Corporate Involvement Helps Drive Research and Development

From its inception, the Agricultural Technology Research Program (ATRP) has relied on industrial collaboration to help focus its research and development activities. The driving force behind this alliance has been the Georgia Poultry Federation, which assisted in initiating the program in 1973. The Federation recognized the expanding role technology was playing in the industry and sought to develop a program focused on evaluating, developing, and implementing technological innovations. The result was a unique partnership that has continued for more than 25 years and which addresses “the industry’s practical needs,” according to Abit Massey, executive director of the Georgia Poultry Federation.

ATRP's prototype Intelligent Integrated Belt Manipulator (IIBM) in early field trials.

Industrial collaborators are the backbone of this partnership. They provide the direction needed to tailor research and development activities to specific industry challenges. They also participate directly in research projects by providing technical expertise and assistance as well as offering in-kind and cash contributions. Equally important is ATRP’s Industrial Advisory Board. These poultry industry leaders give their time to help the program identify research topics that best address industry needs. The Board meets at least once a year to hear updates on program research efforts and to discuss challenges and future direction with program personnel.

“Technology is playing an expanding role in the success of the poultry industry,” notes Allen C. Merritt, vice president for science and technology at Gold Kist Inc. “Continued success in the areas of technology exploration and implementation is key to the continued growth of our industry.”

“Creativity between academia and industry helps to make technology applicable,” adds Randy Payne, process improvement manager at Tyson Foods, Inc. in Cumming, Ga.

ATRP research projects, on average, involve seven or eight industrial participants each year. In some cases, more than one location of an individual company is involved in the program’s research activities. Industrial collaborators have helped drive efforts in automation, ergonomics, food safety, environmental, and information technology by providing financial contributions, supplying products and equipment, offering construction and installation assistance for in-plant field trials, and loaning employees for participation in research projects.

A plant worker performs cutting tasks while sensors from the EWAS system collect stressor data.

Gold Kist Inc. has been one of the program’s most active collaborators, especially in the area of advanced robotics. The goal of the advanced robotics initiative is to design and develop workable systems that can be used practically and affordably in poultry processing operations. Gold Kist’s Live Oak, Fla., poultry plant recently agreed to install Tech’s Intelligent Integrated Belt Manipulator (IIBM) on its weigh/price/label line to evaluate the system’s performance as an automatic case packer.

“Our industry wants access to robots that meet our operational needs. We think Tech’s system is a step in the right direction. By partnering with them in this field trial, we hope to learn more of the IIBM’s capability with the ultimate goal of encouraging manufacturing interest in its commercialization,” says Merritt.

ConAgra Poultry has also played a key role in the development of the IIBM; early field tests were conducted at its Gainesville, Ga., plant. And according to Wayne Painter, plant maintenance engineer, the IIBM shows a lot of potential.

Industrial support has also helped to drive the program’s efforts in ergonomics. The Ergonomic Work Assessment System or EWAS project has established a strong partnership with Gold Kist. The goal of the project is to find ways of reducing stressors that can contribute to cumulative trauma disorders (CTDs) in poultry processing workers. EWAS gathers force, exertion, and motion data from workers while they are making cutting motions. Gold Kist has allowed workers at its Athens, Ga., processing plant to participate in on-line testing of the system in conjunction with studies on work-height adjustments.

“We were excited about the ‘discovery’ potential of this project, which supports our corporate goal of protecting the safety of our employees,” says Mike Nations, safety manager at Gold Kist’s Athens, Ga., plant.

Randy Payne of Tyson Foods demonstrates proper deboning techniques using ATRP's instrumented knife.

Tyson Foods, Inc. has been instrumental in bringing work in the computer vision area from the laboratory to the field. The goal of the computer vision project is to develop and refine computer vision technologies for use in judging the quality of processed poultry. Computer vision allows a computer to analyze video data (such as that from a video camera) and make decisions about what it “sees.” Most recently, Tyson opened its Cumming, Ga., operations to ATRP, providing assistance for installation of the computer vision prototype system. Tyson provided all the manpower, materials, and expertise needed to install the system. The system was installed after the chiller to conduct post-chill grading. Using sophisticated computer algorithms, the system accurately distinguished several of the more common defects on poultry carcasses, such as bruises, gall, discolorations, and missing parts. The system is the first poultry product quality monitoring system of its type installed and tested on-line in a poultry processing plant in the United States.

“Tyson Foods’ primary goals are food safety and customer satisfaction,” stresses Payne. “It is our hope that the new technology increases our ability to detect opportunities in the process that would affect these goals.”

The research team is also initiating work with Gold Kist and Meyn Poultry Processing to evaluate a computer vision prototype system for screening systemic defects on the kill line. The team plans to adopt the techniques used in the Tyson field tests for systemic defect detection. Meyn will develop a product kickoff device for the system, while Gold Kist will provide a plant location for in-plant testing.

Tyson Foods has also provided support to the intelligent cutting project. The goal of this project is to develop a flexible vision-guided system for deboning poultry. Tyson has provided product for use in laboratory tests as well as the time of personnel to assist researchers with learning the proper techniques for performing the deboning cut. DAPEC Corporation is also a project collaborator.

Claxton Poultry and Cagle’s, Inc. have provided ongoing support to the wearable computer initiative. The program’s mobile information system combines job performance support software, wireless communication, and a wearable computer that operates hands-free, allowing plant workers access to information from remote locations. The technology was recently used in field studies related to a HACCP (Hazard Analysis and Critical Control Points) application at Claxton’s processing plant in Claxton, Ga. Claxton’s quality assurance personnel used both handheld and wearable computer technologies to sample and record product HACCP data.

Tech's wearable computer system enables plant workers to collect and retrieve data while keeping their hands free for other tasks.

“By partnering with Tech on this project, we have been able to plug into their considerable information technology expertise, giving us a chance to explore the value of using cutting edge tools, like the wearable computer, in our operation with an insider’s understanding of the technology,” says Jerry Lane, president of Claxton Poultry.

In addition to supporting individual research projects, industrial collaborators regularly contribute to capital fund-raising campaigns that support the various endeavors of the research program. Both Gold Kist and Mar-Jac Poultry have contributed to the Georgia Tech Foundation for the past several years, helping to support general research operations needs.

This past year, nine poultry and allied companies donated generously to a special fund-raising campaign to help construct a 45,000-sq. ft. Food Processing Technology Research Building on the Georgia Tech campus. Gold Kist, Cagle’s, FMC, Claxton, Mar-Jac, Seaboard Farms, The Conti Group, American Proteins, and Stork Gamco each gave donations to what is expected to be a world-class research center for collaborative food processing technology development, academic research, and public interaction. Additional industrial donations are still being sought for this exciting new center.

“Gold Kist is committed to helping our industry develop new technologies for process management, food safety, environmental control, and product quality,” says Merritt. “The company’s support of this new facility reflects this commitment and our willingness to partner with the state of Georgia and Georgia Tech in helping make it happen.”

J. Douglas Cagle, CEO of Cagle’s, Inc., also expresses his thoughts on the new facility. “Cagle’s has enjoyed a long-standing relationship with Georgia Tech and has witnessed the organization’s growing commitment to the special needs of our dynamic industry. Cagle’s is confident that the new Food Processing Technology Research Building will provide the right environment to further this sort of research and development, helping to deliver the tools the poultry industry needs as it moves into the 21st century.”

“As we move into the new millennium, we remain excited about the future of the poultry industry and remain committed to developing the technological tools and resources this industry needs now and into the future,” adds J. Craig Wyvill, ATRP director. “Through mutual collaboration, we hope to strengthen the impact our programs have both on producing commercial product and elevating the industry’s understanding of how best to employ new and emerging technologies.”