items and / or food items in groups, • Generate a plurality of batches based on the weight obtained from individual food items and / or food items in groups, where the batch generation step is controlled so that the weight of the batches is within a predefined weight range, characterized in that the distribution of the batches within the weight range is predefined.

Description

Controlled batch distribution Field of invention The present invention relates to a method for generating batches of food items in a controlled manner. Background: In the past, in most cases, "batch processing" has been considered "fixed-weight batch processing," meaning that when working with a target weight for a batch, for example, 400g, the total weight of a shipment of packages (batches) is expected to be the weight of the package (the batch weight) multiplied by the number of packages, as described in US patent 2008 0283307 A1. All of the above is considered a "gift" that the manufacturer must assume, and therefore, there is a general desire to keep it as low as possible. However, a fixed-weight approach of this type is often not very customer-friendly because the target customer group may differ significantly. Summary of the invention The present invention overcomes the aforementioned problem by means of a method that makes batches with a predefined distribution. According to a first aspect of the invention, a method is provided for generating batches of food items, comprising: • transfer food items to a weight determination medium where the weight of the food items is obtained for individual food items and / or food items in groups, • Generate a plurality of batches based on the weight obtained from individual food items and / or food items in groups, where the batch generation step is controlled so that the weight of the batches is within a predefined weight range, and so that the distribution of the batches within the weight range is predefined. Therefore, it is now possible to adjust batch distribution to customer needs, for example, by adjusting batch weight distribution to the target market. For instance, the target customer group in a particular area might be, on average, a family of two to four people. This means that a two-person customer will obviously be looking for a different target weight batch than a four-person customer. Therefore, by adjusting batch distribution in this way, the weight distribution can match the specific weight distribution demand within that particular area. For example, a large supermarket located on a university campus might have a completely different target customer group than a supermarket located in a suburb without universities. The term "batch" should be understood as the accumulation of two or more food items in a defined area, for example, on a tray or in a bag, to achieve a predefined target weight. This can be done with various devices, such as conveyors, where food items are transported and removed from the conveyor to a bag / container / hopper via sweep arms. Another piece of equipment that can be used is the so-called multi-head combination weighing (MCWD) device, which is well known to experts. In this device, items are randomly distributed into multiple weighing hoppers arranged around a distribution unit, and the optimal combination of items in two or more weighing hoppers is selected to achieve a target weight for that batch.An example of such batches are poultry parts in a tray or bag and the like, where the bag may be, for example, 700g (target weight), where this target weight may, for example, be reached through a combination of poultry parts (or any other type of food item) in two or more weighing hoppers where the poultry parts are simultaneously drawn from the weighing hoppers to, for example, a bag position down there. In one embodiment, the predefined weight range is defined by a first weight value and a second weight value, where the second weight value is greater than the first weight value, and where the predefined weight range is adjustable by adjusting at least one of the first and second weight values. The expression "first weight value" can also be understood as the first target weight value, and the expression "second weight value" can be understood as the second target weight value, where, for example, 500g can be the first weight value and 1000g can be the second weight value, and where 500g–1000g is therefore the defined weight range. In addition, the first / second weights or target weights may be associated with some "tolerance deviation" or margin of error, for example, ±5% (or any other acceptable % value) which means that if, for example, the first weight value above is, for example, 500g ±5% and the second weight value is 1000g ±5%. Therefore, it is possible to easily change and adapt the weight range for, for example, a new order from a new customer, where the new customer may, for example, have a completely different target customer group. In one embodiment, the predefined weight range is divided into two or more sub-weight ranges. Referring to the previous example where the predefined weight range is 500g–1000g, this weight range interval can, for example, be divided into five sub-weight ranges: 500–600g is the first sub-weight range, 600–700g is the second, 700–800g is the third, 800–900g is the fourth, and 900–1000g is the fifth and final sub-weight range. The number of sub-weight ranges can, of course, be fewer than five or more than five. In one embodiment, the batch distribution within a given subweight range selected from two or more subweight ranges is predefined or substantially flat. Another example of a narrower, predefined range is where the distribution of food items is between, for example, 400g and 450g, meaning that all produced batches are between 400g and 450g. In the case of subweight ranges, this predefined range can, as already mentioned, be divided into a plurality of subweight ranges where, for example, within each subrange there is approximately the same number of food items, i.e., a substantially uniform distribution. As an example, there could be 100 batches in the subrange 400g to 410g, 100 batches in the subrange 411g to 420g, 100 batches in the subrange 421g to 430g, 100 batches in the subrange 431g to 440g, and 100 batches in the subrange 441g to 450g. In one embodiment, each of the two or more subweight ranges has an associated prioritization variable that indicates the prioritization of batches within the two or more subweight ranges, and where the prioritization variable is used as an operating parameter to indicate which of the two or more subweight ranges a batch should be selected from. In one embodiment, this variable can be determined based on the percentage of batches within each of the two or more subweight ranges, such that the higher the percentage, the higher the prioritization variable.Referring to the previous example where the weight range is between 500 and 1000g, the highest percentage rate can be from 700 to 800g, for example, 50% of all batches should be within the subweight range, 15% should be within the subweight range of 600-700g and 15% within the subweight range of 800-900g, 10% within the last subweight range of 500-600g and 10% within the subweight range of 900-1000g. In one embodiment, the batch weight generated within a given subweight range selected from two or more subweight ranges is chosen randomly. As an example, a Multi-Cell Weight Disposal (MCWD) system can be used where items are randomly distributed into a plurality of weighing hoppers arranged around a distribution unit. The random selection of the batch weight can be performed such that, for example, the MCWD, or any other device, finds a batch weight within a given range, e.g., 600–700 g, where random selection simply means that it is sufficient for the selected batch weight to fall somewhere within this 600–700 g range.Therefore, the first combination of food items performed, for example, the MCWD, i.e., the combination of items in typically two or more weighing hoppers that results in a target weight that is within a selected subweight range, can be selected, thus saving processing power and the time required. In one embodiment, the predefined subweight ranges are defined by a first subweight value and a second subweight value, where the second subweight value is greater than the first subweight value. The predefined subweight ranges can be adjusted by setting at least one of the first and second subweight values, and / or the predefined subweight ranges are defined by the percentage of batches to be generated within the subweight ranges. Referring to the previous example, where the predefined weight range is 500–1000 g, and the subweight range is 600–700 g, the first subweight value is 600 g and the second subweight value is 700 g. Furthermore, the width of the range(s) can be adjusted by setting one or both of these subweight values. In one embodiment, the remaining subrange values ​​can be automatically adjusted based on these, or they can be adjusted independently.This can be advantageous, for example, when expanding / reducing a specific subweight range because the target customer group may be different or because a specific subweight range simply shouldn't exist for a given batch order. In one embodiment, a random target weight value is selected or defined for each two or more subweight ranges, where the selection of a batch weight within each of the two or more subweight ranges comprises selecting a batch weight that is substantially the same as the target weight value of the selected subweight range. With reference to the previous example, a random target weight selection for this interval could, for example, be 650g (or any individual value within this subweight range), and this target weight value is preferably updated after each batch generation. Consequently, with reference to the previous example, a first target weight value (for the first subweight range) could be 650g at one point within the first weight range, a second target weight value (for the second subweight range) could be 770g at one point, a third target weight value could be 830g, and so on, at one point. Referring to the previous example, and assuming that an MCWD is used to generate the batches, one of the criteria could be to try to make the batch weight as close as possible to the target batch weight and / or at least within the limits of the actual subweight range. That is, the search related to 650g covers the subweight range of 600g to 700g, and if this is not possible, a combination as close as possible to 770g will be sought if this range has the second highest priority. In one embodiment, the step of using the prioritization variable as an operation parameter comprises: • determine if there is a combination of food items within an underweight range that has a higher prioritization variable, where, in the event that such a batch weight exists, • Combine the food items together in a batch, otherwise, determine if there is a range of subweights that has a lower priority that has a lower priority variable followed according to a hierarchical order of priority variables. Referring to the previous example, this could be the case if there is no batch weight within the 700-800g range, i.e., the range with the highest priority, then the 600-700g or 800-900g ranges would be checked, i.e., those with the second highest priority. In one embodiment, the prioritization variable is dynamically adjusted based on the current number of batches within the subweight range and a predefined percentage number indicating a number of batches to generate within the subweight range. In one embodiment, the prioritization variable is dynamically adjusted based on the current number of batches and the predefined distribution of batches in each of the two or more subweight ranges. In this way, batch generation only proceeds if there is no higher priority batch weight, then it checks the second highest priority, and so on, according to the hierarchical order, where the hierarchical order can be constantly updated because the prioritization variable for different subweight ranges is constantly changing. A given subweight range has the highest percentage of batches (for example, 50% of all batches must be within this range) and therefore initially has the highest priority, i.e., when all subweight ranges are "empty".During batch generation, if one subweight range is, for example, close to being filled, while another subweight range has a lower percentage (for example, 10% of all batches must fall within this range) but is, for example, almost "empty" (i.e., very few batches have been generated within this subweight range), then this subweight range will have a higher priority. Therefore, this percentage and the "scarcity" within the subweight ranges can be considered the key variables, if not the only variables, in the constant or repetitive updating of the prioritization variable for the subweight ranges. Another example of the implementation of the method according to the present invention may be able to work with several ranges in parallel - for example: • 20% of batches in the 600g to 650g range • 20% in the range of 651g to 700g • 30% in the 701g to 800g range • 20% in the range of 801g to 850g • 10% in the range of 851g to 900g all ranges that can have approximately the same number of food items, i.e., with a substantial flat distribution, and where all lots can have an individually marked price (not a fixed price). In one embodiment, the lots are of various predefined weights, and where the lots are individually marked according to weight and / or price. In a second aspect of the invention, a batch processing apparatus is provided for generating batches of food items, comprising • means for transferring food items to a weight determination device where the weight of the food items is obtained for individual food items or food items in groups, • means to generate a plurality of batches based on the weight obtained from individual food items and / or food items in groups, • a control unit to control the means of generating the plurality of batches such that the weight of the batches is within a predefined weight range, and such that the distribution of the batches within the weight range is predefined. In one embodiment, the batching apparatus comprises a multi-head combination weighing device (MCWD), wherein food items are weighed individually or in groups, in a number of weight-determining devices and wherein the contents of some of the individual items or groups determined by weight are subsequently combined together to form the batches. In one embodiment, the apparatus comprises weighing means for weighing food items individually or in groups, in at least one dynamic weight determination device, and wherein the individual items or groups are subsequently transported by a conveyor along a number of guide members where the individual items or groups are guided together to form batches, the individual food items or groups of food items being guided together are not necessarily transported side by side. In one embodiment, batches of various predefined weights are made into subweight ranges, the subweight ranges being of predefined size relative to each other in relation to the number of individual items or groups. In general, the various aspects of the invention can be combined and coupled in any way possible within the scope of the invention. These and other aspects, features, and / or advantages of the invention will become apparent and clear with reference to the embodiments described below. Brief description of the drawings Embodiments of the invention will be described, by way of example only, with reference to the drawings, in which Figure 1 is a flow diagram of a currently accepted method for generating batches of food items, Figures 2 and 3 graphically represent examples of a use of the method in Figure 1, Figure 4 shows a batch layout with a combined multi-head weighing device (MCWD), and Figure 5 illustrates how a target weight range for batches can be achieved. Description of achievements Figure 1 shows a flowchart of a current method for generating batches of food items. In step 101, food items are transferred to a weight determination medium where the weight of the food items is obtained for individual food items and / or food items in groups, where the group of food items can be where two or more food items are found below or, for example, one on top of the other or in some way overlapping. In step 102, a predefined weight range is defined, where the predefined weight range consists of a first weight value and a second weight value, the second being greater than the first. For example, the first weight value could be 500g and the second weight value could be 1000g, where 500-1000g is therefore the predefined weight range. In step 103, a plurality of batches is generated based on the weight obtained from individual food items and / or food items in groups, wherein the batch generation step is controlled so that the weight of the batches is within at least a predefined target weight range, and such that the distribution of the batches within the weight range is predefined. The diagrams shown in Figures 2 and 3 graphically represent examples of the use of the method in Figure 1 where the vertical axis is the percentage of batches to be produced and the horizontal axis shows different weight ranges in grams, where in Figure 2 the predefined weight range is from 600g to 900g, and in Figure 3 the predefined weight range is from 600g to 800g. In the example shown in Figure 2, the defined weight range is divided into five subweight ranges, namely, subweight range 600-649g 201, subweight range 650-699g 202, subweight range 700-799g 203, subweight range 800-849g 204, and subweight range 850g-900g 205. In addition, a predefined distribution of the batches to be generated is shown where each of the subweight ranges has an associated percentage number that indicates the percentage of batches within the subweight ranges to be prepared, i.e., 15% for subweight range 201, 20% for subweight range 202, etc. As Figure 2 shows, the amplitude of the underweight ranges 201-205 does not have to be the same; that is, the amplitude of the underweight range 203 extends from 700-799g and is therefore obviously wider than the amplitude of the remaining underweight ranges that cover the 50g weight range. Figure 3 shows another example of a different batch distribution where the predefined weight range is from 600g to 800g, and where this predefined weight range is divided into four subweight ranges, 301-304, all of which have a width of 50g. In this example, 45% of the batches must be within the subweight range of 700-750g, while, for example, only 5% of the batches produced must be within the subweight range of 600-650g. The equipment that generates such batches may be, for example, but is not limited to, a conventional classifier comprising a conveyor belt and a plurality of sweeping arms operated by a control unit to move into an open position to sweep a food item into a receiver location where the batch is generated. Another example of such equipment is commonly called a multi-head combination weighing device (MCWD), in which a plurality of items are collected in a plurality of weighing containers and / or hoppers, and when an optimal combination is reached, the items in the weighing container / hopper are dropped into, for example, a bag, tray, and the like. In one embodiment, the underweight ranges shown in Figures 2 and 3 may have an associated prioritization variable to rank the underweight ranges, meaning that, for example, a lagging underweight range can be prioritized when determining which interval a drop should be directed to. If, for example, two intervals are even, then the subweight range with the highest percentage value can have the highest priority (e.g., an interval that is planned to collect 30% is prioritized higher than an interval that is planned to collect 15%). Furthermore, this prioritization variable can be automatically updated so that, although a given subweight range has the highest percentage, another subweight range with a lower percentage can be prioritized due to the shortage of batches within this lower percentage subweight range. In one embodiment, when a subweight range is selected, a random target value can be chosen from the minimum and maximum subweight values ​​that define the subweight range in question, where the method can be configured to attempt to find a combination as close as possible to this target weight. If it is not possible, for example, for the MCWD to find a combination with a weight between the minimum and maximum of the interval in question, then the MCWD will preferably continue searching for a combination for the second highest priority, and so on. In this way, a type of hierarchical structure can be used. In one embodiment, if a container and / or weighing hopper in the MCWD is overfilled, it can be checked whether its contents alone fit within one of the defined intervals. If so, it is used there even if it is not "first in line." Example 1: Controlled batch distribution with a combined / multihead weigher: To form a specific batch, a commonly used MCWD batch processing algorithm selects a combination from a set of possible combinations, where the selection criterion may be that the combination must be between a lower and upper target limit, and must be as close as possible to the target weight as shown graphically in Figure 4. An additional criterion may be that a moving average of the batch weights must be equal to or greater than the target weight. The possible combinations can be compared during the combination search, so that the best possible solution is found at the end of the search; or the possible combinations found can be organized in a way that facilitates selection, for example, the results can be sorted into a list of possible item weights in ascending order. The typical result of a traditional MCWD is that the batch weights become concentrated around the target weight. By moving the target weight it is possible to obtain a different batch distribution, and if for example the target weight is moved back and forth between the lower and upper target limits (while keeping the original lower and upper target limits) in small equal steps for each new batch, it will normally result in a flatter distribution of batch weights. The target weight can also be moved according to a target distribution, for example, a normal distribution, and in this way affect the batch distribution towards a similar shape. Another way to affect the lot distribution is to compare the actual lot distribution with a desired lot distribution and, with a given lot weight, let the difference between the desired and actual distribution represent a preference value for the given lot weight. To facilitate the definition of a desired distribution, the desired distribution can be defined by weight bands, each with an associated percentage of batches or raw materials. Distribution control can be performed in one or two steps. The one-step method can be any of the methods mentioned above, while in a two-step method, a preferred combination is calculated for each individual weight band, and the selection is made from the possibilities found, either by means of the target distribution or the difference between the desired and actual percentage in the given weight bands. Example 2: Controlled batch distribution using the reverse method: The term "reverse method" is sometimes used to describe a process in which several batches are accumulated in parallel, and for each weighed item, a decision process is carried out to determine which unfinished batch (i.e., accumulated low batch) that particular item will be transferred to. The term "reverse" refers to the decision process in which the missing quantity of a batch is a dominant parameter in deciding where the item should go. This method is primarily used when items are grouped into batches using a sorter. This sorter typically contains a weighing station with a conveyor belt where the weight of each item is determined one by one as it passes over the weighing station. A conveyor is located next to the weighing station to carry the weighed items further.Alongside this conveyor are several swinging arms, each capable of picking up a selected item from the conveyor and placing it in a container located next to it. The batches are collected in these containers, and mechanisms are provided for emptying them. To form a specific batch, with this equipment, calculations are performed backwards from a target point or target range, and then used as an acceptance criterion or control mechanism for batch accumulation. Figure 5 illustrates how a target weight range can be achieved. By keeping unfinished batches within a funnel defined by an upper and lower limit for expected item weights, the average item weights needed to complete the batch will always fall between this upper and lower item weight. Apart from the above, the reverse method has similar types of solutions, such as the methods described for batch processing combination, related to targeting a target weight or target weight range. The moving target implementation can be accomplished by defining a new target weight range for each batch started, or the target weight range can be moved during batch accumulation. A method can be implemented where the target is defined by means of weight bands with associated percentages using a modified desired distribution with a feedback value based on the difference between the desired and actual distribution.

Claims

1. A method for generating batches of food items, comprising: • transferring food items to a weight determination device where the weight of the food items is obtained for individual food items and / or food items in groups, • generating a plurality of batches based on the weight obtained from the individual food items and / or food items in groups, wherein the batch generation step is controlled so that the weight of the batches is within a predefined weight range, characterized in that the distribution of the batches within the weight range is predefined.

2. The method according to claim 1, wherein the predefined weight range is defined by a first weight value and a second weight value, wherein the second weight value is greater than the first weight value, and wherein the predefined weight range is adjustable by adjusting at least one of the first weight value and the second weight value. 3.The method according to any of the preceding claims, wherein the predefined weight range is divided into two or more subweight ranges.

4. The method according to claim 3, wherein the batch distribution within a given subweight range selected from the two or more subweight ranges is predefined or substantially flat.

5. The method according to claim 3, wherein the batch weight generated within a given subweight range selected from the two or more subweight ranges is randomly selected. 6.The method according to any one of claims 3 to 5, wherein the predefined underweight ranges are defined by a first underweight value and a second underweight value, wherein the second underweight value is greater than the first underweight value, and wherein the predefined underweight ranges are adjustable by adjusting at least one of the first underweight value and the second underweight value, and / or the predefined underweight ranges are defined by the percentage of batches to be generated within the underweight ranges.

7. The method according to any one of claims 3 to 6, wherein a random target weight value is selected for each two or more underweight ranges, and wherein the selection of a batch weight within each of the two or more underweight ranges comprises selecting a batch weight having a batch weight substantially equal to the target weight value of the selected underweight range. 8.The method according to any of claims 3 to 7, wherein each of the two or more subweight ranges has an associated prioritization variable that indicates the scarcity of lots within the two or more subweight ranges, and wherein the prioritization variable is used as an operating parameter to indicate the prioritization of which of the two or more subweight ranges a lot should be selected from. 9.The method according to claim 8, wherein the step of using the prioritization variable as an operating parameter comprises: • determining whether there exists a combination of food items within a subweight range that has a higher prioritization variable, wherein, if such a batch weight exists, • combining the food items into a batch; otherwise, • determining whether there exists a subweight range that has a lower priority and a lower prioritization variable, followed by a hierarchical order of priority variables.

10. The method according to any of claim 8 or 9, wherein the prioritization variable is determined based on the percentage of batches within each of two or more subweight ranges, such that the higher the percentage, the higher the prioritization variable. 11.The method according to claim 10, wherein the prioritization variable is dynamically adjusted based on the actual number of lots within the subweight range and a predefined percentage number indicating a number of lots to be generated within the subweight range.

12. The method according to any of the preceding claims, wherein the lots are of various predefined weights, and wherein the lots are individually marked according to weight and / or price. 13.A batch processing apparatus for generating batches of food items, comprising: • means for transferring food items to a weight determination means where the weight of the food items is obtained for individual food items and / or food items in groups, • means for generating a plurality of batches based on the weight obtained from the individual food items and / or food items in groups, • a control unit for the control means for generating the plurality of batches such that the weight of the batches is within a predefined weight range, characterized in that the distribution of the batches within the weight range is predefined. 14.The batching apparatus according to claim 13, wherein the batching apparatus comprises a multi-head combination weighing device (MCWD), wherein the food items are weighed individually, or in groups, in a number of weighing devices and wherein the contents of some of the individual items or groups of determined weight are subsequently combined to form the batches. 15.The batch processing apparatus according to claim 13 or 14, wherein the apparatus comprises weighing means for weighing food items individually or in groups, in at least one dynamic weight determination device, and wherein the individual items or groups are subsequently transported by a conveyor along a number of guide members where the individual items or groups are guided together to form batches, the individual food items or groups of food items being guided together are not necessarily transported side by side.

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