Interstation Food Line Control for Consistent Product Quality
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Solution Overview
Problem
Existing food processing lines lack effective control mechanisms for optimizing process parameters across multiple stations, leading to inefficiencies and inconsistencies in food product quality.
Innovation Solution
A food process line with an interstation control system that connects actuators and sensors across multiple stations, allowing for intelligent feedback and anticipation of settings based on data from downstream sensors to control actuators upstream, thereby enhancing process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional food processing lines are used without advanced control mechanisms, then the system is simpler and easier to operate, but the food quality consistency and production efficiency are poor
Solution Approach 1:
The patent implements feedback control by connecting sensors at downstream stations (e.g., forming station) to actuators at upstream stations (e.g., pump station). The sensor data about food product characteristics is fed back to automatically adjust processing parameters, ensuring consistent quality without manual intervention.
Solution Approach 2:
The interstation control system performs preliminary actions by adjusting upstream processing parameters based on anticipated needs. For example, viscosity measurements from the pump station are used to pre-adjust forming station parameters before the food mass arrives, ensuring optimal processing conditions.
2Productivity
If real-time monitoring and control across multiple stations are implemented, then processing efficiency and quality control improve, but the system complexity and cost increase
Solution Approach 1:
The interstation control system serves multiple functions: it monitors food product characteristics, automatically adjusts processing parameters across different stations, and coordinates actuators and sensors. This multi-functionality improves productivity while limiting the need for separate specialized control systems for each station.
Solution Approach 2:
The patent merges the control functions of multiple stations into a single interstation control system. By combining sensor data acquisition, data processing, and actuator control into one integrated system, the patent achieves coordinated control across stations without requiring separate complex control systems for each station.
3Reliability
If processing parameters are adjusted based on real-time sensor data from downstream stations, then food quality and consistency improve, but the control system complexity increases
Solution Approach 1:
The system uses feedback control where sensors at downstream stations (e.g., forming station measuring food product dimensions) provide real-time data to the interstation control system, which automatically adjusts upstream processing parameters (e.g., pump speed, viscosity) to maintain consistent quality.
Solution Approach 2:
The patent replaces manual mechanical adjustment of processing parameters with an automated electronic control system. The interstation control system uses sensor data to automatically control actuators, eliminating the need for manual monitoring and adjustment, thereby improving reliability while keeping the control system manageable through automation.
Data Source
AI summary
A food process line and method are provided for processing food in a food process line. The food process line includes at least two of the following process line stations: a food preparation station, cold store, pump station or forming station for a pumpable food mass, or a dry coater, wet coating device, fryer, heater or freezer for the discrete food products. In each process line station at least one process step is carried out, the process line station having one or more actuators and/or one or more sensors. The food process line comprises an interstation control system configured to control an actuator of a first process line station on the basis of data from a sensor of a second process line station.