AMF Tromp has developed a smart applicator solution for pizza production, cloud-based software that uses artificial intelligence to automate quality control for pizza toppings such as cheese. At the end of the production line, this means minimizing product waste, standardization and efficiency.
Pizza production still routinely requires manual work for quality checks, even when done with automated lines, with operators regularly weighing and (subjectively) assessing products. Artificial intelligence has the potential to improve this process and effectively take variations out of the pizza topping equation. AMF Tromp’s Smart Applicator Solution, launched in June this year, analyzes in real-time images of all the products on the pizza line, to evaluate the application of the cheese topping, based on a database with preloaded pizza images. The software recognizes the cheese toppings and compares them with the established baseline. It does this by translating data into values. Based on the findings, the software adjusts the speed and volume settings of the applicator, to ensure consistency within the preset parameters. “Every anomaly will be detected, and our system and algorithms will change settings immediately, to go back to the ‘base’ value, explains Lex van Houten, regional marketing manager, AMF Bakery Systems.
The waterfall applicator unit is strewing cheese at many pizza production sites, but the goal was to improve it and make it smarter. In conjunction with the company’s pizza production machines, the Smart Applicator Solution can be either retrofitted or newly configured for the AMF Tromp Waterfall Applicator. This enables weight control management and ensures quality depositing of the toppings, with the right amount of cheese perfectly spread on the surface of the pizza. AMF Tromp will add this Software-as-a-Service to a production line together with its customers; all that is required is the hardware unit with cameras, lights and Internet connection. It is placed above the line, and the service is then activated in AMF’s Service Center. All the specifications and settings are determined during installation and commissioning. “The first run will immediately give valuable data for the dataset to start building and training itself,” the specialist points out. From point on, (remote) support is also available, anytime.
Staying on top of pizza toppings
AMF Tromp prioritized the producers’ efforts towards sustainability and digitalization in the development stage. This meant minimizing giveaways, reducing waste, and replacing manual work to automate the process. The AI-based solution answers all challenges in applying toppings consistently. The Smart Applicator has started the quality control check with the cheese deposited on pizza (but not limited to it), so significant savings are evident when dealing with an expensive ingredient.
Multiple aspects can contribute to variations in pizza weight and quality. In their R&D process, AMF Tromp observed among recurring factors the humidity and temperature in the production area, fluctuations caused by the operator handling manual operations, as well as the characteristics of the cheese itself. “The thickness of the grated cheese, the length of the pieces, their moisture and stickiness, temperature, and density, will determine whether the waterfall applicator strews an even and smooth bed of cheese,” van Houten explains. Changes in any of these parameters can impact the amount of cheese that is strewed.
The Software-as-a-Service uses machine learning technology to optimize this process over time, as it detects and indicates anomalies. Process parameters it learns include weight control, even distribution of the topping, and the list is growing. The data is used instantly, but as it continues to gather information and learn, it continuously improves. The result: pizzas with standardized topping distribution, regardless of external influences, human interaction, or the sophistication of AI technology. The specialist shares how the new smart solution learns: “We generate the data by taking images of each pizza, which are added to the dataset, and the algorithm will learn and improve based on this data, to become value. During a single production run, thousands of quality checks are done, and all this data trains and the machine learns how to act, so the next runs will only be better.” By comparison, an operator usually performs four checks per hour, all of which require time, manual labor and personal skill – and this can vary between persons and shifts. “That is why the value of the data solution is better and trustworthy for reducing giveaways and cost,” he underlines. So when are staff needed, in this case? It depends, according to the size of the operation and the level of automation in the manufacturing facility. Fully automated, industrial-scale lines can apply toppings on pizza at an optimum level with no operator supervision, using this smart applicator software.
To ensure the ingredients are deposited evenly and in the correct amount, the data analyzing each piece determines if the amount of cheese, weight and distribution match the specifications determined with the producer. When the software identifies pizza outside of the parameters, the applicator adjusts the cheese dispersion to correct the process. In addition to having consistent topping perfected, the system also provides the added benefit of identifying every single piece falling over or under the presets, so the manufacturer can choose a course of action for them as well, by either removing the sub-standard product from the line or correcting the issue. The result will be ingredient distribution exactly as intended, for every single piece.
Any production speeds and volumes can make use of this smart solution: “We work with the largest manufacturers with thousands of pizzas per hour, but also entry volumes can benefit from this new service of AMF Tromp. It requires no investment, only a monthly subscription fee to have all data deliver immediate savings up to 3% per day. Our ROI calculations show most cases become profitable in less than one year. A no-brainer!” van Houten points out.
The Smart Applicator Solution
Smart processes in pizza manufacturing will generate immediate savings and impact the production process and topping application, by:
1. Reducing giveaways and having accurate weight control for every pizza
2. Minimizing waste of expensive ingredients
3. Reducing operator time, handling, and cost
4. No hands touching the product, thanks to vision-based monitoring
5. Machine-learning: not only AMF machines, but all applicators in the production area will be trained with this data, and results will only become better based on data analysis
Flexibility
The Smart Applicator is designed to handle any type of grated cheese, places on pizzas of any shape and size, from mini to standard and large, oval or square, even baguettes or flatbreads. And cheese is only the beginning: “We kick off the new service with cheese application on pizza, but we are developing new services as we speak, to also add other topping devices to the platform, like target applicating (exact positioning of a topping instead of a waterfall) and sauce application. Autonomous pizza production lines are the dot on the horizon for us and our customers,” explains the specialist.
Both application methods come with their own benefits and can be the better choice in certain settings, depending on the process, production volume, speed and the type of topping. Waterfall application fares well with high speeds, and it helps prevent waste with recirculation. The targeted application works best when a certain amount of topping is needed, and precision/central placement on a pizza or flatbread, and is best suited for low to medium production speeds.
Waste is controlled and minimized by constantly adjusting the ingredient quantity and dispersion, to stay within specifications. No product is wasted when using the AMF Tromp waterfall applicator, for example, as the recirculation system reuses the cheese during a run. When products are constantly within standards, fewer have to be removed at the end of the line, which further counts towards minimizing waste. “The OEE of our customers will go up, and we will offer new tools soon, for more smart quality control,” van Houten anticipates.
Such smart, autonomous lines will inherently increase the efficiency of the process, as minimizing waste and product loss also means shorter runs and less energy consumption. The software adds to AMF’s portfolio of tools aimed at improving efficiency, which includes the gas-fueled tunnel ovens, and the latest development – the hydrogen-powered oven. The specialist also recommends these types of ovens for pizza and flatbread production. They can be tested at its Dutch Innovation Center.
Enter the age of Artificial Intelligence
The Smart Applicator Solution is AMF’s first such service in a line of many, which finds the company at the beginning of a new chapter. “The world of AMF will become smart, digital, sustainable and focus on what our customers need to be successful. AI, machine learning, data-to-value, robotics, and autonomous bakery production – these are all concepts and technologies you will see more at AMF in the coming years,” van Houten anticipates. The company aims to add process and bakery knowledge to analyzing and imaging solutions, and is working on changing and improving the machine and process itself. AMF Tromp’s Smart Applicator Solution is the first step to smart solutions meant to optimize production processes and enhancing productivity across the plant floor.
