Integrated quality control refers to the combined use of tools and inspection technologies for the maintenance of desirable quality. Such an integrated approach is vital within the food sector for regulatory compliance, safety, and customer satisfaction. Read on as we explore the automation of this process and how the use of quality control technologies makes for increased operational efficiency.
The Power of Integration
From checkweighers to seal testers and X-ray systems, the integration of quality control technologies enables streamlining of the production line. Working in combination, such technologies allow for real-time monitoring and valuable insights into product quality. The reliable detection of defects and contaminants can be assured without the traditional risk of human error. Quality control automation makes for improved throughput and reduced downtime. Consistent compliance can also be ensured, with the reduced risk of recalls and protection of brand reputation.
Real-time Visibility and Analytics with Sentinel
Ishida has developed a range of quality control technologies for the reduced risk of human error, assurance of product quality, and improvement of operational efficiency. Unlocking greater efficiency, reduced waste, and resource preservation, the Sentinel production monitoring system is a prime example. It brings the power of connected technology to your fingertips.
See what’s possible with the Ishida Sentinel:
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Minimise downtime through 24/7 remote monitoring and proactive maintenance
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Boost productivity with increased throughput
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Enhance product safety with paperless e-marking proof of compliance and HACCP management.
You can customise the Sentinel platform for the most user-friendly experience and configure the settings based on your production line needs. With adaptive AI, data learning, and industry 5.0 technology, this production monitoring system drives continuous quality improvement.
Reducing False Rejects and Rework
There’s no denying the importance of minimising false rejects and the need for rework on food production lines. In the first instance, the incorrect rejection of good products has a direct impact on productivity, waste, and profitability. Such rejects result in production line stoppages and slowdowns, with products having to be unnecessarily reworked. Where such rejects are common, there’s bound to be reduced confidence in inspection technology. This will negatively impact vigilance and quality control effectiveness.
False rejects and rework can be effectively minimised through quality control automation. The combined use of X-ray systems, checkweighers, seal testers, and other quality control technologies can reduce false positives and negatives, with accuracy and product yield being improved. The integration of AI and machine learning technologies enables the real-time analysis of product data, with potential quality issues identified before they occur. Such technologies allow for continuous improvement of the food production line, meaning less waste, reduced rework, and more consistent product quality.
Boosting Confectionery Production Efficiency
Such quality control improvements have been realised by a confectionery producer through the integration of the Ishida Sentinel. With their existing monitoring system delivering a lack of transparency, accuracy, and insights, the company recognised the need for an update. Connecting a range of multihead weighers and checkweighers, the Sentinel would allow for improved clarity over efficiency levels and product build-up issues.
Ishida’s Sentinel enabled the identification and resolution of a regular product build-up issue on one multihead line, with an efficiency gain of 15%. Advanced data insights have also helped increase throughput from 30,000 to 35,000 cases per hour, working towards an overall aim of 40,000. The production monitoring system has been integrated into the daily workflow, with mounted screens showing live data specific to everything from product rejects to machine throughput. It’s been a case of optimisation across the entire site.
Enhancing Quality with Ishida
Examples like that of the confectionery producer illustrate the potential to drive operational efficiency, product quality, and rapid return on investment with Ishida technologies. Enhancing production lines with real-time analytics and smarter inspection capabilities, Ishida’s systems can support food manufacturers in raising standards, ensuring compliance, and achieving optimal levels of customer satisfaction. As such, our integrated quality control solutions can be seen as strategic investments for growth.
Get in touch to find out more and arrange a live demonstration of Ishida’s transformative quality control systems.