Quality Control Solutions for Tortilla and Flatbreads

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Measurement Capability

  • 2D/Shape & Size - diameter, roundness, length, width (accuracy: 0.5mm)
  • 3D/Height - peak/mean height, slope, surface texture, stack height (accuracy: 0.3mm)
  • Top & Bottom bake color (Lab and BCU coordinates, accuracy: 0.2 ΔE)
  • Toasted marks - color, coverage, distribution, voids (accuracy: 0.5% of product surface)

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Defects Detection Capability

  • Misshapen products
  • Edge defects (e.g. bites, dents, straight edges, etc.)
  • Out of specification products (e.g. too small, too big, etc.)
  • Spots (light, dark, foreign material on product surface)
  • Holes
  • Toast marks defects (e.g. too little marks, voids, etc.)
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Available Configurations

  • On-line - Line Width from 900mm up to 2.200mm (36" - 86"), Product Throughput from 200 pcs/min up to 1.500 pcs/min
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Available Modules

Vision Module:

  • Top Side 2D & Color
  • Top Side 3D
  • Bottom Side Color

Rejection Module: air nozzle rejection mechanism

Stainless Steel Frame

Conveying System with modular belts

Control Unit:

  • Industrial PC
  • Industrial Touch
  • Screen Stainless steel electrical cabinet

Inspection Software with Real Time Statistics displayed on integrated touch screen

Data Collection & Reporting Software

Metal Detector Integration with Dual-Stage Rejection Mechanism (optional)

Tortilla & Flatbread

Distributed Vision-Based Process Control Systems

KPM Analytics provides a range of vision system modules designed to monitor a specific production process step.

The measurements taken at each vision module at each point in the line can be collected and displayed at the control station and reported in real time. This data can also be added to a database allowing further analysis and correlation of this data to assist in improving the production process and the quality of the finished product.

Examples of process steps that can be monitored are the following:

  • Forming (physical dimensions)
  • Proofing (height, scoring)
  • Baking (bake color, oven feedback)

Feedback Loops – Automatic Press Control for Flour Tortilla Lines

By installing a KPM Analytics Vision System after the press on a flour tortilla line, it is possible to integrate our exclusive Real-Time Press Feedback Module, which uses the measured diameters to automatically adjust the press settings.

Key benefits:

  • automatic control of the tortilla press settings
  • objective tortilla diameter measurement
  • continuous automatic monitoring of product quality
  • automatic real time actions to correct out of specification situations
  • improved product size consistency over the time
  • waste reduction
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