At Kyubi System, we are proud to be the technological partner that has enabled one of the main fruit and vegetable plants in the Lleida region to revolutionise its fresh fruit management. This project is a clear example of how RFID technology has transformed the traceability of fruit from its origin in the field to the end customer, providing efficiency, security and unprecedented control.
The challenge for this important company, a benchmark in the sector, was to optimise the complex process of receiving, sorting, storing, portioning and dispatching fruit. They needed comprehensive, automated traceability that would guarantee quality, reduce losses and comply with the most stringent food safety regulations.
This is how a transformative RFID solution was implemented, step by step:
The RFID Traceability Process in a Leading Fruit Processing Plant:
Traceability at Origin: The Palot is Born with RFID Identity
Control of the fruit begins long before it arrives at the plant’s premises. Directly from the origin, in the farmer’s field, each pallet or container of fruit is marked with a unique RFID tag. This tag is not just an identifier; it is pre-loaded with vital information such as fruit type, variety, grower of origin and harvest date.
Implementing RFID identification at source is key; this ensures that fruit traceability information is immutable and available from the outset, guaranteeing a strong chain of custody.
Intelligent Receiving and Automatic Verification at the Weighbridge
When the lorry arrives at the central facility, it is directed to the weighbridge. This is where technology comes into play in a crucial way. While the truck is being weighed, a set of strategically placed RFID antennas simultaneously read the RFID tags on each pallet it is carrying.
This massive and automatic reading allows the system to corroborate in real time the information provided from the origin (product, declared weight, origin) with the captured data. This phase is revolutionary: the automated double check of truck weight and individual pallet information via RFID eliminates manual errors, speeds up the receiving process and ensures data integrity before the fruit enters the warehouse, providing instant validation that saves time and prevents discrepancies.
Inventory Control and Flow to Washing and Portioning
Once verified at the scale, RFID-tagged pallets or boxes are automatically logged into the system as they move into cold storage or temporary storage areas. From here, each pallet goes directly to the washing process. Once the fruit is washed, a new traceability process is initiated specifically for this stage.
The fruit is immediately portioned according to its degree of ripeness, colour, quality, possible visible nicks, etc., which defines its destination. Then, the portioned fruit, already separated by quality or ripeness, is distributed to different storage chambers optimised for each type of product.
At this point, they are re-labelled or a new RFID tag is associated with the final units, ready for distribution to the customer. 100% real-time inventory control is guaranteed, even through critical transitions such as washing and portioning. The solution allows the creation of sub-batches with legacy traceability, ensuring that each piece of portioned fruit retains full information on its origin and process.
The flexibility of the system facilitates the management of multiple chambers and destinations according to maturity, minimising losses and optimising the final quality of the product before re-labelling for distribution.
Intelligent Dispatch and Loading
Before loading onto trucks, boxes or pallets of portioned and re-labelled fruit pass through RFID dispatch portals. The system automatically validates that the correct product is being loaded for the correct customer and the specific order. This eliminates shipping errors, incorrect deliveries and the resulting return costs.
Loading times are drastically reduced, improving logistics efficiency and end-customer satisfaction with faster and more accurate deliveries.
Comprehensive Visibility and Analytics (ERP/WMS Integration)
All data captured by the RFID readers is centralised in the software platform and synergistically integrated with the company’s existing ERP/WMS systems. This provides management and operational teams with 360° visibility of their entire operation.
Not only does it facilitate audits and certifications (such as GlobalG.A.P. or IFS), but it also provides business intelligence for strategic decision making: knowing the state of the fruit in terms of ripeness is fundamental for the commercial area, which then knows when it has available what quantity for sale, as well as route optimisation, demand forecasting, quality management and yield per supplier/plot.
How has our technology contributed to the improvement of this fruit and vegetable company?
- 100% Traceability Guaranteed: Ability to reconstruct the history of any product in seconds, from the farmer to the final consumer. This has strengthened its position as a reliable supplier and has speeded up its response to any incident.
- Drastic Reduction of Errors and Losses: Fewer inventory errors, less wastage due to expired products and fewer errors in order preparation translate directly into significant operational savings and increased profitability.
- Process and Time Optimisation: The automation of reading and recording has freed up human resources, allowing them to focus on higher value tasks. Loading and unloading times have been reduced, improving the efficiency of the entire logistics chain.
- Improved Compliance: Digitisation and data accuracy facilitate internal and external audits, ensuring compliance with the most stringent food safety and quality regulations.
- Visibility and Strategic Decision Making: The centralisation of data and the ability to generate detailed reports has provided the company with operational intelligence it did not previously possess, allowing them to anticipate and optimise their business.
- Reinforced Reputation and Competitiveness: By guaranteeing the highest quality and safety in its products, this fruit and vegetable centre has strengthened its brand image and its position in a highly competitive market, differentiating itself through its commitment to excellence.
At Kyubi System, we are proud to be the technological ally that drives efficiency and safety in the fruit and vegetable sector. This case in Lleida is proof of our commitment and the transformative capacity of our advanced RFID solutions.
