GERMANY | Increasing data-based added value via innovative technology has become the primary focus of the IFFA trade fair in Frankfurt.
Data had become a valuable asset in the meat-processing industry. By collecting and analysing data, companies could optimise production processes and identify problems early, allowing them to respond flexibly to market fluctuations and evolving customer preferences. IFFA, the leading global trade fair for meat and alternative proteins, showcased the latest technologies under the theme ‘Creating Value from Data’.
Data collection occurred at almost every stage of the production chain. During slaughtering and cutting, sensors and high-resolution cameras monitored processes by assessing weight, meat quality and hygiene. In processing and packaging, measuring instruments recorded temperature and humidity to ensure product quality and detect irregularities. In storage and logistics, temperature and humidity sensors maintained optimal conditions to prevent spoilage. In sales, intelligent algorithms analysed purchasing patterns to predict future demand and manage supply chains efficiently.
Klaus Schröter, Chairman of the VDMA Meat and Protein Processing Technology Division, believed data added value in many ways. “By collecting data in real time, purchasing, production and sales processes can be optimised. Sensory solutions improve efficiency in production and cleaning processes,” he said.
Data also played a role in predicting and preventing unplanned downtime by monitoring plant availability. Companies used data to simulate process sequences, aiding investment decisions and ensuring investment security. Several manufacturers developed central command units to control and optimise entire production processes. These units interconnected filling and portioning lines, analysing production, storage and sales data. Machine performance metrics, such as output, quality, capacity utilisation and downtimes, were recorded via standardised Ethernet connections, offering real-time insights into production efficiency.
Beyond integrated solutions, individual machine control modules enhanced specific production stages. For example, data on slicer blade sharpness and wear improved high-precision tool performance. Intelligent portion cutters used modern image-processing systems to ensure accurate slicing and even portioning in terms of shape, size and weight.
Smaller artisan businesses also benefited from automation, alleviating staff shortages. Automated systems enabled butchers to mix complex recipes precisely using pre-set parameters. Tracking ingredient usage facilitated long-term procurement planning. Data from various processes was automatically transferred to inventory and accounting systems, ensuring product consistency and streamlining administrative tasks.
Like many industrial sectors, artificial intelligence (AI) played an increasingly significant role in meat processing. AI harnessed the potential of data by identifying patterns and causal relationships. AI applications included optimising the cutting of pork sides to maximise efficiency.
“AI is a major trend in our sector,” Schröter said. However, integrating AI into smaller artisan businesses remained challenging due to diverse business structures, as acknowledged by Herbert Dohrmann, President of the German Butchers' Association.
In quality assurance, particularly in packaging, AI-powered image processing detected defects such as colour variations, foreign objects and faulty packaging. Inline inspection systems, equipped with self-learning cameras, automatically rejected defective products and visualised complex defects, such as melted ham fat resembling packaging material.
Predictive maintenance was another AI-driven advancement. AI-aided systems monitored machine conditions, predicting potential failures. Maintenance work was carried out during operations, reducing downtime and preventing breakdowns. AI also played a crucial role in cybersecurity, identifying and countering potential cyberattacks in modern, interconnected smart factories.
In packaging, data was used to develop alternative, sustainable materials. Researchers at the Fraunhofer Institute for Process Engineering and Packaging (IVV) analysed factors such as carbon dioxide concentration in packaging to simulate food shelf life. These simulations determined the technical properties needed to preserve flavour. The IVV also produced recyclable polymer-based multi-layer sheeting with oxygen barriers comparable to conventional materials.
AI further optimised packaging design by suggesting the most efficient material use while considering factors like shelf life, environmental impact, recyclability and consumer acceptance. As the industry continued to embrace data and AI, innovations in production, packaging and logistics improved efficiency, sustainability and product quality.
IFFA - Technology for Meat and Alternative Proteins will take place in early May. This year's IFFA trade fair will focus on state-of-the-art technology and dynamic growth.
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