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A New Normal

Global crises trigger far reaching and fundamental transformations in consumer preferences, industrial practices, and government policies. The COVID-19 pandemic is no different. It will force manufacturers to comprehend those aspects of business, society, and politics that will be radically modified. Furthermore, they will have to proactively build capacity to deal with the new normal [1].

Paradigm Shifts

Following areas will experience paradigm shifts:

  1. Automation: will be increasingly deployed to resurrect the manufacturing sector. Productivity expansion via robotics and automation will be at the focal point of this effort, which will generate fresh employment opportunities for digitally proficient workers, but not for the low-skilled ones [1].
  2. Rapid Factory Digitalization: that places a premium on flexible and precise management of factory operations from a remote location. Such management will necessitate fast incorporation of industrial IoT based on superior data visualization, sensing, artificial intelligence, and tools for remote collaboration [1].
  3. Digital Divide among Manufacturers: two broad sets of manufacturers will emerge in the wake of the socio-economic decline. At the top end will be the digitally-savvy ones who embarked on the digital journey years ago. The late entrants will be at the other end [1].
  4. Greater Attention to Health & Safety: Good Manufacturing Practice (GMP) and Current GMP (cGMP) will assume more significance given their focus on plant and operator hygiene. Employees can expect greater monitoring and tracking of their movements and geographical data viz. residence location, recent travels and particularly international travel [2].
    Industries will also rearrange workspaces, operate in staggered shifts, maintain more distance between employees, and prohibit visitors on the shop floor to prevent coronavirus transmissions [2].
  5. Improved Strategies for Worker Retention & Deployment: particularly for workers who have to be on-site. Such workers will receive more education on how to respond to symptoms and contain the spread of the virus [2].
  6. Flexible Management Practices: that incorporate change management and adaptable work schedules to effectively handle greater automation levels, more number of remote employees, and the learning curves of such employees [2].
  7. “Virtual Shift” Replacing “Physical Shift”: with fewer people on the shop floor (on site), a team of virtually-connected experts will be continuously available online for consultation by the shop floor personnel. Facilitating the virtual shift will be AI-enabled tools, real time handling of data, and numerous collaboration cum communication instruments [1].
    The virtual shift will digitally scale the expertise of the specialist team over the entire institution while boosting the productivity of the shop floor team [1].
  8. Emphasizing Cybersecurity & System Capacity to Resist Attacks: with more employees gaining online access to the main system areas, security of cyber network will be of paramount importance. The system design has to be resilient in order to withstand repetitive attacks [2].
  9. Supply Chain Overhaul: is necessary in order to avoid last minute unavailability of parts, particularly the critical elements. Manufacturers will take more efforts to thoroughly understand in real time their supply networks. Suppliers identified as vulnerable to disrupting the chain will be replaced [2].

Survival of the Adaptable

Adaptability will be the key to survival at a time when the COVID-19 pandemic has unleashed rapid and extensive transformation in most aspects of the manufacturing sector. The challenge also presents a huge opportunity for the digitally savvy manufacturer.

Cybernetik Technologies delivers customized automation solutions for a whole range of manufacturing operations.

Contact us at +91 20 6790 9600 or write to us at [email protected] for automation services that prepare your business for the future.

References

  1. What Will Manufacturing’s New Normal Be After COVID-19?, IndustryWeek.
  2. COVID-19: What it means for industrial manufacturing, PwC.

Safety: A Paramount Necessity

Robots are not a new entrant in the food industry. They have handled palletizing and packaging jobs with speed and efficiency. It is only with the recent advances in gripper and vision technology that they are foraying into secondary food processing.

Managing sturdy or even the not-so-delicate parts is not a big task for robots. What is challenging is dealing with handle-with-care parts [1]. Take fragile foodstuffs such as raw eggs, soft chocolates, or strawberries for example. Or odd shaped apples and pears.

Quality and Speed are the two pivotal benefits of automation [2]. Employing conventional robots will damage these foodstuffs, and negate the quality advantage. In their mission to get over this barrier, robotic engineers turned to nature and came up with a simple yet excellent solution – the bionic gripper.

Nature has always triggered engineering developments. Bionics or engineering modelled on biology or living creatures [3] goes back centuries [4]. Jack Steele conceived the term bionics back in 1958 to describe engineering based on biology [5].

Japan’s Shinkansen trains for example employ the design of the Kingfisher’s beak to avoid sonic boom. Whale fin contours are the basis for the quieter, more efficient wind turbines with serrated edges [6]. And, there was the Gator Sharkote project that studied shark shin to develop an anti-fouling coating [7].

Robots & Grippers

Robots utilize two types of end effectors viz. grippers and tools. Connected at the robot wrist, they are usually custom built for specific operations. End-of-Arm Tooling (EOAT) is among the principal robot parts because it comes in touch with the part [8].

Grippers are generally involved with loading-unloading operations. One area where robots have an edge over manual labour is that they cause minimal damage to the handled part – the quality advantage of automation. But this advantage materializes only with the proper design and fabrication of gripper [8].

Robots utilize four main types of grippers [8]:

  • Vacuum Grippers are flexible, making them a standard EOAT. Polyurethane or rubber suction cups or closed cell layer of foam rubber acts as the pickup mechanism.
  • Hydraulic Grippers deliver up to 2000 psi gripping force, but are prone to oil leakages and maintenance issues.
  • Pneumatic Grippers are small sized and lightweight.
  • Servo-Electric Grippers use electronic motors for better control over gripper jaws. Plus, they are cost effective and can operate with varied material tolerances when working with parts.

Bionic Grippers

Tertiary Food Processing delivers Ready to Eat (RTE) foods and Heat to Serve foods [1]. RTE foods include instant snacks and soups, ready meals, baked goods, instant/breakfast cereals, meat products and the like [2]. Young people in the 18-35 age-group are the most active consumers of RTE foods [2].

Safety is at the core of all processes for manufacturing RTE foods. This is because they are not processed any further [3] – their hygiene has to be ingrained in their processing. Regulatory bodies prescribe strict standards for operators across the food supply chain.

For example, the Food Safety and Standards Authority of India (FSSAI) mandates a documented Food Safety Management System (FSMS) plan for every operator. FSMS plan includes Good Manufacturing Practices and Good Hygienic Practices specific to the sector [4].

Apart from safety, these standards ensure nutritional value of foods. Such standards establish what foods can and cannot contain as well as what are the minimum and/or maximum limits of ingredients they can contain. This, they do by:

  • Restricting the amount and type of natural and synthetic contaminants including microbes, pesticide/insecticide residues, and metal, antibiotic, and crop contaminants [4].
  • Laying down guidelines for which food additives can be included and in what quantity [4].
  • Instituting norms for packaging, labeling, and advertisement claims [4].
  • Capping the industrial trans-fat content in foods for them to qualify as trans-fat-free [5].

RTE Manufacturing Process

Safety is of course the core principle for RTE foods manufacturing. The process must also be rapid, energy efficient, and ergonomic while developing the required food flavor and texture.

Following are the general stages in manufacturing RTE foods:

  • Unloading & Transport: Unloaded raw materials are transported to the location of the cleaning equipment.
  • Cleaning: Removes dirt, dust, mud, stones, wood pieces and other such contaminants from the main raw materials. The cleaning stage may also include mechanisms for drying the raw materials wetted by the cleaning solution. Quality control check will affirm the efficacy of the cleaning process.
  • Transit: Cleaned raw materials are loaded into cooking kettles. Cybernetik Technologies’ Buggy Lifters have:
    • 350 liter Eurobins to hold raw materials.
    • Brake motor driven belt and pulley mechanism to lift the loaded Eurobin to the required height.
    • Tipping system to tilt the bin to the necessary angle for unloading raw material into the cooking kettle. Workers don’t have to lift and tilt the bin, something which eliminates the risk of injury. Safety features include photoelectric sensors, emergency stops, and alarm interlocks.
  • Pressure Cooking: Industrial cooking kettles are fundamental equipment in the food industry. These can cook, mix, stew, pasteurize, sterilize, or lower the moisture content in raw materials or partially processed foods.

High pressure cooking improves the shelf life and safety of foods, maintains their nutritional value, and saves energy costs [6] while lending them better odor and taste, maintaining their attractive appearance, and minimizing cooking times [7].

Industrial pressure cooking involves multiple steps. Different raw materials are added at various stages after the cooked material is drained, rinsed, simmered etc. Quality control checks at the end of certain steps are instituted.

  • Features of Cybernetik Technologies’ Cooking/Steam Kettles:
    • Automated for stop-start and the feeding-discharge of products.
    • Precise temperature control.
    • Uniform heating from all sides.
    • High-strength limpet/dimple jacket design allows use of thinner vessel shells.
    • Level indicators for accurate material feeding.
    • Load cell weighing option for batch-to-batch consistency.
    • Scraped surface agitator mixes materials to a homogeneous stage and prevents “burn-on” by not allowing material to stick to kettle wall.
    • Brisk meter checks process completion.
    • Safety devices and mechanisms include pressure-temperature sensor, pressure relief valves, safety interlocks, emergency stops, and indicator lamps.
    • Condensate recovery system for water reuse.
    • Clean in Place (CIP) provision for easy cleaning-maintenance.
  • Mixing: Double/twin shaft paddle mixers are the favorite mixers of the food industry for over three decades for bulk solid mixing. Cybernetik Technologies’ Twin/Double Shaft Paddle Mixers:
    • Are automated.
    • Mix products gently to rapidly produce a homogeneous mix.
    • Are suitable for wet mixing.
    • Come with safety features such as emergency stop and alarm interlocks.
    • Have CIP facility for easy cleaning-maintenance.
  • Buffering: After pressure cooking, the mixture is buffered and checked for shelf life. Cybernetik Technologies’ Buffer Tank has:
    • Dimple jacket design for high strength.
    • Ribbon blades for slow mixing.
    • Speed sensor to monitor mixing speed.
    • PID control for automatic temperature regulation.
    • Safety mechanisms such as emergency stop and alarm interlocks.
    • CIP system for easy cleaning-maintenance.
  • Holding: Maintaining or holding the temperature of cooked raw materials the required temperature for a specified duration prevents the growth of harmful disease causing microbes [8]. Holding process can be hot holding or cold holding.

Finally

Technological innovation empowers engineers to deliver on all the requirements of the RTE manufacturing process – safety, speed, efficiency, operator comfort, and quality.

Cybernetik Technologies has been delivering high-quality, purpose-built equipment and automation solutions to the Ready-to-Eat (RTE) food industry for decades. Contact us at +91 20 6790 9600 or [email protected] to get a first hand feel of the excellence of our experience.

References

  1. Food Processing, Wikipedia.
  2. Ready-to-Eat Food Market Report, Mordor Intelligence.
  3. Safety of Ready-to-Eat Foods, ResearchGate.
  4. Ministry of Food Processing Industries India Reports.
  5. Food safety agency FSSAI launches ‘Trans Fat Free’ logo, Hindustan Times.
  6. High Pressure Equipment Designs for Food Processing Applications, Food Engineering Series.
  7. Industrial Pressure Kettle VKP, FoodTechProcess.
  8. Food Storage, Preparation and Safety: In-depth, Croner-i.
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