Chocolate Residue Detection System for Mold Integrity
The customer requires an efficient solution to monitor empty chocolate molds entering the filling machine to detect any chocolate residues. Residual chocolate or fragments left in the molds can contaminate the machine, causing shutdowns and production downtime. These disruptions lead to wasted time, decreased productivity, and higher operational costs.
Challenge
The customer faced a critical need to efficiently monitor empty chocolate molds entering the filling machine to detect chocolate residues. Leftover chocolate bars or fragments in the molds posed a serious risk of contaminating the machine, leading to production shutdowns and costly downtimes. These disruptions resulted in wasted time, reduced productivity, and increased operational costs.
The most common errors identified included:
- Chocolate residues in the mold: Small fragments or leftovers that were not completely removed before the mold re-entered the filling machine.
- Partially emptied molds: Molds with small debris or chocolate remnants from the previous cycle, compromising the quality of the new chocolates and causing additional production issues.
Proposal
To address these challenges and enhance the production process, a system of two intelligent cameras was proposed. These cameras monitor the molds as they approach the filling machine. If chocolate residues are detected, the cameras send a signal to the Programmable Logic Controller (PLC), which immediately halts the filling process for the specific mold, preventing contamination and machine shutdowns.
The system is designed to accommodate different mold types, including those for long and short chocolates, ensuring flexibility and adaptability to various production needs.
Solution
An automated mold inspection system was developed and implemented to meet the customer's requirements. The key components of the system include:
- Cognex Checker 4G7 cameras: These intelligent cameras enable real-time monitoring of molds and precise detection of chocolate residues.
Checker System Details
To optimize the production process, a program was developed for the "Left" and "Right" Checkers. Each camera monitors 13 specific regions in the molds, searching for the presence of chocolates or their residues. This targeted approach ensures accurate detection and quick intervention when necessary.
The Results
- Elimination of Defects: The system prevents production issues and significantly reduces downtime caused by contamination.
- Prevention of Machine Damage: By halting the filling process before contaminated molds enter, the system safeguards the machinery from potential harm.
- Enhanced Efficiency: Smooth production with reduced interruptions and consistent product quality.
- Cost Savings: Minimization of downtime and prevention of costly repairs or machine maintenance.
The automated solution has transformed the production process, minimizing errors, ensuring product quality, and maximizing operational efficiency.
