Antimicrobial Application Control for Real-Time Treatment Adjustment
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Solution Overview
Problem
Industrial plant operations face challenges in efficiently managing and monitoring antimicrobial treatment processes for meat products due to information gaps between complex processes, equipment, and stakeholders, leading to overlooked interactions and potential synergies.
Innovation Solution
An antimicrobial application system with integrated controls, including a rotary screen filter, spray nozzles, dip tanks, suction boxes, and capture units with activated carbon filters, along with a controller that executes monitoring programs to analyze real-time data and initiate responses to trigger events, ensuring effective antimicrobial treatment and solution recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional divisional methods are used to manage plant operations, then operational simplicity is maintained, but information gaps and missed synergies occur between processes and equipment
Solution Approach 1:
The patent merges previously divided operational divisions into an integrated system where the controller centrally coordinates all equipment (rotary screen filter, spray nozzles, dip tank, suction box, capture units). This integration eliminates information gaps by enabling real-time data exchange between all components while the controller synthesizes operational decisions, thus resolving the contradiction between information completeness and operational simplicity.
Solution Approach 2:
The controller serves multiple functions simultaneously: it monitors equipment status, analyzes real-time data, determines operational decisions, and coordinates all processing steps. This multi-functional approach consolidates what were previously separate operational divisions into a single universal control system, reducing information loss while maintaining operational manageability.
2Reliability
If real-time monitoring and control is implemented, then treatment effectiveness is improved, but system complexity increases
Solution Approach 1:
The system implements continuous feedback loops where sensors monitor antimicrobial solution concentration, flow rate, and equipment status in real-time. The controller receives this data, compares it against target parameters, and automatically adjusts operational decisions to maintain optimal treatment effectiveness. This feedback mechanism ensures reliability while the automated nature of the controller keeps the system manageable despite its complexity.
Solution Approach 2:
The controller autonomously monitors all equipment, analyzes data trends, and makes operational adjustments without requiring constant human intervention. The system self-regulates antimicrobial solution delivery, filter operation, and equipment coordination, thereby ensuring consistent treatment effectiveness while reducing the operational burden despite the sophisticated control architecture.
3Productivity
If integrated control system is used, then resource optimization is achieved, but initial system complexity increases
Solution Approach 1:
The integrated control system enables continuous monitoring and adjustment of antimicrobial treatment processes, ensuring that all equipment operates optimally at all times. The controller maintains continuous data flow from sensors and continuously adjusts operational parameters, eliminating idle time and ensuring maximum productivity. This continuous operation justifies the initial complexity investment by delivering sustained efficiency gains.
Solution Approach 2:
The controller dynamically adjusts operational parameters (antimicrobial solution concentration, flow rates, equipment timing) based on real-time conditions and historical data analysis. This parameter optimization maximizes resource utilization and production efficiency. The ability to adapt parameters in real-time compensates for the initial system complexity by delivering measurable productivity improvements through precise control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances the efficiency and effectiveness of antimicrobial treatment by maintaining optimal antimicrobial solution concentrations, reducing microbial contaminants, and optimizing resource usage through real-time monitoring and adjustment, thereby improving food safety and production efficiency.
Implementation Method 1
a rotary screen filter comprising a rotatable, cylindrical body defined by a screen and into which antimicrobial treatment solution is received for filtration of solid components
Implementation Method 2
a capture unit comprising a series of activated carbon filters to filter antimicrobial component from an antimicrobial treatment solution
Data Source
AI summary
A control system for monitoring an antimicrobial application system may include a controller having a monitoring program including an operations unit and an interface unit. The operations unit may include a sensor module operatively coupled to a plurality of sensors positioned to detect operation data associated with the application system in real-time. An adjustment module may adjust the operation of the application system. An analysis module may analyze real-time operation data and initiate a specified response when the analysis indicates that a trigger event has occurred. The response may include issuing a notification to a notification device or initiating the adjustment module to perform a control operation to modify the operation of the antimicrobial application system. A remote monitoring center may control multiple and remote application systems. Mobile devices and a control panel may be operable to interface with operations of the antimicrobial application system via the control system.