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Machine vision brings PTI compliance

Sun Pacific, the largest grower/packer/marketer of citrus fruits in the U.S., is reaping the benefits of machine vision in its packing houses.

The VR-3000's HMI.
The VR-3000's HMI.

The produce industry is moving to implement a systematic, industry-wide approach to closely track where fresh produce comes from and where it goes. One of the great challenges in this effort is the automatic recognition of a wide range of different package designs and hand stamps currently used to provide information about the produce. Sun Pacific, the largest grower, packer and marketer of citrus fruits in the United States, recently overcame this challenge by implementing the HarvestMark Product Traceability Initiative (PTI) solution with Saber Engineering VR-3000 vision inspection systems in several of its packing houses. These vision inspection systems utilize Cognex PatMax pattern recognition technology to consistently recognize case designs and hand stamps in spite of varying case positions and orientations, changes in ambient lighting, and other variables.

The produce industry handles an estimated 6 billion cases of produce in the United States each year. On very rare occasions, contaminated produce finds its way into the supply chain. The PTI is designed to identify the source of contaminated produce much faster and more accurately than is possible with conventional methods. The number one benefit is reducing the risk to consumers by ensuring that contaminated products are removed from the supply chain as quickly as possible. The PTI also has the potential for large cost savings by narrowing the impact of potential recalls and helping the supply chain resume normal operation much faster than is currently possible.

The PTI is based on a Global Trade Item Number (GTIN) that can be used for identifying trade items at all levels of packaging including item, case, and pallet. Under current best practices brand owners assign a 14-digit GTIN to every possible type of case based on the commodity, subtype, size, count, area of origin, grower, packer, etc. The GTIN along with the lot number is provided in human-readable form and encoded in a barcode on each case. Each subsequent handler then needs to have the capability to read and store the GTIN and lot number from each case of produce received. In case of a problem, this approach makes it possible to quickly trace goods through each handling step all the way back to their source.

But the produce industry faces challenges in achieving PTI compliance. Packers typically handle many different types of packages that are mixed together on their production lines. Often customers have their own case design and the produce is packed into many different customers’ cases in the packing plant. The workers in the packing line normally stamp the specifications such as the commodity, subtype, size, and count on the side of the case with a rubber stamp. The number one PTI compliance challenge for the packer is to automatically read the rubber stamp and identify the product associated with the package design and then automatically generate a label that contains all this information in both human-readable and 2D barcode format and affix it to the side of the case.

Saber Engineering developed the self-contained VR-3000 system that utilizes advanced machine vision technology to distinguish between the different types of packages and stamps with nearly perfect accuracy. The VR-3000 recognizes and verifies attributes such as type of shipping container, commodity, and size and passes this information to the HarvestMark database for processing. Trace-back, trace-forward and production data is securely hosted on the HarvestMark platform, delivering supply chain reporting and enabling on-demand traceability anywhere in the supply chain.

Saber Engineering’s vision solution uses a custom Visual Basic human machine interface (HMI) integrated with Cognex VisionPro vision tools to recognize package designs and stamps. The primary tool used is the PatMax part and feature location tool that uses advanced geometric pattern matching technology to reliably and accurately identify and locate patterns.

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