Development of a sensor, control and monitoring system for cookie production

Nowadays, automated and very complex production plants handle the efficient production of cookies. But even when state-of-the-art machines are used, waste, overproduction and degradation of quality can occur, for example, when the type of flour or the production batches are changed. The SensoBack research project aims to lower waste in cookie production and increase product quality. With the help of condition monitoring and artificial intelligence (AI), complex interactions of the processes will be recorded and evaluated, and a sensor concept will be developed and integrated into the baking process. 

The research objective is accomplished by the project partners in a two-stage process: with the help of the sensor technology developed, all process parameters of the line, such as dough quantity, temperature and humidity, are recorded, compared and evaluated. They provide information about which settings are critical for the quality of production. A cloud-based control station will also enable bakeries to implement ideal process control and achieve long-term quality improvements by automatically evaluating all relevant parameters.

Fraunhofer IEM established communication between sensors and systems and developed technical communication standards. Tangible quality characteristics were extracted from the extensive volumes of data and approx. 100 parameters with a significant influence on the production process were derived. Together with the project partners, the scientists designed a hygiene sensor system that detects possible impurities and provides notification of upcoming maintenance.