Conti’2008, 5-6 june, 2008, Timisoara

Authors: Gheorghe Sebestyen, Sergiu Nedevschi, Gavril Saplacan, Mihai Cerghizan, Nicolae Todor and Mircea

Rusu

Towards a Traceability Solution on the Food Supply Chain

◦ Consortium:◦ Technical University of Cluj-Napoca – project

coordinator◦ University of Agricultural Sciences and Veterinary

Medicine, Cluj-Napoca (domain specific)◦ SISTEC SA, Cluj-Napoca (IT partner)◦ Applied Informatics Company SA (IT partner) Project’s duration: 2006/08/01- 2008/08/31 Interdisciplinary project

◦ Goal: to provide a logistic infrastructure for traceability and quality assurance in food industry

Evaluate and analyze worldwide state-of-the-art in food chain traceability,

Evaluate the traceability and quality assurance requirements for Romania, in the context of EU membership

Definition of a generic Traceability and Quality Model for the Romanian food industry

Implementation of a prototype/pilot system for a meat processing unit

Dissemination of the acquired experience to other food processing organizations

The main producers of Standards and Regulations in domain:

International Organization for Standardization – ISO European Food Safety Authority - EFSA and their main

regulatory documents: ISO 9001:2000, ISO 22000 and complementary systems such

as BS 8800 Health and Safety, BRC/IOP Packaging Standard HACCP: The Hazard Analysis and Critical Control Point The White Paper of Food Safety (Bruxelles, Jan 2000), The White paper on the quality systems HACCP, the European Council Directive no. 178/2002 (General Food

Law), regarding the compulsoriness of supplying the traceability information for food products

Directive 2003/89/EC – referring to food ingredients

For good results in quality monitoring and traceability the systems should assure:

◦ Real time parameters values acquisition from production lines

◦ Unique products identification◦ Unique identification of product’s composition (sub-products)◦ Storage of processing parameters values ◦ Storage of risks traceability information ◦ Information exchange features for business partners

Documentation of the systems should include:

◦ Quality manual, with quality policy and quality objectives◦ Documented procedures to ensure the conformity of the

product◦ Documented instructions to ensure the control of the risk

parameters◦ Quality & Traceability information records.

There exist several applicative research projects in the field, among which:◦ TRACE - aims to develop generic and sector-

specific traceability systems for use in the food industry (http://www.trace.eu.org)

◦ Auto-ID project - developed at MIT for automatic product identification(RFID) (GS1, EAN UCC)

◦ AGRO program (Romania) - animals identification

Products and material flow

Upstream and downstream traceability data-exchange

Process monitoring

Intrabusiness

Process monitoring

Process monitoring

Figure 1.The Quality and Traceability system view

Interbusiness – B2B

Foodtrace Traceability Portal

Producers Consumers Distributors Authorities

Intrabusiness

Intrabusiness

Operating System & Communication Support Layer (Windows, Unix)

Operating System & Communication Support Layer (Windows, Unix)

Database Management SystemDatabase Management SystemData Access Layer (Unified Set of Access drivers)Data Access Layer (Unified Set of Access drivers)

Data Persistency Layer Data Persistency Layer Long Term

PreservationLong Term

Preservation

Data StoreData Store Metadata Catalogs

Metadata Catalogs

LDAP, Active Directory

LDAP, Active Directory

Application Services Layer (food production monitoring)

Application Services Layer (food production monitoring)

Web Service Layer (Web server, EPC, ONS)

Web Service Layer (Web server, EPC, ONS)

Multi-users Interface LayerMulti-users Interface LayerIntra-business user interfaces

Intra-business user interfaces

Business to Business user interfaces

Business to Business user interfaces

System Config.

System Config.

Decision support

Decision support

Process monitoringProcess

monitoring

Product offers

Product offers

AdvertisingAdvertisingQuality,

TraceabilityQuality,

Traceability

Foodtrace Graphic User Interface LayerFoodtrace Graphic User Interface Layer

Specialized Webservices, GUI Description LanguageSpecialized Webservices, GUI Description Language

Mobile devicesMobile devices

Embeded devices

Embeded devices

Desktop ComputersDesktop

Computers

Industrial ComputersIndustrial

Computers

Reception Processing Labeling Storage

Food Processing line

Handheld devices

SensorsBarcode Printer

Barcode Scanner

RFID writer

RFID reader

Wireless I/O devices

Industrial Ethernet

Industrial Computer Process Floor DatabaseIndustrial Ethernet

Router

Serial to Ethernet

Convertor

Wireless AP

Administration LAN

ReceptionBeef casePork case

C.C.P.1B – Traceability parameters:

Temperature (0°C)Time ()Humidity (5%)Oxidation (0.1%) Weight (Kg)

Warehouse C.C.P. 2B - Traceability parameters:

Temperature (0-4°C)Time (12h)Humidity (3%)

Ham Preparation

C.C.P.3B,4B - Traceability parameters:

Temperature (<5°C)

…

d) web service response for parameter inquiry<DataSet> <xs:schema id="Sensor7DataSet"> <xs:element name="IdtrtLogRecords" type="xs:int" minOccurs="0"/> ….</xs:schema><Sensor7DataSet> <Table diffgr:id="Table1" msdata:rowOrder="0"> .... <Time>2008-01-01T17:00:06+02:00</ Time > < MeasuredVal >72 </ MeasuredVal > </Table> ....</ Sensor7DataSet> </diffgr:diffgram></DataSet>

<PROCESSINGUNIT id="PRODUCTION COMPANY"> <TYPE id="UNIT TYPE"/> <ADDRESS id="ADRESS">

… </ADDRESS > <SUBUNIT id="PRODUCTION COMPANY – FIRST SUBUNIT "> <DEPARTMENT id="PROCESSING DEPARTMENT 1"> <PRODUCTIONLINE id=”Meat production line”> <EQUIPMENT id=”Mixing equipment”> <SENSOR name=”Temperature sensor 1” id=”1”> <SENSOR name=”Humidity sensor 2” id=”2”>

… </EQUIPMENT <EQUIPMENT id=”Boiling equipment”> <SENZOR name=”Temperature sensor 7” id=”7”>

… </EQUIPMENT></SUBUNIT> …</PROCESSINGUNIT>

Web service request

a) Desktop view b) PDA viewc) Configuration of a production line

Product technology = set of technological operations

Technological operation

(Production phase)

Material quantities

Input product codes

HACCP( CCP)

Generated GTIN associated with:

- Input lot codes

- Monitored values- Risk parameter values

Allowed risk limits

Product’s Parameter Values

Logical scheme of a technological operation

Traceability information

Inp

ut

pro

du

cts

iden

tifi

cati

onIn

pu

t p

aram

eter

id

enti

fica

tion

Diagrama Plan HACCPtcfDiagrameFluxIdtcfDiagrameFlux

tctNomenclatorProduseId

DenDiagrama

tcfPlanHACCPId

trtDocumentId

tcfEtapeFluxIdtcfEtapeFlux

tcfDiagrameFluxId

DenEtapeFlux

NrEtapa

NrEtapaAnt

FK_EtapeFlux_DiagrameFlux

tcfPC_PCCIdtcfPC_PCC

Cod

Denumire

tcfLocatiiId

tcfDiagrameFluxId

tcfEtapeFluxId

FK_PC_PCC_DiagrameFlux

FK_PC_PCC_EtapeFlux

tcfPlanHACCPIdtcfPlanHACCP

tcfUnitatiEcId

DescrierePlan

tcfResUmaneId

FK_DiagrameFlux_PlanHACCP

tcfRiscuriPCCIdtcfRiscuriPCC

tctCatElementeRiscId

tcfPC_PCCId

FK_RiscuriCPP_PCC

tcfRiscuriPCCMarimiDeMasuratIdtcfRiscuriPCCMarimiDeMasurat

tcfRiscuriPCCId

tctPC_PCCMarimiId

tcfTehnologiiId

tcfTehnoMaterialeId

tcfEchipmenteId

ValMin

VAlMax

trtDocumenteId

trtActiuniCorectiveId

Obs

FK_RiscuriCPPMarimi_RiscCPP

tcfTehnologiiIdtcfTehnologii

tctNomeclatorProduseId

tctTipEchipamenteId

tctCatOperTehId

tcfEtapeFluxId

NrOper

NrOperAnter

DurataOper

DataCrea

TipTehno

FK_Tehnologii_EtapaFlux

FK_RiscuriCPPMarimi_Tehnologie

tctPC_PCCMarimiIdtctPC_PCCMarimi

DenMarime

DenStiintPCCMarime

TipPC_PCCMarimeId

tctUnitatiDeMasId

FK_RiscuriCPPMarimi_PC_PCCMarimi

tctNomenclatorProduseIdtctNomenclatorProduse

DenArticol

Cod

Gtin

tctUnitatiDeMasId

DataCrea

Obs

FK_DiagrameFlux_NomenclatorProduse

FK_Tehnologii_Nomenclator1

tcfEchipamenteIdtcfEchipamente

DenEchipament

tcfLocatiiId

tcfLiniiProductieId

tcfDepartamenteId

tcfResUmaneId

tctTipEchipamenteId

trtDocumenteGestId

tctClaseEchipamenteId

DataPF

CoordX

CoordY

CoordZ

FK_RiscuriCPPMarimi_Echipament

tcfTehnoMaterialeIdtcfTehnoMateriale

tcfTehnologiiId

tctNomenclatorProduseId

TipIE

Cantitate

FK_TehnoMateriale_Tehnologii

FK_TehnoMateriale_NomenclatorProduse

FK_RiscuriCPPMarimiDeMasurat_TehnoMat

Configuration parameters for:• Production lines• Product recepies• HACCP plans• Workflow diagrams• Monitored parameters• Workflow phases

FoodTrace Framework provides integrated support for development of applications using:◦ Virtual devices with adapted drivers for specific

devices◦ Modbus Message Protocol◦ Partial class diagram for Modbus device

Finally each product from the warehouse has a dataset containing:

quality parameter values risk parameters values

A sample of HACCP log record:

Ham/Roast Beef Establishment 1: Cooler Temperature Log

ROOM: Cold-Frozen Raw Meat DATE: 01.01.2008

Time Temp Deviation from CL?(Check if yes)

If yes, Action? Monitored by: Verified by:

08:00 -15.0ºC No No Smith John Supervisor

08:05 -14.9ºC No No Smith John Supervisor

… … … … … …

◦ Modbus, Profibus Communications protocols◦ Simex-TRS◦ OPC, SCADA◦ SOA – Service Oriented Architecture◦ SOAP – Simple Object Access Protocol◦ MS SQL 2005◦ Web Services◦ XML, XSLT, XAML, HTTP◦ C#, .NET, ASP.NET

Benefits• Automatic real-time monitoring of food processing lines. • risk monitoring for food generated disease;• products identification • Infrastructure for food lots recall in case of incidents;• Increased confidence in the food product suppliers;• Improved quality of life (health and socio-economic).

Barriers

The barriers may include:• Lack of full standardization• Absence of complete local specified legal requirements;• Financial constraints;•Lack of human expertise and/or technical support;• Inadequate infrastructure and facilities; • Inadequate communications.

Using standards and highly accepted data exchange technologies the proposed system offers an open, flexible and scalable solution.