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Automatic Process Laboratory

Patented plug-and-play analytical technology
Re-uses existing laboratory calibrations
Integrated quality reporting software

Automatic Process Laboratory

The CheckMaster™ is a patented robot-operated laboratory which can be used both in process and laboratory environments. The automatic plug-and-play process laboratory includes best practice bench-top instruments such as NIR. By re-using existing calibrations, the CheckMaster™ provides accurate analysis of feed & food products before, during and after manufacturing, all without human interference.

The implementation of the CheckMaster™ technology in our production, automates several of our laboratory analysis routines. This result in an increased analysis frequency which provides a superior understanding of the product quality for a complete manufacturing order. Analytical values are automatically transferred to both our operators as well as our ERP-system. ATLINE has done an excellent job in developing and customizing the CheckMaster™ to our products and manufacturing process, with great focus on cooperation and service.

Jacob Mikkelsen,

NIR Specialist & Data Scientist, BioMar A/S

Product categories subject to analysis by the CheckMaster™

Aquatic feed

Pet food

COMPOUND FEED

Forage

Snacks & cereals

Dairy

Coffee

Grain & flour

The CheckMaster™

The CheckMaster™ is a patented laboratory technology which, by means of robot technology, automated standard bench-top analysis instruments subject for, amongst others, Near Infrared Spectroscopy. The Atlytics™ software program ensures total quality analysis reporting and presentation during manufacturing.

 

  • Re-uses ALL existing calibrations
  • Fully automated NIR analysis including grinding
  • Physical product analysis

Automatic bench-top analysis

Automated bench-top NIR analysis without human interference. The technology includes grinding of product samples, interfacing with the NIR instrument and calibration software as well as washing and drying of the sampling cup. ALL existing calibrations are re-used.

  • Re-uses existing NIR calibrations
  • Sample grinding
  • Cup washing
  • Controlled compaction of sample

Quality reporting software

The ATLYTICS™ quality reporting software is an integral part of the CheckMaster™. The software monitors that the product being manufactured is within the specified minimum & maximum tolerances. Both the laboratory and production staff are consistently notified if potential analytical parameters are not complied with.

 

  • Total analytical overview for operators and the laboratory while manufacturing
  • Alarms are raised if analytical values are not within specifications
  • Quality report including KPI for all analytical values

Physical analysis

The CheckMaster™ is configurated with multiple sensors and vision cameras enabling the machine to conduct physical product analysis. The vision systems are supplied with plug-and-play ATLINE algorithms for checking specific properties of the food & feed product. Examples of physical product analysis parameters are bulk density, texture, sizing, colour, hardness, water activity, odour, durability, dust, tapped density and much more…….

  • Total analytical overview for operators and laboratory while manufacturing
  • Alarms if analytical values are not within specifications
  • Final quality report

Automatic sampling & conveying

During production samplers installed at specific control points will automatically collect product samples according to pre-set timers. The product samples are collected and conveyed to the CheckMaster™ for analysis.

  • Sampling technology installed at HACCP
  • All hardware & software supplied by ATLINE

Inline sampling

Inline sampling technology can be beneficial in order to execute a specific analysis, such as bulk density or gloss at a given point in the process. Frequent analysis can support the process performance of specific process equipment such as an extruder or dryer. The analytical result is typically provided every 20-40 sec. and is displayed to the process operator by means of the ATLINE Atlytics™ software. Alternatively, test results can be communicated to the SCADA system by means of an analogue or bus signal

    PackMaster™

    An inline sampler will collect a product sample from a process line on demand. PackMaster will receive the product sample to be packed, sealed and labelled with a flexible choice of information such as date, time, MO number, LOT number etc.

    • Inline sampling and conveying of product to PackMaster™
    • Automatic packing, sealing & labelling of the sample bag
    • No human interference involved in product reference packing process

    ReferenceMaster™

    The ReferenceMaster™ system is designed for automatic sampling, conveying and product pick-up. A centralised collecting location can be allocated for manual product pick-up at a manufacturing site. Each production line can have its own reference pick-up station or one common pick-up station

    The ReferenceMaster™ system can be combined with ATLINE CheckMaster™ & PackMaster™ systems, or operate as stand-alone system

    • Inline sampling and vacuum conveying of product
    • Multiple samplers and reference masters in one system
    • Pre-programmed or forced sampling times

    Inline bulk density analysis

    The inline DensityMaster is designed to analyse bulk density in a free flow of product. Bulk density from post extrusion with a high moisture content to dried or coated product can be analysed. Accuracy is very high due to the unique high speed average analysis technology (patented) thus enabling the DensityMaster to automatically adjust an extrusion process. DensityMaster can analyse the following parameters:

    • Bulk density
    • Gloss
    • Colour
    • Temperature
    • Image