Introduction

There should be no wood or plastic pieces in a chicken burger. To structurally improve food safety and product quality, Plukon, one of Europe’s largest poultry processors, decided to automate the inspection process for foreign materials. In collaboration with Canadian company P&P Optica (PPO), machine builder De Weus, and system integrator Hellebrekers, PPO’s innovative Smart Imaging System (SIS) was successfully adapted and implemented in Europe. The system is now running at full capacity in the factory in Ommel,

Food safety is a top priority in the food industry. Until recently, foreign materials such as plastic, rubber, or clothing fibers in chicken products were detected manually—a labor-intensive and error-prone process. At the same time, PPO aimed to bring its technology to the European market, but its machines did not yet meet CE standards, used a different electrical system, and were based on the imperial rather than the metric system.

This combination of food safety challenges and market entry ambitions formed the basis for an international collaboration between PPO, De Weus, and Hellebrekers.

Solution

Together with PPO, Hellebrekers developed a customized system based on hyperspectral imaging and machine learning. During the testing phase, PPO’s standard model did not perform optimally when identifying certain colored packaging liners. In response, a new detection model was developed.

The project involved:

• On-site data collection at Plukon in Ommel;

• Redesign of the mechanical system by De Weus in compliance with CE standards;

• Replacement of Allen-Bradley PLCs with Siemens controls by Hellebrekers;

• Complete engineering, cabling, and installation;

• Delivery of virtually the entire line, including the PPO vision machine and X-ray system;

• Commissioning scheduled for early 2025.

Solution

The upgraded PPO Smart Imaging System has been operational at Plukon Ommel since early 2025 and is delivering impressive performance:

• Detection capacity: scans 24 meters per minute at a width of 800 mm .

• Detection accuracy: reliably detects even low-density foreign materials.

• Robustness: hygienic washdown design, easy to clean, and low maintenance.

• Efficiency: replaces six visual inspectors with two camera modules.

• Up-time: >98.5% availability.

The inspected products are currently still in cold storage, so the full impact on customer complaint rates is not yet measurable. However, initial operational feedback is very positive, and the project stands as a successful example of international collaboration and smart technology in the food industry.