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Volume 12 - Issue 3 - Spring 2008
The Food Processing Advisory Council (FoodPAC) has approved a total of 13 projects for FY 2009 funding at a combined amount of $1,300,200 (amount includes both general and bond funds). The projects address a research priority in one of FoodPAC’s three technical focus areas and are divided as follows: 5 in Process and Product Improvement, 4 in Food Safety and Health, and 4 in Environmental. The projects (grouped under their respective technical focus area), principal investigator/institution, and their individual funding amounts are listed below. Project funding begins July 1.
Process and Product Improvement
Mid-Line Inspection System Field Trials
PI: Colin Usher, Georgia Tech Research Institute
FY 2009 Funding: $111,697
Imaging and Oven Control Development for Bottom
Color of Baked Goods
PI: Doug Britton, Georgia Tech Research Institute
FY 2009 Funding: $117,913
Robotic Packing of Trays
PI: Jonathan Holmes, Georgia Tech Research Institute
FY 2009 Funding: $34,673
Automated Live Bird Transfer System
PI: Kok-Meng Lee, Georgia Institute of Technology
FY 2009 Funding: $106,861
Sensor Fusion Approach to Integrate Spectral Imaging,
X-Ray Imaging, and Electronic Nose for Vidalia Onion Quality Measurement
PI: Changying Li, University of Georgia
FY 2009 Funding: $72,100
Food Safety and Health
Reduction of Salmonella Enteritidis in Pre-Harvest
Poultry
PI: Mike Doyle, University of Georgia
FY 2009 Funding: $136,500
Development of a Free Available Chlorine Sensor
of Red-Water Chillers and Other Food Processing Liquid Streams
PI: Jie Xu, Georgia Tech Research Institute
FY 2009 Funding: $113,338
Use of a Multiphase Antimicrobial/Modified Atmosphere
Packaging Material/Technology to Control the Safety and Quality of Processed,
Ready-to-Eat Meats
PI: Jinru Chen, University of Georgia
FY 2009 Funding: $110,500
Validation of Pathogen Intervention Strategies
for E. coli O157:H7 and Quality Characteristic Analysis of Several Antimicrobial
Products Used in
Conjunction with Multi-Needle Injection for Whole-Muscle, Non-Intact
Beef
PI: Alexander Stelzleni, University of Georgia
FY 2009 Funding: $70,750
Environmental
Development of the Georgia Food Processor Alternative Fuels
and Biodiesel Feedstock Database
PI: Daniel Geller, University of Georgia
FY 2009 Funding: $112,050
Free Fatty Acid Recovery from Unrefined and Waste
Oils as Value-Added Products
PI: Robert Wallace, Georgia Tech Research Institute
FY 2009 Funding: $147,173
Water Conservation and Reuse in Food Processing
and Agricultural Industries
PI: John Pierson, Georgia Tech Research Institute
FY 2009 Funding: $95,245
Production of Fuel from the Pyrolysis of Poultry
Processing Wastes (DAF Skimmings)
PI: K.C. Das, University of Georgia
FY 2009 Funding: $71,400
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Co-op student Parker McGee tests the missed bone screening system, which uses a special cone with internal illumination that has the effect of backlighting the frame (skeleton) so that it appears like an x-ray image. |
Further processed products are the mainstay of the poultry industry, with the key player usually being deboned fillets. However, missed bones, particularly the clavicle and fan, in these fillets continue to be of concern to processors. Current screening techniques are labor-intensive and can be expensive, not to mention, they are not as accurate as desired. Georgia Tech researchers are developing a new approach for automatic screening of bone on the cone line providing an opportunity not only to assist in finding missed bones but also providing real-time monitoring of product yield.
Currently, one of two methods is used to inspect the product for bones. Plant personnel manually screen the product, through sight and feel, or the processing plant uses sophisticated x-ray systems to inspect the product. However, neither method fully addresses the missed bone challenge; in some cases, missed bones still actually end up in the final product.
“One user of deboned fillets we have contacted reports 0.2 to 20 bones per thousand pounds, and the manufacturers of automated deboning systems report high enough rates of missed bones in final product to require automated inspection systems, usually x-ray, after the machines,” comments Wayne Daley, associate division chief of Georgia Tech’s Food Processing Technology Division and project director.
“Because of this, deboned product customers are now placing additional pressures on suppliers to reduce the incidence of missed bones,” explains Daley.
According to Daley, current bone detection methods are reactive as opposed to proactive allowing little opportunity for process control. Complicating the problem is the fact that bones are extremely difficult to find at the inspection station on the end of the deboning line.
“From a quality control perspective, the ability to detect these bones early in the process could improve production efficiencies by helping to reduce the possibility of rework while optimizing yield,” says Daley. “We set out to develop an approach that allows for detection of missed bones where the information can be used for process control and also where the problem is more tractable, ” adds Daley.
The prototype system under development by Daley and his team addresses this challenge by scanning for missed bones on the debone line immediately after the fillets are pulled from the skeleton or frame. This allows for a timely response to remove and evaluate suspect fillets before they are mixed through general transfer mechanisms. The approach requires the use of a special cone with internal illumination that has the effect of backlighting the frame (skeleton) so that it appears like an x-ray image. This image provides a clear view of the bone structure that makes up the frame. The system then analyzes the image to determine if the fan bone or clavicle bone is present. If these bones are absent, the potential exists for them to be in the meat that was just removed from the frame. These suspect fillets can then be removed for closer examination. Daley says the approach reduces the screening effort and will work on both automated and manual deboning lines.
In addition to missed bone, it would also be possible to monitor the frame for excess meat so that a measure of yield could be tracked and fed back into the process so as to maintain acceptable levels of performance, adds Daley.
A provisional patent has been filed on the overall approach and development is continuing. It is anticipated that field trials will be conducted in the coming year.
This FY 2008 project received bond funds from FoodPAC. For more information,
contact:
Project Director: Wayne Daley – Georgia Tech Research Institute, Food
Processing Technology Division
Phone: (404) 407-8828 | Email: wayne.daley@gtri.gatech.edu
Principal Investigator of FY 2009 Project:
“Mid-Line Inspection System Field Trials”
Job title: Research Scientist
Education: B.S., Computer Science, University of Georgia; current graduate student pursuing a Master’s degree in Systems Engineering at Southern Polytechnic State University
Areas of research expertise: Software systems design, systems integration, robotics and automation technologies
What I find most rewarding about working on FoodPAC projects: The ability to be involved in the entire life-cycle of a system development and take it from an idea to a viable commercial product
A talent I wish I had: To be able to fly
Another occupation I’d like to try: Martial Arts Instructor
My first paid job: Surprisingly, in a chicken house feeding baby chickens
If I could meet someone famous, who would it be and why: Mike Rowe of Dirty Jobs, because I bet he has a lot of interesting stories
Hobbies: Chinese Martial Arts, hobby robotics, camping
My day would not be complete without: The sun setting
The last book I read: “State of Fear” by Michael Chriton
The last movie I saw: Indiana Jones and the Temple of the Crystal Skull
My favorite song: “Crush” by Dave Matthews Band
My motto: Strive for perfection in everything that you do
Pilgrim’s
Pride Corporation is the largest chicken company in the United States and
the second largest in Mexico. The company has the capacity to process more
than 45 million birds per week for a total of more than 9 billion pounds
of poultry per year. Pilgrim’s products are sold to foodservice,
retail, and frozen entrée customers. The company’s primary
distribution is through retailers, foodservice distributors, and restaurants
throughout the United States and Puerto Rico, and in the Northern and Central
regions of Mexico. Pilgrim’s owns and operates 37 chicken processing
plants (34 in the United States and three in Mexico) and 12 prepared-foods
plants; 36 feed mills and 49 hatcheries support these plants. Approximately
6,400 growers supply poultry for the company’s operations. To learn
more about Pilgrim’s Pride Corporation, visit www.pilgrimspride.com.
Final Reports Due September 2
Final reports for FoodPAC projects conducted during FY 2008 are due by 5 p.m., Tuesday, September 2. Report guidelines will be e-mailed to principal investigators soon. All reports must be submitted by email (Microsoft Word files only) to foodpac@gtri.gatech.edu.
June 30, 2008 – FY 2008 projects are completed
July 1, 2008 - Funding for FY 2009 projects begins
September 2, 2008 – FY 2008 projects final written reports are due by 5 p.m.
At its Spring Meeting held in Atlanta at Georgia Tech’s Food Processing Technology Building, FoodPAC’s Process and Product Improvement Technical Committee announced the appointment of Clayton Muggridge of SNL Distribution Services as Committee Chair. Clayton assumes the chair from departing Chair Ann Hollingsworth of Better Built Foods, who recently assumed the position of Vice Chair of the FoodPAC Steering Committee. Also, Bill Leverett of Durand-Wayland was recognized for his outstanding service as a long-standing active member. Bill retires from committee membership after 12 years of service.
FoodPAC welcomes the following individuals who have volunteered their time and expertise to serve as members of the Food Processing Advisory Council. As committee members, these food processing industry professionals join other committee members in helping to guide and select the FoodPAC research program each year.
Steering Committee
Charles Stallworth, Georgia Power
Process and Product Improvement Technical Committee
Alberto Bazan, Alos Cuisine
Bob Burns, World Technology Ingredients (WTI)
Dan Hydock, Northside Foods
Mariano Loza, Mission Foods
Doug Britton, research engineer with Georgia Tech’s Food Processing Technology Division, and his research team along with industrial partner Baking Technology Systems, Inc. (BakeTech) recently received a Centers of Innovation Research Grant of $33,704 to aid in the commercialization of an imaging-based inspection and control system for high-volume baking operations. Britton is the project director of the FY 2009 FoodPAC project that will improve the yield and quality of baked goods by automatically controlling baking ovens based on color. The team will soon begin field testing and deployment of the system in a plant for an extended period of time.
The Georgia Centers of
Innovation program, launched by Governor Sonny Perdue in 2003, builds
on the state’s world-class assets and homegrown industries
to provide support for researchers and entrepreneurs in the areas of aerospace,
agriculture, biotech, information technology, and maritime logistics. Funding
for the Centers of Innovation Research Grant program is provided by the
OneGeorgia Authority.
