Over-Line Vision Process Control (VPC) Solutions for Bakery Production
100% Inspection at Multiple Stages of Food Production
Vision Process Control solutions are powerful tools used in the food manufacturing industry for controlling and improving production process, increasing product consistency, and reducing waste. Vision Process Control solutions are installed at key production stages where data visualization and optional direct feedback integration can automatically act to keep process performance on target. Combining process control modules with product inspection, and rejection of the final product, provides you with the best possible results in terms of process understanding, improvement, and product quality.
Features
- From product counting to key parameters monitoring, Feedback Loops make it possible to automatically modify the parameters of single processing phases on the basis of the analysis of their output
- A set of functional modules to meet any production and management needs in terms of data collection, analysis, and reporting
- Can be integrated into a specific robot guidance application
Benefits
- Improved production processes
- Increased product consistency
- Reduced labor costs
- Reduced waste
Common System Configurations
Communication Throughout the Process
Vision-Based Lane Balancing
Distributed Vision-Based Process Control
Vision Process Control (VPC) allows you to control the output of every step of your process. We provide a range of vision system modules designed to monitor a specific production process step.
Continuous Monitoring for Better Quality Control
Vision Technology can be used to provide accurate product counting in any location along the line, as a data input to any OEE (Overall Equipment Efficiency) or SPC (Statistical Process Control) third party software. 2D/shape, 3D/height, and color can be checked not only during the final inspection, but also after each phase of your production process, to ensure every step is working at its best and to be able to identify the causes of any possible defects in your product. Single or multiple vision control stations continuously monitor the key product attributes after single production process steps. The supervision station displays real time information (statistics, tables, trend charts, histograms) and automatically generates warnings when the process parameters move outside the operator defined limits.The data can also be added to a database allowing further analysis and correlation of this data to assist in improving the production process and the quality of the finished product.
Automatic Feedback Loops
Through feedback loops, it is possible to automatically modify the parameters of single processing phases on the basis of the analysis of their output.
Real-Time Adjustments for Better Efficiency
Automatic Oven Control
By installing an EyePro Vision System at the oven exit, it is possible to integrate our exclusive Real-Time Oven Feedback module, which uses the measured bake color to automatically adjust the oven settings.
Key benefits:
- Automatic control of the last two zones of the oven
- Objective bake color measurement
- Continuous automatic monitoring of product quality
- Automatic real-time actions to correct out of specification situations
- Improved product color consistency over time
- Waste reduction
Automatic Press Control
By installing an EyePro Vision System after the press on a flour tortilla line, it is possible to integrate our exclusive Real-Time Press Feedback module, which uses the measured diameters to automatically adjust the press settings.
Key benefits:
- Automatic control of the tortilla press settings
- Objective tortilla diameter measurement
- Continuous automatic monitoring of product quality
- Automatic real time actions to correct out of specification situations
- Improved product size consistency over time
- Waste reduction
The system continuously monitors key product features and automatically adjusts, in real time, on the basis of the obtained results and the settings of the upstream processing equipment. The combination of vision technology and real-time feedback control improves the product consistency and at the same time reduces the waste due to incorrect production equipment operation.
- Distributed Vision Process Control (VPC) modules monitor the output of production process steps singularly, allowing you to fully understand and optimize your process.
- The data, collected by a Centralized Control Station, can either be displayed in real time or analyzed at a later stage (through generation of customized off-line reports).
- Feedback Loops allow to you to modify key process parameters automatically and in real time, on the basis of the information collected by the Vision module; in this way, you will be able to achieve the best product quality and line efficiency.
- Furthermore, Vision gives also the capability to control and drive other parts of the process, such as scoring or topping deposition.
Vision-Based Robot Guidance
All-In-One Solution
KPM Vision Inspection Solutions can be integrated into a specific robot guidance applications. Our team will work in partnership with your qualified robot system integrator in order to provide a complete solution based on our state of the art vision inspection technology. This allows a customer to deploy vision inspection (and advanced data analysis and reporting) as well as robot guidance, using just one vision module.
Data Analysis & Reporting
KPM offers a set of functional modules to meet any production and management needs in terms of data collection, statistical analysis and reporting.
The Information You Need, In Real Time
- Real-time data display via operator interface (HMI)
- Automatic storage on database and accessibility through a client software
- Data collection and integration from different sources within the bakery (vision, scaling, temperature, other control devices and equipment)
- Capability to centralize data from multiple plants into a corporate data warehouse
- Generate a full set of reports (selecting the preferred visualization, product type, product features of interest, inspection time, file format)
- Choose from included pre-defined reports or customize for your specific needs
- Automatic reports delivery to a customized recipients list
Specifications
Resources
We've highlighted a few knowledge center resources here to help you understand the product better. Please also visit our Knowledge Center for additional information and downloads, and don't forget that our team is always happy to answer any questions you have.
