Food processing method and system
First Claim
1. A method for forming a packaged product and ensuring that the packaged product is adequately filled, the method comprising:
- a) forming a product, wherein forming the product comprises;
a-1) supplying a plurality of ingredients to a mixer; and
a-2) mixing the plurality of ingredients to form the product, the product having a viscosity;
b) introducing the product into a package, thereby forming the packaged product;
c) obtaining an x-ray image of the packaged product utilizing an x-ray apparatus;
d) analyzing the x-ray image utilizing a processor to identify whether bounded contours exist in the x-ray image;
e) for each of the bounded contours identified in step d), the processor determining whether the bounded contour is a threshold defect based at least in part on a bounded area of the bounded contour;
f) for each of the threshold defects identified in step e), the processor classifying the threshold defect as one of a plurality of pre-determined defect types; and
g) determining a source of at least one of the threshold defects in the packaged product based at least in part on the classification of the at least one of the threshold defects; and
h) adjusting the supply of one or more of the plurality of ingredients to adjust the viscosity of the product being formed in the mixer to minimize and/or eliminate the formation of threshold defects in a subsequent packaged product,wherein the plurality of pre-determined defect types includes a spin hole, an air cell and a side void.
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Abstract
A method and system for forming a packaged product (100) and ensuring that the packaged product (100) is adequately filled. In one aspect, the method includes forming a product (101); introducing the product (101) into a package (103), thereby forming a packaged product (100); obtaining an x-ray image (201) of the packaged product (100); analyzing the x-ray image (201) utilizing a processor (118) to identify whether bounded contours (200) exist in the x-ray image (201) for each of the bounded contours (200), the processor (118) determining whether the bounded contour (200) is a threshold defect based at least in part on bounded area (208) of the bounded contour (200) for each of the threshold defects, the processor (118) classifying the threshold defect as one of a plurality of pre-determined defect types; and determining a source of at least one of the threshold defects in the packaged product (100) based at least in part on the classification of the at least one of the threshold defects.
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Citations
17 Claims
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1. A method for forming a packaged product and ensuring that the packaged product is adequately filled, the method comprising:
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a) forming a product, wherein forming the product comprises; a-1) supplying a plurality of ingredients to a mixer; and a-2) mixing the plurality of ingredients to form the product, the product having a viscosity; b) introducing the product into a package, thereby forming the packaged product; c) obtaining an x-ray image of the packaged product utilizing an x-ray apparatus; d) analyzing the x-ray image utilizing a processor to identify whether bounded contours exist in the x-ray image; e) for each of the bounded contours identified in step d), the processor determining whether the bounded contour is a threshold defect based at least in part on a bounded area of the bounded contour; f) for each of the threshold defects identified in step e), the processor classifying the threshold defect as one of a plurality of pre-determined defect types; and g) determining a source of at least one of the threshold defects in the packaged product based at least in part on the classification of the at least one of the threshold defects; and h) adjusting the supply of one or more of the plurality of ingredients to adjust the viscosity of the product being formed in the mixer to minimize and/or eliminate the formation of threshold defects in a subsequent packaged product, wherein the plurality of pre-determined defect types includes a spin hole, an air cell and a side void. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A system for forming packaged products, the system comprising:
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a product formation subsystem configured to form a gel or paste product; a filling subsystem configured to dispense the product into packages to form packaged products; an x-ray apparatus configured to generate an x-ray image of each of the packaged products; a memory device configured to store a plurality of pre-determined defect types; and a processor operably coupled to the x-ray apparatus and the memory device, the processor configured to;
(1) analyze the x-ray images to determine whether bounded contours exist in the x-ray images;
(2) for each of the bounded contours, determine whether the bounded contour is a threshold defect based at least in part on the bounded area of the bounded contour; and
(3) for each of the threshold defects, classify the threshold defect as one of a plurality of pre-determined detect types,wherein the plurality of pre-determined defect types includes a spin hole, an air cell, and a side void; and wherein the classification of the threshold defect as one of the plurality of pre-determined defect types is based on a shape of the threshold defect in a packaged product portion of the x-ray image. - View Dependent Claims (9, 10)
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11. A method for ensuring a packaged product is adequately filled, the method comprising:
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a) generating an x-ray image of the packaged product; b) detecting at least one bounded contour in the image; c) for each bounded contour detected in step b), (i) determining a bounded area and (ii) identifying whether the bounded contour is a threshold defect based at least in part on the bounded area; d) for each of the threshold defects identified in step c), (i) calculating a severity score based on the bounded area and (ii) classifying the threshold defect as one of a plurality of pre-determined defect types, wherein the plurality of pre-determined defect types includes a spin hole, an air cell, and a side void, and wherein the classification of the threshold defect as one of the plurality of pre-determined defect types is based on a shape of the threshold defect in a packaged product portion of the x-ray image; and e) rejecting the packaged product based on the severity score and the classified defect type. - View Dependent Claims (12, 13)
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14. A system for ensuring packaged products are adequately filled, the system comprising:
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an x-ray apparatus configured to generate an x-ray image of a packaged product in a processing system; a memory device configured to store a plurality of pre-determined defect types, wherein the plurality of pre-determined defect types includes a spin hole, an air cell, and a side void; a rejection mechanism configured to remove the packaged product from the processing system; and a processor operably coupled to the x-ray apparatus, the memory device, and the rejection mechanism, the processor configured to; detect at least one bounded contour in the image; for each of the bounded contours, (i) determine a bounded area and (ii) identify whether the bounded contour is a threshold defect based at least in part on the bounded area; for each of the identified threshold defects, (i) calculate a severity score based on the bounded area and (ii) classify the threshold defect as one of a plurality of pre-determined defect types, wherein the classification of the threshold defect as one of the plurality of pre-determined defect types is based on a shape of the threshold defect in a packaged product portion of the x-ray image; and send an instruction to the rejection mechanism to remove the packaged product from the processing system, the sending of the instruction based on the severity score and the classified defect type. - View Dependent Claims (15, 16, 17)
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Specification