jeffrey roberts director of engineering and applications reducing … · 2019-10-08 · • through...

Jeffrey Roberts

Reducing Risk, Recalls, and Rework with Bizerba‘s Vision Solutions

Director of Engineering and Applications

Bizerba 150+ Years of Industry ExperienceReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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Bizerba 150+ Years of Industry ExperienceReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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Bizerba 150+ Years of Industry ExperienceReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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Bizerba 35 Years of Machine VisionReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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410 Currently Running Vision Inspection Systems in the Food Industry World Wide.

Vision SolutionsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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LabelSecure - S LabelSecure PackSecure SealSecure ClassCheck

Vision Solution – integrated Thermoformer

Reducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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a. Presence of undeclared allergens due to cross-contamination — for example when a product containing a specific allergen is mixed with a product that does not contain the ingredient and labelling is not changed to acknowledge the fact.

b. Contamination with pathogenic bacteria due to improper personal hygiene or product handling practices

c. Growth of pathogenic bacteria due to temperature abuse — for example, rework material that requires refrigeration is left at room temperature overnight and used as an ingredient in the next day's production. Another example of rework mishandling would be to allow frozen rework to thaw at room temperature rather than at refrigeration temperature.

d. Growth of pathogenic bacteria due to time abuse — for example, rework material stored for long period of time due to improper stock rotation

e. Presence of undeclared restricted ingredients in the final product — for example, addition of cured meat to a fresh meat product, which should not contain curing agents

Causes of Rework/RecallsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

08.10.2019(n.d.). Agriculture: Province of Manitoba. Retrieved from https://www.gov.mb.ca/agriculture/food-safety/at-the-food-processor/handling-rework.html

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US Department of Agriculture. (January 19, 2018). Number of USDA food recalled pounds in the United States from 2010 to 2017 (in millions) [Graph]. In Statista. Retrieved August 27, 2019, from https://www.statista.com/statistics/618343/number-of-usda-food-recalled-pounds-us/

RecallsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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US Department of Agriculture. (January 19, 2018). Number of USDA food recalls in the United States from 2010 to 2017 [Graph]. In Statista. Retrieved August 27, 2019, from https://www.statista.com/statistics/947646/number-of-usda-food-recalls-us

RecallsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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FSM. (February 6, 2018). Leading causes of food recalls in the United States in 2017 [Graph]. In Statista. Retrieved August 27, 2019, from https://www.statista.com/statistics/947726/leading-causes-of-food-recalls-us/

a. Timeb. Laborc. Utilitiesd. Materialse. Moralef. Equipment capacity (fewer orders)g. Equipment maintenanceh. Increase opportunity for errorsi. Traceability and Lot Control

Cost of Rework/RecallsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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• Through the use of Bizerba‘s Vision Systems and ensuring the quality and correctness of packaging and labeling the first time, rework and the risks and costs associated with rework is removed.

Removing ReworkReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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1. Customer Satisfactiona. Shelf life

• Consistent Packaging Quality Encourages Customer Purchases• Proper Seals Ensures Maximum Longevity

b. Foreign Contaminantsc. Appearance

2. Profitabilitya. Labor

• Automation reduces labor overhead• Correct Packaging and Labeling reduces labor hours

b. Logistics• Correct Packaging and Labeling reduces returns from customers

c. Branding• Consistent Packaging Quality Improves brand value

Identifying the RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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1.Customer Satisfactiona.Shelf life

•Consistent Packaging Quality Encourages Customer Purchases

Removing RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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1.Customer Satisfactiona.Shelf life

•Proper Seals Ensures Maximum Longevity

Removing RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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1.Customer Satisfactionb.Foreign Contaminants

Removing RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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1.Customer Satisfactionc.Appearance• Fat• Holes• Missing pieces• Broken Pieces

Removing RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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2.Profitabilitya.Labor

•Check every package•Correct Packaging and Labeling reduces labor hours•Automation reduces labor overhead

Removing RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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2.Profitabilityb.Logistics

•Correct Packaging and Labeling reduces returns from customers•Undeclared Allergens due to wrong labels

Removing RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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2.Profitabilityc.Branding

•Consistent Packaging Quality Improves brand value

Removing RiskReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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ApplicationsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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LabelSecure SealSecure PackSecure ClassCheck

Seal check Label presence Option Label recognition Option Label position Option OCR and code reading Option Consistency of labels Option Product appearance Option Option Option Pack appearance Option Option Option

1.Automatic Case Packing

TrendsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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The end of line robot processes the packs according to the mapping sent by the vision system

The ink-jet printer prints a spot closed to the use-by date onto faulty packs

Turn Key SolutionsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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Possible to condense and integrate LDI 160 1T 1B with XRE-D, MD and LabelSecure 1T 1B in 3.26m foot print.

Turn Key SolutionsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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Possible to condense and integrate GLM-I 150 1T 1B with LDI 160 T MD and LabelSecure 1T 1B in under 5m.

AdaptationsReducing Recalls, Rework, and Risk with Bizerba‘s Vision Solutions

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Over existing conveyor LabelSecure. Depending on available space and gap in belts for bottom label inspection.

Jeffrey RobertsDirector of Engineering and Applications

Bizerba Engineered Solutions5200 F Anthony RdSandston, VA 23150USA

T: +1 804 822 3908F: +1 804 649 0310M: +1 804 787 3004 Jeffrey.Roberts@Bizerba.com