From the IPPE 2025 Tech Talk series, watch Tim Stork, PPO Senior Solutions Engineering Manager, dive into how artificial intelligence (AI) and machine learning (ML) are transforming food safety. PPO specializes in using these technologies to detect foreign materials in food processing, leveraging its expertise to improve efficiency and safety in the industry.
Key Points:
In modern food processing, ensuring product safety and quality is paramount. PPO is at the forefront of this effort, leveraging artificial intelligence (AI) and hyperspectral imaging to revolutionize foreign material detection. Here’s how these technologies are making a significant impact.
Why AI is Essential for Foreign Material Detection
PPO’s hyperspectral imaging systems generate enormous amounts of data—up to 20 terabytes per eight-hour shift. Analyzing this data manually is impossible, making AI and machine learning critical. These technologies process real-time data on the production line, identifying contaminants within fractions of a second and triggering rejection mechanisms instantly.
Optimizing Efficiency Through Data Insights
Beyond detection, AI helps plants operate more efficiently by identifying trends and sending alerts. For example, one customer noticed a spike in bone detections in chicken breasts. AI traced the issue back to misaligned auto-deboners due to changes in preventive maintenance schedules. Adjustments were made promptly, reducing product defects and customer complaints.
Addressing the Challenges of AI Implementation
While AI offers powerful solutions, it comes with challenges:
- Data Quality & Bias: AI models require accurate, unbiased data that reflects real-world conditions. In one case, PPO’s system over-rejected products because the AI wasn’t trained on rare rooster breasts. Updating the training data resolved the issue.
- Risk Management: New technologies should be tested thoroughly before full-scale deployment to understand their decision-making processes and potential impacts.
- Data Privacy: Ensuring data security, especially when handling sensitive information, is crucial.
The Human Factor: Culture and Engagement
Successful AI implementation isn’t just about technology. It requires engaging plant staff—from executives to line workers. When employees understand how AI benefits their work and the company, they become active participants in its success, often finding opportunities for career growth through new tech adoption.
Making the Business Case for AI
To justify AI investments, companies need clear ROI metrics. PPO helps customers identify key benefits, including:
- Reduced Product Waste: Detecting contaminants early minimizes product loss.
- Enhanced Automation: Replacing human inspection with AI improves accuracy and efficiency.
- Fewer Customer Complaints: Better quality control leads to higher customer satisfaction.
Projects succeed when stakeholders at all levels align on goals, expectations are clear, and everyone sees the value. With the right strategy, AI in food processing can deliver significant returns—often within six to nine months.
Watch our Tech Talk from IPPE 2025 – Creating an AI Implementation Plan – A Roadmap for Processors and Producers