Poultry Packaging System Weight Matching and Order Allocation
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Solution Overview
Problem
Current poultry packaging systems face inefficiencies due to variations in portion sizes, leading to increased giveaway and waste, as they struggle to accurately match poultry weights to customer orders within set tolerances, resulting in 'bulk' or 'overweight' products being sold.
Innovation Solution
A system comprising a receiving unit for orders, a measurement unit for poultry weights, a recommendation unit to match orders with available poultry based on weight and quality parameters, and a control unit to direct processing, ensuring optimal allocation and packaging to minimize giveaway and enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional poultry packaging systems package portions without precise weight matching, then packaging speed is maintained, but giveaway increases and manufacturing precision deteriorates
Solution Approach 1:
The system performs preliminary weighing and classification of individual poultry portions before packaging. By pre-sorting portions based on their weights and matching them to specific order requirements, the system ensures accurate batch weights without compromising packaging speed. This advance preparation allows portions to be quickly assembled into correct batches during packaging.
Solution Approach 2:
The system continuously monitors the weight of portions being packaged and provides real-time feedback to adjust the selection of individual portions. The control unit tracks cumulative batch weight and dynamically selects additional portions to meet target weights within tolerances, preventing both underweight and overweight packaging that would cause giveaway.
2Manufacturing precision
If the system implements precise weight matching for all orders, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The system uses a single multi-functional apparatus that combines weighing, classification, storage, and selection functions. Rather than separate dedicated devices for each function, the system integrates these operations into one modular unit that can handle multiple order types and portion specifications, reducing overall system complexity while maintaining precision.
Solution Approach 2:
The control unit automatically performs weight matching, portion selection, and batch assembly without requiring manual intervention. The system self-regulates by comparing actual batch weights against target weights and autonomously adjusting portion selection to meet specifications, eliminating the need for complex manual monitoring and adjustment mechanisms.
3Manufacturing precision
If portions are sorted and matched by weight before packaging, then manufacturing precision improves, but productivity decreases
Solution Approach 1:
The system maintains continuous operation by processing portions through weighing, classification, and packaging in an uninterrupted flow. Portions that do not immediately match current order requirements are automatically stored and reused for subsequent orders, ensuring that no portion is wasted and the system operates continuously without idle time or batch interruptions.
Solution Approach 2:
The system dynamically adjusts its operation based on real-time conditions, including available portions, current orders, and weight tolerances. The control unit flexibly reconfigures batch composition and selection criteria to optimize both precision and throughput, adapting to varying demand patterns and portion availability without reducing overall productivity.
4Manufacturing precision
If the system rejects batches that do not meet weight tolerances, then manufacturing precision is maintained, but loss of substance increases due to bulk selling
Solution Approach 1:
The system adjusts selection parameters and weight tolerance thresholds based on the specific characteristics of available portions and order requirements. By flexibly modifying acceptance criteria within acceptable ranges, the system can incorporate portions that would otherwise be rejected, converting potential waste into compliant batches while maintaining quality standards.
Solution Approach 2:
Instead of discarding portions that slightly miss weight targets, the system recovers them for use in subsequent batches. The control unit tracks underweight portions and automatically incorporates them into future batch assemblies where they can reach acceptable weights, transforming what would be waste into valuable product and reducing overall loss.
Data Source
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AI summary
Apparatus for controlling a poultry packaging system is provided. The apparatus comprises a first receiving unit operable to receive a plurality of orders for poultry product, wherein said poultry product is either a whole or a portion of a poultry bird;a second receiving unit operable to receive at least one measurable parameter of at least one poultry bird from a measurement unit;a recommendation unit operable to determine which of the plurality of received orders best corresponds to the received at least one measurable parameter, and a control unit operable transmit a signal to a poultry processing system such that said poultry processing system processes the at least one poultry bird in accordance with the determined order.