Description:FIELD OF THE INVENTION
Embodiments of the present invention generally relate to a food industry. Particularly, present disclosure relates to provide an automated organic coating system to enhance food safety, increase productivity, and ensure regulatory compliance.
BACKGROUND OF THE INVENTION
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of it being mentioned in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
Coating for food items refers to the application of a layer or film on the surface of various food products to achieve specific objectives, such as enhancing taste, texture, appearance, and shelf life. Food coating is a widely used technique in the food industry, and it plays a crucial role in the development of processed and convenience foods. Coatings can be applied to a variety of food items, including meat, poultry, seafood, vegetables, snacks, and bakery products. The primary purposes of food coating are as preservation, texture and appearance enhancement, flavor improvement, heat protection, oil absorption reduction, and adherence of seasonings and ingredients.
Food coatings offer several benefits, including preservation by acting as a barrier against moisture, oxygen, and contaminants to extend food shelf life. They also enhance texture and appearance, improve flavor, and protect against excessive heat during cooking. In frying, coatings reduce oil absorption, promoting healthier eating, and they aid in the adherence of seasonings and ingredients to food surfaces.
Coating food items presents a range of complex challenges that span the realms of food safety, production efficiency, cost management, and environmental responsibility. The present challenges faced by manufacturers and processors in the area of food coating.
Coating food items involves a multitude of challenges that span from ensuring safety to meeting the ever-evolving demands of consumers. Food safety and regulatory compliance take center stage, as coatings must not introduce contaminants or health risks into the food, making adherence to stringent regulations and labeling requirements paramount to protect consumer health and trust. Consistency and uniformity present a daunting task, especially in high-speed production environments, where achieving a uniform coating thickness and quality across a large volume of food items is essential. Proper adhesion of coatings is critical to prevent peeling or separation during processing and storage. Cost management plays a significant role in the overall cost of food production, necessitating effective strategies to manage expenses.
Quality preservation is another crucial challenge, as coatings must maintain the texture, color, and flavor of food items throughout their shelf life. Managing allergen risks is of utmost importance, as cross-contamination should be avoided in facilities producing both coated and uncoated items. Maintaining cleanliness in equipment and production environments is essential for food safety. The environmental impact of coating materials and their disposal is a growing concern, prompting the search for eco-friendly alternatives.
The rising demand for healthy and natural foods, driven by an increasing global population, has created a need for year-round availability of fresh produce in the market. However, existing food processing facilities often fall short of meeting this demand in an eco-friendly manner. Additionally, fresh produce is highly perishable and prone to quality deterioration during storage and transportation, resulting in significant post-harvest losses.
Further studies indicate that approximately one-third of food is wasted globally, with 14% of waste occurring during harvesting, farming, and processing. This has led to a growing demand in the food industry for innovative ways to extend the shelf life of fresh foods, including fruits and vegetables. Packaging plays a critical role in this, with conventional non-biodegradable materials causing environmental concerns. As consumers prioritize safe and stable food products, the use of biodegradable films and coatings in packaging has gained importance. Edible coatings, considered as a primary form of packaging, are applied as thin layers over food surfaces to prevent rapid deterioration while maintaining sensory qualities. These coatings are made from edible materials, often incorporating essential oils from plants with antimicrobial and antioxidant properties, making them suitable for functional foods. Edible films, with thicknesses above 0.050 mm, and coatings below 0.025 mm play vital roles in preserving various food items, including fresh produce, cheese, and meat products. The concept of edible coatings was first applied to fruit surfaces using wax in 1992, marking an important development in this field.
Adapting coating methods to suit specific food items can be challenging, often requiring process optimization. Meeting consumer preferences for healthier, natural, or allergen-free coatings requires constant adaptation and innovation. Shelf life considerations extend not only to food items but also to the coatings themselves, with ingredients needing to remain stable. Balancing the enhancement of flavor with nutritional goals, such as reduced fat or sodium content, presents a complex culinary challenge. Lastly, transitioning from small-scale to large-scale production necessitates adjustments in equipment, processes, and quality control to maintain consistent product quality. In the world of food coatings, these challenges are both daunting and ever-present, requiring innovation, dedication, and a commitment to ensuring the safety and satisfaction of consumers.
Fully automatic organic coating for food items offers a range of benefits, including shelf life extension, improved visual appeal, flavor preservation, hygiene, and safety. However, implementing these processes comes with various challenges, including ensuring uniform coating, selecting appropriate coatings, maintaining equipment, addressing food compatibility issues, and complying with regulations.
Therefore, there is a need for recognizing the challenges; a novel method has been proposed, a system for fully automatic organic coating in the food industry, ensuring that food products are not only safe but also appealing and sustainable, which can overcome the above mentioned drawbacks.
OBJECT OF THE INVENTION
An object of the invention is to provide a system for fully automatic organic coating.
Another object of the invention is to provide an automated organic coating system to enhance food safety, increase productivity, and ensure regulatory compliance.
Yet another object of the present invention is increase operational efficiency and productivity with automation.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, a system for fully automatic organic coating, the system comprising: an input section designed to categorize food items; a washing unit configured to use pure water for thorough cleansing of the categorized food items; a collection unit configured to collect spoiled food items into a designated bucket; a drying unit configured to dry the freshly categorized food items; a recycling unit configured to detect any unwanted or misplaced items during processing and stores them in an output unit; an organic coating unit configured to apply a nano-coating to foods deemed fit for consumption, resulting in coated foods; a coated foods undergoes a post-coating drying mechanism, which may be powered by either electrical power or solar energy; an automatic testing process ensures the quality and safety of the dried and coated foods, resulting in tested foods; a packaging unit is configured to package the tested foods based on the predetermined weights; an incorrect bucket is provided for collecting non-compliant items during the testing phase; a processing module is configured to: a plurality of sensors for monitoring the drying process, washing process, coating process, and testing process; a camera for capturing images of the washing, drying, coating, and testing food items; and a fan for controlling the airflow and enhancing the drying process.
In accordance with an embodiment of the present invention, the organic coating process is automated and continually monitored with sensors, cameras, and AI for precise coating application.
In accordance with an embodiment of the present invention, the automatic testing process employs a plurality of sensors, cameras, and AI to assess various quality and safety parameters of the dried and coated foods, including texture, color, and microbial contamination.
In accordance with an embodiment of the present invention, the incorrect bucket is configured to receive and store non-compliant items identified during the testing phase by the sensors, cameras, and AI, ensuring that only safe and high-quality products are packaged for consumption.
In accordance with an embodiment of the present invention, the system is designed for increased food safety, reduced waste, and improved efficiency in food processing and packaging.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments. These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:
Fig. 1 illustrates a system for fully automatic organic coating, in accordance with an embodiment of the present invention; and
Fig. 2 illustrates a block diagram to depict the flow of working of the system, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description.
While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like is included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.
Food items are often coated with organic materials to enhance their appearance, taste, and shelf life. Fully automatic organic coating processes have gained significant attention in the food industry due to their efficiency, consistency, and cost-effectiveness.
As shown in figure 2, a block diagram to depict working of the system (100) and the components in the system, in accordance with an embodiment of the present invention. As shown in figure 1, the system may comprise, but not limited to, a communication module (1026), a memory unit (1022), processor (1024), data depository (108), and a processing module (102).
In accordance with an embodiment of the present invention, the system (100) incorporates a processing module (200) equipped with a variety of sensors to monitor the drying, washing, coating, and testing processes. It also employs a camera for capturing images of food items at various stages of processing and a fan to control airflow, enhancing the drying process. In summary, this system represents an integrated, automated, and quality-controlled solution for applying organic coatings to food items, ensuring their safety, quality, and uniform packaging.
In accordance with an embodiment of the present invention, the user device (1064) is further connected to the processing module (102). As shown in figure 1A, the processing module (102) may comprise a processor (1024), connected with a memory unit (1022). The processer may obtain the machine-readable instructions from the memory unit (1022). The processor (1024) is envisaged to include computing capabilities such as a memory unit (1022) configured to store machine readable instructions. The machine-readable instructions may be loaded into the memory unit (1022) from a non-transitory machine- readable medium, such as, but not limited to, CD-ROMs, DVD-ROMs and Flash Drives. Alternately, the machine-readable instructions may be loaded in a form of a computer software program into the memory unit (1022). The memory unit (1022) in that manner may be selected from a group comprising EPROM, EEPROM and Flash memory.
In various embodiments, the processor (1024) may be a microprocessor selected from one of, but not limited to an ARM based or Intel based processor in the form of field-programmable gate array (FPGA), a general-purpose processor and an application specific integrated circuit (ASIC). Additionally, the processor (1024) may further include a configurable processing unit, an operating system (100), an Application Processing Unit (APU), Hardware (HW) threads, Software (SW) threads, SSD storage, EMCC, SD etc.
In accordance with an embodiment of the present invention the system (100) may also include a data repository (108). The data repository (108) may be a local storage (such as SSD, eMMC, Flash, SD card, etc.) or a cloud-based storage. In any manner, the data repository is envisaged to be capable of providing the data to the processor (1024), when the data is queried appropriately using applicable security and other data transfer protocols. The data repository may store, but not limited to, previous and/or live images, verbatim files, processing files, videos, audios, 3D immersive content, solutions. It is also envisaged to store various charts, tables, learning contents such as practical videos, manipulatable 3D content, prepared for users.
The invention works in following manner:
Figure 1 illustrates a system (100) for fully automatic organic coating, in accordance with an embodiment of the present invention. The provided system is a comprehensive and fully automated solution for applying organic coatings to food items. This system is equipped with several distinct units that work together seamlessly to ensure the efficient processing of food products. It begins with an input (101) section that categorizes food items. The washing unit (104) follows, utilizing pure water to thoroughly cleanse the categorized food items. Any spoiled food items are collected in a designated bucket by the collection unit (105), preventing them from entering the production line. The freshly categorized food items then proceed to the drying unit (106), ensuring they are free from moisture.
Further, the recycling unit (108) is responsible for identifying and storing any unwanted or misplaced items during the processing stages. For the foods deemed fit for consumption, the organic coating unit (110) applies a nano-coating, resulting in coated foods. Subsequently, these coated foods undergo a post-coating drying mechanism, which can be powered by either electrical power or solar energy, enhancing energy efficiency. An automatic testing process (112) is implemented to evaluate the quality and safety of the dried and coated foods, ultimately resulting in tested foods.
Furthermore, a packaging unit (116) is in place to package the tested foods based on predetermined weights, ensuring uniformity and convenience. Any non-compliant items discovered during the testing phase are collected in an incorrect bucket (114), maintaining separation and preventing contamination.
In accordance with an embodiment of the present invention, using various sensors in a food processing and coating system to closely monitor and control different aspects of the production process. These sensors are crucial for ensuring the production of high-quality, safe, and efficiently packaged food items. These sensors include those for temperature, humidity, weight, pressure, flow, optics, chemistry, images, and fan speed. Their integration ensures real-time adjustments, quality control, and safety, resulting in high-quality, efficient, and safe food products.
Further, the temperature and humidity sensors for environmental conditions. Weight sensors for tracking food item weights. Pressure sensors for monitoring coating and washing processes. Optical sensors for verifying food item appearance. Chemical or spectrophotometric sensors for quality assessment. Image sensors (camera) for capturing images of food items during different stages. Fan speed sensors for controlling airflow and optimizing the drying process. The integration of these sensors ensures that each step of the food processing and coating system is closely monitored, controlled, and optimized to produce high-quality, safe, and efficiently packaged food items. It also allows for real-time adjustments and quality control throughout the process.
Examples:
a) Fresh Produce Processing: Imagine a large-scale fruit and vegetable processing facility. The system categorizes incoming produce, cleans them thoroughly, and applies a protective organic nano-coating. For example, it could apply a natural wax coating to apples to extend their shelf life. The coated apples are then tested for quality and packaged according to weight, ready for distribution to supermarkets.
b) Poultry Processing: In a poultry processing plant, the system can categorize and wash chicken pieces, apply an organic antimicrobial coating to reduce bacterial contamination, and then automatically test the product for safety. The correctly processed chicken pieces are then packaged based on weight, ensuring food safety and quality for consumers.
c) Snack Food Production: In a snack food manufacturing facility, the system categorizes snack items like potato chips or nuts. It cleans and applies a protective coating, such as a seasoning or flavoring, then checks for consistent quality. The snacks are then packaged in specific quantities for distribution to retail stores.
d) Seafood Processing: At a seafood processing plant, the system categorizes various seafood products like shrimp or fish fillets. It washes and applies an organic antimicrobial coating to extend their freshness, and the products are then tested for quality. Finally, the seafood is weighed and packaged for sale in supermarkets or restaurants.
e) Bakery Operations: In a bakery, the system categorizes freshly baked bread and pastries, applies a natural preservative coating to extend their freshness, and tests them for quality. The baked goods are then packaged in standardized quantities for delivery to local stores.
f) Salad Preparation: In a salad production facility, the system categorizes and washes various salad ingredients. It applies an organic coating to maintain freshness, tests for quality, and packages the salad components in ready-to-eat portions for the foodservice industry.

The present invention has various advantages. Fully automatic organic coating processes have become a pivotal innovation in the food industry. These processes play a crucial role in enhancing the overall quality of food products by improving their appearance, taste, and shelf life. By providing a protective coating, these methods help extend the freshness and longevity of food items, consequently reducing waste. Moreover, the efficiency of fully automated systems significantly streamlines production, reducing the reliance on manual labor and increasing overall productivity. The consistency they bring to the application of coatings ensures uniform quality and taste across all batches. Additionally, these processes are cost-effective, as they decrease labor costs and minimize material wastage. Furthermore, their automation enhances food safety and hygiene by reducing human contact with food items. Consequently, fully automatic organic coating processes have emerged as a basis of modern food production, driving efficiency, quality, and sustainability in the industry.
In general, the word “module,” as used herein, refers to logic embodied in hardware or firmware, or to a collection of software instructions, written in a programming language, such as, for example, Java, C, or assembly. One or more software instructions in the modules may be embedded in firmware, such as an EPROM. It will be appreciated that modules may comprised connected logic units, such as gates and flip-flops, and may comprise programmable units, such as programmable gate arrays or processors. The modules described herein may be implemented as either software and/or hardware modules and may be stored in any type of computer-readable medium or other computer storage device.
Further, while one or more operations have been described as being performed by or otherwise related to certain modules, devices or entities, the operations may be performed by or otherwise related to any module, device or entity. As such, any function or operation that has been described as being performed by a module could alternatively be performed by a different server, by the cloud computing platform, or a combination thereof. It should be understood that the techniques of the present disclosure might be implemented using a variety of technologies. For example, the methods described herein may be implemented by a series of computer executable instructions residing on a suitable computer readable medium. Suitable computer readable media may include volatile (e.g., RAM) and/or non-volatile (e.g., ROM, disk) memory, carrier waves and transmission media. Exemplary carrier waves may take the form of electrical, electromagnetic or optical signals conveying digital data steams along a local network or a publicly accessible network such as the Internet.
It should also be understood that, unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as "controlling" or "obtaining" or "computing" or "storing" or "receiving" or "determining" or the like, refer to the action and processes of a computer system, or similar electronic computing device, that processes and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.
, Claims:We claim

1. A system (100) for fully automatic organic coating, the system (100) comprising:
an input (101) section designed to categorize food items;
a washing unit (104) configured to use pure water for thorough cleansing of the categorized food items;
a collection unit (105) configured to collect spoiled food items into a designated bucket;
a drying unit (106) configured to dry the freshly categorized food items;
a recycling unit (108) configured to detect any unwanted or misplaced items during processing and stores them in an output unit (107);
an organic coating unit (110) configured to apply a nano-coating to foods deemed fit for consumption, resulting in coated foods;
a coated foods undergoes a post-coating drying mechanism, which may be powered by either electrical power or solar energy;
an automatic testing (112) process ensures the quality and safety of the dried and coated foods, resulting in tested foods;
a packaging unit (116) is configured to package the tested foods based on the predetermined weights;
an incorrect bucket (114) is provided for collecting non-compliant items during the testing phase;
a processing module (200) is configured to:
a plurality of sensors for monitoring the drying process, washing process, coating process, and testing process;
a camera for capturing images of the washing, drying, coating, and testing food items; and
a fan for controlling the airflow and enhancing the drying process.
2. The system (100) as claimed in claim 1, wherein the organic coating process is automated and continually monitored with sensors, cameras, and AI for precise coating application.
3. The system (100) as claimed in claim 1, wherein the automatic testing process employs a plurality of sensors, cameras, and AI to assess various quality and safety parameters of the dried and coated foods, including texture, color, and microbial contamination.
4. The system (100) as claimed in claim 1, wherein the incorrect bucket is configured to receive and store non-compliant items identified during the testing phase by the sensors, cameras, and AI, ensuring that only safe and high-quality products are packaged for consumption.
5. The system (100) as claimed in claim 1, wherein the system (100) is designed for increased food safety, reduced waste, and improved efficiency in food processing and packaging.