Automated Inspection Systems
Automated inspection systems are used in various applications to detect and
remove defects and foreign material from the product stream and help processors
improve quality and increase the value of their end product. Key offers a sophisticated
range of digital sorting systems that recognize color, size, shape, structural
properties and chemical composition to detect the widest range of visible and
invisible defects.
Depending on the needs of each application, our sorters can be designed with
a combination of cameras and lasers to detect and remove a wide variety of defects
and foreign material, which is an important contributor to food safety. When
lasers are combined with high resolution cameras for superior shape, size, color,
texture and density determination, the result is a high quality product sort.
Advanced color and shape sorting can be accomplished with monochromatic or color
cameras, coupled with powerful software algorithms. In addition, BioPrint®
technology identifies defects and foreign material based on unique biological
characteristics and achieves enhanced performance, even under high incoming
defect loads, and detects invisible defects.
In September 2015, the Company introduced the all-new VERYX™ digital
sorting platform. This suite of belt-fed and chute-fed sorters offers high-performance
capabilities for fresh, frozen and dried vegetables and fruits, processed potato
products, nuts and other products. The innovative mechanical architecture and
intelligent decision-making help maintain optimal performance while minimizing
operator interaction. VERYX advancements include sustained all-sided surface
inspection and Pixel Fusion™ that, together with the highest resolution
cameras and laser sensors available on a digital sorter, enable VERYX to achieve
new levels of foreign material and product defect removal. Advanced auto-learn,
self-adjusting capabilities and recipe-driven operation offer enhanced ease-of-use.
Available in a range of inspection widths, VERYX will satisfy food processors
with small to very large production capacity requirements. Veryx was deliberately
designed as a modular, configurable, and flexible platform that will be the
intelligent core of an entire suite of digital sorting solutions, able to support
a broad range of applications and processing needs.
VERYX complements our belt-fed sorters, Optyx®, Tegra® and Manta®,
used primarily in the fresh and frozen fruit, vegetable and potato products
market segments, and our chute-fed sorters, Taurys™, Spyder®, Python
and Cayman®, which are well-suited for sorting nuts, dried fruits and frozen
fruits and vegetables. Our other automated inspection systems include Veo™,
an optical sorter designed specifically for seed corn; VitiSort® for red
wine grapes; Tobacco Sorter™ systems used in tobacco threshing and primary
processing; and ADR® automatic defect removal systems used in the potato
strip industry.
In November 2014, we introduced ADR 5 with CIT®, an advanced hyperspectral
solution that evaluates the chemical composition of objects. CIT detects ‘sugar
ends,’ an invisible defect that plagues potato processors, which the ADR
then cuts from the wet potato strips, along with other defects, to recover the
good product. As the first hyperspectral imaging solution for potato strips,
ADR 5 with CIT permits sugar end detection to occur at a point on the production
line where the defect can be removed without losing yield. CIT is a proprietary
solution developed by EVK DI Kerschhaggl GmbH and Insort GmbH, which we have
exclusively licensed to deploy in our products in the potato market. The new
CIT hyperspectral imaging module is available as an option on new ADR 5 systems
and as an in-field upgrade for installed ADR 5 systems.
In January 2015, the Company introduced Information Analytics, a suite of software
capabilities embedded within our digital sorters that enables the collection,
analysis and sharing of data across the food processor’s enterprise. Equipped
with Information Analytics, the sorter continuously collects and stores a variety
of information about the sort process and the product flowing through the sorter
to drive more intelligent sorting or generate customized statistical reports.
It helps food processors better manage raw materials and optimize processes
upstream and downstream of the sorter in addition to improving the sorter’s
accept/reject decisions.
Software-driven intelligence, such as our Sort-to-Grade™ technology for
potato strip processing, continues to extend the value of sorting. Sort-to-Grade
allows sorters to grade defects and length by count, accepting or rejecting
each strip to control the quality of the output to a defined grade, as defined
by the processor.
We also offer automated inspection equipment for solid dose pharmaceuticals
and nutraceuticals through our SYMETIX pharmaceutical product line. Available
in a range of sizes, VeriSym® sorting systems inspect the color, size and
shape of tablets and softgels and automatically remove defects and foreign tablets
or softgels from the product stream at rates of up to 1,000,000 tablets or capsules
per hour. These inspection systems help product manufacturers and contract packers
assure the quality of their finished product and are designed to replace batch
processing systems historically used in this industry. In August 2015, the Company
introduced its Cruise Control and Counting software-driven capabilities as an
option on new and installed VeriSym systems. Cruise Control regulates the throughput
to optimize inspection, and the Counting tool eliminates the need for a weigh
scale by enabling VeriSym to fill bulk containers to the desired count.
We have a large installed base of automated inspection systems, which we support
with upgrades to extend the life of the equipment and enable customers to continue
operating at peak performance as technology advances. Upgrades often provide
customers with a less capital intensive alternative to acquiring new automated
inspection systems.
Process Systems
Conveying and processing equipment are utilized worldwide throughout many industries
to move and process product within a production plant. The process systems group
includes standard and custom designed equipment that conveys, dewaters, transfers,
distributes, aligns, feeds, meters, separates, grades, cleans, washes and polishes
products. Our Smart Shaker® vibratory solutions, which include Iso-Flo®,
Impulse® and Horizon™ systems, combine gentle material handling with
a wide variety of processing functions in addition to vibratory conveying. Rotary
sizing and grading systems and SYMETIX equipment for pharmaceuticals and nutraceuticals,
complete our conveying and processing equipment product line.
The mechanical sizing, sorting, separating and grading equipment manufactured
at our facilities is used in many food processing and fresh vegetable packing
operations. These rotary sizing and grading technologies can remove oversized,
undersized and small irregular-shaped pieces of product from the line or separate
product into predetermined size categories. Additionally, this equipment can
remove field debris, broken pieces, seeds, juice, fines, and other targeted
material.
Preparation Systems. We design and manufacture preparation systems to prepare
a wide range of food products prior to cooking, freezing, canning, or other
types of processing. Equipment in this group includes air cleaners, air coolers,
vegetable metering and blending systems and bulk handling equipment. This equipment
represents our most mature product line. Sales of these solutions over the years
have formed a customer base for sales of our other solutions and are also establishing
a new customer base in developing markets. Preparation system revenues include
sales of a variety of third-party supplied equipment and installation services,
which are sold as components of larger, integrated processing lines, for which
we have assumed turn-key sales responsibility. In addition, we maintain an agreement
with ABCO Industries to sell its thermal processing equipment through our distribution
channels.
Line Solutions
Integrated Solutions. Our Integrated Solutions Group (ISG) provides integrated
whole-line solutions. From pre-engineering and project definition to plant start-up,
ISG offers complete turn-key solutions that can include the integration of third-party
products along with Key’s sorting, conveying and processing systems to
meet the specific needs of each application. We leverage our industry expertise
and strong engineering and project management capabilities to deliver complete
integration services, all from a single source.
Parts and Service
We have a large installed base of inspection and processing systems, which
generates potential business for our parts, service and training programs. Our
PROliance™ suite of support services, parts, protection plans and training
solutions provides spare parts and post-sale field and telephone-based repair
services to support our customers’ routine maintenance requirements and
seasonal equipment startup and winterization processes. Our field service personnel
are geographically located around the world close to customers, enabling quick
response time and regional technical support. We typically provide incidental
system installation support services in the sale price of select systems, principally
automated inspection systems.
RemoteMD™. RemoteMD is a real-time condition monitoring and diagnostics
analysis tool for G6 optical sorters - Manta, Optyx and Tegra - as well as G6
ADR systems. RemoteMD proactively monitors the condition of the customer’s
system, assesses the status and alerts the customer if problems are detected.
By automating detection and diagnosis, RemoteMD provides detailed information
to our service technicians, which increases the first-time fix-rate, reduces
in-plant service calls, speeds resolution time and enhances customer productivity.
We offer three distinct levels of RemoteMD services as part of our comprehensive
protection plans - SelectPRO, PlusPRO and PremierPRO. Each of the three protection
plans is sold via annual subscription.
Online Training. This program provides customers with an interactive multimedia
curriculum covering selected optical inspection systems and vibratory conveyors.
The flexible, web-based program offers a wide variety of self-paced training
modules designed for operators, maintenance personnel, sanitation crews, supervisors
and others working with this equipment. Our online training program includes
modules that cover ADR hardware, Optyx hardware, Tegra hardware, G6 software,
Iso-Flo vibratory conveyors and a variety of industry-related compliance topics.