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1The world leader in serving science
Bob Ries, Lead Product Manager, X-Ray Inspection and Metal Detection
Pack Expo 2014
X-Ray Product VerificationA New and Unique Application Framework
GOOD BAD
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Premier Brands
Global Scale • 50,000 employees in 50 countries
• $17 billion in annual revenues
• Unparalleled commercial reach
• 10,000 employees working with customers every day
The World Leader in Serving Science
Unmatched Depth• Innovative technologies
• Applications expertise
• Lab productivity partner
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We enable our customers to make the worldhealthier, cleaner and safer
A Mission We’re Proud Of
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Product Inspection History One Brand
1947 Goring Kerr founded
1985 Ramsey Purchased ICORE
1998 Thermo Electron acquires Goring Kerr
1994 Thermo Electron purchases Ramsey
2000
2007
2002
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On-Line Inspection Solutions for Food and Pharma
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• Incidents and recalls are more public• Mass, easy communication via the internet• Consumers are more educated and concerned
• Detection systems more capable and less costly• X-ray systems can find more types of objects
• Typically smaller metal can be found too• Systems are very easy to use and own
• Heading toward zero tolerance• 3-5 mm was OK, now 1mm can be detected• Recognition that all hazards must be detected, they can
never be eliminated completely
Why Food Safety is More Important Today Than Ever
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Thermo Scientific™ NextGuard™ X-ray
• The next generation in the X-ray inspection market
• Unique value proposition
1. Detects more2. Simple-to-use3. Easy-to-own
• Makes the migration from metal detection to X-ray more compelling
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Some Sample X-Ray Images/Contaminants
Random shape glass pieces in cans>= 0.8mm metal spheres in cheese
>= 2.5 mm ceramic spheres (rocks) coffee beans
>= 1 mm metal spheres in cookies(edge mask shown)Plastic gasket pieces in pies
1 mm metal sphere at bottom of juice bottle
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Common Quality Checks Customer Ask For Next
• Gross under/overfill• When a checkweigher is NOT present
• Missing products or components (counting)• Did everything end up in the bag/box?
• Cracks• Rigid products that are damaged in handling
• Incorrect size and/or shape• Misformed products
• Presence of dense objects (e.g. dessicants)
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Why Simple Menu Driven Systems Won’t Work
• The software provider can’t foresee all the applications so they must make constant enhancements
• Many image processing and analysis steps are “hard wired” together so flexibility is limited
• New applications require new addition(s) to the menus, dialog boxes, parameters, etc.
• Sometimes hidden parameter changes are needed so you must wait for the manufacturer to help you
• Why are spreadsheets so useful?• Flexible, powerful, extendable, easy to use
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The NextGuard Approach to Product Verification
• Flexible vision tools you can apply to x-ray images
• Dataflow model: image processing, thresholding (if needed), image analysis
• Immediate feedback during set-up
• Multiple inspections (individual or linked) possible
• Dual rejection systems for root cause determination
12The world leader in serving science
Sample inspections with NextGuard
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Checking Count: Detect a Missing Chocolate
• Problem statement: Screen for random, missing chocolates in a closed box.
• The NextGuard solution:• The product verification tool with
minimum area and counting
• Application considerations:• Package and product consistency
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Finding Quality Defects: Crack in a Granola Bar
• Problem statement: Find large cracks in cereal bars after packaging.
• The NextGuard solution:• The product verification tool with either
minimum area measurement or the line profile tool looking for white spaces.
• Application considerations• Consistent placement with guiderails (line
profile)• Multiple layers and orientation?
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More Complex Counting: Missing Sticks of Gum
• Problem statement: Determine if gum sticks are missing in a 2D matrix (3 X 2)
• The NextGuard solution:• Product verification tool with precise threshold
setting, min/max area and counting.
• Application considerations:• Consistent product density and size
Good
Bad – 1/6 Missing
Bad – 2/6 Missing
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Verifying Assembly: Ice Cream Bar Stick Presence
• Problem statement: Detect random missing wood sticks
• The NextGuard solution• Product verification with either area
measurement or line profile
• Application considerations• Product orientation/position and density
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Detecting Pattern Differences: Stacked Cookies
• Problem statement: Determine if a cookie is missing in a stack
• The NextGuard solution• Product verification line profile tool,
thresholding not possible for blob counting
• Application considerations• Product density and angle/stacking
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X-Ray Mass Estimation: Detect Gross Under Fill
• Contaminant detect AND look for 5% underfill errors in 1.5 oz peanut butter packs
• Must consider accuracy (offset) and repeatability (std deviation) for total precision
SCALE WEIGHT (g)
NEXTGUARD WT (g) ACCURACY STANDARD DEVIATION (g) REPEATABILITY (g) PRECISION
(Offset + 3σ)
Min Max AverageOffset (Ave -Expected) (g) 3σ Range (g) 3σ
Absolute value %
48.3 47.8 49.3 48.3 0.0 1.7 1.5 3.6% 3.7%47.87 48.7 49.7 49.1 1.2 1.3 1 2.6% 5.1%48.06 47.8 49 48.6 0.5 1.4 1.2 2.8% 3.9%46.59 46.3 47.5 46.8 0.2 1.5 1.2 3.1% 3.5%48.85 47.4 48.8 48.2 -0.7 1.6 1.4 3.2% 4.6%
Average Across Samples 48.2 0.3 1.5 1.26 3.1% 4.2%
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Next Steps for Your Applications
• Determine what products could benefit most from X-ray detection and inspection
• Ask Thermo Fisher to recommend a system• Aperture size, X-ray power beam orientation
• Send samples and your requirements in for testing• 5-10 of each type/size
• Receive a report stating feasibility and performance
• See a live demo either in person or via the web• Ways to deploy a system
• Purchase, Lease, Rental/Test Drive, PASS (Product Assurance Solutions and Services)
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Food and Beverage community www.thermoscientific.com/foodandbeve
rage
Food and Beverage Resources
Examining Food Blogwww.acceleratingscience.com/food
Videos, webinars, audio podcasts, white papers, case studies, and more!
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Questions?
Thank youBob [email protected]
Your partner in product and process improvement
www.thermoscientific.com/productinspection