Automated Peeling with Sorted Secondary Processing for Lower Product Loss
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Solution Overview
Problem
Existing peeling systems face challenges in minimizing good product loss while maximizing peel removal, particularly with inconsistent peel qualities among products, leading to over-peeling or under-peeling issues, and high energy consumption.
Innovation Solution
A peeling system comprising a primary peeler, sorting device, and secondary peeler, with a peel control system to monitor and adjust the peeling process based on detected peel quality, ensuring consistent product quality and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the peeler is adjusted to be more aggressive to remove peel from difficult products, then peel removal efficiency is improved, but product loss increases due to over-peeling of easy-to-peel products
Solution Approach 1:
The system segments the product flow into two separate streams: easily peeled products and difficult-to-peel products. This is achieved through a sorting device that diverts difficult-to-peel products into a secondary peeling line, while easily peeled products proceed through the primary peeling line. This segmentation allows each peeling line to be optimized for its specific product type, resolving the contradiction between peel removal efficiency and product loss.
2Loss of substance
If the peeler is adjusted to be less aggressive to minimize product loss, then product yield is improved, but peel removal completeness deteriorates for difficult-to-peel products
Solution Approach 1:
The system applies different peeling qualities to different product streams. The primary peeling line uses gentler peeling conditions optimized for easily peeled products, while the secondary peeling line uses more aggressive peeling conditions for difficult-to-peel products. This local quality differentiation ensures each product type receives the appropriate peeling intensity, achieving both high product yield and complete peel removal.
3Device complexity
If a single peeling device is used to handle all products, then device complexity is reduced, but the ability to handle inconsistent peel qualities deteriorates
Solution Approach 1:
The system dynamically adapts to different product types through an automated sorting device that identifies difficult-to-peel products and redirects them to the secondary peeling line. This dynamic routing allows the system to handle inconsistent peel qualities effectively while maintaining a relatively simple overall structure. The sorting device acts as an intelligent intermediary that enables adaptability without requiring a completely complex system redesign.
4Measurement precision
If optical inspection devices are used to monitor peel quality, then measurement precision is improved, but system complexity and energy consumption increase
Solution Approach 1:
The sorting device performs preliminary action by identifying and diverting difficult-to-peel products before they enter the primary peeling line. This preliminary sorting based on product characteristics allows the system to pre-configure the appropriate peeling line, reducing the need for complex real-time optical inspection and adjustment systems during the peeling process itself.
Data Source
AI summary
A peeling process and system comprising a primary peeling device; a sorting device arranged to sort product output from the primary peeling device into peeled product and partially peeled product; a secondary peeling device arranged to receive the partially peeled product output from the sorting device; and a peel control system to monitor the peel quality of product detected in at least one position after the primary peeling device and control the peeling system in response to same.