Food Production · Protein & Meat Processing

Cook Line HACCP Compliance & Yield

Eliminate CCP deviations and recover yield margin by tightening cook line control to ±1°F.

−88%

HACCP Deviations

From 3.2 CCP deviations per shift to 0.4. Zero USDA enforcement actions in 6-month period

+2.1 pts

Cook Yield

Tighter CCP-2 control reduced moisture drive-off, equivalent to $420K annual raw material value recovery

−91%

Rework Batches

Vision-correlated cook deviation detection eliminated nearly all hold-and-reprocess batches

How Allie Works Here

From signal to action in real time.

Process ControlQuality ControlProduction OptimizationPredictive Maintenance

The Process Control agent monitors COOK01.CCP2.TMP at 1-second intervals and compares against the HACCP plan's critical limit of 158°F for a minimum 15-second dwell. If the tag drifts below 157°F, the agent triggers an automatic dwell-time extension via OPC-UA write to the conveyor speed setpoint, logs the corrective action to the USDA-compliant SCADA record, and sends an immediate alert to the food safety lead. The Quality Control agent correlates Cognex color scores with CCP temperature history in a rolling 20-batch window, identifying which zone temperature profiles predict optimal cook yield before the batch exits the line. The Predictive Maintenance agent monitors steam regulator valve hysteresis and probe RTD drift, scheduling calibration during planned sanitation windows, and the Maintenance agent surfaces the relevant USDA-traceability work-order template with one-tap acknowledgment for the maintenance lead.

Machines & Connectivity

OT-connected, protocol-native.

Stork Townsend Continuous Cooker

Marel

OPC-UA

Continuous steam cooking with four independent temperature zones and internal product probe

Rockwell FactoryTalk Historian

Rockwell Automation

EtherNet/IP

SCADA historian archiving all CCP tags for USDA traceability

Cognex In-Sight 9000

Cognex

EtherNet/IP

Vision system measuring product color, cross-section area, and surface texture post-cook

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Internal Product Temp at CCP-2	`COOK01.CCP2.TMP`	°F	153–162	158–161	Tighter
Steam Zone 2 Dwell Time	`COOK01.Z2.DWELL`	s	180–240	195–215	Tighter
Cook Yield %	`COOK01.YIELD.PCT`	%	83.1–87.6	86.2–88.0	Higher
CCP Deviation Events per Shift	`COOK01.CCP.DEV`	events	3.2	0.4	Lower

Internal Product Temp at CCP-2Tighter

COOK01.CCP2.TMP

Baseline: 153–162 °F→ 158–161 °F

Steam Zone 2 Dwell TimeTighter

COOK01.Z2.DWELL

Baseline: 180–240 s→ 195–215 s

Cook Yield %Higher

COOK01.YIELD.PCT

Baseline: 83.1–87.6 %→ 86.2–88.0 %

CCP Deviation Events per ShiftLower

COOK01.CCP.DEV

Baseline: 3.2 events→ 0.4 events

In the Field

"a USDA-inspected fully cooked protein manufacturer processing 400,000 lbs per week across two cook lines"

Deployed at a USDA-inspected fully cooked protein manufacturer processing 400,000 lbs per week across two cook lines. The results above reflect production data from the 60–90 day period following full deployment.

−88%haccp deviations

+2.1 ptscook yield

−91%rework batches

Next Step

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