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Objectifs du client

\n

Gerber Poultry traite et emballe des produits à base de poulet destinés à la distribution au détail dans le Mid-Ouest des États-Unis sous la marque Gerber Amish Farms Chicken. Afin de répondre à une demande croissante, les responsables de l'usine de traitement de Kidron, dans l'Ohio, ont décidé de moderniser et d'optimiser leur ligne de scellage des barquettes. Pour mener à bien ce projet, les barquettes devaient être correctement réparties entre les différentes machines d'emballage en fonction du produit qu'elles contenaient.

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Lors de ce projet de renouvellement de la zone de scellage des barquettes, Gerber Poultry s'était fixé plusieurs objectifs :

\n\n

L'intervention d'Intralox

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Pour atteindre leurs objectifs, les responsables de l'usine ont déduit qu'ils auraient besoin d'une solution de tri de barquettes automatisée et multifiles intégrant un système de reconnaissance des produits par caméra. Ils ont opté pour un trieur Active Integrated Motion (AIM) multifiles d'Intralox combiné à un système de classement par caméra InVISION de Foodmate. Le système combiné AIM/InVISION est disponible sur le marché sous le nom Foodmate TraySort Packing System.

\n

Le trieur AIM multifiles assure un meilleur rendement grâce à un accroissement des vitesses des lignes ainsi qu'une réduction des détériorations de produits et des temps d'arrêt. Doté d'une fonction de nettoyage, le système AIM automatisé permet de prendre en charge la manutention en douceur des produits à des vitesses élevées, évitant ainsi aux opérateurs manuels de devoir trier, remanier ou réorienter les barquettes. Les frais de main-d'œuvre sont supprimés, de même que les risques de contamination croisée associés à la manutention manuelle des barquettes.

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Reposant sur des technologies avancées de caméra et d'éclairage, le système de classement par caméra InVISION identifie et classe les barquettes en fonction des exigences de production spécifiées et les répartit en conséquence (ou effectue d'autres actions). Il communique ensuite la répartition ou l'action au trieur, le tout sans nécessiter d'étiquettes, de codes à barres ou autre procédé. La solution combinée, le Foodmate TraySort Packing System, optimise les fonctionnalités des deux composants pour offrir un système irréprochable entièrement automatisé.

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Résultats

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Intralox a travaillé en étroite collaboration avec Gerber Poultry et Foodmate lors de l'installation du système en mai 2018, mais également lors des phases qui ont précédé et suivi cette installation (assistance technique, conseils en agencement et tests de produits). Depuis son installation, le système combiné AIM/InVISION a permis à Gerber Poultry de dépasser les objectifs fixés pour ce projet.

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Le trieur AIM multifiles trie automatiquement et avec précision des barquettes de différentes tailles, contenant différents types de produits. Grâce à ce système, Gerber Poultry préserve la qualité de ses produits dans le respect des règles de sécurité alimentaire, réduit les déchets et atteint ses objectifs en matière de productivité. Plus important encore, Gerber Poultry a supprimé quatre postes en équivalents temps plein (ETP) dans la région, ce qui lui a permis d'économiser plus de 280 000 $ par an. La société prévoit d'inclure d'autres convoyeurs AIM dans les phases suivantes de son projet.

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