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Presented By-Aman Chhibber M. Sc. Food Science & TechnologyRoll No. RH1425A10 Registration No. 11409419

The Future of Food Processing Industry

Masters Seminar (FOT 591)

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Definition by:- British Automation and Robot Association (BARA)

An industrial robot is a reprogrammable device designed both to manipulate and/or transport parts, tools, or specified manufacturing implements through variable programmed motions, for the performance of specific manufacturing tasks.

Definition by:- International Standards Organization (ISO)

An automatically controlled, re-programmable, multipurpose, manipulative machine with several degrees of freedom, which may be either fixed in place or mobile for use in industrial automation applications.

DEFINITION

History

In 1956, George Devol and Joe Engelberger established a company called Unimation, a shortened form of the words Universal Animation.The first modern industrial robot, called Unimate, were developed by George Devol and Joe Engelberger in 1959. Engelberger formed Unimation and was the first to market robots. As a result, Engelberger has been called as the 'father of robotics.'

WORLD ROBOT POPULATION

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Potential Benefits From Robotics System

The requirement for reduced floor space Good hygiene levels Improved efficiency Improved quality The ability to work in cold or hostile environments Increased yields and reduced wastage Increased consistency Increased flexibility for some operations

Area of Manufacturing where Robots are used

AerospaceAutomotive manufacturing and supplyChemical, rubber and plastics manufacturingElectrical and electronicsEntertainment-movie makingFood stuff and beverage manufacturingGlass, ceramics and mineral productionPrinting Wood and furniture manufacturing

Some example of Robots used in Food Manufacturing

INDUSTRIES SERVED

Types of Robots used in food industryThe main types of robots used in the food industry arePortal robots: Portal robots are mounted robotic systems that span a cubic handling area by means of three linear axes The actual robotic kinematics (the moving axes) are located above the mounting

Articulated robots:Articulated robots are industrial robots with multiple interacting jointed arms that can be fitted with grippers or tools Articulated robots offer a high degree of flexibility

SCARAs:Selective Compliance Assembly robot Arms, or SCARAs, are a particular form of articulated robots They have a single articulated arm that can only move horizontally. They work in a similar way to human arms and are often called horizontal articulated arm robots

Delta robots:Spider-like delta robots a special form of parallel robot typically have three to four articulated axes with stationary actuators. Because their actuators are located in the base, these kinds of robots have only a small inertia. This allows for very high speeds and acceleration (Khodabandehloo, 1996)

Components of Robots

AREA OF WORK Cartoning

Cleaning

Coding and Marking

Conveyors

Filling

Form Fill Seal

Inspection

Labelling

Packing

Palletising & De-palletising

Wrapping

Handling

CARTONINGMotoman robotics :Yaskawa Electric Corporation

PALLETIZING & DEPALLETIZING

Cost:-$85,000 to $95,000Cost in Rs:- Rs 3,931,250 to Rs 4,393,750FANUC Robotics America, Inc.

LABELLING CODING AND MARKING

FANUC Robotics America, Inc.SATO Asia Pacific . Ltd

HANDLING AND PACKAGING

PICKING

This is an area in which a multitude of products, applications and packaging line set-ups. Frozen food, bakery and confectionary, ice cream, meat and fish, cheese, pet food, medical products, shampoo and perfume bottles Delta robot is more commonly used

FILLING ROBOTS

Liquibox Pakaging solutions, Cost :- $3,243.2 cost in Rs:- Rs 1,50,000 onwards

SOME INDUSTRIES PRODUCING ROBOTS FOR FOOD PROCESSING

Yield control, legislation, difficulties in staff availability will increase commercial pressures and encourage more meat processor organisations to automate, simply to maintain throughput (Balkcom et al., 2008)

Initially many meat automation research projects developed spoke robots for their particular task (Ranger et al ., 2004 )

The main aim of using an industrial robot is to reduce production costs and occupational injuries while improving process efficiency and hygiene

Robotics in Meat Processing

Application in Meat Industry

Primal cutting (ARTEPP) Splitting Deboning Removal of hair or hide of pig , cattle/ cow (KUKA robot)

Evisceration and Dressing

Stunning

Robotics in Fruits and Vegetables Processing

The first automated grading facilities for fruit and vegetables became available more than 10 years ago

A grading system using robots has been developed for use with deciduous fruits such as peaches, pears, and apples. System automatically picks fruit from containers and inspects all sides of the fruit (Kondo, 2003)

Robot technology has proved able to handle agricultural products delicately and with a high degree of precision, and to gather information to create a database of products every season

Application in Fruits and Vegetables Harvesting of food products :Industrial Robot (1999) reports that, in the last 15 years, mechanisation in farming has increased massively and the labour force has shrunk proportionately

Kondo et al. (1996) developed a fruit harvesting robot for use in Japanese agriculture systems which commonly produce crops in greenhouses and in small elds

Reed et al. (2001) developed an end-effector for the delicate harvesting of mushrooms

Ceres et al. (1998) designed and implemented a human aided fruit-harvesting robot (Agribot)

The Agribot approaches the problem of fruit picking by combining human and machine operations

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Grading of Fruits and Vegetables

Robotics in Dairy IndustryRobotic or automatic milking systems (AMS) are becoming increasingly important in dairy farming

Automatic Milking Systems (AMS) milk cows any time without the need for a human worker to be present

Cows choose when to be milked and detailed data is recorded by the robot which can be accessed remotely by computer or mobile device

Relatively small base, robotic milking has been predicted to become increasingly common

DeKoning and Rodenburg (2014) estimated that Internationally there were around 5,200 machines in operation in 2014

MILKING ROBOT

This systems cost approximately: $190,524[: Fullwood. (UK) Merlin AMS

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SENSORY ROBOTICSElectronic Nose

Electronic Tongue

Electronic Chewing machine

Uses the pattern of responses from an array of gas sensors to examine and identify a gaseous sample

DEFINITION : ELECTRONIC NOSE

ANALOGY BETWEEN ELECTRONIC NOSE AND BIOLOGICAL NOSEInhaling PumpMucus FilterOlfactory Epithelium SensorsBinding With Proteins InteractionEnzymatic Reactions ReactionCell Membrane Depolarized SignalNerve Impulses Circuitry & Neural Network

VaporArray ofSensors

Pattern Recognition

ResultArray ofSignalsBASIC DESIGN OF AN ELECTRONIC NOSE

FUNCTION: Identify gases and quantify concentrations (ppb- ppt)

APPLICATION: Air, Water, Soil, Plant volatiles.

PRINCIPLE: SAW sensor(s) & Micro-GC

PROS: Quick (10 sec), Small, Sensitivity, Remote option

CONS: so far none

COST: $19, 450 - $24, 950+ http://www.estcal.com/Products.html

ELECTRONIC NOSE (S)

http://www.businessplans.org/Vusion/Vusion00.html FUNCTION: Identify chemical composition of liquids

APPLICATION: Dissolved organics & inorganics, Aquatic mold growth, Soil analysis

PRINCIPLE: 100s of microsensors on chip, Colors change depending on chemicals, Results read by camera on a chip

PROS: Cheap, Disposable, Qualitative, Quantitative, Several analyses simultaneously

CONS: Not commercially available in US

COST: Inexpensive

http://www.alpha-mos.com/proframe.htmL

ELECTRONIC TONGUE (ET)

What is an electronic tongue ?

Taste cellNerve cell

Taste compounds

Electric responses

Brain

Tastereception

Biological taste systemArtificial liquid system - electronic tongue

Sensor responses

Computer

Sensor array

Patternrecognition

Y. Vlasov, A. Legin, A. Rudnitskaya, Anal. Bioanal. Chem. 2002, 373, 136.

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It can be used to:Analyze flavour ageing in beverages (for instance fruit juice, alcoholic or non alcoholic drinks, flavoured milks)

Quantify bitterness or spicy level of drinks or dissolved compounds (e.g. bitterness measurement and prediction)

Quantify taste masking efficiency of formulations (tablets, syrups, powders, capsules, lozenges)

RANGE OF APPLICATION

A schematic representation of the artificial mouth apparatusJournal of Agricultural and Food Chemistry vol:-May 5, 2008 Reproduce the result of masticationChewing, the release of saliva The rate of food breakdown And the temperature all affect the flavor and smell of food before its swallowed.

Munch-o-matic: Scientists develop the Artificial Mouth

WHAT FOR INDIA ?The $70 billion food and beverage industry & $24 billion FMCG industry has an annual growth rate of 20 per cent.

With the Indian economy expected to grow at the rate of six to eight per cent, the $14 billion logistic industry is poised for a leap thereby providing a huge potential for palletizing robots.

This heavy duty palletizing Robots are claimed to safely load goods of about 700 kg to 1300kg.

Palletizing robots are very useful in loading and wrapping big and heavy goods & are typically used by FMCG, logistics and consumer goods companies.

CONCLUSIONRobots will help Indian manufacturers to increase productivity & quality, leading to increased profitability.

Sensory robots provides solutions for Accuracy, sensitivity of the process and safety of Human Sensors.

The high acquisition costs continues to be the main barrier for the expansion of this technique.

While factors related dependency of humans on robots need to be considered seriously.

REFERENCESErzincanli F. and Sharp J. M. 1997. Meeting the need for robotic handling of food products, Food Control, Vol. 10 (4), : 185-190

Hillerton Eric J. 1997. Milking equipment for robotic milking, Computers and Electronics in Agriculture (17): 41-51.

Luque de Castro M.D, Torres P. 1995. Where is analytical laboratory robotics going? Trends in analytical chemistry, vol. 74 (10), :492 - 495.

Wallin Peter j. 1997 Robotics in the food industry : An update, Trends in Food Science & Technology Vol. 81: 193-198.

Kondo N (2003) Fruit grading robot. In Proceedings of IEEE/ASME International Conference on Advanced Intelligent Mechatronics on CD-ROM, July 2024 2003, Kobe, Japan

CROSS SECTION OF TEAT CUPTeat ChamberRubber LinerStainless Steel ShellPulsation ChamberVacuumVacuum or atmosphere

CROSS SECTION OF TEAT CUP-Pulsator allows air into chamber-liner collapses

CROSS SECTION OF TEAT CUPCollapsed linermassages teatcauses milk flowto stopLiner collapses, teat stretches

CROSS SECTION OF TEAT CUPVacuum removesair, lineropens

CROSS SECTION OF TEAT CUPMilk removed from teat by vacuum when liner is open

CROSS SECTION OF TEAT CUP

CROSS SECTION OF TEAT CUPPulsator repeats process