industrial robots for flexible food manufacturing · flexible food manufacturing. contents •...
TRANSCRIPT
Farah Bader2nd year PhD student at Centre for SMART
Industrial Robots for Flexible Food Manufacturing
Contents
• Status of food industry & the need for change
• Industrial Robots for food manufacturing
• Challenges to Uptake of Industrial Robots by Food Industry
• Research focus
• Future Work
2
Food Industry
3
Continuously changing demands by consumers, government and workforce poses increased pressure on organisations to improve their manufacturing operations
Current Status
Need for Change
Assembly, packaging and palletizing lines are crowded with employees or packed with fixed, dedicated machinery which produce mass quantities of a single product
Benefits
Industrial Robots for the Food Industry
4
Bottleneck Situations
Ideal Allocations
Hazardous or unfavorable environments Simple and repetitive tasks
Increase; productivity, flexibility, configurability, hygiene,
safety, legislation compliance and efficiency
Reduce;cost, direct labor, floor space and production time
Improve;product quality, uniformity and
working environment
Challenges to Uptake of Industrial Robots by Food Manufacturers
Limited Access to Engineering & IT Skills
Limited Time
Limited Resources
Complex Food Characteristics
Limitations of Organizational Infrastructure
Economic & Social
Concerns
Non-Rigid
Delicate
Bruising
Discoloration
Variable Sizes
Variable Shapes
Hygiene Requirements
Hygiene
Negative Perception
Technophobia
Layoffs
Cost
Return of Investment
5
Industrial Robot Applications in Food Manufacturing
Assembly
Mixing
Assembling
Decorating
Material Handling
Sorting
Transporting
Un/Loading
Material Processing
Slaughtering
Separating
Size Reduction
Packaging &
Palletizing
Primary
Secondary
Tertiary
Inspection
Quality
Deformities
Adulteration
Source: Atria
6
Source: ArtyzaSource: Scott Technology Ltd. Source: Miso Robots
Source: ROBOTNOR Centre for Advanced Robotics
Research aim : to improve the Uptake of Industrial Robots in Food Manufacturing
• Increase industrial robot awareness amongst food manufacturers and support selection via a distinct Decision Support System (DSS)
• To evaluate cost and environmental benefits of robots and validate applicability through simulation of processes
DSS
7
A Methodology for the Stages of Industrial Robot Uptake
8
Stage 1. Specification
Stage 2. Investigation
Stage 3. Preliminary Concept Selection(s)
Stage 4. Evaluation & Concept Selection
Stage 5. Simulation Modelling & Final Selection
Stage 6. Purchase & Transition
1.1. Identify production line requirements 1.2. Identify foodstuff requirements 1.3. Identify processing requirements
2.1. Identify robot(s) physical parameters 2.2. Identify robot(s) operational parameters
3.1. Selection of 3 concepts of robot(s) physical and operational parameters for identified food ingredient(s) and process(s)
4.1. Economic assessment of concepts 4.2. Environmental assessment of concepts 4.3. Select final concept of robot(s) physical and operational
parameters for food ingredient(s) and process(s)
5.1. Visualization in preparation for implementation 5.2. Assess feasibility; Yes or No. 5.3. If Yes, continue to purchase and implement robot. 5.4. If No, return to stage 1.
DSS offerings will assist:
Information Flow for Robot Physical Parameter Identification
9
Start Search as Ingredient Based Product Based
Breakdown Product to LevelsFoodstuff Type
Process Type
Process Method Process Technique
Automation Solution
Robot Gripper
Tool
RGT ★
Process handling difficult
Process NOT labour intensive
Maximum automation achieved
Requires human interference
Robotic Other
Process Type
Process Method
Foodstuff Type
Meat & Poultry
High Temp Processing
Low Temp Processing
Fruit & Veg
Ambient Temp Processing
Post-Processing Operations
Size Reduction
Raw Material Handling
Mixing & Forming
Separation
Washing
Sorting
De-Stemming
Trimming
De-Seeding
Peeling
Cutting
Grinding
Slicing
Squeezing
Adding syrups, enhancers, stabilisers,
preservatives
Loading & Unloading
Blending
Adding dry rubs, sugars
Cooking Preservation
Pasteurisation
Canning
Drying
Blanching
Frying
Baking
Preservation
Finishing Processes
End-of Line
Storage
Filling/Sealing
Mixing
Labelling
Palletising
Collating
PackagingCold Stores
Warehouse
R4T8
Freez ing
Chilling
Two R4G1T5
R1, R2
G1, G2, G6, G7
R1, R2
G1, G2, G6, G7
R1, R4 G4, G6,
G7
Leathers
Simmering
High Temp Processing
Low Temp Processing
Fish
Ambient Temp Processing
Post-Processing Operations
Size Reduction
Raw Material Handling
Mixing & Forming
Separation
Scaling
Evisceration (gutting)
Beheading
Washing
Trimming
Pick & Place for Sorting &
Grading
Weighing
Filleting
Slicing
Portioning (i.e. cutting)
Adding liquid brines,
enhancers, stabilisers,
preservatives
Forming, Encasing
Loading & Unloading
Blending
Adding dry rubs, Spices
Cooking Preservation
Smoking
Canning
Curing
Blanching
Frying
Grilling
Baking
Preservation
Finishing Processes
End-of Line
Storage
Filling/Sealing
Coating
Labelling
Palletising
Collating
PackagingCold Stores
Warehouse
Freez ing
Chilling
R1 T1, T3, T14
R1T1, T3
R1 T1, T2, T4, T9, T13
R2, R4 T8
R1, R2 G1, G2, G6, G7
R1, R2, R4 G1, G2, G6, G7
R1, R4 G6, G7
R1, G6, G7
R1, R4 G4, G6, G7
R1 G7
T1, T2, T9, T13
R1G6, G7
Salting
High Temp Processing
Low Temp Processing
Dairy Products
Ambient Temp Processing
Post-Processing Operations
Size Reduction
Raw Material Handling
Mixing & Forming
Separation
Scaling
Evisceration (gutting)
Creaming
Washing
Skimming
Buttering
Pick & Place for Sorting &
Grading
Weighing
Slicing
Portioning (i.e. cutting)
Adding liquid enhancers, stabilisers,
preservatives
Forming, Encasing
Loading & Unloading
Blending
Adding spices,
flavourings
Cooking Preservation
Smoking
Canning
Frying
Baking
Preservation
Finishing Processes
End-of Line
Storage
Filling/Sealing
Waxing
Labelling
Palletising
Collating
PackagingCold Stores
Warehouse
Freez ing
Chilling
R1T1, T3
R1 T1, T2, T4, T9, T13
R2, R4 T8
R1, R2 G1, G2, G6, G7
R1, R2, R4 G1, G2, G6, G7
R1, G6, G7
R1, R4 G4, G6, G7
R1G6, G7
Waxing
Aging
Pasteurisation
Fermentation
High Temp Processing
Low Temp Processing
Meat & Poultry
Ambient Temp Processing
Post-Processing Operations
Size Reduction
Raw Material Handling
Mixing & Forming
Separation
Slaughtering/Bleeding
Evisceration
Beheading, Hoof/Feet Removal
Washing
Skinning
Boning
Pick & Place for Sorting &
Grading
Weighing
Comminuting (i.e. mince)
Slicing
Portioning (i.e. cutting)
Adding liquid brines,
enhancers, stabilisers,
preservatives
Forming, Encasing
Loading & Unloading
Blending
Adding dry rubs, Spices
Cooking Preservation
Smoking
Canning
Curing
Blanching
Frying
Grilling
Baking
Preservation
Finishing Processes
End-of Line
Storage
Filling/Sealing
Coating
Labelling
Palletising
Collating
PackagingCold Stores
Warehouse
R1T2
Freez ing
Chilling
R1 T3, T5, T12
R1T1, T3, T9
R1T1, T3
R1 T1, T2, T4, T9, T13
R2, R4 T8
R1, R2 G1, G2, G6, G7
R1, R2, R4 G1, G2, G6, G7
R1, R4 G6, G7
R1, G6, G7
R1, R4 G4, G6, G7
R1 G7
T1, T2, T9, T13
R1,R5G7
T1, T3, T9, T12
Fleece/Hair/
Feather Removal
Stunning
Splitting R1, R5 G6, G7
T1, T2, T4, T9
R1G6, G7
TrimmingR1
T1, T3, T14
10
Ingredient Based
Fish
Fruit & Vegetables Dairy Products
Meat & Poultry
Ambient Temp Processing
Size Reduction Mixing & FormingSeparation
Beheading, Hoof/Feet Removal
Skinning
Boning Comminuting (i.e. mince)
Slicing
Portioning (i.e. cutting)
Adding liquid brines,
enhancers, stabilisers,
preservatives
Forming, Encasing
Blending
Adding dry rubs, Spices
R1 T3, T5, T12
R1T1, T3, T9
R1T1, T3
R1 T1, T2, T4, T9, T13
R1 G7
T1, T2, T9, T13
Splitting R1, R5 G6, G7
T1, T2, T4, T9
TrimmingR1
T1, T3, T14
Ready Meals
Soups
Salads
11
Product Based
Material Processing Assembly
Fillings
Material Handling
Finishing Processes
Size Reduction
Raw Material Handling
Separation
Loading & Unloading
Sorting
Peeling
Washing
De-Seeding
Pureeing
Slicing
Cooking/Preservation
Simmering
Blanching Poaching
Grilling
Forming/Layering
End-of Line
Storage
Labelling
Palletising
Collating
Packaging
Cold Stores
Trimming
Plant Based Animal Based
Plant Based Animal Based
Plant Based Animal Based
Skinning
Boning
Loading & Unloading
Sorting
Washing
Trimming
Shredding
Slicing
Plant Based Animal Based
Grilling
Frying
Steaming Smoking
BasePasta – rice -
grains
Finished Product
Packaging & Palletising
Ready Meal
Material Processing
Material Handling
Dry IngredientsLiquid
Ingredients
Liquid Ingredients
Mixing
Kneading
Proofing
Forming
Loading & Unloading
Loading & Unloading
Weighing Measuring
Dry Ingredients
Baking
Slicing
Cooking/Preservation
Dough
Baking
Material Forming
Raw Material Handling
Bread Plant Based Animal Based Condiments
Positioning
Closing
Positioning Positioning
Depositing
Spreading
Portioning
Frying
Material Processing Assembly
SolidsVeg-protein
Material Handling
Finishing Processes
Size Reduction
Raw Material Handling
Separation
Loading & Unloading
Sorting
Peeling
Washing
De-Seeding
Pureeing
Slicing
Cooking/Preservation
Simmering
Blanching Poaching
Grilling
Forming/Layering
End-of Line
Storage
Labelling
Palletising
Collating
Packaging
Cold Stores
Trimming
Plant Based Animal Based
Plant Based Animal Based
Plant Based Animal Based
Skinning
Boning
Loading & Unloading
Sorting
Washing
Trimming
Shredding
Slicing
Plant Based Animal Based
Grilling
Frying
Steaming Smoking
Base Tomato – cream
- broth
Finished Product
Packaging & Palletising
Soups
Material Processing
Material Handling
Dry IngredientsLiquid
Ingredients
Liquid Ingredients
Mixing
Kneading
Proofing
Forming
Loading & Unloading
Loading & Unloading
Weighing Measuring
Dry Ingredients
Baking
Slicing
Cooking/Preservation
Dough
Baking
Material Forming
Raw Material Handling
Bread Plant Based Animal Based Condiments
Positioning
Closing
Positioning Positioning
Depositing
Spreading
Portioning
Material Processing
Assembly
Base Lettuce
Material Handling
Finishing Processes
Size Reduction
Raw Material Handling
Separation
Loading & Unloading
Sorting
Peeling
Washing
De-Seeding
Cubing
Slicing
Cooking/Preservation
Simmering
Blanching Poaching
Grilling
Plating
End-of Line
Storage
Labelling
Palletising
Collating
Cold Stores
Trimming
Plant Based Animal Based
Plant Based Animal Based
Plant Based Animal Based
Skinning
Boning
Loading & Unloading
Sorting
Washing
Trimming
Shredding
Slicing
Plant Based Animal Based
Grilling
Frying
Steaming Smoking
Toppings Finished Product
Packaging & Palletising
Salads
Material Handling
Raw Material Handling
Base Plant Based Animal Based Sauces
Dispensing
Dispensing Positioning
Depositing
Size Reduction
Loading & Unloading
Sorting
Washing
Trimming
Plant Based Plant Based
Shredding
SlicingDispensing
Plates
Milk Derivatives
Positioning
Milk Derivatives
Shredding
Slicing
Covering Plates
Material Processing Assembly
Toppings
Material Handling
Finishing Processes
Size Reduction
Raw Material Handling
Separation
Loading & Unloading
Sorting
Peeling
Washing
De-Seeding
Pureeing
Slicing
Cooking/Preservation
Simmering
Blanching Poaching
Grilling
Forming/Layering
End-of Line
Storage
Labelling
Palletising
Collating
Packaging
Cold Stores
Trimming
Plant Based Animal Based
Plant Based Animal Based
Plant Based Animal Based
Skinning
Boning
Loading & Unloading
Sorting
Washing
Trimming
Shredding
Slicing
Plant Based Animal Based
Grilling
Frying
Steaming Smoking
BaseFinished Product
Pizza
Material Processing
Material Handling
Dry IngredientsLiquid
Ingredients
Liquid Ingredients
Mixing
Kneading
Proofing
Forming
Loading & Unloading
Loading & Unloading
Weighing MeasuringDry Ingredients
Cooking/Preservation
Finished Pizza
Baking
Material FormingRaw Material
Handling
Base Plant Based Animal Based Sauce
Positioning
Positioning Positioning
Depositing
Spreading
Portioning
Milk Derivatives
Positioning
Milk Derivatives
Shredding
Slicing
Cooked Pizza
Material Processing Assembly
Fillings
Material Handling
Finishing Processes
Size Reduction
Raw Material Handling
Separation
Loading & Unloading
Sorting
Peeling
Washing
De-Seeding
Pureeing
Slicing
Cooking/Preservation
Simmering
Blanching Poaching
Grilling
Forming/Layering
End-of Line Storage
Labelling
Palletising
Packaging
Cold Stores transport &
management
R1, R2G4
R1G4, G6
R1 G4, G6
Trimming
Plant Based Animal Based
Plant Based Animal Based
Plant Based Animal Based
Skinning
Boning
Loading & Unloading
Sorting
Washing
Trimming
Shredding
Slicing
Plant Based Animal Based
Grilling
Frying
Steaming Smoking
Bread Finished Product
Packaging & Palletising
Sandwiches
Material Processing
Material Handling
Dry IngredientsLiquid
Ingredients
Liquid Ingredients
Mixing
Kneading
Proofing
Forming
Loading & Unloading
Loading & Unloading
Weighing Measuring
Dry Ingredients
Baking
Slicing
Cooking
Dough
Baking
Material Forming
Raw Material Handling
Bread Plant Based Animal Based Condiments
Positioning
Closing
Positioning Positioning
Depositing
Spreading
PortioningR1T1
Milk Derivatives
Shredding
Slicing
Milk Derivatives
Positioning
Sandwich
Finishing Processes
End-of Line Storage
Labelling
Palletising
Packaging
Cold Stores transport &
management
R1, R2G4
R1G4, G6
R1 G4, G6
Packaging & Palletising
Sandwiches
PortioningR1T1
Sandwich
Sandwiches
Pizza
Future Work
12
• Build support system for selection of industrial robot operational parameters based on physical parameters identified
• Modelling solutions to support stage 5 to allow validation of selected robot concept within the production line.
• Solutions to support stage 4 and allow for economic and environmental assessment
