Conti’2008, 5-6 june, 2008, Timisoara

Authors: Gheorghe Sebestyen, Sergiu Nedevschi, Gavril Saplacan, Mihai Cerghizan, Nicolae Todor and Mircea

Rusu

Towards a Traceability Solution on the Food Supply Chain

◦ Consortium:◦ Technical University of Cluj-Napoca – project

coordinator◦ University of Agricultural Sciences and Veterinary

Medicine, Cluj-Napoca (domain specific)◦ SISTEC SA, Cluj-Napoca (IT partner)◦ Applied Informatics Company SA (IT partner) Project’s duration: 2006/08/01- 2008/08/31 Interdisciplinary project

◦ Goal: to provide a logistic infrastructure for traceability and quality assurance in food industry

Evaluate and analyze worldwide state-of-the-art in food chain traceability,

Evaluate the traceability and quality assurance requirements for Romania, in the context of EU membership

Definition of a generic Traceability and Quality Model for the Romanian food industry

Implementation of a prototype/pilot system for a meat processing unit

Dissemination of the acquired experience to other food processing organizations

The main producers of Standards and Regulations in domain:

International Organization for Standardization – ISO European Food Safety Authority - EFSA and their main

regulatory documents: ISO 9001:2000, ISO 22000 and complementary systems such

as BS 8800 Health and Safety, BRC/IOP Packaging Standard HACCP: The Hazard Analysis and Critical Control Point The White Paper of Food Safety (Bruxelles, Jan 2000), The White paper on the quality systems HACCP, the European Council Directive no. 178/2002 (General Food

Law), regarding the compulsoriness of supplying the traceability information for food products

Directive 2003/89/EC – referring to food ingredients

For good results in quality monitoring and traceability the systems should assure:

◦ Real time parameters values acquisition from production lines◦ Unique products identification◦ Unique identification of product’s composition (sub-products)◦ Storage of processing parameters values ◦ Storage of risks traceability information ◦ Information exchange features for business partners

Documentation of the systems should include:

◦ Quality manual, with quality policy and quality objectives◦ Documented procedures to ensure the conformity of the

product◦ Documented instructions to ensure the control of the risk

parameters◦ Quality & Traceability information records.

There exist several applicative research projects in the field, among which:◦ TRACE - aims to develop generic and sector-

specific traceability systems for use in the food industry (http://www.trace.eu.org)

◦ Auto-ID project - developed at MIT for automatic product identification(RFID) (GS1, EAN UCC)

◦ AGRO program (Romania) - animals identification

Products and material flow

Upstream and downstream traceability data-exchange

Process monitoring

Intrabusiness

Process monitoring

Process monitoring

Figure 1.The Quality and Traceability system view

Interbusiness – B2B

Foodtrace Traceability Portal

Producers Consumers Distributors Authorities

Intrabusiness

Intrabusiness

Operating System & Communication Support Layer (Windows, Unix)

Database Management SystemData Access Layer (Unified Set of Access drivers)

Data Persistency Layer Long Term

PreservationData Store Metadata

CatalogsLDAP, Active

Directory

Application Services Layer (food production monitoring)

Web Service Layer (Web server, EPC, ONS)

Multi-users Interface LayerIntra-business user interfaces

Business to Business user interfaces

System Config.

Decision support

Process monitoring

Product offers

Advertising Quality, Traceability

Foodtrace Graphic User Interface Layer

Specialized Webservices, GUI Description Language

Mobile devices

Embeded devices

Desktop Computers

Industrial Computers

Reception Processing Labeling Storage

Food Processing line

Handheld devices

SensorsBarcode Printer

Barcode Scanner

RFID writer

RFID reader

Wireless I/O devices

Industrial Ethernet

Industrial Computer Process Floor DatabaseIndustrial Ethernet

Router

Serial to Ethernet

Convertor

Wireless AP

Administration LAN

ReceptionBeef casePork case

C.C.P.1B – Traceability parameters:

Temperature (0°C)Time ()Humidity (5%)Oxidation (0.1%) Weight (Kg)

Warehouse C.C.P. 2B - Traceability parameters:

Temperature (0-4°C)Time (12h)Humidity (3%)

Ham Preparation

C.C.P.3B,4B - Traceability parameters:

Temperature (<5°C)

…

d) web service response for parameter inquiry<DataSet> <xs:schema id="Sensor7DataSet"> <xs:element name="IdtrtLogRecords" type="xs:int" minOccurs="0"/> ….</xs:schema><Sensor7DataSet> <Table diffgr:id="Table1" msdata:rowOrder="0"> .... <Time>2008-01-01T17:00:06+02:00</ Time > < MeasuredVal >72 </ MeasuredVal > </Table> ....</ Sensor7DataSet> </diffgr:diffgram></DataSet>

<PROCESSINGUNIT id="PRODUCTION COMPANY"> <TYPE id="UNIT TYPE"/> <ADDRESS id="ADRESS">

… </ADDRESS > <SUBUNIT id="PRODUCTION COMPANY – FIRST SUBUNIT "> <DEPARTMENT id="PROCESSING DEPARTMENT 1"> <PRODUCTIONLINE id=”Meat production line”> <EQUIPMENT id=”Mixing equipment”> <SENSOR name=”Temperature sensor 1” id=”1”> <SENSOR name=”Humidity sensor 2” id=”2”>

… </EQUIPMENT <EQUIPMENT id=”Boiling equipment”> <SENZOR name=”Temperature sensor 7” id=”7”>

… </EQUIPMENT></SUBUNIT> …</PROCESSINGUNIT>

Web service request

a) Desktop view b) PDA viewc) Configuration of a production line

Product technology = set of technological operations

Technological operation

(Production phase)

Material quantities

Input product codes

HACCP( CCP)

Generated GTIN associated with:

- Input lot codes

- Monitored values- Risk parameter values

Allowed risk limits

Product’s Parameter Values

Logical scheme of a technological operation

Traceability information

Inpu

t pro

duct

s id

entif

icat

ion

Inpu

t par

amet

er

iden

tific

atio

n

Diagrama Plan HACCPtcfDiagrameFluxIdtcfDiagrameFluxtctNomenclatorProduseIdDenDiagramatcfPlanHACCPIdtrtDocumentId

tcfEtapeFluxIdtcfEtapeFluxtcfDiagrameFluxIdDenEtapeFluxNrEtapaNrEtapaAnt

FK_EtapeFlux_DiagrameFlux

tcfPC_PCCIdtcfPC_PCCCodDenumiretcfLocatiiIdtcfDiagrameFluxIdtcfEtapeFluxId

FK_PC_PCC_DiagrameFlux

FK_PC_PCC_EtapeFlux

tcfPlanHACCPIdtcfPlanHACCPtcfUnitatiEcIdDescrierePlantcfResUmaneId

FK_DiagrameFlux_PlanHACCP

tcfRiscuriPCCIdtcfRiscuriPCCtctCatElementeRiscIdtcfPC_PCCId

FK_RiscuriCPP_PCC

tcfRiscuriPCCMarimiDeMasuratIdtcfRiscuriPCCMarimiDeMasurattcfRiscuriPCCIdtctPC_PCCMarimiIdtcfTehnologiiIdtcfTehnoMaterialeIdtcfEchipmenteIdValMinVAlMaxtrtDocumenteIdtrtActiuniCorectiveIdObs

FK_RiscuriCPPMarimi_RiscCPP

tcfTehnologiiIdtcfTehnologiitctNomeclatorProduseIdtctTipEchipamenteIdtctCatOperTehIdtcfEtapeFluxIdNrOperNrOperAnterDurataOperDataCreaTipTehno

FK_Tehnologii_EtapaFlux

FK_RiscuriCPPMarimi_Tehnologie

tctPC_PCCMarimiIdtctPC_PCCMarimiDenMarimeDenStiintPCCMarimeTipPC_PCCMarimeIdtctUnitatiDeMasId

FK_RiscuriCPPMarimi_PC_PCCMarimi

tctNomenclatorProduseIdtctNomenclatorProduseDenArticolCodGtintctUnitatiDeMasIdDataCreaObs

FK_DiagrameFlux_NomenclatorProduse

FK_Tehnologii_Nomenclator1

tcfEchipamenteIdtcfEchipamenteDenEchipamenttcfLocatiiIdtcfLiniiProductieIdtcfDepartamenteIdtcfResUmaneIdtctTipEchipamenteIdtrtDocumenteGestIdtctClaseEchipamenteIdDataPFCoordXCoordYCoordZ

FK_RiscuriCPPMarimi_Echipament

tcfTehnoMaterialeIdtcfTehnoMaterialetcfTehnologiiIdtctNomenclatorProduseIdTipIECantitate

FK_TehnoMateriale_Tehnologii

FK_TehnoMateriale_NomenclatorProduse

FK_RiscuriCPPMarimiDeMasurat_TehnoMat

Configuration parameters for:• Production lines• Product recepies• HACCP plans• Workflow diagrams• Monitored parameters• Workflow phases

FoodTrace Framework provides integrated support for development of applications using:◦ Virtual devices with adapted drivers for specific

devices◦ Modbus Message Protocol◦ Partial class diagram for Modbus device

Finally each product from the warehouse has a dataset containing:

quality parameter values risk parameters values

A sample of HACCP log record:Ham/Roast Beef Establishment 1: Cooler Temperature Log

ROOM: Cold-Frozen Raw Meat DATE: 01.01.2008Time Temp Deviation from CL?

(Check if yes)If yes, Action? Monitored by: Verified by:

08:00 -15.0ºC No No Smith John Supervisor

08:05 -14.9ºC No No Smith John Supervisor

… … … … … …

◦ Modbus, Profibus Communications protocols◦ Simex-TRS◦ OPC, SCADA◦ SOA – Service Oriented Architecture◦ SOAP – Simple Object Access Protocol◦ MS SQL 2005◦ Web Services◦ XML, XSLT, XAML, HTTP◦ C#, .NET, ASP.NET

Benefits• Automatic real-time monitoring of food processing lines. • risk monitoring for food generated disease;• products identification • Infrastructure for food lots recall in case of incidents;• Increased confidence in the food product suppliers;• Improved quality of life (health and socio-economic).

BarriersThe barriers may include:• Lack of full standardization• Absence of complete local specified legal requirements;• Financial constraints;•Lack of human expertise and/or technical support;• Inadequate infrastructure and facilities; • Inadequate communications.

Using standards and highly accepted data exchange technologies the proposed system offers an open, flexible and scalable solution.