METHODS AND SYSTEMS FOR MONITORING COOKING AND COOLING CYCLES OF FOOD PRODUCTS

A method for monitoring a food production process, includes: receiving real-time temperature data associated with a food product during the food production process; processing the real-time temperature data to produce a temperature profile for the food product; comparing the temperature profile to a temperature benchmark associated with the food production process; and raising an alert associated with the food production process when the temperature profile differs from the temperature benchmark beyond a predetermined threshold.

TECHNICAL FIELD

The present disclosure relates generally to food production operations.

BACKGROUND OF THE ART

In a variety of food production scenarios, food producers are required to monitor temperatures of food products while processing operations are being performed. Regulatory bodies may establish a variety of regulations governing the cooking and cooling processes, which food producers must respect. Deviation from the established regulations may require that the food products be recooked or subjected to a lab analysis to assess whether they are safe for consumption. This causes time delays in the production chain, reducing efficiency and incurring additional costs. In certain cases, the regulations may require that food products be disposed of, resulting in loss of stock.

Depending on the type of food product, regulations may stipulate a number of food production parameters, including maximum and minimum temperatures, maximum and minimum time frames for achieving or maintaining certain temperatures, and the like. Existing approaches for monitoring the temperature of food product typically rely on data loggers which are collocated with the food product. At the end of a cooking or cooling cycle, the data loggers are removed and the collected data is extracted, for instance via a USB interface. While these existing approaches may be suitable for their purposes, improvements remain desirable.

BRIEF SUMMARY

In one aspect, there is provided a method for monitoring a food production process, comprising: receiving real-time temperature data associated with a food product during the food production process; processing the real-time temperature data to produce a temperature profile for the food product; comparing the temperature profile to a temperature benchmark associated with the food production process; and raising an alert associated with the food production process when the temperature profile differs from the temperature benchmark beyond a predetermined threshold.

The method may include any of the following features, in any combinations.

In some embodiments, the comparing of the temperature profile to the temperature benchmark comprises determining whether part of the temperature profile differs from a corresponding part of the temperature benchmark beyond the predetermined threshold.

In some embodiments, the comparing of the temperature profile to the temperature benchmark comprises determining whether the temperature profile is comprised within an upper bound and a lower bound defined by the temperature benchmark.

In some embodiments, the comparing of the temperature profile to the temperature benchmark comprises comparing the temperature profile to a first benchmark and to a second benchmark, and wherein the raising of the alert associated with the food production process comprises: issuing a first alert when the temperature profile differs from the first benchmark beyond a first predetermined threshold; and issuing a second alert when the temperature profile differs from the second benchmark beyond a second predetermined threshold.

In some embodiments, the comparing of the temperature profile to the temperature benchmark comprises: determining a rate of change for the temperature profile at a particular time; projecting a value for the temperature profile at a subsequent time based on the rate of change at the particular time; and comparing the projected value to the temperature benchmark.

In some embodiments, raising the alert includes issuing an indication of at least one potential fault of a food production device performing the food production process.

In some embodiments, raising the alert comprises causing a visual and/or auditory signal to be produced in a vicinity of the food production process.

In some embodiments, raising the alert comprises sending a message to an administrator associated with the food production process.

In some embodiments, the receiving of the real-time temperature data includes receiving the real-time temperature data over a wireless communication channel.

In some embodiments, the comparing the temperature profile to the temperature benchmark associated with the food production process includes: determining a projected time for the food product to increase to a determined temperature; and raising an alert if the projected time is below a first time threshold or above a second time threshold.

In some embodiments, the determining of the projected time includes extrapolating a value for the temperature profile at a subsequent time as a function of the receiving real-time temperature data.

In some embodiments, the comparing of the temperature profile to the temperature benchmark includes: issuing a warning if the temperature deviates from a steady-state temperature profile beyond a first temperature threshold; and raising an alert if the temperature deviates from the steady-state temperature profile beyond a second temperature threshold greater than the first temperature threshold.

In some embodiments, the comparing of the temperature profile to the temperature benchmark includes: determining a projected time for the food product to decrease to a determined temperature; and raising an alert if the projected time is above a time threshold.

In some embodiments, the determining of the projected time includes extrapolating a value for the temperature profile at a subsequent time as a function of the receiving real-time temperature data.

In another aspect, there is provided a system for monitoring a food production process, the system comprising: a processor; and a non-transitory computer-readable medium having stored thereon computer-readable instructions executable by the processing unit for: receiving real-time temperature data associated with a food product during the food production process, the temperature data received over a wireless communication channel; processing the real-time temperature data to produce a temperature profile for the food product; comparing the temperature profile to a temperature benchmark associated with the food production process; and responsive to determining that the temperature profile differs from the predetermined temperature profile beyond a predetermined amount, raising an alert associated with the food production process.

The system may include any of the following features, in any combinations.

In some embodiments, comparing the temperature profile to the temperature benchmark comprises determining whether part of the temperature profile differs from the temperature benchmark beyond the predetermined threshold.

In some embodiments, comparing the temperature profile to the temperature benchmark comprises determining whether the temperature profile is comprised within an upper bound and a lower bound defined by the temperature benchmark.

In some embodiments, comparing the temperature profile to the temperature benchmark comprises comparing the temperature profile to a first benchmark and to a second benchmark, and wherein raising an alert associated with the food production process comprises: issuing a first alert when the temperature profile differs from the warning benchmark beyond a first predetermined threshold; and issuing an second alert when the temperature profile differs from the warning benchmark beyond a second predetermined threshold.

In some embodiments, comparing the temperature profile to the temperature benchmark comprises: determining a rate of change for the temperature profile at a particular time; projecting a value for the temperature profile at a subsequent time based on the rate of change at the particular time; and comparing the projected value to the temperature benchmark.

In some embodiments, raising the alert includes issuing an indication of at least one potential fault of a food production device performing the food production process.

In some embodiments, raising the alert comprises causing a visual and/or auditory signal to be produced in a vicinity of the food production process.

In some embodiments, raising the alert comprises sending an textual message to an administrator associated with the food production process.

In some embodiments, the comparing the temperature profile to the temperature benchmark associated with the food production process includes: determining a projected time for the food product to increase to a determined temperature; and raising an alert if the projected time is below a first time threshold or above a second time threshold.

In some embodiments, the determining of the projected time includes extrapolating a value for the temperature profile at a subsequent time as a function of the receiving real-time temperature data.

In some embodiments, the comparing of the temperature profile to the temperature benchmark includes: issuing a warning if the temperature deviates from a steady-state temperature profile beyond a first temperature threshold; and raising an alert if the temperature deviates from the steady-state temperature profile beyond a second temperature threshold greater than the first temperature threshold.

In some embodiments, the comparing of the temperature profile to the temperature benchmark includes: determining a projected time for the food product to decrease to a determined temperature; and raising an alert if the projected time is above a time threshold.

In some embodiments, the determining of the projected time includes extrapolating a value for the temperature profile at a subsequent time as a function of the receiving real-time temperature data.

In yet another aspect, there is provided a system for monitoring a food production process, the system comprising: a temperature sensor coupleable to a food product undergoing the food production process, the temperature sensor configured for obtaining real-time temperature data from the food product; a wireless transmitter communicatively coupled to the temperature sensor for transmitting the real-time temperature data; and a computing system configured for: receiving the real-time temperature data from the wireless transmitter; processing the real-time temperature data to produce a temperature profile for the food product; comparing the temperature profile to a temperature benchmark associated with the food production process; and raising an alert associated with the food production process when the temperature profile differs from the temperature benchmark beyond a predetermined threshold.

In still another aspect, there is provided a method for monitoring a food production process, comprising: receiving real-time temperature data associated with a food product during the food production process; determining a projected time for a temperature of the food product to reach a given temperature as a function of the received real-time temperature data; and raising an alert associated with the food production process when the projected time differs from a prescribed time by a given time value.

In some embodiments, the determining of the projected time includes performing a regression of the received real-time temperature data and the determining of the projected time includes determining the projected time based on the regression.

DETAILED DESCRIPTION

With reference toFIG.1A, there is illustrated a food production system100which is used in the preparation of various types of food products for sale and consumption. The food production system100may be implemented in an industrial setting, for instance as part of a production line in a factory, which performs one or more food production steps as part of a food production operation. The food production system100includes of one or more food production devices: in the embodiment ofFIG.1A, the food production system100has an oven102and a cooler104. It should be understood, however, that the food production system100may include any suitable number of food production devices, including smokers, steamers, showers, and the like.

In many industrial food production settings, food products are loaded into movable transport devices, illustrated here as racks110. For example, the racks110are equipped with wheels or other moving elements which allows the racks110to be displaced. The food product may be moved between different food production devices, for instance from the oven102to the cooler104, by way of the racks110. For example, as illustrated inFIG.1A, the rack110′ is removed from the oven102, for instance after a cooking cycle. The rack110′ may then be moved to the cooler104, where the food product stored thereon will be subject to a cooling cycle.

Depending on the type of food product being processed, certain jurisdictions or regulatory agencies mandate that food products be processed in accordance with predetermined regulations. These regulations may dictate cooking times, cooking temperatures, and the like. For instance, a particular regulation requires that a food product be heated to a predetermined temperature within a first time period, and that the food product be maintained at the predetermined temperature for a second time period. In another example, a particular regulation requires that once a cooking cycle for a food product is complete, the food product is cooled to a predetermined temperature within a third time period. To ensure compliance with existing regulations, food producers use temperature-sensing devices affixed to racks110, or inserted in the food product disposed within the racks110. Typically, these temperature sensors are removed from the racks110or the food product after a food production cycle (e.g., a cooking cycle, a smoking cycle, a cooling cycle, or the like) in order to perform data extraction, whereby the data collected by the temperature sensors is transferred therefrom to a computer or similar system. As a result, temperature data collected from the food product is only available once the food production cycle is complete, and any deviations from established regulations can only be ascertained thereafter. This limits the ability of food producers to detect deviations from regulations as they are occurring, which can in turn result in wasted food product or lost time due to re-cooking or external analysis of the food product.

With continued reference toFIG.1A, in order to address at least some of the shortcomings of existing food production systems, it is considered that the food production system100includes a monitoring and control system120and a wireless receiver122. The processing system is also provided with one or more monitoring devices, illustrated at112, which are associated with respective racks110. The monitoring devices112are configured for monitoring the temperature of the food product during processing, and wirelessly providing temperature data to the monitoring and control system120in real-time. In this fashion, the monitoring and control system120can detect anomalies or deviations from regulations as they are occurring, thereby reducing the risk of the food product not being processed according to the established regulations. The different components of the control system120may communicate between them via the LoRaWAN protocol, but any other suitable wireless communication means are contemplated. In some cases, wired connections may be used.

In some embodiments, all of the monitoring devices112may communicate with the wireless receiver122(e.g., gateway). The wireless receiver122may communicate with a computer132and/or mobile device134via an Ethernet connection, or any other suitable communication means. The wireless receiver may include an enclosure, which may be IP67 certified.

Referring toFIG.1B, one of the monitoring device112is shown in greater detail. The monitoring devices112, which may also be referred to as loggers, are composed of a temperature sensor114and a wireless transmitter116. The temperature sensor114may be inserted in, or affixed to, a food product, in order to sense the temperature of the food product. Alternatively, the temperature sensor114can be disposed in the vicinity of the food product and measure the temperature of the environment in which the food product is located. The temperature sensor114can be any suitable type of temperature sensor, which may acquire temperature data at any suitable frequency. The temperature sensor114and the wireless transmitter116are communicatively coupled, allowing the wireless transmitter116to obtain the temperature data acquired by the temperature sensor114. The wireless transmitter116transmits the temperature data acquired by the temperature sensor114over a wireless communication channel to the receiver122of the monitoring and control system120. The particular wireless protocols used by the wireless transmitter116and the monitoring and control system120, as well as the encoding techniques, can vary based on the implementation. The temperature sensor114and the wireless transmitter116can be coupled through any suitable wireless and/or wired techniques.

Each of the monitoring devices112may include a heat resistant housing116A that may be hooked to cooking racks. The housing116A houses the wireless transmitter116. The temperature sensor114may include a RTD 2 wires probe to read internal temperature of the product being cooked. An operating range of the monitoring devices112may be between −20 and 125 degrees Celsius since they may operate inside the oven102and the cooler104. The monitoring devices112may meet IP67 certification to be operated in high humidity ambient, steam, and water washings facilities. The monitoring devices112may be battery-powered and may be turned off for increasing battery life. They may include a G sensor (e.g., accelerometer) to manually start the device after sleep. A wire115may operatively connect the temperature sensor114to the wireless transmitter116.

In some embodiments, the monitoring devices112are provided with a securing mechanism via which they can be permanently or semi-permanently affixed to the racks110. For example, the wireless transmitter116can be provided in an enclosure that is removably affixable to a portion of the rack110. A cable or other connector which communicatively couples the temperature sensor114and the wireless transmitter116can also physically tether the temperature sensor114to the wireless transmitter116, for instance by coupling to the aforementioned enclosure. In some other embodiments, the temperature sensor114and the wireless transmitter116are wirelessly coupleable, for instance via Bluetooth or a similar wireless protocol. The wireless transmitter116, whether in an enclosure or not, may be affixable to the rack110, and the temperature sensor114may be physically separated therefrom. It should be noted that in some embodiments, an individual rack110may be provided with more than one monitoring device112, for instance so that multiple temperature sensors114can obtain temperature data from different portions of the food product being processed.

The monitoring and control system120is configured for receiving the temperature data from the monitoring device112, and for processing the temperature data to monitor the food production process occurring in the oven102and/or in the cooler104. The monitoring and control system120may be embodied as a server that gather all of the data sent from the temperature sensor114via the wireless transmitter116. In the embodiment illustrated inFIG.1A, the food processing system100is composed of the singular wireless receiver122and the monitoring and control system120. It should however be understood that in other embodiments, the food processing system100includes multiple wireless receivers112in communication with the monitoring and control system120, and/or includes one or more wireless repeaters118which serve to communicatively couple the monitoring devices112to the monitoring and control system120. The wireless receiver122is communicatively coupleable to the monitoring devices112, for instance via respective wireless transmitters116, for receiving therefrom the temperature data recorded by the temperature sensors114. As noted above, the particular wireless protocols and encoding techniques used to effect communication between by the wireless transmitter116and the wireless receiver122can vary from one implementation to another.

The wireless receiver122and the monitoring and control system120are communicatively coupled to one another in any suitable fashion. In some embodiments, the monitoring and control system120is implemented by way of a suitable computing device, which can have integrated therein the wireless receiver122and which uses any suitable computing components to implement the functionality ascribed to the monitoring and control system120.

The monitoring and control system120is couplable to any suitable number of external devices, illustrated inFIG.1Aas including an alarm130, the computer132, and the mobile device134. The monitoring and control system120may be configured for raising alerts based on the temperature data received from the monitoring device112and/or based on various analyses performed using the temperature data. For example, the monitoring and control system120raises an alert via the alarm130, which causes a visual signal and/or an auditory signal to be produced, which may include a flashing light, an alarm sound, or the like. The visual and/or auditory signals can be perceived by administrators responsible for operating the oven102and/or the cooler104, who can then investigate the alert, for instance via the monitoring and control system120, and take appropriate action. In another example, the monitoring and control system120raises the alert by issuing a message (textual or otherwise) to the computer132and/or to the mobile device134. The message can include any suitable information, including the nature of the alert, one or more potential faults of the food production devices, one or more possible solutions to implement, and the like. For instance, the message can indicate a potential fault of a door of the oven102being left open, of a cooling system of the cooler104malfunctioning, or of a malfunctioning temperature sensor114, for instance if the temperature data provided by one temperature sensor114in a group of racks110differs from the temperature data provided by the other temperature sensors114.

During a food production process, the monitoring and control system120receives the temperature data from the monitoring device112, and is configured for analyzing the temperature data to monitor food production processes performed by food production devices, for instance the oven102and the cooler104ofFIG.1A. As noted hereinabove, certain regulatory agencies set out specific requirements for food production which must be observed by food producers, failing which a food product may require reprocessing or be disposed of. To this end, the monitoring and control system120is provided with, or develops, one or more temperature benchmarks against which the temperature data is compared, in order to determine whether the food product is being processed in accordance with the established regulatory requirements.

Referring now toFIG.2A, a temperature profile for a heating step of a cooking process is illustrated. During the heating step, the product is heated from an initial temperature T0to a final temperature T1. The monitoring and control system120may gather temperature data at a plurality of time periods and determine whether or not the temperature increases as it should. An alarm may be generated if it is not the case since this may imply a problem with the oven102and/or with one or more of the temperature probe(s)114.

FIG.2Aillustrates a temperature profile320of an actual temperature of the product being cooked. The monitoring and control system120may issue an alarm when the temperature is decreasing during the heating step since a decreasing temperature during the heating step may be an indication of a malfunction of the oven102. In other words, the monitoring and control system120may issue an alarm if the temperature of the product is not continuously increasing during the heating step. For instance, if the temperature is constant for a given time interval, a warning/alarm may be issued. If the temperature is decreasing, a warning/alarm may be issued.

During the heating step, the temperature of the product should increase from an initial temperature T0to a final temperature T1within a specific or prescribed time interval t1. For instance, the product may have to increase from the initial temperature T0to the final temperature T1within at least a first time interval and within at most a second time interval greater than the first time interval. These two time intervals correspond to tminand tmaxonFIG.2A. For example, the product may have to increase from 20 degrees Celsius to 75 degrees Celsius in no more than 2 hours but not before 1 hour.

The monitoring and control system120may be able to predict the time at which the product will reach the desired final temperature T1. As shown inFIG.2A, a prediction curve321may be generated from the temperature data points of the actual profile320. A regression may be carried based on the actual temperature data points of the actual profile320. This extrapolation may predict a time tprojectedat which the product is expected to reach the desired final temperature T1. In the case ofFIG.2A, the projected time tprojectedis less than the minimal time tmin. This implies that the heating of the product occurs faster than desired. Hence, the monitoring and control system120may issue a warning or an alarm notifying a user of this abnormality. In other words, an alert or warning may be raised when the projected time differs from a prescribed time by a given time value (e.g., 30 minutes). Corrective actions may then be taken to rectify the heating. This may be done, for instance, by varying the internal temperature of the oven102.

This prediction may be carried at every pre-determined time intervals (e.g., every 5 minutes). In some cases, a learning period may be set. The learning period allows the monitoring and control system120to gather sufficient temperature data points of the actual profile320in order to generate an accurate extrapolation of the cooking time to reach the desired final temperature T1. The prediction may be carried via a regression based on the gathered temperature data points. The regression may be linear, polynomial, Support Vector Machine, Support Vector Classifier, and any suitable combination any of the above regression methods. For instance, the regression may be linear for a first time range and polynomial for a second time range. Any suitable extrapolation method may be used.

In some cases, the heating may include a plurality of criteria. For instance, it may be required to heat the product from the initial temperature T0to an intermediate temperature being less than the final temperature T1within less than a first time interval and to heat the product from the initial temperature T0to the final temperature T1within a second time interval, which is greater than the first time interval. In some cases, it may be required to heat the product from the initial temperature T0to an intermediate temperature within less than a first time interval and to heat the product from the intermediate temperature to the final temperature T1within a second time interval. The monitoring and control system120may performed regression at any particular time to determine whether or not the heating step is expected to meet these criteria.

Referring now toFIG.2B, in some cases, a steady-state step follows the heating step. During the steady-stage step, a temperature of the product is to be maintained at a specific temperature, depicted with the optimal temperature profile335. However, as explained above, temperature variations may arise. The monitoring and control system120gathers data point about the temperature and an actual temperature profile331is generated.

The monitoring and control system120may issue warning when the temperature of the product falls below a first low temperature threshold335A or exceeds a first high temperature threshold335B. The monitoring and control system120may issue an alarm when the temperature of the product falls below a second low temperature threshold335C, which is less than the first low temperature threshold335A, or when the temperature exceeds a second high temperature threshold335D, which is greater than the first high temperature threshold335B.

As shown inFIG.2B, two warnings may be generated for the markers331A,331B and an alarm may be generated for another marker331C. In some embodiments, an extrapolation may be carried to predict whether or not the temperature is expected to fall under or rise higher than the different thresholds,335A,335B,335D,335D.

Referring now toFIG.2C, in some embodiments, a cooling step follows the steady-state step. During the cooling step, it may be required that the temperature of the product does not remain between a given temperature range for more than a given time interval.FIG.2Cillustrates an actual temperature profile340during the cooling step. As shown a maximum time tmaxis allowed for the cooling of the product to decrease in temperature from an initial temperature, which may correspond to the final temperature T1of the heating step, to a final temperature T2.

During the cooling step, the temperature of the product should decrease from the initial temperature T1to the final temperature T2within a specific or prescribed time interval t2. For instance, the product may have to cool down from the initial temperature T1to the final temperature T2within at least a first time interval and within at most a second time interval greater than the first time interval. These two time intervals correspond to tminand tmaxonFIG.2C. The monitoring and control system120may be able to send warnings/alarms if the cooling step is projected to be too fast or too slow.

The monitoring and control system120may issue an alarm when the temperature is increasing during the cooling step since an increase in temperature during the cooling step may be an indication of a malfunction of the cooler104. In other words, the monitoring and control system120may issue an alarm if the temperature of the product is not continuously decreasing during the cooling step. For instance, if the temperature is constant for a given time interval, a warning/alarm may be issued. If the temperature is increasing, a warning/alarm may be issued.

The monitoring and control system120may be able to predict the time at which the product will reach the desired final temperature T2. As shown inFIG.2C, a prediction curve341may be generated from the temperature data points of the actual profile340. A regression may be carried based on the actual temperature data points of the actual profile320. This regression may predict a time tprojectedat which the product is expected to reach the desired final temperature T2. In the case ofFIG.2C, the projected time tprojectedis more than the maximal time tmax. This implies that the cooling of the product occurs slower than allowed. Hence, the monitoring and control system120may issue a warning or an alarm notifying a user of this abnormality. In other words, an alert or warning may be raised when the projected time differs from a prescribed time by a given time value (e.g., 30 minutes). Corrective actions may then be taken to rectify the cooling. This may be done, for instance, by varying the internal temperature of the cooler104.

This regression may be carried at every pre-determined time intervals (e.g., every 5 minutes). In some cases, a learning period may be set. The learning period allows the monitoring and control system120to gather sufficient temperature data points of the actual profile320in order to generate an accurate extrapolation of the cooking time to reach the desired final temperature T2.

In some cases, the cooling may include a plurality of criteria. For instance, it may be required to cool down the product from the temperature of the product after the steady-state step to an intermediate temperature within less than a first time interval and to cool down the product from the temperature of the product after the steady-state step to the final temperature T2within a second time interval, which is greater than the first time interval. For example, it may be required to cool the product from 49 degrees Celsius to 4 degrees Celsius within no more than 20 hours. In some cases, it may be required to cool down the product from 54 degrees Celsius and 27 degrees Celsius within no more than 20 hours and it may be required that the product cools down from 54 degrees Celsius to 4 degrees Celsius within no more than 7 hours. The monitoring and control system120may performed regression at any particular time to determine whether or not the heating step is expected to meet these criteria.

In some cases, it may be required to cool down the product from the temperature of the product after the steady-state step to an intermediate temperature within less than a first time interval and to cool down the product from the intermediate temperature to the final temperature T2within a second time interval. For example, it may be required to cool the product from 54.4 degrees Celsius to 26.6 degrees Celsius within no more than 1.5 hours and to cool down the product from 26.6 degrees Celsius to 4.4 degrees Celsius within no more than 5 hours.

The monitoring and control system120may be configured to issue a plurality of alarms, which may include process alarms, technical alarms, and notifications. Process alarms relate to the temperature behaviour and prediction. Technical alarms relate to the hardware. Notifications are a special type of process alarm. The alarms are summarized in the table below.

The monitoring and control system may include a graphical user interface (GUI) that may include a process information area displaying batch and product information (e.g., batch number, product number, quantity, customer, current step, state, etc). The GUI may display the graphs, for instance the graphs shown inFIGS.2A to2C, The GUI may have one or more recipe tabs in which parameters (e.g., time, temperatures, criteria, etc) of each of the heating, steady-state, and/or cooling step are displayed.

With additional reference toFIG.3, an example graphical user interface (GUI)200is illustrated. The GUI200can be presented by the monitoring and control system120, for instance via a screen associated therewith, or via the computer132and/or the mobile device134. For example, the monitoring and control system120is accessible to the computer132and/or to the mobile device134via an application-program interface (API), or via some other approach, via which the monitoring and control system120can provide the computer132and/or the mobile device134with the GUI200, or with the information required to produce the GUI on the computer132and/or the mobile device134. The GUI200includes a chart area202, which illustrates a temperature benchmark at210and the temperature data obtained from the monitoring device112, in the form of a temperature profile220. The GUI200also includes various food production parameters205, which can include an identifier associated with the monitoring device212, an identifier indicating the food production batch number, the food production recipe, client, and lot size, and the like. The food production parameters205can also include a numerical representation of temperatures at a selected time, which may be indicated by the cursor206.

In some embodiments, the temperature benchmark210used by the monitoring and control system120may take the form of one or more curves, illustrated here as curves212,213,215,217, and218(collectively the “benchmark210”). The benchmark210may be provided to the monitoring and control system120by an operator or developer associated therewith. For instance, the developer can establish the benchmark210by identifying various key temperatures and associated times at which the temperatures should be reached, or time periods during which the temperature should be maintained. Alternatively, or in addition, the benchmark may be developed by the monitoring and control system120based on rules provided by the operator or developer. For instance, the monitoring and control system120can be provided with maximum and minimum temperatures for different periods of a food production process, and can devise the benchmark210based thereon, using any suitable algorithm or set of rules. The monitoring and control system120is provided with different benchmarks210for different food production processes, and for different types of food being subjected to the same types of food production processes. For instance, different benchmarks210are provided for different types of meat to be smoked, and a single type of meat can be provided with different benchmarks210for a smoking process, a shower process, a cooling process, and the like.

The monitoring and control system120uses the temperature data obtained from the monitoring device112to produce a time-varying temperature profile of the food product being processed, illustrated inFIG.3by markers220. The monitoring and control system120may compare the temperature profile220of the food product to the benchmark210to assess whether the food product is being processed according to the established regulatory requirements; when a deviation or discrepancy is identified, the monitoring and control system120raises an alert as described above. In the example depicted inFIG.3, the temperature profile220is based on discrete times at which the monitoring and control system120received temperature data from the monitoring device112. In some embodiments, the monitoring device112provides data at a higher frequency, or in a pseudo-continuous fashion, and the temperature profile220can include additional markers, or can be illustrated as a continuous curve. Other approaches are also considered.

In the embodiment illustrated inFIG.3, the benchmark210includes two “alarm” curves212,218, two “warning” curves213,217, and a “recipe” curve215. The recipe curve215represents an optimal processing temperature profile for the food product; under ideal conditions, the temperature profile220would be aligned with the recipe curve215. The warning curves213,217define temperatures closer to the recipe curve215than the alarm curves212,218; when the temperature profile220reaches the warning curves213,217, the monitoring and control system120raises a first type of alert. The alarm curves212,218define temperatures farther from the recipe curve215and beyond the warning curves213,217; when the temperature profile220reaches the alert curves212,218, the monitoring and control system120raises a second type of alert, different from the first type. For example, the alarm curves212,218indicate that the cooking process is likely to, or in the process of, failing to achieve the established regulatory requirements, which would result in a need for reprocessing or disposing of the food product, whereas the warning curves213,217indicate that the cooking process is trending toward failing to achieve the established regulatory requirements. Thus, the monitoring and control system120can issue different alerts based on how the temperature profile220compares to the different curves212,213,215,217,218of the benchmark210. It should be noted that in other embodiments, the benchmark210includes fewer, or more, curves, which can be associated with additional alerts, as appropriate.

The comparison between the temperature profile220and the benchmark210can be performed in any suitable fashion. In some embodiments, the discrete values of the temperature profile220are compared to the recipe curve215of the temperature benchmark210: when a value of the temperature profile differs from the recipe curve215beyond a predetermined threshold, for instance associated with one of the alarm curves212,218or the warning curves213,217, the monitoring and control system120raises an appropriate alert. In some other embodiments, the differences between the temperature profile and the different curves212,213,215,217,218are determined, and the monitoring and control system120compares the differences to associated thresholds for each of the different curves212,213,215,217,218to assess whether an alert is to be raised, and which alert in particular. In some further embodiments, the temperature profile220is compared to upper and lower bounds established by the alarm curves212,218and/or the warning curves213,217. When the temperature profile220is determined to be outside the bounds established by the warning curves213,217, but not beyond the bounds established by the alarm curves212,218, the monitoring and control system120issues the first alert associated with the warning curves213,217. When the temperature profile220is determined to be outside the bounds established by the alarm curves212,218, the monitoring and control system120issues the second alert associated with the alarm curves212,218.

Other approaches for comparing the temperature profile220and the benchmark210are also considered. For example, the monitoring and control system120interpolates a temperature curve based on the discrete values forming the temperature profile220, and compare portions of the temperature curve to the curves212,213,215,217,218to assess whether the portions of the temperature curve exceed any one or more of the curves212,213,215,217,218, and raise alerts when appropriate. In another example, the monitoring and control system120assesses one or more derivative temperature curves at one or more points along the interpolated temperature curve. The derivative temperature curves can be used to project one or more values for the temperature profile220at subsequent times (i.e., at times in the future for which no temperature data is available) and/or to assess rates of change for the temperature curve. The projected value(s) and/or rates of change may be used as part of the comparisons performed by the monitoring and control system120to assess whether the temperature profile220is likely to follow the recipe curve215, or likely to approach or intersect one of the warning or alarm curves212,213,217,218. In some embodiments, the monitoring and control system120is configured for pre-emptively raising alerts based on the projected value(s), for instance to allow administrators responsible for operating the oven102and/or the cooler104to adjust their operation, thereby increasing the likelihood of complying with the established regulatory requirements.

In some embodiments, the monitoring and control system120prepares reports regarding ongoing and/or completed food production processes. The reports, which indicate the nature of the food production process performed, the type of food product, and the like, may additionally detail a degree to which the temperature profile220tracked to the recipe curve215, an amount of time the temperature profile220was above or below the warning curves213,217and/or the alarm curves212,218, or other relevant information. These reports can include the temperature data, for instance in a tabular format, which can be timestamped or provided with additional metadata, as appropriate, so that the reports can be used as part of an audit or other compliance process which may be executed by a relevant regulatory agency. In some embodiments, the reports are digitally signed or otherwise authenticated to indicate that they are tamperproof.

In operation, an administrator preparing a batch of food product to be subjected to a food production process provides the monitoring and control system120with various information. The information may be provided by an input device associated with the monitoring and control system120, for instance the computer132, the mobile device134, or another input device, for instance a keyboard, a touchpad, or the like. The information may include an indication of the customer associated with the food product, the type of food product, the size of the batch, and the like, and can select a benchmark210for the food production process being performed. The monitoring and control system120receives the temperature data during the food production process from the monitoring device112, and compares the temperature data to the benchmark210as described hereinabove. The monitoring and control system120can also produce one or more reports during or following the food production process, as appropriate. In some embodiments, once the food production process is complete, the administrator of the food production process confirms the temperature data obtained by the monitoring and control system120, for instance using a digital signature or similar approach.

In some embodiments, each of a plurality of users having access to the monitoring and control system120may be assigned a respective personal identification number (PIN). This may provide traceability and accountability of the cooking process. This may allow audit trailing. In some cases, two types of users may be used: operator and administrator. Operators are users in charge of the cooking process whereas administrator may have more options to modify parameters of the monitoring and control system.

In addition, although the present disclosure focuses primarily on temperature monitoring based on temperature data gathered by the temperature sensor114, it should be noted that the monitoring device112may be provided with additional sensors and/or sensing functionality. For example, the monitoring device112is provided with humidity-monitoring functionality and/or airflow-monitoring functionality, for instance using additional sensors. Any additional data gathered by the monitoring device112(e.g. humidity data, airflow data, and the like) can be transmitted to the monitoring and control system120and processed similarly to temperature data, as described above.

With reference toFIG.4, the monitoring and control system120may be implemented by a computing device410, comprising a processing unit412and a memory414which has stored thereon computer-executable instructions416. It should be noted that the monitoring device112may also be implemented by way of the computing device410, although the monitoring device112and the monitoring and control system120are separate entities, and would be implemented by different computing devices410.

The processing unit412may comprise any suitable devices configured to implement the functionality ascribed to the monitoring and control system120such that instructions416, when executed by the computing device410or other programmable apparatus, may cause implementation of some or all of the functionality ascribed to the monitoring and control system120described herein. The processing unit412may comprise, for example, any type of microprocessor or microcontroller, a digital signal processing (DSP) processor, a central processing unit (CPU), an integrated circuit, a field programmable gate array (FPGA), a reconfigurable processor, other suitably programmed or programmable logic circuits, or any combination thereof.

With reference toFIG.5, there is illustrated a method500for monitoring a food production process. The method500may be implemented, for example, by the monitoring and control system120. The method500includes, at step502, receiving real-time temperature data associated with a food product during the food production process. The temperature data is received over a wireless communication channel, for instance the wireless communication channel established between the wireless transmitter116and the wireless receiver122ofFIG.1. The temperature data can be received at any suitable frequency, and using any suitable communication protocol and encoding. In some embodiments, the temperature data includes a timestamp or other relevant metadata, for instance an indication of the food production device in which the temperature sensor114, which records the temperature data, is located, or the like.

The method500includes, at step504, processing the real-time temperature data to produce a temperature profile for the food product. In some embodiments, the temperature profile produced by the monitoring and control system120includes a temperature curve based on an interpolation between discrete temperature data points received at step502.

The method500includes, at step506, comparing the temperature profile to a temperature benchmark associated with the food production process. The temperature benchmark may be defined by one or more curves, one or more pairs of upper and lower bounds, or the like. The comparison between the temperature profile and the temperature benchmark may include comparing discrete temperature data values to the temperature benchmark, comparing portions of an interpolated temperature curve to the temperature benchmark, obtaining projected temperature values based on a derivative and/or a rate of change of the interpolated temperature curve, or the like.

The method500includes, at step508, raising an alert associated with the food production process when the temperature profile differs from the temperature benchmark beyond a predetermined threshold. For example, the temperature benchmark includes a recipe curve, and when the temperature profile differs from the recipe curve by more than a predetermined amount (whether as an absolute value or a relative value), an alert is raised. In another example, the temperature benchmark includes upper and lower bound, and an alert is raised when the temperature profile is outside the bounds.

In some embodiments, the alert raised as part of step508includes a visual and/or auditory signal, as appropriate, to alert administrator associated with the food production process of the presence of a fault or issue with the food production process. In some embodiments, the alert additionally, or alternatively, includes sending a message to the administrator, which may include an indication of potential faults of the food production device performing the food production process.

In some embodiments, and as shown inFIG.2A, the method400includes determining a projected time for the food product to increase to a determined temperature; and raising an alert if the projected time is below a first time threshold or above a second time threshold. The determining of the projected time may include extrapolating a value for the temperature profile at a subsequent time as a function of the receiving real-time temperature data.

In some embodiments, and as shown inFIG.2B, the method400includes issuing a warning if the temperature deviates from a steady-state temperature profile beyond a first temperature threshold; and raising an alert if the temperature deviates from the steady-state temperature profile beyond a second temperature threshold greater than the first temperature threshold.

In some embodiments, and as shown inFIG.2C, the method400includes determining a projected time for the food product to decrease to a determined temperature; and raising an alert if the projected time is above a time threshold. The determining of the projected time includes extrapolating a value for the temperature profile at a subsequent time as a function of the receiving real-time temperature data.

The embodiments of the devices, systems and methods described herein may be implemented in a combination of both hardware and software. These embodiments may be implemented on programmable computers, each computer including at least one processor, a data storage system (including volatile memory or non-volatile memory or other data storage elements or a combination thereof), and at least one communication interface. Program code is applied to input data to perform the functions described herein and to generate output information. The output information is applied to one or more output devices. In some embodiments, the communication interface may be a network communication interface. In embodiments in which elements may be combined, the communication interface may be a software communication interface, such as those for inter-process communication. In still other embodiments, there may be a combination of communication interfaces implemented as hardware, software, and combination thereof.

The methods and systems described herein may be implemented in a high level procedural or object oriented programming or scripting language, or a combination thereof, to communicate with or assist in the operation of a computer system, for example the computing device410. Alternatively, the methods and systems described herein may be implemented in assembly or machine language. The language may be a compiled or interpreted language. Program code for implementing the methods and systems described herein may be stored on a storage media or a device, for example a ROM, a magnetic disk, an optical disc, a flash drive, or any other suitable storage media or device. The program code may be readable by a general or special-purpose programmable computer for configuring and operating the computer when the storage media or device is read by the computer to perform the procedures described herein. Embodiments of the methods and systems described herein may also be considered to be implemented by way of a non-transitory computer-readable storage medium having a computer program stored thereon. The computer program may comprise computer-readable instructions which cause a computer, or more specifically the processing unit412of the computing device410, to operate in a specific and predefined manner to perform the functions described herein, for example those ascribed to the monitoring and control system120, and those described in the method500.

The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.