Automated monitoring and control of food processing systems
Systems and methods for automated monitoring and control of food processing systems are disclosed. Data from one or more controllers of a food processing system is received during operation of the food processing system at a remote food processing facility. Values of one or more operating parameters of the food processing system are monitored, based on the received data. At least one event of interest occurring during the operation of the food processing system is detected, based on the monitored values of the one or more operating parameters. Control signals for adjusting a configuration of the food processing system are transmitted to the one or more controllers, based on the detected event.
1. A method comprising:
receiving, via a communication network, data from one or more controllers of each food processing system of a remote food processing facility during operation of the food processing system, wherein the food processing systems each comprise a plurality of subsystems corresponding to different stages of a workpiece treatment process;
based on the received data, monitoring values of one or more operating parameters for each subsystem as workpieces are processed by that subsystem over one or more stages of the workpiece treatment process, wherein the one or more operating parameters are selected by the user from a list of available operating parameters provided via an options menu of the GUI of the client application executable at the user's computing device, and the GUI includes a dashboard view for presenting information related to the operation of the food processing system over a specified time period and, wherein the one or more operating parameters include a dilution ratio representing a concentration of antimicrobials relative to water within an antimicrobial composition applied to the workpieces over one or more stages of the workpiece treatment process;
detecting at least one event of interest occurring during the operation of at least one subsystem of the remote food processing facility over at least one stage of the workpiece treatment process, based on the monitored values of the one or more operating parameters;
sending a notification of the detected event to a computing device of a user associated with the at least one subsystem, wherein the notification is sent to the user's computing device for display via a graphical user interface (GUI) of a client application executable at the user's computing device, and the user interacts with the GUI for controlling the configuration of the at least one subsystem; and
responsive to receiving a command from the user's computing device for adjusting the configuration of the at least one subsystem based on the detected event, transmitting, via the communication network to the corresponding one or more controllers of the at least one subsystem at the remote food processing facility, control signals for adjusting a configuration of the at least one subsystem based on the detected event, wherein the control signals include signals for making appropriate adjustments to the concentration of antimicrobials relative to water within the antimicrobial composition applied such that the dilution ratio stays within a predetermined range for the at least one stage of the workpiece treatment process.
2. The method of claim 1 , wherein the occurrence of the event of interest is detected based on predefined criteria for the particular event of interest with respect to a value of at least one operating parameter during the operation of the food processing system.
3. The method of claim 1 , wherein the event of interest is one of a plurality of events specified by the user via a control panel of the GUI, and the event of interest is displayed as part of an event log within the dashboard view of the GUI.
4. The method of claim 3 , further comprising:
calculating performance metrics related to the operation of the food processing system for the specified time period, based on the monitored values of the one or more operating parameters; and
generating a visualization of the performance metrics to be displayed via the dashboard view of the GUI.
5. The method of claim 1 , wherein the remote food processing facility is one of a plurality of remote food processing facilities for which operating parameters of corresponding food processing systems are monitored.
6. The method of claim 1 , wherein the remote food processing facility is a poultry processing facility, the plurality of subsystems correspond to different zones of the poultry processing facility, and the antimicrobial treatment system is at least one of an antimicrobial application system, an antimicrobial recycle system, or an antimicrobial capture system that is located within a corresponding zone of the poultry processing facility at which one or more stages of the workpiece treatment process are performed.
7. The method of claim 6 , wherein the plurality of subsystems include at least one of an evisceration system or a chiller system.
8. The method of claim 1 , wherein the workpieces comprise meat.
9. The method of claim 1 , wherein the workpieces comprise fruits or vegetables.
10. The method of claim 1 , wherein the workpieces comprise fish or seafood.
11. The method of claim 1 , wherein the workpieces comprise food packaging.
12. A system for monitoring and control of food processing systems, the system comprising:
a processor; and
a memory coupled to the processor, the memory including instructions, which, when executed by the processor, cause the processor to perform a plurality of functions, including functions to:
receive, via a communication network, data from one or more controllers of each food processing system of a remote food processing facility during operation of the food processing system, wherein the food processing systems each comprise a plurality of subsystems corresponding to different stages of a workpiece treatment process;
based on the received data, monitor values of one or more operating parameters for each subsystem as workpieces are processed by that subsystem over one or more stages of the workpiece treatment process, wherein the one or more operating parameters are selected by the user from a list of available operating parameters provided via an options menu of the GUI of the client application executable at the user's computing device, and the GUI includes a dashboard view for presenting information related to the operation of the food processing system over a specified time period and, wherein the one or more operating parameters include a dilution ratio representing a concentration of antimicrobials relative to water within an antimicrobial composition applied to the workpieces over one or more stages of the workpiece treatment process;
detect at least one event of interest occurring during the operation of at least one subsystem of the remote food processing facility over at least one stage of the workpiece treatment process, based on the monitored values of the one or more operating parameters;
send a notification of the detected event to a computing device of a user associated with the at least one subsystem, wherein the notification is sent to the user's computing device for display via a graphical user interface (GUI) of a client application executable at the user's computing device, and the user interacts with the GUI for controlling the configuration of the at least one subsystem; and
responsive to receiving a command from the user's computing device for adjusting the configuration of the at least one subsystem based on the detected event, transmit, via the communication network to the corresponding one or more controllers of the at least one subsystem at the remote food processing facility, control signals for adjusting a configuration of the at least one subsystem based on the detected event, wherein the control signals include signals for making appropriate adjustments to the concentration of antimicrobials relative to water within the antimicrobial composition applied such that the dilution ratio stays within a predetermined range for the at least one stage of the workpiece treatment process.
13. The system of claim 12 , wherein the occurrence of the event of interest is detected based on predefined criteria for the particular event of interest with respect to a value of at least one operating parameter during the operation of the food processing system.
14. The system of claim 12 , wherein the event of interest is one of a plurality of events specified by the user via a control panel of the GUI, and the event of interest is displayed as part of an event log within the dashboard view of the GUI.
15. The system of claim 14 , wherein the functions performed by the processor further include functions to:
calculate performance metrics related to the operation of the food processing system for the specified time period, based on the monitored values of the one or more operating parameters; and
generate a visualization of the performance metrics to be displayed via the dashboard view of the GUI.
16. The system of claim 12 , wherein the remote food processing facility is one of a plurality of remote food processing facilities for which operating parameters of corresponding food processing systems are monitored.
17. The system of claim 12 , wherein the remote food processing facility is a poultry processing facility, the plurality of subsystems correspond to different zones of the poultry processing facility, and the antimicrobial treatment system is at least one of an antimicrobial application system, an antimicrobial recycle system, or an antimicrobial capture system that is located within a corresponding zone of the poultry processing facility at which one or more stages of the poultry treatment process are performed.
18. The system of claim 12 , wherein the remote food processing facility is a meat processing facility, a fish processing facility, a seafood processing facility, a vegetable processing facility, or a fruit processing facility.
19. A non-transitory computer-readable medium having instructions stored therein, which, when executed by a processor, cause the processor to perform a plurality of functions, including functions to:
receive, via a communication network, data from one or more controllers of each food processing system of a remote food processing facility during operation of the food processing system, wherein the food processing systems each comprise a plurality of subsystems corresponding to different stages of a workpiece treatment process;
based on the received data, monitor values of one or more operating parameters for each subsystem as workpieces are processed by that subsystem over one or more stages of the workpiece treatment process, wherein the one or more operating parameters are selected by the user from a list of available operating parameters provided via an options menu of the GUI of the client application executable at the user's computing device, and the GUI includes a dashboard view for presenting information related to the operation of the food processing system over a specified time period and, wherein the one or more operating parameters include a dilution ratio representing a concentration of antimicrobials relative to water within an antimicrobial composition applied to the workpieces over one or more stages of the workpiece treatment process;
detect at least one event of interest occurring during the operation of at least one subsystem of the remote food processing facility over at least one stage of the workpiece treatment process, based on the monitored values of the one or more operating parameters;
send a notification of the detected event to a computing device of a user associated with the at least one subsystem, wherein the notification is sent to the user's computing device for display via a graphical user interface (GUI) of a client application executable at the user's computing device, and the user interacts with the GUI for controlling the configuration of the at least one subsystem; and
responsive to receiving a command from the user's computing device for adjusting the configuration of the at least one subsystem based on the detected event, transmit, via the communication network to the corresponding one or more controllers of the at least one subsystem at the remote food processing facility, control signals for adjusting a configuration of the at least one subsystem based on the detected event, wherein the control signals include signals for making appropriate adjustments to the concentration of antimicrobials relative to water within the antimicrobial composition applied such that the dilution ratio stays within a predetermined range for the at least one stage of the workpiece treatment process.