Antimicrobial Application Controls 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 control and monitoring equipment, 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 adjustments or notifications based on trigger events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional division-based operation management is used, then operational simplicity is maintained, but information gaps and missed synergies occur between processes and equipment
Solution Approach 1:
The patent merges multiple previously separate operational divisions into a single integrated control system. The controller consolidates control of the rotary screen filter, spray nozzles, dip tank, conveyer, suction box, and capture unit into one unified system, eliminating information gaps between divisions while maintaining operational simplicity through centralized management.
Solution Approach 2:
The integrated control system performs multiple functions simultaneously - it controls antimicrobial application, monitors solution levels, manages filtration, operates conveyors, and coordinates capture units all through one universal controller. This multi-functional approach reduces information loss while managing complexity through consolidation rather than proliferation of separate control systems.
2Manufacturing precision
If manual monitoring and adjustment of antimicrobial treatment is used, then operational simplicity is maintained, but treatment consistency and efficiency decrease
Solution Approach 1:
The controller continuously monitors operational parameters such as dip tank solution levels, filter status, and equipment operation. This feedback mechanism ensures consistent antimicrobial application by automatically adjusting operations based on real-time conditions, maintaining precision while reducing manual intervention requirements through automated decision-making algorithms.
Solution Approach 2:
The system performs self-monitoring and self-adjustment of antimicrobial treatment parameters. The controller automatically detects when adjustments are needed and implements them without manual intervention, ensuring treatment consistency while simplifying operator tasks to monitoring and oversight rather than hands-on adjustment.
3Productivity
If antimicrobial solution is not recycled and captured, then operational simplicity is maintained, but resource efficiency and cost effectiveness decrease
Solution Approach 1:
Instead of discarding used antimicrobial solution, the system recovers it through the capture unit and recycles it back through the rotary screen filter. This closed-loop approach maximizes resource efficiency by continuously reusing the antimicrobial solution, reducing waste and cost while managing complexity through integrated automation that handles the recycling process without significant manual intervention.
Solution Approach 2:
The recycling system maintains continuous useful action by constantly circulating and reusing the antimicrobial solution rather than allowing it to be discarded. The controller ensures uninterrupted operation of the filtration and recapture processes, maintaining solution availability and resource efficiency throughout operational cycles.
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 ensuring consistent application and recycling of antimicrobial solutions, reducing microbial contaminants on meat products while optimizing resource usage and maintaining operational 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.