The answer to this question is a little more complex than a yes or no. Is carcass tracking with trolley vision a viable option?
Whether a radio tracking system like Trolley Vision® RF (radio frequency) will work for you largely depends on your plant and your needs.
For bigger plants, it is hard to beat the standard Trolley Vision® system, but RF could be a viable option for a lot of middle to small-sized plants.
In large-scale operations like beef or pork plants, you probably want to avoid RF for several reasons.
First of all, these operations often have a lot of interference which can severely limit the performance of radio signals.
On top of that, the trolleys can get beat up on quite a bit in these environments (I’ll explain how this affects performance later).
For smaller plants, there are fewer machines running and thus less radio frequency issues, which are the biggest reasons for interference.
Radio antennae are also a cheaper solution to camera stations.
The biggest thing that keeps most larger companies from investing in RF technology is that the RFID tags required are subject to wear from rough-handling of trolleys.
They start off with a very good read rate, but that can drop if they take a beating.
The technology for these radio chips is expected to become sturdier and stable in the future, but as is it is right now, the chips need to be replaced occasionally in rough environments.
Trolleys should be easier to maintain in a plant with less volume, so it still remains a viable option.
Aside from that, the other advantages to Trolley Vision® RF are the lack of a blower to clean out the vision system holes and the non-intrusive installation.
ID tags are clamped to the trolley’s wheel with a molded RF tag holder, no drilling necessary.
This shows you some of the positives of using Trolley Vision® RF for a smaller operation.
It may not be the tried-and true, one-time installation standard Trolley Vision®, but it definitely has its place in certain tracking applications.
Radio frequency (RF) tracking is a system used for plant traceability where radio frequency tags are embedded into a material and attached to the trolleys in a plant. They travel with the trolley through a plant and pass by reading stations which read each trolley’s tag as a unique identification. The system can then attach data to these tags via a database. Sounds easy enough, doesn’t it?
Unfortunately, a plant with trolleys and carcasses is not a welcoming place for a fragile radio tag. Trolleys are subject to very harsh treatment generally. First, they are often mishandled and thrown around. Trolleys themselves are very sturdy pieces of equipment, so this doesn’t seem like a big deal usually, but once a small chip is attached, it requires more refined handling. Aside from mishandling, wash down and oil bath procedures are usually performed on the trolleys which can cause damage to any additions to the trolley. For tags embedded in metal and welded to the trolley, oil baths with other trolleys can wear at the welded piece and break or remove the tag.
Our solution for RF is to encase the tag in a plastic molding and mounted inside the spoke of the trolley wheel where it will be better protected. Still, damage from the environment and handling is difficult to avoid and radio frequencies can be difficult to master. If you have to constantly replace RF tags, we might have other options for you as well. Our Trolley Vision® is another variant of traceability based on vision systems rather than RF systems. It requires a specially drilled pattern into the trolley strap which decodes as a unique ID that can be read by cameras around the plant. It does not compromise the strength of the trolley, but at the same time it is permanent. This bypasses the fragility of RF systems entirely.
Both systems work, but the Trolley Vision® system is a more permanent solution. We can help you in knowing what solution might fit your operations best.
The carcass tracking tool known as Trolley Vision® is a proven method of positively linking vital information about each carcass as it progresses through a slaughter facility. Yields, shrink data, and even trolley maintenance can be managed with Trolley Vision®.
There are two approaches to Trolley Vision®. In one approach, we drill a unique pattern of holes in each trolley strap. The other is called Trolley Vision® RF, in which the RF stands for Radio Frequency.
With either approach, you will not get a mis-read. The difficulty is in trying to maximize read rates and to minimize no reads.
The challenges in maximizing read rates for the RF tag approach are:
- Keeping the transponder attached to the trolley
- Minimizing chip failure
- Delaying impact deterioration of the insert
Our patented approach addresses all three of these problems. Here’s how.
First, our two-part molded clamp attaches to the trolley by a screw that passes through the trolley wheel and the two pieces. While this does not make it impossible for the RF tag to become detached from the trolley, it is a very secure method of attachment that reduces that likelihood.
Secondly, to help minimize chip failure, those molded pieces have a low profile and fit in the recessed cavities on both sides of the trolley wheel. The embedded RF chip is contained in the molding opposite the trolley strap to add an additional degree of protection against failure.
Finally, it is important to be realistic about what happens to trolleys in slaughter facilities. The rough treatment they receive can be seen in the nicks, dents, and grooves that appear in the metal. It is inevitable that RF ID tags are going to be on the receiving end of impact damage, also In order to delay the deterioration that will occur from these impacts we encase the tag in a protective polymer to increase its longevity. We chose to protect the chip in this polymer instead of steel so that the communication signal would not be compromised.
Over the years we have seen a multitude of RF solutions for the trolley ID application. While we know that we have the best RF application, our experience has also taught us that RF is difficult to maintain in a plant environment that has a lot of inherent radio frequency interference and electromagnetic interference. Due to the high cost of a trolley tracking system, it behooves the purchaser to thoroughly evaluate the Trolley Vision® vision system whenever contemplating a radio frequency solution.
Whether your preference is drilled trolleys or RF tags, we have many years of experience designing trolley tracking systems that fit your needs and your budget.
Using vision systems for trace ability is a very powerful solution to current carcass tracking problems, and we have been harnessing that with our Trolley Vision® system, but it isn’t as simple as stuffing a camera into an industrial plant and assuming that it will work without any outside aid. What happens when that vision is blocked by something?
Our Trolley Vision® analyzes an encoded pattern of holes drilled into each trolley’s strap. This works exceptionally, but because of certain regular plant processes, these holes can be blocked. One particular process that can have this effect is the oil baths that trolleys receive regularly.
Trolleys are submerged in oil regularly so that they roll smoothly and are protected from things like rust since they are often made from metals that aren’t rust-proof. When the small holes in the trolley are submerged, oil tends to stick in the holes because of its high viscosity. This can make it more difficult to see through the holes when they reach the Trolley Vision® camera, even if a back light is used.
We knew this was going to be an issue in most plants, so we added a component to the Trolley Vision® system. Initially, this was a blower which would blast each trolley with air to remove excess oil in the holes. However, this couldn’t be the ultimate solution because the oil was not controlled as it was removed and could end up on carcasses. Even if the oil was food grade, we thought it would be better to avoid that scenario entirely.
The next option was to use a suction system, which proved to be the better idea. This would remove the oil like a vacuum, and a hose would direct it somewhere where it wouldn’t get on any future food products. After being cleaned, these trolleys would proceed past the camera and back light which would send that image to an interface where the software would automatically determine the ID of that trolley.
Every day brings challenges in the industry, but with the right systems and proper installation, solutions such as Trolley Vision® can easily accomplish trolley tracking where other systems fail.
Country of Origin Labeling (COOL) is an important practice in the meat industry. It helps businesses to make more informed selections and assures the customer that this product has been followed and monitored through all the processing steps.
The difficulty with country of origin labeling itself is not due to the actual labeling so much as it is due to the demands for consistent, accurate tracking. Tracking has always been a hardship of meat producers everywhere. For example, tracking the trim of every single animal going into some ground beef makes COOL nearly impossible in that situation without careful planning.
Though COOL might struggle with varied, mixed products, it is much easier to enact when dealing with boxes of product that contain a smaller number of similar cuts. We can help you run a well-organized COOL operation with Trolley Vision®.
Trolley Vision® is a vision-based identification system that enables producers to assign specific numbers to each carcass that comes through a plant. When an animal arrives at a processing plant, Trolley Vision® can take all the preliminary information like country of origin, lot, and supplier and link it directly to that carcass.
Once you have linked that information, the next step in COOL requires careful planning. After going through the hot scale and the cooler the carcasses are ready to be cut down to individual cuts of meat. This means removing them from their trolleys which could mean losing the data assigned to that meat.
There are a few viable ways to keep the info intact to meet COOL standards. You could simply use time. If you know an animal’s origin and when it started down the cutting line, you can use the average cutting time to estimate the origin for the cuts that come out at the labeling end. This is easy to do, but there are a lot of factors with cutting time that could make it inaccurate.
A better way could be organizing your cutting schedule to run animals from certain lots in a row so that you know that they are all originating in the same place. Markers can be placed on the conveyor to signal labeling operators when a change in lot or supplier is occurring.
Lastly, you can use distance-based encoding to know when products of specific origin are going to arrive at labeling, as long as products are not allowed to pass one another.
Country of origin labeling might be a difficult process, but we are dedicated to making it easy on you, so that you can maintain a high quality operation. With proper tracking, software, and planning, you could have a secure handle on where each of your products is coming from. Let us help you make that a reality.