Real-Time Carcass Weight Control via RFID and Load Cell Feedback
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Solution Overview
Problem
Current methods for maintaining carcass weight during the chilling process in meat processing facilities result in significant weight loss due to the lack of real-time monitoring and constant weight adjustment, leading to substantial financial losses despite regulatory constraints against weight gain.
Innovation Solution
Integration of wireless load cells and RFID modules on trolleys for continuous, real-time weight measurement and location tracking, enabling the computerized control of water spray zones to maintain carcass weight by adjusting the spray duration based on instantaneous weight changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single scale is used to weigh carcasses before and after chilling, then weight data can be collected for later reference, but real-time monitoring and constant weight adjustment are not possible, resulting in significant weight loss
Solution Approach 1:
The patent implements continuous weight monitoring during the entire chilling process using multiple scales positioned along the track, replacing the conventional single pre-chilling weight measurement. This continuous measurement approach enables real-time detection of weight changes and immediate adjustment of spray water application, eliminating the time delay inherent in before-after weighing methods and minimizing weight loss.
Solution Approach 2:
The system establishes a closed-loop feedback control mechanism where weight measurements from multiple scales are continuously fed back to the control system, which automatically adjusts spray water application rates. This feedback loop enables dynamic response to weight changes, allowing the system to maintain optimal moisture levels and prevent both weight loss and weight gain during chilling.
2Loss of substance
If spray water is applied to maintain carcass moisture, then weight loss is reduced, but carcass weight gain may occur which is prohibited by regulations
Solution Approach 1:
The patent employs dynamic adjustment of spray water application based on real-time weight measurements and environmental conditions. The control system continuously modifies spray rates, duration, and distribution to match actual carcass moisture needs, transitioning from static pre-programmed spray schedules to adaptive real-time control. This dynamic approach prevents both excessive weight loss and prohibited weight gain.
Solution Approach 2:
The system monitors and responds to changes in multiple parameters including carcass weight, temperature, humidity, and spray water characteristics. By detecting and reacting to parameter changes in real-time, the control system adjusts spray water application to maintain carcass weight within regulatory limits, preventing both weight loss and weight gain through adaptive parameter modification.
3Loss of information
If multiple scales are installed along the track for continuous monitoring, then real-time weight data is available, but system complexity and cost increase
Solution Approach 1:
The patent divides the chilling facility into multiple zones with scales positioned at strategic locations along the track. This segmentation approach provides comprehensive weight monitoring coverage without requiring a scale at every possible position. The segmented zone-based system balances information availability with system complexity by placing measurement points where they provide maximum operational insight.
Solution Approach 2:
The control system integrates multiple functions including weight measurement, temperature monitoring, humidity sensing, spray control, and data management into a single unified platform. This multi-functional approach reduces overall system complexity by consolidating control activities and eliminating the need for separate dedicated systems for each function, despite the presence of multiple measurement devices.
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
Significantly reduces carcass weight loss and prevents weight gain by allowing for real-time monitoring and continuous adjustment of the chilling process, providing valuable data for optimizing future processes and reducing revenue loss.
Implementation Method 1
a wireless (remote readable) load cell to provide a continuous, real-time weight measurement of the carcass hanging thereon
Implementation Method 2
Radio Frequency Identification (RFID) to provide the location of the carcasses hanging on the selected trolleys
Implementation Method 3
all the carcasses are refrigerated and sprayed with chilled water to drop the internal temperature of the carcasses to the desired processing temperature
Implementation Method 4
sprayed with chilled water to drop the internal temperature of the carcasses to the desired processing temperature
Data Source
AI summary
Provided, is a fully integrated system to monitor and control carcass weight to minimize weight loss in carcasses during the chilling cycle. This will be accomplished by incorporating a load cell and a radio frequency identification device on the trolley operating on the elevated track system extending through the packing plant, including the carcass chilling rooms. This method and apparatus will provide the needed location and weight data to control a water spray system to maintain a constant carcass weight during the entire chilling cycle.