Maximizing profit margins and avoiding misbranding means
knowing just what goes into your petfood and treat products.
Accurate measurement and precise adherence to levels of
moisture, fat, proteins and other key nutrients is more
important than ever. That means ideal process control
technology should be able to:
-
Operate in harsh industrial
environments;
-
Take measurements in real-time;
-
Have little to no human intervention
for operation and calibration; and
-
Provide instant, accurate data.
Ometric provides manufacturing and process spectroscopy
solutions for a broad range of industry categories, including
petfood manufacturers, that share a need for real-time, in-line
continuous process control and final product testing. The
company has recently unveiled its SpectrInLine Process Control
Suite, which is installed directly in the process line. This
technology allows manufacturers to measure, monitor and control
their manufacturing process and can be applied to:
The technology also works for a variety of shapes and sizes
of feline and canine food and the results are not affected by
sample color.
"Due to significant limitations associated with sample
testing, modern manufacturers can no longer afford to rely on
traditional methods. Large amounts of out of spec product can
be produced waiting for lab results," says Walter Alessandrini,
chairman and CEO of Ometric Corp. "Our revolutionary technology
is specifically designed to address manufacturing process
control concerns by providing real-time benefits that ensure
fewer product recalls, less waste, minimized liability and an
increased savings on resources."
Ometric's technology allows users to view production runs by
their choice of dates, shifts, product lines and plants.
Results are shown in a graphical format and are designed for
easy interpretation. Information may also be shared with
others, allowing managers to analyze current and historical
data and adjust their processes as needed to ensure proper
quality and final product formulation.
According to the company, SpectrInLine Processware is a
complete system that utilizes application specific multivariate
optical computing to provide continuous spectroscopy in
real-time for industrial processes. The SpectrInLine process
control suite's web-based interface gives users access to
critical manufacturing information from any computer, PDA or
smart phone with Internet access.
CSB-System now offers a method that ensures constant and
reliable monitoring of your entire manufacturing process.
Quality Management is a fully integrated feature of the
business process solution, according to the company. It fully
complies with all industry standards for HACCP, ISO 9001:2000
and the International Food Standard. The QM and HACCP module is
completely integrated into the materials management of an
existing CSB system to ensure that all tests that may be done
during production can be recorded in process (e.g., right at
receiving). The Quality Management arrangement also makes
certain that the proper action is initiated instantly as the
results are processed. In extended options of the system, you
can use the results to adjust your pet product recipes based on
raw material potential (meat protein, fat, sugar content).
The InAlyzer system using the Thermo Scientific Guided
Microwave Spectrometer (GMS) is an in-line, multi-constituent
analyzer that monitors any process flowing through a pipeline.
The GMS uses very low-powered microwave energy at hundreds of
specific frequencies to analyze the physical and chemical
properties of a sample. GMS is best at determining multiple
constituent concentrations of a process with varying particle
sizes. The system includes the chamber, electronics control
module, industrial PC and PC-based software for developing
calibrations and SQL database for key data and configuring the
InAlyzer. It is available in both online process and at-line
laboratory configurations.
InAlyzer can measure water activity in petfood in real-time
and in-line, a very important factor with regard to spoilage
and shelf life. Unlike other analyzers, its simple design
contains no moving parts or optical components that require
routine maintenance, resulting in extremely low long-term cost
of ownership, says Aaron Chabino, project manager at
ScanAmerican Corp, which distributes the InAlyzer in North
America. Advantages of GMS include:
-
Analyzes multiphase products such as
slurries, dough, liquids and larger particle size
products;
-
Analyzes multiple components;
-
Measurement is representative of the
bulk product even for heterogeneous materials, as it is not
a surface measurement; and
-
Results are not affected by the sample
color.
Analytical tests that were once carried out in the lab can
now become part of the online inspection process, which reduces
the risk of producing out-of-specification product. The Thermo
Scientific Spectra-Quad online moisture and constituent
analyzer provides continuous, accurate, real-time information
about the concentration of key product components. According to
Darrel T. Butler, GMS specialist and key account manager for
Thermo Fisher Scientific, the Spectra-Quad detects not only
melamine present in petfood but protein independently as
well.
The Spectra-Quad uses a measurement technique based on near
infrared (NIR) light absorption. It is a non-contact,
nondestructive and non-hazardous method. Chemical bonds absorb
NIR light at well-defined wavelengths. The absorption intensity
at a given wavelength is proportional to the amount of the
constituent in the material.
A quartz-halogen light source emits NIR light and the light
from the source passes through a rotating filter wheel. The
filters in the wheel allow only a narrow band of NIR
wavelengths to pass through. The reference wavelength provides
a baseline for the measurement of the sample. Some of the light
is absorbed by the sample and the rest is reflected. The
reflected light is collected and then focused onto a detector.
The signal at the detector is processed to provide a reading
that is proportional to the constituent concentration.
A full function operator interface permits easy access to
all of the analyzer's setup and diagnostic functions. The
display includes the product's name and its measured values,
and can be configured to function in several languages. The
Spectra-Quad is available with a wide range of environmental
options, which enables the analyzer to perform in virtually any
petfood or treat production situation, according to the
company.
1. Respond quickly to product fluctuations;
2. Reduce off-spec production;
3. Improve profitability;
4. Enable customer complaint investigations;
5. Control feedback;
6. Spot production artifacts;
7. Eliminate sampling errors;
8. Characterize drift in processes;
9. Provide statistical analysis of processes; and
10. Control "fast" processes.
From the Petfood Forum 2008 presentation, "In-Line
Analysis of Water Activity and Nutrients Using Multivariate
Optical Computing" by M.L. Myrick, University of South
Carolina. Watch the complete PowerPoint presentation
here:
http://breeze.sc.edu/petfoodforum08
.