Post-IQF Nugget Inspection
Post-IQF inspection is the final opportunity to verify that every piece meets food safety and quality specifications before it leaves the facility. At this stage, AI-enabled automated vision inspection checks 100% of product for foreign material and quality defects.
Typical Products
- Breaded chicken nuggets (formed or whole muscle)
- Pre-cooked and raw frozen nuggets
- Nuggets for QSR, retail, and foodservice channels
100% Inspection, Foreign Material Detection, Rejection, and Reporting Solution
Automated post-IQF inspection addresses the defects that matter most to nugget producers:
- Foreign material: Plastics & films (clear or colored, soft, & hard plastics), wood, foils, rubber, cardboard, PPE, etc.
- Cooking defects: Undercooked product, overcooked product, uneven color, burnt spots
- Batter and breading: Bare or thin areas, excess coverage, uneven distribution
- Shape and dimension: Fused pieces, broken pieces, product outside length/width/weight specification
Every piece is inspected using top and bottom cameras, and non-conforming product can be automatically rejected in line, without stopping production, and rejection behavior can be configured separately for food safety defects and quality defects.Beyond detection, the system connects to the wider production environment. Inspection data feeds back to upstream equipment - ovens and batter applicators - to correct process drift before it affects volume. Integration with MES and SCADA systems supports traceability reporting and customer audit documentation. For producers supplying QSR chains or major retail customers, the system applies consistent, calibrated inspection standards across multiple lines and plant locations, generating the documented conformance records those customers require.
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The Solution You Need and the Industry Experts You Need
KPM’s solutions address your requirements in the following ways:
- Top and bottom simultaneous inspection using high-resolution calibrated cameras
- Hyperspectral and infrared imaging available for non-visible spectrum foreign material detection
- AI-based analysis, including anomaly detection via the TensorUP® computing platform and measura® software
- Automated rejection configurable by defect type and severity
- Real-time feedback control output to upstream equipment
- MES and SCADA integration
- IP69K washdown-rated hygienic construction
- Over 100 pre-configured measurement types for meat and poultry products, with full customization capability
- Optional integrated metal detector
- Factory color-calibrated cameras, consistent across multiple units and locations
- Inspection data output for HACCP, audit, and customer reporting
Every installation is configured for the specific products, line speeds, and facility requirements of that site. KPM’s application specialists have direct experience in meat and poultry processing and work with customers through commissioning, validation, and ongoing optimization.
FAQs
Vision inspection systems can detect a variety of defects, including discoloration, foreign objects, missing pieces, and misshapen products.
Yes, we can customize the system based on your line configuration, the type of product you are producing, etc.
Yes, you can install multiple dashboards to monitor lines in real-time. All data from multiple lines and locations can be collected and packed together into detailed reports for enhanced production insights and compliance visibility.
Yes, we have interfaced to a variety of systems for real-time data collection and reporting. We also offer real-time process monitoring dashboards.