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Double vision for pizza improves

On three frozen pizza lines, Frozen Specialties upgrades to six Ethernet-linked machine-vision systems to check for damaged pizzas and unsealed carton flaps. See in-plant video

The first inspection checks the pizzas for any damage following shrink wrapping;
The first inspection checks the pizzas for any damage following shrink wrapping;

For a long time, packaged pizzas at private-label specialist Frozen Specialties Inc., of Archbold, OH, have been worth a first and second look. Done online in two stages, machine vision sensors have been used since the 1980s to detect pizzas damaged during wrapping and open carton flaps.

Now, FSI’s shrink-wrapped and cartoned pizzas are getting a fresher, more powerful, and more accurate look. Its previous inspection setup has been replaced with modern capability through Insight™ 1000 machine vision sensors and software from Cognex (Natick, MA). Providing ongoing support is line integrator Single Source Automation (Defiance, OH), which configured, installed, and programmed the vision systems. Heading SSA’s integration is Mike Kitchenmaster, who had been employed by FSI for three years as an electrician.

Operational by the latter part of 2001, the six new vision systems replace nine older cameras. FSI’s vision improvements are more numerous than toppings on a supreme pizza:

• Quality standards are enforceable due to more accurate inspections.

• A larger image-capture view and more sophisticated software compensates for product drift on the conveyors.

• The system is easier to use and offers quicker changeovers and less tweaking and maintenance.

• All six cameras and systems are networked over the Ethernet, which adds backup redundancy and can simplify access.

• The new inspection system includes data collection capability and expandability.

• FSI receives local support since SSA is just 30 minutes from the plant.

Maintenance manager John Behm says that the old system was “obsolete. It was unreliable, including having false rejects or, even worse, missed rejects. Also, uncartoned pizzas could not be detected by the downstream system. Spare parts for the old system were expensive and very difficult to find, too. The new system provides fast, real-time data.”

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