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Margaret Malloch, general manager of the company, said that the laboratory receives up to 20,000 - 30,000 round plastic bottles from the dairy every day. However, the recognition system previously using bar code and manual detection could not meet SAITL requirements, she said, too time-consuming and error-prone.
“We plan to automate the lab and RFID is part of it. For this we set up a project to study the best practices and required changes to implement the RFID system,†explains Malloch.
One passive RFID tag on the bottom of each plastic bottle
In early 2009, SAITL gradually introduced RFID applications, including the provision of labeling vials to several sample collection stations within months. A TI Laundry Transponder DS105 13.56 MHz passive RFID tag was attached to the bottom of each bottle during the manufacturing process. The bottles were then sent to dairy factories across New Zealand to collect milk samples. The samples were later gathered and sent by the milk producer Fonterra to SAITL's laboratory. Fonterra has 11,000 dairy farms and is one of SAITL's shareholders. During the launch of the project, barcode labels are also placed on the bottles to double check the correctness of the information written on the labels. When the system is officially activated, the bar code label will be removed from the bottle.
The lab is a challenging RFID application environment. Due to the close spacing of the samples and the high metal content of many inspection instruments, SAITL spent a great deal of time debugging RFID antennas and readers to ensure read accuracy and accuracy. Another challenge is that the new label lacks a visually readable interface. Barcode labels used by companies in the past have included human-readable text. However, if passive 13.56 MHz RFID tags are replaced with barcodes and affixed to the bottom of each bottle, it may be difficult for technical workers to locate and identify a particular sample.
"This requires the use of a custom large antenna and reader software that reads multiple tags in a short period of time," Malloch said.
In the SAITL laboratory, the worker first placed the bottle filled with milk on a tray and then moved the tray through a set of RFID readers. There were three rows, each with 10 readers. A single tray can hold 250 bottles, and 30 readers quickly read the bottle labels. The labels conform to the ISO 15693 standard and can store 250 bytes of data. The tag data is then sent to the SAITL database, and the data returns a letter for each sample that must go through the details of the specific test. This ensures that the staff performs the correct biological and chemical tests on each sample and also guarantees the quality and safety of Fonterra's dairy products sold to customers. Multiple applications of the SAITL laboratory employ multiple RFID readers and readers. Most readers are customized by Tracient to solve SAITL specific problems. Lab employees also manually read some bottle labels using the Tracient handheld readers already on the market.
Fonterra installed the system for SAITL and has also participated in the Milk Collection Programme of Work project, which is part of the SATL project. In January 2006, Fonterra Milk Supply officially launched MCPOW, using RFID to track farm-to-factory milk collection. When Fonterra collects the milk stored on the farm vat, the RFID reader on the milk tanker automatically reads the information of each vat's RFID tag. Each barrel's TI DS105 RFID tag contains the company ID code, farm ID code, milk temperature, collected dose, collection time, and status code.
In SAITL applications, special RFID antennas are connected to Tracient readers and send information to a central database via mobile data transmission or standard synchronization tools. Tracient also customizes the reader for use in the special environment of the laboratory. SAITL management data software MADCAP is provided by Contec Group.
The readers used in the Milk Collection Programme of Work project include handsets, milk tankers, and lab readers for a total of 1,000 units. At the Fonterra plant in various parts of New Zealand, more than 14,000 milk storage vats are also labeled, which means that the company can use label information to trace the source of the milk samples, the amount collected, and the temperature at the time of collection. This project uses more than 600,000 total labels.
The ultimate goal of the SAITL project is to achieve a complete RFID milk collection chain: milk samples are labelled, collected from dairy farms to factory storage, and then SAITL laboratories implement full monitoring and information traceability.
She added, “For those who still use barcodes, we use both barcodes and RFID tags. Once the tests are completed, the tag identification information is eliminated, the tags are removed from the sample bottles, and the bottles are returned to the plastic manufacturer for reuse. Can use 100,000 times.
Sample bottle recycling is an additional revenue for SAITL and is one of the benefits of RFID projects. Previously, the sample bottles were made of two different plastics, and recycling was impractical, but the collection of new bottles of milk could be recycled. According to Malloch, RFID speeds sample processing. Such as a single RFID reader can handle 150 bottles. RFID also improves the accuracy of sample identification and determines which samples need to be tested, which increases productivity and reduces costs.
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