Packaging Technologies-Dairy Processors / Dairy Processing and Equipment / Operations
Good cup, bad cup

Yogurt maker turns to vision system to eliminate leakers, dented cups

The ThermoChecker inspects the surface of 600 cups per minute, every 3 degrees, within 30 milliseconds.

July 10, 2014
Trans

Prepared and submitted by Industrial Control


Yogurt makers and other dairy processors using thermoformed cups know that leakers or dents in cups can halt production, creating waste and expense.

Industrial Control Inc., Zeeland, Mich., has developed an adaptable, high-speed 3D vision system to detect defective parts in existing systems in the thermoforming industry. Its ThermoChecker inspection system uses a 3D vision camera to monitor the surface for small defects which can affect the seal, resulting in spoiled product.

A large yogurt manufacturer discovered our solution and encouraged their supplier base to implement the ThermoChecker on their printing lines. Since last fall, 11 systems are installed at five production facilities between three different customers in the United States and Canada.

The ThermoChecker inspects the surface of 600 cups per minute, every 3 degrees, within 30 milliseconds. That’s almost 120 inspections per cup and 800,000 cups per day on each machine.

The ThermoChecker is installed just past the curing light in the print machine and is not affected by the intense light. Industrial Control’s high-speed PLC and computer instruct a dairy processor’s existing machine and reject station when to reject bad cups.

The IC ThermoChecker was developed due to a client request to check for dimensional defects in a thermoformed part on a dry o?set printer, running at a rate of up to 600 parts per minute. Due to a variety of issues, traditional machine vision was found to be neither reliable nor e?ective because each inspection needed to be done in under 250 microseconds.

A 3D smart camera is at the heart of the inspection system

Partnering with its client, Industrial control developed a system using a 3D smart camera to reliably detect and reject the defective parts, resulting in a substantial increase in defect detection before parts left the client’s facility.

In the configuration used, the system is able to measure up to 130 distinct profiles per part over the course of 30ms, resulting in approximately 75,000 distinct profiles per minute with multiple tools and measurements for every pro- file. The camera itself is calibrated at the factory to real world values, allowing the user to set limits based on a measurement, rather than an arbitrary value, resulting in a system much more easily understood by operators and engineers alike.

The ThermoChecker kit comes complete with a control panel, touchscreen computer, mounting hardware, a stack light, an integrated plc, and an internet support appliance. The system does not require programing and can be used with any web browser on any device. Industrial Control has successfully installed this system in production facilities in the United States and Canada.

Industrial Control lists the following turn-key benefits of the ThermoChecker system:

  • Reduce the risk of recalls and protect your company and customers.
  • Save money with fully automatic inspection of every cup, no costly manual inspectors.
  • See exactly how your machine is running and reduce setup time.
  • Calibrate your machine faster with real data from our system.
  • Shift counts for rejects onscreen or emailed/texted to your phone.
  • Reduced regrind cost.
  • Remote Internet support.


The company offers a free analysis of part samples with defects to determine feasibility. View the ThermoChecker in operation at www.industrialcontrol.com/thermochecker. For further information, telephone 616-931-1314.

Did you enjoy this article? Click here to subscribe to Dairy Foods Magazine. 
You must login or register in order to post a comment.

Multimedia

Videos

Image Galleries

Bel Brands, Brookings, S.D.

The 170,000-square-foot facility on 48 acres in Brookings has the capacity of producing more than 22 million pounds of cheese annually. That is approximately 1.5 million Mini Babybel portions every day. It makes Original (a Gouda type cheese), Light and Mozzarella.

BehindtheScenes

This photo gallery contains additional, unpublished photos of dairy processing facilities featured in Dairy Foods magazine. To view more Behind the Scenes galleries go to our archives page!

3/31/15 2:00 pm EST

Raising the bar with in-line mixing and blending technologies: high output with flexibility and low costs

In this webinar, you will be introduced to advanced in-line blending, dosing and mixing technologies that offer high flexible productions, reduced product losses, shorter batch times, uniform products, and reduced ingredient costs. As a result, Food Manufacturers can optimize their productions and increase their profitability.

Dairy Foods Magazine

march dairy foods

2015 March

The cheese issue: A look inside Bel Brands; Karoun Dairies' success; A preview of the WCIC Cheese Show

Table Of Contents Subscribe

Cheese

What is your favorite way to eat cheese?
View Results Poll Archive

THE DAIRY FOODS STORE

tharp-and-young-on-icecream.gif
Tharp & Young on Ice Cream: An Encyclopedic Guide to Ice Cream Science and Technology

An at once an all-inclusive guide to the meaning of hundreds of technical terms and ideas needed for ice cream manufacturing, as well as a practical introduction to the ingredients, freezing methods, flavoring, and packaging of ice cream, sherbet, sorbet, gelato, frozen yogurts, novelties and many other kinds of frozen desserts.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications, Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.

STAY CONNECTED

Facebook logo 40px 2-12-13 Twitter logo 40px 2-12-13  YouTube logo 40px 2-12-13  LinkedIn logo 40px 2-12-13google plus

Dairy Foods Buyers Guide

cover df july 2013Resource for buyers in the dairy processing industry to find information on the leading suppliers and manufacturers.

Find Ingredients, Equipment, Distribution, R&D and More.

Start Your Search Today.