TECHNICAL FIELD

This invention relates to a system and a related method for processing poultry in a poultry slaughterhouse, which method includes a procedure of checking for dead individuals among the incoming live, but anaesthetized animals, or among incoming anaesthetized and killed animals, i.e., for screening for animals that are considered dead on arrival (DOA).

The system of the invention may additionally be combined with a system for visualisation of the results to a process operator, and the method of the invention may be combined with a process for performing a bleeding control of the killed animal.

BACKGROUND ART

In the poultry- processing industry, the birds are usually transported to the slaughterhouse in cages containing a number of live animals. Upon arrival, the cages are typically unloaded and brought into the slaughterhouse, where the animals may be subjected to gas stunning while still in the cages, or they are removed from the cages and hung on the slaughter line for subsequent electrical stunning. After stunning, the birds are sent on for killing, which process is typically carried out on the bird, hanging on a conveyor, by vein section using rotating knifes.

Current legislation on the processing of slaughtered poultry requires that only healthy, live, or properly anesthetized poultry may be hung in the slaughter line, and it is important, that birds that have died on arrival, are removed, and thus are not being processed.

However, at slaughterhouses, animals arrive, are handled, and transported on conveyor belts at very high speeds, which makes it a very difficult task for the process operator to perform visual inspection of the incoming birds. In fact, when the animals are transported on the processing line, two to four birds can pass the operator every second, meaning that manual, visual inspection may be flawed. Especially, the manual inspection can be especially difficult if the bird has died in the cage late in the process very close to entering the stunning ("recently dead"; late DOA).

Physiologic parameters as hock flexion stiffness and wing position are considered possible early DOA indicators when slaughtering laying hens or broilers. However, these characteristics can be difficult to detect when the birds are hanging very close together and partially overlapping each other, and moreover being conveyed at high speed.

Although changes in rigor mortis appear early in the chicken (typically after 1-3 hours), all associated appearance indicators may occur too late for recently dead birds to be detected. Moreover, when chickens are kept very close in boxes they will isolate and keep each other warm, so any temperature drop will occur slowly, especially if it happens during transport or in seasons, where high ambient temperature prevail in the processing environment, where ambient peak temp may rise to above 30°C.

EP819381 describes a method for processing a slaughtered animal in which method may include the step of determining, at the start of the slaughter line, the temperature and/or the stiffness of the animal for slaughtering and/or corneal reflex and/or a scan of the brain activity, so that it can be established whether the animal for slaughtering was still alive or was already dead on arrival at the slaughterhouse, followed by removal of the relevant animal from the slaughter-line and discharged from a discharging station.

W02004057969 describes a method for converting a fluctuating stream of poultry into a uniform stream of poultry, and mentions, that a check for dead on arrival (DOA) may be carried out by means of an infrared sensor which measures the temperature or presence of the bird. Removal of the dead bird may be carried out manually by the unloader, or it may be carried out mechanically.

EP2534953 describes a method for processing a slaughtered poultry, which method includes the step of establishing whether the poultry was alive or "dead on arrival" at the slaughterhouse and is based on detection of the temperature at the slaughtered poultry's breast, when said poultry is suspended by the legs on the slaughter line after stunning said poultry.

US2018360054 describes a system and method for detecting woody breast condition in broilers using image analysis of carcass features.

US9786060 discloses device for controlling the anesthetization of an animal to be slaughtered using image capturing and determination of movement of the animal, and W02006029628 discloses an apparatus for checking bleeding from slaughter animals after they have been stuck by photographic colour analysis of pictures taken covering a region below the slaughter animal.

Finally, WO2017174768 discloses a system for recording and presenting performance data to an operator.

However, the monitoring system and the corresponding method described herein have never been disclosed.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a system and a corresponding monitoring method, for use at abattoirs and in similar food processing companies, for monitoring the status of incoming, stunned and optionally killed, poultry, suspended by the legs in shackles from a conveyor line, and for alerting an operator of any irregularities determined.

The system and related method of the present invention assist in implementing good product quality and compliance with food processing regulations, as well as for ensuring animal welfare.

Experience have shown an early change to a more bluish, rather than a traditional pale pink, breast colour, in the very recently dead birds. This contrasts with the limited change in breast and blood temperatures, which in the recently dead animals are recorded as for healthy live or stunned birds at the time of death. Therefore, monitoring solely using temperature control may not necessarily be an adequate indication of the very late DOA.

According to the present invention, we suggest applying a dual vision/twin camera technology, wherein a thermographic (IR) camera, that provides a thermographic image of the bird in question, is combined with a standard (RGB/colour) camera, that provides a reference colour image of the chicken breast and is capable of checking for a deviant more bluish breast colour.

By applying this dual vision technology, the colour camera additionally offers the advantage of correcting and interpreting the IR heat image more correctly, as it will be possible to differentiate other image features like feathering covering wings over the throat and appearing lumps of faecal and bedding material stuck to the breast which will impair correct understanding of the IR heat image if used alone.

Furthermore, using thermal imaging together with standard RGB photographic imaging, supplemented with the use of artificial intelligence and/or machine learning techniques on the resulting images, it is possible not only to identify the - often low - frequency of newly DOA outliers, but will also allow to train the system to better handle variations in appearance. Appearance of the bird may be affected, e.g., by seasonal and processing fluctuations, as well as variations in temperature, incl. the ambient temperature at the processing line and at the measuring area.

Therefore, in its first aspect, the invention provides a dual vision/twin-camera monitoring system (1), configured for tracking and monitoring the condition or status of one or more incoming, stunned poultry (2), suspended by the legs in shackles from a conveyor line (3) in a poultry slaughterhouse, with their head hanging down, which system comprises the following elements: a. an inlet conveyor (3), optionally in communication with the processing means (7), and configured for supply of stunned poultry (2); b. a monitoring station (4), configured for determining the actual or relative colour and/or temperature of the body of the incoming poultry (2) in a measuring or monitoring area on the poultry (2), comprising: bl. a thermographic camera (5), in communication with the processing means (7), configured for monitoring of the arriving poultry (2), and for recording of temperature performance data; and b2. a colour camera (6), in communication with the processing means (7), configured for monitoring of the arriving poultry (2), for validating the thermographic data obtained by the thermographic camera (5), and for recording the resulting colour performance data; c. a processing means/PC (7), in communication with the thermographic camera (5), with the colour camera (6), and, optionally, in communication with the encoder (3A), and/or with an information system (8), configured for tracking and for determining the condition or status of the incoming poultry (2), and for sharing data/information between other/remaining components of the monitoring system; and d. an information system (8), in communication with the processing means (7), configured for presenting performance data to a process operator (10) positioned down-stream of the monitoring station (4).

In another aspect, the invention provides a method for monitoring the condition/status of one or more incoming, stunned poultry (2) suspended by the legs in shackles from a conveyor line (3) in a poultry slaughterhouse, and alerting the process operator of any irregularities determined, which method comprises the subsequent steps of: i. supplying the stunned animals (2) on an inlet conveyor (3), suspended in their legs with their head hanging down, and the breast side facing towards a monitoring station (4) that comprises a thermographic camera (5) and a colour camera (6) in communication/operation with a processing means (7); ii. thermographic and photographic monitoring and recording of performance data of the incoming poultry (2) of step i, while on the fly, using the thermographic camera (5) and the colour camera (6) of the monitoring station (4); and iii. transmitting the recorded thermographic and photographic data obtained in step ii to the processing means (7) configured for determining the condition/status of the incoming stunned poultry (2).

Other objects of the invention will be apparent to the person skilled in the art from reading the following detailed description and accompanying drawings.

Any combination of two or more of the embodiments described herein is considered within the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further illustrated by reference to the accompanying drawing, in which Fig. 1 shows the essential elements of the system (1) of the invention.

DETAILED DISCLOSURE OF THE INVENTION

The system of the invention

In its first aspect the invention provides a dual vision/twin-camera monitoring system (1), configured for capturing image data and monitoring the condition or status of one or more incoming, stunned poultry (2), suspended by their legs in shackles from a conveyor line (3) in a poultry slaughterhouse, with their head hanging down.

After arrival, the birds are unloaded and introduced into the slaughterhouse, usually kept in cages. Before the poultry can be processed, they are first stunned and then killed, after which further processing take place.

In one embodiment, the system of the invention is intended for incorporation into the overall slaughterhouse process after the stunning step, but prior to the killing step.

In another embodiment, the system of the invention introduced into the overall slaughterhouse process after the stunning and the killing steps have been accomplished.

The monitoring system of the invention may be characterised by comprising the following essential elements: a. an inlet conveyor (3), optionally in communication with the processing means (7), and configured for supply of stunned poultry (2); b. a monitoring station (4), configured for determining the actual or relative colour and/or temperature of the body of the incoming poultry (2) in a measuring or monitoring area on the poultry (2), comprising: bl. a thermographic camera (5), in communication with the processing means (7), configured for monitoring of the arriving poultry (2), and for recording of temperature performance data; and b2. a colour camera (6), in communication with the processing means (7), configured for monitoring of the arriving poultry (2), for validating the thermographic data obtained by the thermographic camera (5), and for recording the resulting colour performance data; c. a processing means/PC (7), in communication with the thermographic camera (5), with the colour camera (6), and, optionally, in communication with the encoder (3A), and/or with an information system (8), configured for tracking and for determining the condition or status of the incoming poultry (2), and for sharing data/information between other/remaining components of the monitoring system; and d. an information system (8), in communication with the processing means (7), configured for presenting performance data to a process operator (10) positioned down-stream of the monitoring station (4).

In one embodiment, the system of the invention further comprises the following element: b3. a temperature contrast panel (9), configured for improving the imaging quality.

The monitoring system of the invention comprises an inlet conveyor (3) for supplying the poultry (2) to be processed.

After arrival in cages, the birds are unloaded and introduced into the slaughterhouse. Before the poultry can be processed it is first stunned and then killed, after which further processing take place.

In most slaughterhouses, the conveying assembly comprises product carriers which are arranged below an overhead conveyor path, thus constituting a line of shackles for carrying the birds, suspended by their feet.

It is customary for poultry suspended from the transport assembly to have their breasts facing one side, so that all poultry has a similar direction, allowing subsequent thermographic monitoring of the animal's breast region.

As a result, the inlet conveyor for use in the monitoring system of the invention is able to supply unloaded animals on the conveying line, suspended in their legs with their head hanging down, and the breast side facing (outwards) towards the monitoring station of the system.

The encoder

In one embodiment, the inlet conveyor for use in the monitoring system of the invention is in communication with the processing means (7). For this purpose, the conveying assembly (3) for use according to the invention may optionally be equipped with a position sensor (3A), e.g., an encoder, which may in particular be a rotary encoder, in communication with the processing means (7), configured for controlling (e.g., determine and adjust) the speed of the conveying line and for calculating the position of the bird in question, and synchronize with the down-stream information system (8). There are four widely used methods of applying encoders to conveyors: motor mount, roller shaft mount, belt/chain driven and surface mount. Any type of encoder may be employed according to the invention.

Alternatively, the system may comprise a sensor capable of registering the position of each shackle, which system may be used to trigger image acquisition and estimate the speed and changes, as the distance between switches is relatively constant.

The monitoring station

The monitoring system according to the invention also comprises a monitoring station (4), configured to determine the absolute or relative colour and/or temperature, or a gradient hereof, of the body of the incoming poultry (2) in a measuring or monitoring area on the poultry (2A, 2A1, and/or 2A2).

This measuring or monitoring area may be defined in different ways. In one embodiment, the cameras, i.e., the thermographic camera (5) and/or the colour camera (6) are aimed at a main monitoring (body and/or breast monitoring) area (2A), and/or the thermographic camera (5) and/or the colour camera (6) are aimed at a body and/or breast monitoring area (2A1), or at a head/facial region monitoring area (2A2), which area(s) thus constitutes the measuring or monitoring area.

The monitoring station of the system of the invention may be characterised as a dual vision/twin-camera monitoring station and shall comprise at least one (i.e., one or more) thermographic camera (5) as well as at least one (i.e., one or more) colour camera (6).

The at least two cameras for use in the monitoring system of the invention shall be configured for monitoring of the arriving poultry (2) and shall be in communication with the processing means (7), and capable of recording data for verification and validation of the images obtained by the other camera.

For obtaining comparable images, the two cameras used in the system of the invention shall off course be aimed at the same bird (2), and preferably aimed at the same measuring and/or monitoring area.

Recording of the images by the at least two cameras (5 and 6) shall be aimed at the same bird (2). In one embodiment, recording using the two cameras (5 and 6) may be accomplished either simultaneously, with the cameras placed side by side or within a (shorter or longer) distance between them, or may be accomplished by a temporal displacement, with the cameras placed at different positions along the conveying line, with the help of calculations carried out by the processing means (7).

The monitoring station of the invention is used for validation of the thermographic image, obtained with the thermographic camera (5), using of the colour camera (6), thereby, i.a., correcting for feathering or contamination and covering body parts, e.g., the wings of the bird in question or of a neighbouring bird, which correction may be achieved by overlaying and aligning the various images recorded by the cameras.

In another embodiment, the monitoring station of the invention may be used for checking the breast colour of the poultry (2) using the colour camera (6) to verify any newly dead-on-arrival (DOA) birds, having a more bluish coloured breast.

The thermographic camera

The art of capturing and analysing the data provided using a thermal camera is called thermography. Thermal imaging devices comprises detectors/sensors for measuring infrared radiation, which detector may measure infrared radiation emitted by the birds.

The system of the present invention is based on the use of infrared thermography or thermal imaging, and therefore includes the use of an infrared or thermal imaging device, i.e., a thermographic camera (5).

The thermographic camera (5) for use in the system of the invention shall be in communication with the processing means (7) and shall be configured for monitoring of the arriving poultry (2), and for recording data.

The thermographic camera for use according to the invention is a device that creates an image using infrared radiation. Instead of the 400-700 nanometre range of the visible light (colour) camera, infrared cameras are sensitive to wavelengths from about 1,000 nm (1 pm) to about 14,000 nm (14 pm).

The colour camera

The monitoring system of the invention also includes a visible light/colour camera (6). The colour camera for use according to the invention may be any commercially available 2D and/or 3D camera. Commercially available 3D cameras include scanners and range cameras such as the time-of-flight camera, the structured light camera, stereo camera, or 3D camera.

The use of a 3D camera in the system of the invention allows for an automatic removal of possible disturbing backgrounds, as 3D cameras, based on the distance to the camera, are capable of (automatically) filtering out any background.

The colour camera for use according to the invention shall be in communication with the processing means (7), configured for monitoring of the arriving poultry (2), for validating the thermographic data obtained by the thermographic camera (5), and for recording the resulting data. Lighting means

For obtaining clear photographic images, the system shall be equipped with visible lighting means capable of illuminating the birds in question.

Lighting means for use according to the invention may include ordinary visible (RGB) light sources, including LED light systems, and/or UV-light sources.

The lighting means for use according to the invention may be in communication/operation with and controlled by the processing means (7) of the system of the invention.

The temperature contrast panel

For improving the quality of the image recorded by the thermographic camera, the system of the invention may include the use of a temperature contrast panel (9).

Therefore, in another embodiment, the monitoring system of the invention further comprises a temperature contrast panel (9), i.e., a cold back-wall.

The temperature contrast panel (6) for use according to the invention essentially may be characterised as a back-wall of a substantially cooler temperature, i.e., a temperature that is significantly below that of the ambient temperature, e.g., less than 3- 20°C, or less than 5-15°C below ambient temperature. The greater the temperature difference, the greater the contrast, and the better the image quality.

The contrast panel may be made of any material, e.g., a non-reflecting panel surface driven by cold tap-water, or by glycol chilling or similar chilling systems, available in processing plants.

Moreover, in order to improve the quality of the photographic image obtained with the colour camera (6) for use according to the invention, the contrast panel (9) may be painted in a colour contrasting the colour of the chicken blood.

The processing means/processor/PC

The monitoring system of the invention also comprises a processing means/processor/PC (7), in communication with the thermographic camera (5), with the colour camera (6), and, optionally, in communication with the lighting means (6A), and/or with the encoder (3A), and/or with an information system (8), and which processing means (7) is configured for tracking and for determining the condition or status of the incoming poultry based on analysis of the images from the two cameras (5, 6), and for sharing data/information between other/remaining components of the monitoring system.

The processing means (7) for use according to the invention may be any commercially available processor/PC, in operation with, and capable of receiving and processing data obtained from the thermographic camera (5), and configured for providing control of, and information to, the information system (8), and, optionally, also for receiving velocity signals from the encoder (3A).

Bleeding control

Due to the presence of a colour camera (6) in the system of the invention, capable of recording the colour images of the incoming birds, and the presence of the processing means (7), configured for making photographic colour analysis, the system of the invention may additionally be used for performing a bleeding control of the killed bird.

According to this embodiment, the system of the invention introduced into the overall slaughterhouse process after the stunning and the killing steps have been accomplished. Moreover, according to this embodiment, the colour camera (6) should be especially aimed at a head/facial region monitoring area (2A2), so that any blood on its head or dripping from the animal, while suspended by the legs on the slaughter line with their head hanging down, can be recorded by the colour camera (6) and quantified by the processing device (7), to be subsequently used as a means of determining whether the animal has been effectively killed.

A similar procedure has been disclosed in, e.g., W02006029628, that discloses an apparatus for checking bleeding from slaughter animals after they have been stuck by photographic colour analysis of pictures taken covering a region below the slaughter animal.

Another feature of the system of the invention is the use of an information system (8), for presenting performance data calculated based on analysis of images obtained by the two camera devices (5 and 6) of the monitoring station (4), to the process operator(s) (10) positioned down-stream of the monitoring station (4).

The information system (8) for use according to the invention shall be located along the down-stream transport system and may have different designs.

In one embodiment, the information system (8) for use according to the invention may comprise light bands or lamps located along with or above the transport system and the information which can be emitted or presented by the information system may be light and the colour of the light may be correlated with the information which should be communicated by the system. Preferably the light signal moves along the information system with similar speed as the related subject or product moves in the transport system.

The information system (8) for use according to the invention may include the classification of the subjects or products based on the performance data into a number of predetermined categories, e.g., two categories: product OK (V), or product needs further attention (!); or products may e.g. be classified into three or more categories which may indicate 'the subject/product is as it should be', 'the subject/product must be evaluated' and 'the subject/product shall be discarded', and the status may be presented to the process operator in the form of light signs, e.g. a red and a green light, or a red, a yellow and a green light (like a traffic light), or any alternative visual sign, capable of emitting or presenting categorized performance data to the process operator, for further action, dependent of the nature of the performance data.

An example of an information system (8) for use according to the invention is described in, e.g., WO2017174768.

At abattoirs and food processing companies, animals are arriving and transported at conveying lines at very high speed, e.g., of up to 15,000 chickens/hour, making it a very difficult task for the process operator (10) to perform a dedicated visual inspection of the incoming birds, while also carrying out the necessary (occasional) corrective actions, e.g., removing birds from, or stopping, the conveying line.

The system of the invention is intended to assist the inspecting process operator(s) during inspection procedures, i.e., identification of birds that are considered dead on arrival (DOA), e.g., after the stunning process, as well as, optionally, also in checking for unsuccessfully killed animals, as indicated by lack of bleeding, thus reducing and possibly fully eliminating any bird unfit for processing continuing on the processing line.

By employing an information system (9), the work process is likely to become less stressful as the operator(s) main attention will be drawn to the birds requiring extra control or action.

The system of the invention may further be combined with an acknowledgement function, e.g., a push button or similar acknowledgement device, which is to be activated by the inspecting process operator, thereby confirming he has observed and reacted on any bird requiring action.

The method of the invention

In another aspect, the invention provides a method monitoring the condition/status of one or more incoming, stunned poultry/birds (2) suspended in shackles from a conveyor line (3) in a poultry slaughterhouse, and for alerting the process operator of any irregularities determined.

The method of the invention may be characterised by comprising the subsequent steps of: i. supplying the stunned animals (2) on an inlet conveyor (3), suspended in their legs with their head hanging down, and the breast side facing towards a monitoring station (4) that comprises a thermographic camera (5) and a colour camera (6) in communication/operation with a processing means (7); ii. thermographic and photographic monitoring and recording of performance data of the incoming poultry (2) of step i, while on the fly, using the thermographic camera (5) and the colour camera (6) of the monitoring station (4); and iii. transmitting the recorded thermographic and photographic data obtained in step ii to the processing means (7) configured for determining the condition/status of the incoming stunned poultry (2).

In another embodiment of the method according to the invention, the condition/status of the incoming stunned poultry (2) as determined by the processing means (7) according to step iii is transmitted to an information system (8) for presentation of performance data, to an operator (10) positioned down-stream of the monitoring station (4), for carrying out corrective actions.

In a further embodiment of the method of the invention, and to ensure sharper images, in step i, the incoming poultry (2) are suspended on the inlet conveyor (3) and are being conveyed in front of a temperature contrast panel (6) of a substantially cooler temperature.

The thermographic and photographic monitoring and recording of performance data of step ii by the at least two cameras of the monitoring station, i.e., the thermographic camera (5) and the photographic colour camera (6), shall be aimed at the same bird (2), and may be accomplished either simultaneously, with the cameras placed side by side or within a distance between them, or accomplished by a temporal displacement, with the cameras placed at different positions along the conveying line.

After the performance date obtained in step ii has been recorded it shall be presented to the process operator (10) positioned down-stream of the monitoring station (4), for further action, and this presentation takes place via an information system (8) for presentation of performance data.

As described above, the information system (8) for use according to the invention may comprise light bands or lamps located along with or above or below the transport system and the information which can be emitted or presented by the information system may be light and the colour of the light may be correlated with the information which should be carried on by the system. Preferably the light moves along the information system following the actual bird, with similar speed as the related subject or product moves in the transport system. In another embodiment, the method of the invention is accomplished using a system comprising an encoder (3A), in communication with a processing means (7), configured for calculating the actual position of the bird in question.

Alternatively, the position of the bird in question may be calculated using a position indicating device located on the particular shackle, holding the bird in question.

Finally, in a further embodiment, the method of the invention may find additional use as a method for determining whether the animal has been effectively killed, wherein the photographic colour camera (6) employed in step i is aimed especially at a head/facial region monitoring area (2A2) of the incoming poultry for recording any blood dripping from the animal, and transmitting the data thus obtained to the processing device (7) for subsequent quantification and determination, and, optionally, transmitting the transmitted to the information system (8) configured for presentation of performance data to an operator (10) positioned down-stream of the monitoring station (4), for carrying out corrective actions.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention is further illustrated by reference to the accompanying drawing, in which:

Fig. 1 shows the essential elements of the system (1) of the invention: Incoming bird (2) with a main monitoring area (2A), a body and/or breast monitoring area (2A1), a head/facial monitoring area (2A2); Conveyor line (3) with encoder (3A), and an indication of the direction of transportation (3X); Thermographic monitoring station (4) comprising a thermographic camera (5), standard colour camera (6), and a temperature contrast panel (9), i.e. a back-wall of a cooler temperature when compared to the ambient temperature; A processing means/PC (7); An information system for presentation of status data (8), wherein (V) represents a stunned animal fit for further processing, and (!) represents an early dead animal that shall be disposed of; An operator (10) who is monitoring the process and is responsible for taking corrective actions.

List of reference signs

This is a listing of various elements relating to the present invention and shown in the appended figures. Alternative/synonymous designations are separated by slashes.

1. Dual vision/twin-camera monitoring system of the invention

2. Incoming, stunned and/or killed poultry/birds 2A Main monitoring/measuring area

2A1. Body and/or breast monitoring area 2A2. Head/facial region monitoring area

3. Conveyor/conveying line, with arrow-indicated direction of transport 3A. Encoder

3X. Direction of transportation

4. Monitoring/imaging station

5. Thermographic/heat sensitive camera/infrared (IR) camera

6. Colour camera/visible light camera/photographic (RGB) camera 6A. Lighting means/light source

7. Processing means/processor/PC

8. Information system for the presentation of status data

9. Temperature contrast panel/chilled back-wall

10. Process operator