Automation plays a central role in modern food and drink manufacturing, with high-tech machinery and equipment enabling firms to boost productivity, cut costs and improve product quality.
And as technology evolves, machinery developers are embracing new solutions that further elevate manufacturing processes.
Below, Food Manufacture documents some of the latest automation news from firms including Ishida, Mettler Toledo, Igus and DC Norris.
Ishida launches AI software
Japanese machinery manufacturer Ishida unveiled the new Sentinel 5.0 software at Gulfood Manufacturing in November 2024, a new solution that has been designed to elevate production and packing automation to “another level” through the use of AI.
Sentinel 5.0 combines machine performance monitoring with data capture to provide food manufacturers with smarter, consolidated and in-depth analysis of entire production lines. The software can connect and communicate with both Ishida and non-Ishida machines and once installed can “learn” how each machine operates and gathers data on performance.
Once Sentinel 5.0 has been able to communicate with other machinery, it can increase speed and efficiencies across the full production and packing line by notifying operators about the accuracy and consistency of filling machines, inconsistent line speeds or excessive downtime. It is also capable of alerting operators to machinery that is not working at full capacity and diagnosing why this is the case.
“One of the main benefits of AI is that it can instantly identify deviations from standard operating protocols,” an Ishida spokesperson said.
“Errors can be corrected much quicker so that any negative impact can be kept to a minimum.”
Meanwhile, Ishida has introduced AirScan, a new solution that works to detect leaks within Modified Atmosphere Packaging (MAP) before products leave the factory. AirScan works by identifying CO2 from holes as small as 0.5mm in sealed MAP products at speeds of up to 160 packs per minute.
“The Ishida AirScan offers fast, reliable and non-destructive inline leak detection so that every pack on the line is inspected without compromising on throughput,” the spokesperson added.
“Investment into quality control measures can offer quick commercial returns by ensuring 100% seal integrity of MAP.”
Mettler Toledo introduces new checkweighing technologies
Global machinery firm Mettler Toledo has launched its new CM (checkweighing and metal detection) and CX (checkweighing and x-ray) combination systems.
The new combination inspection systems integrate the new M30 R-Series metal detectors and X2 Series of x-ray inspection systems into high-precision C-Series checkweighers that provide food manufacturers with the flexibility to choose the right system to suit their individual application, packaging and budget requirements.
“The new Combination Systems offer simplified operation, a space-saving design and reduced total cost of ownership,” said Frank Borrmann, market manager for the checkweighing and vision strategic business unit at Mettler-Toledo Garvens.
“The integration of the new M30 R-Series and X2 Series also offers higher detection sensitivity, providing an added layer of security and quality control.”
By integrating the C-Series checkweighers with the M30 R-Series metal detectors, the CM Combination System creates a flexible solution that enhances the portfolio of combination systems with an optimised price-to-performance ratio. The C-Series checkweighers deliver “unparalleled” accuracy and precision in weight measurement, while the M30 R-Series metal detectors are equipped to detect a range of ferrous and non-ferrous metals, including aluminium and stainless-steel contaminants.
For high-end applications, these systems can be configured with Mettler-Toledo FlashCell load cell technology, which means that the checkweighers can complete precision weighing checks at higher product throughputs of up to 800ppm.
Meanwhile, the CX Combination System integrates the C-Series checkweighers with X2 Series x-ray inspection systems, creating a “powerful solution for comprehensive quality control”.
The X2 Series x-ray inspection systems feature ContamPlus Software, which runs over 30 inspection algorithms continuously and simultaneously, detecting hard-to-find foreign bodies while reducing waste. The X2 Series also features the HiGain detector technology which generates sharper images to deliver improved contaminant detection.
“The CX combination solution offers unparalleled accuracy and consistency for various packaging needs,” added Borrmann.
“By bringing checkweighing and x-ray inspection technologies together into one solution, manufacturers can benefit from increased productivity and decreased total cost of ownership.”
igus uses robots for pizza picking and packing
Motion plastics manufacturer igus has partnered with research institutes and the University of Bonn to develop a language model for low-cost automation solutions in order picking.
During a hackathon hosted by igus in Cologne, Germany, the partners developed “advanced but cost-effective automation solutions” that involved programming a robot to recognise the right products based on voice instructions from employees.
During the hackathon, three teams worked on a real-world situation where an igus ReBeL robotic arm was placed in front of a conveyor belt with various pizza products. Using a webcam and an AI-based segmentation system, the system identified the various objects on the conveyor belt and their position.
The language model then mapped these objects to the right products, based on the language instructions, and placed the products in the correct boxes by following the instructions of the language model. The project has helped igus display the potential for real manufacturing processes to be automated with low-cost robotics to customers.
Reflecting on the day, Alexander Mühlens, head of low-cost automation at igus, said: “The cooperation with these institutes gives us the opportunity to show our customers what is possible with the help of AI and low-cost robotics.
“Our dream is to be able to easily control robots via a voice command, in any application.”
“We are very pleased to be able to use igus’ robotics know-how to develop real proof-of-concepts for customers in industry,” added Alexander Zorn from the Fraunhofer IAIS science institute.
“The combination of artificial intelligence and robotics offers enormous potential for automating work processes and making them more efficient.”
DC Norris unveils the AutoCan 1000
Food processing equipment manufacturer DC Norris launched the AutoCan 1000 into the UK and overseas market earlier this year.
The new can processing system is capable of handling up to 1,000 A10 cans per hour and combines can pre-rinsing, opening, emptying, washing and crushing. Other features include interlocked guarding and safety switches that provide operator with protection, pre-rinse and water blow-off nozzles that prevent contamination and an integrated electric can crusher that reduces the volume of can processing waste and prepares cans for streamlined collection and recycling.
Designed to maximise productivity while minimising floor space and labour requirements, the AutoCan 1000 has been tailored for industrial-scale can processors. It also possesses easily interchangeable components that enable quick adaptation to different standard can sizes.
“The AutoCan 1000 addresses common bottlenecks in can processing,” said David Norris, managing director at DC Norris.
“By integrating multiple functions into a single compact system, it allows one operator to efficiently and safely manage the entire process, reducing labour costs and utility usage.
“Meanwhile, its compact design is ideal for facilities with limited floor space, while its ease of use and adaptability make it a practical addition to any production line.”
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