Agent QC is a can-shaped device that can be installed within a production line and be programmed to report back any defects, cracks or problems. As a result, any data pertaining to handling, filling and packaging can be instantly and continually relayed to a users' remote computer or PDA.
This then displays force, pressure, temperature or any other feature that the manufacturer feels is required. Data can be viewed, stored, statistically analysed and reported for quality assurance and quality control.
Manufacturer Sensor Wireless says that the product has been developed as an alternative to existing customised solutions offered by the company.As a result the concept is likely to be initially targeted at small and medium-sized food and beverage manufacturers, bottlers and fillers.
The universal design gives companies three standard-sized devices to simplify monitoring and accommodate a wide range of container sizes. It is this, says marketing and communications manager Tammy Wall, which enables the company to offer the product at a lower price.
"Agent QC comes in three different sizes - 4.5 by 2 inches, 5.5 by 2.5 inches and 8 by 3.5 inches," she said. "These reach the shoulder-height of various sizes of bottles and cans, and can be inserted into any line. This is useful for a company that uses multiple sizes of cans."
So while customised devices are tailor-made but more costly, Wall believes that manufacturers will be able to buy the product straight off the shelf.
In addition, Sensor Wireless is confident that the cheaper price will turn more food manufacturers onto the benefits of installing real-time diagnostic technology rather than relying on time-consuming data-logging to identify problems along a production line.
"As far as we're concerned, there is no real competition in this particular sector," said Wall. "Data logging tends to be cheaper, but you have to go through loads of data to find out about a particular problem. Agent QC lets you know instantly."
Along with the three-sized sensor, which is made of food-grade acrylic plastic, Agent QC also comes with new desktop data management software, a wide variety of functionalities and, according to the company, future upgradeability. In addition, force monitoring is a new technology being developed under the Agent QC brand to identify in-line problems associated with back pressure, accumulation and label scuffing.
The sensor can be used in PET, aluminium, steel and glass applications, and users can also add temperature monitoring. This allows for instant ambient temperature display.
The technology is also adaptable for use with RFID software and other tracking and traceability applications. The system, in combination with individual wireless readers, will allow automated line traceability and troubleshooting with minimal operator supervision.
"Many companies such as Wal-Mart are ensuring that all their products will be RFID-capable in the future," said Wall. "This device is therefore another step in the traceability line."
As the largest single customer of many manufacturers in the US, Wal-Mart is seen as the driving force behind the concept. The organisation is trying to create the critical mass necessary for RFID to take off, and expects all 10,000 of its suppliers to tag their cases and pallets by January 2006.
In addition, integratable GPS technology allows in-transport tracking and transportation monitoring via remote web-based servers. As Wall points out, quality standards within the food industry are continually being tightened, with significant pressure coming from both retailers and an increasingly concerned public. In Europe, legislation enforcing manufacturing traceability is coming into force as early as January 2005.
"Here in Canada, the outbreak of BSE made everyone realise how important in is to keep records and keep track of the food supply," said Wall.
The new technology will be available from 15 September 2004. Wall told FoodProductionDaily.com that while tests runs are currently being carried out in North America, the company is looking into the possibility of marketing the technology in the UK and the rest of Europe.