Food Portioning and Stacking With In-Line Weight Feedback
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Solution Overview
Problem
Existing food processing systems struggle to produce uniform large food portions with precise weight control, especially when dealing with varying product composition, requiring manual adjustments and separate weight checks due to fluctuations in slice weight and portion weight.
Innovation Solution
A system with a transport device and scale positioned downstream of the portioning section to measure the weight of partial portions and food portions, allowing for dynamic adjustments to ensure consistent weight, including a distribution unit to separate and space portions for accurate weighing and a control device to adjust cutting parameters based on weight measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high cutting speed is used to achieve high product throughput, then productivity is improved, but weight uniformity of portions deteriorates
Solution Approach 1:
The system incorporates scales that measure the weight of each portion in real-time and feeds this information back to the control device. The control device then dynamically adjusts cutting parameters (blade speed, feed rate, slice thickness) to compensate for weight deviations, ensuring uniform portion weights even at high cutting speeds of up to 2,000 slices per minute.
Solution Approach 2:
The system dynamically adjusts cutting parameters based on real-time weight measurements. The control device modifies blade rotation speed, product feed rate, and slice thickness on-the-fly to maintain consistent portion weights, transitioning from static pre-set parameters to dynamic adaptive control.
2Adaptability or versatility
If multiple partial portions are stacked to form large food portions, then portion size flexibility is improved, but process complexity increases
Solution Approach 1:
The system divides the portion formation process into two independent stages: (1) a standardized portioning section that creates uniform partial portions, and (2) a stacking device that assembles these partial portions into larger food portions. This segmentation allows the portioning section to operate at high speed with simple mechanics, while the stacking device handles the complexity of assembling multiple portions according to desired final sizes.
Solution Approach 2:
The portioning section performs preliminary portioning by creating standardized partial portions with consistent weights and dimensions before they are stacked. This preliminary action simplifies the subsequent stacking process, as the control device only needs to assemble pre-formed uniform units rather than controlling the entire portion formation process from scratch.
3Productivity
If portions are produced in close succession to maintain high throughput, then productivity is improved, but weight measurement accuracy deteriorates
Solution Approach 1:
The system introduces intermediate buffer zones and timing mechanisms between consecutive portion measurements. The control device coordinates the measurement, cutting, and stacking operations with precise timing, ensuring that each portion is fully formed and stationary on the scale before the next portion begins its formation, thereby eliminating measurement interference despite high throughput.
4Manufacturing precision
If manual adjustments are made to achieve target weight, then weight precision is improved, but productivity deteriorates
Solution Approach 1:
The system implements self-service automated control where the control device automatically adjusts cutting parameters based on real-time weight measurements from the scales. This eliminates the need for manual intervention, as the system autonomously compensates for weight deviations by modifying blade speed, feed rate, or slice thickness, thereby maintaining high productivity while achieving precise target weights.
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
A food processing system comprises a slicing device configured to cut slices of food products and form portions of one or more slices in a portioning section. A conveying device is provided downstream of the portioning section, and the portioning section includes a conveyor that transfers the portions to the conveying device. The system includes a stacking device configured to form a food portion consisting of several portions. The conveying device is configured to transport the portions onto a product platform of the stacking device, and the conveying device and/or the stacking device includes a scale for measuring the weight of the portions and/or the food portion.