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International Patent Application W0/2011/121346

Overview of NIR Defect Detection System. CONFIDENTIAL. International Patent Application W0/2011/121346. Background. CONFIDENTIAL. International Patent Application W0/2011/121346. Technical Overview.

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International Patent Application W0/2011/121346

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  1. Overview of NIR Defect Detection System CONFIDENTIAL International Patent Application W0/2011/121346

  2. Background CONFIDENTIAL International Patent Application W0/2011/121346

  3. Technical Overview For the detection of plastics and other materials in foodstuffs, it is not always possible to use traditional methods such as x-ray and metal detectors as these materials often cannot be detected via these approaches. Often x-ray or metal detectors detection apparatus are not easily deployed at strategic points in the production process due to restricted access or radiation hazard concerns etc. ITL’s near-infrared (NIR) imaging technique uses NIR beams of light—around the wavelengths found in ordinary domestic remote controls—and signal recovery techniques commonly used in astronomy. Work in the area of industrial application of NIR in NDE was reported initially at the annual QNDE conference in 2008 [1,2] and has enjoyed considerable success since in various deployments. It is a zero-radiation technique CONFIDENTIAL International Patent Application W0/2011/121346

  4. Originally developed for security applications, this technique has also had commercial application for in-line food inspection and has now been applied to HB Fuller products . • Unlike x-rays this apparatus is low-voltage and low powered and is completely free of non-ionising radiation. • The technique of NIR imaging can detect things which are detectable by x-rays and metal detectors but also many things which often are not, such as rubber, paper, wood and plastics . • Also provide simultaneous in situ chemical analysis by transmission spectroscopy and detection of chemical signatures. CONFIDENTIAL International Patent Application W0/2011/121346

  5. The figure opposite shows a cardboard box that contains several specimens made of wood and cotton (Q-tip), plastic (pen lid) and metal (tack and paper clip). Note that it shows several materials in shot at the same time, three of which are normally highly radiolucent (plastic, cotton and wood are not well imaged by x-rays). CONFIDENTIAL International Patent Application W0/2011/121346

  6. Real-Time Industrial Application • In-line inspection of moving objects requires a compromise or “trade-off” in clarity and sharpness of imaging in return for real-time detection at practical belt speeds. • This often means that an image will become less recognisable - but this does not necessarily mean that that detection is still not possible • The main approach is to use “blob” extraction and histogram distribution analysis to distinguish between product and contaminant. The software may not know what the defect actually is but it knows that it is not product and hence activates a reject mechanism CONFIDENTIAL International Patent Application W0/2011/121346

  7. Real-Time Industrial Application: Detectivity Vs. Image Distortion The image is blurred - but there is no doubt that an object is being detected. CONFIDENTIAL International Patent Application W0/2011/121346

  8. Example - Plastic and Rubber in Cheese Detection of plastic contaminants at realistic production rates involved a deal of distortion of the NIR image but did not compromise the detection of the presence of these materials in cheese, as illustrated below The photograph of the black rubber, o-ring and the pen top The image scan of the black rubber, o-ring and the pen top. CONFIDENTIAL International Patent Application W0/2011/121346

  9. 850 nm 980 nm 1064 nm Moisture Detection using 980 nm Wavelength • The NIR of 980 nanometres is strongly absorbed by free water and moisture and appears to be darker. • Below, a water bearing sample with two defects, illuminated at various NIR wavelengths, illustrates this. • If two wavelengths were used the simultaneous imaging/defect detection and moisture content determination is possible . CONFIDENTIAL International Patent Application W0/2011/121346

  10. Initial In-Situ NIR Defect Detector Results from HB Fuller Plant in 6th October City, Egypt 17th January 2011 CONFIDENTIAL International Patent Application W0/2011/121346

  11. 1. Recorded NIR Image of Single Bag on Belt NO CONTAMINANT CONFIDENTIAL International Patent Application W0/2011/121346

  12. Click on image to Start REPLAY CONFIDENTIAL International Patent Application W0/2011/121346

  13. Bagged product containing no defect and its equivalent NIR Image CONFIDENTIAL International Patent Application W0/2011/121346

  14. 2. Recorded Image of Single Bag on Belt Containing Contaminants CONFIDENTIAL International Patent Application W0/2011/121346

  15. PAPER Yellow paper underneath yellow product (Defect in bottom of bag as it rests on belt and hidden from sight) CONFIDENTIAL International Patent Application W0/2011/121346

  16. Click on picture opposite to Start REPLAY CONFIDENTIAL International Patent Application W0/2011/121346

  17. Bagged product containing paper contaminant and its equivalent NIR Image CONFIDENTIAL International Patent Application W0/2011/121346

  18. Other Contaminants CONFIDENTIAL International Patent Application W0/2011/121346

  19. Wood Washer (Both Contaminants laying in bottom of bag as they rest on the belt and thus hidden from sight) CONFIDENTIAL International Patent Application W0/2011/121346

  20. Bagged product containing washer and equivalent NIR Image (NB: Similar results obtained with both metal and nylon washers) CONFIDENTIAL International Patent Application W0/2011/121346

  21. Bagged product containing wood contaminant and its equivalent NIR Image CONFIDENTIAL International Patent Application W0/2011/121346

  22. 3. Next stage of installation and proposed validation procedure. CONFIDENTIAL International Patent Application W0/2011/121346

  23. Timeline October 2011 First stage of installation was in October 2011 and was for the purpose of data-collection and characterisation trials in order to tune the operational parameters of the machine (illumination intensity, gain settings etc.) and train the software to be able to distinguish between product and contaminant for a range of different glues. Although this was a successful installation it was not without problems: fortunately was memorialised and fully documented with a photographic record by Chris Blears how after delivery of the working machine to Duckinfield in the UK, Egyptians Customs officials had prised opened the machine and caused extensive damage to fittings and internal components which required an extended stay of an extra two days by ITL staff to affect a field-repair. Joe Kijowski later instigated a complaint with the Egyptian Customs regarding this. The machine ran continuously and trouble free from thereon. CONFIDENTIAL International Patent Application W0/2011/121346

  24. Timeline January 2012 Following the successful characterisation trials, and based on the data gathered , ITL decided to provide HB Fuller with an upgraded-specification detector beyond that originally contracted for. ITL staff took another visit to the site in Egypt to implement the next stage and also be on hand to assist with the P&G Audit. Based on the previous experience with Egyptian Customs, the new detector unit and illumination modules were carried as hand luggage to ensure their safe delivery. Other specialised test equipment such as oscilloscopes, and general tools were shipped as checked-in luggage due to airport security regulations. Unfortunately, on the outbound journey luggage with all the test equipment, tools and personal effects were permanently lost by Air France .....Egypt can be a very arduous environment in which to conduct business where basic things which are often simple to source in the USA or Europe such as fully-threaded 3 mm stainless screws with slotted cheese or hex heads (also lost in the luggage) can be difficult to get. This was compounded by the fact that the first two days of the visit were public holidays. Most crucial though, was the lack of test equipment such as oscilloscopes. This was a major impediment as the installation and setting-up process depends upon such specialised tools. Trying to make-do with out the proper equipment was unfortunately not successful and resulted in the illumination module being damaged and an incomplete installation and the electronics being returned to the UK for diagnosis and repair. CONFIDENTIAL International Patent Application W0/2011/121346

  25. Timeline February 2012 ITL diagnosed and replaced the lighting module and delivered it to Duckinfield along with the upgraded detection unit. HB staff watched a successful demonstration of the upgraded unit’s performance and were briefed regarding its installation. However, it proved technically too difficult to assist the installation process via remote tele-conferencing and the installation remains to be completed. CONFIDENTIAL International Patent Application W0/2011/121346

  26. Immediate problems and proposed action CONFIDENTIAL International Patent Application W0/2011/121346

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