Digital twins of food process operations: the next step for food process models?

Transforming plant-based waste and by-products into valuable products using various "Food Industry 4.0" enabling technologies: A literature review

The last several years have seen unprecedented strain on food systems as a result of pandemics, climate change, population growth, and urbanization. Thus, academic and scientific communities now view global food security as a critical issue. However, food loss and waste are a major challenge when adopting food security and sustainability strategies, since a large proportion of food is lost or wasted along the food supply chain. In order to use resources efficiently and enhance food security and sustainability, food waste and by-products must be reduced and properly valorized. Plant-based food production generates various by-products which are generally rich in nutrients and bioactive compounds. Emerging technologies have been effectively employed to extract these valuable compounds with health benefits. Recently, Industry 4.0 technologies such as artificial intelligence, the Internet of Things, blockchain, robotics, smart sensors, 3D printing, and digital twins have a great deal of potential for waste reduction and by-products valorization in food industry. Reducing food waste not only benefits the environment, but also reduces greenhouse gas emissions and thus contributes to sustainable resource management. This review provides up-to-date information on the potential of Industry 4.0 for converting plant-based waste and by-products into valuable products. Recent studies showed that innovations in Industry 4.0 provide attractive opportunities to increase the effectiveness of manufacturing operations and improve food quality, safety and traceability. By leveraging Food Industry 4.0, companies can transform plant-based waste and by-products into valuable products and contribute to a more sustainable and efficient food production system.

Digital Twin Methodology in Food Processing: Basic Concepts and Applications

PURPOSE OF REVIEW

The goal of this article is to present a concise review about digital twin (DT) methodology and its application in food processing. We aim to identify the building blocks, current state and bottlenecks, and to discuss future developments of this approach.

RECENT FINDINGS

DT methodology appears as a powerful approach for digital transformation of food production, via integration of modelling and simulation tools, sensors, actuators and communication platforms. This methodology allows developing virtual environments for real-time monitoring and controlling of processes, as well as providing actionable metrics for decision-making, which are not possible to obtain by physical sensors. So far, main applications were focused on refrigerated transport and storage of fresh produces, and thermal processes like cooking and drying. DT methodology can provide useful solutions to food industry towards productivity and sustainability, but requires of multidisciplinary efforts. Wide and effective implementation of this approach will largely depend on developing high-fidelity digital models with real-time simulation capability.

Modernization of digital food safety control

Foodborne illness remains a pressing global issue due to the complexities of modern food supply chains and the vast array of potential contaminants that can arise at every stage of food processing from farm to fork. Traditional food safety control systems are increasingly challenged to identify these intricate hazards. The U.S. Food and Drug Administration's (FDA) New Era of Smarter Food Safety represents a revolutionary shift in food safety methodology by leveraging cutting-edge digital technologies. Digital food safety control systems employ modern solutions to monitor food quality by efficiently detecting in real time a wide range of contaminants across diverse food matrices within a short timeframe. These systems also utilize digital tools for data analysis, providing highly predictive assessments of food safety risks. In addition, digital food safety systems can deliver a secure and reliable food supply chain with comprehensive traceability, safeguarding public health through innovative technological approaches. By utilizing new digital food safety methods, food safety authorities and businesses can establish an efficient regulatory framework that genuinely ensures food safety. These cutting-edge approaches, when applied throughout the food chain, enable the delivery of safe, contaminant-free food products to consumers.

Virtualization and digital twins of the food supply chain for enhanced food safety

Meeting food safety requirements without jeopardizing quality attributes or sustainability involves adopting a holistic perspective of food products, their manufacturing processes and their storage and distribution practices. The virtualization of the food supply chain offers opportunities to evaluate, simulate, and predict challenges and mishaps potentially contributing to present and future food safety risks. Food systems virtualization poses several requirements: (1) a comprehensive framework composed of instrumental, digital, and computational methods to evaluate internal and external factors that impact food safety; (2) nondestructive and real-time sensing methods, such as spectroscopic-based techniques, to facilitate mapping and tracking food safety and quality indicators; (3) a dynamic platform supported by the Internet of Things (IoT) interconnectivity to integrate information, perform online data analysis and exchange information on product history, outbreaks, exposure to risky situations, etc.; and (4) comprehensive and complementary mathematical modeling techniques (including but not limited to chemical reactions and microbial inactivation and growth kinetics) based on extensive data sets to make realistic simulations and predictions possible. Despite current limitations in data integration and technical skills for virtualization to reach its full potential, its increasing adoption as an interactive and dynamic tool for food systems evaluation can improve resource utilization and rational design of products, processes and logistics for enhanced food safety. Virtualization offers affordable and reliable options to assist stakeholders in decision-making and personnel training. This chapter focuses on definitions and requirements for developing and applying virtual food systems, including digital twins, and their role and future trends in enhancing food safety.

Unleashing the Potential of Digitalization in the Agri-Food Chain for Integrated Food Systems

Digitalization transforms many industries, especially manufacturing, with new concepts such as Industry 4.0 and the Industrial Internet of Things. However, information technology also has the potential to integrate and connect the various steps in the supply chain. For the food industry, the situation is ambivalent: It has a high level of automatization, but the potential of digitalization is so far not used today. In this review, we discuss current trends in information technology that have the potential to transform the food industry into an integrated food system. We show how this digital transformation can integrate various activities within the agri-food chain and support the idea of integrated food systems. Based on a future-use case, we derive the potential of digitalization to tackle future challenges in the food industry and present a research agenda.

Digital Twins in Agriculture: Orchestration and Applications

Digital Twins have emerged as an outstanding opportunity for precision farming, digitally replicating in real-time the functionalities of objects and plants. A virtual replica of the crop, including key agronomic development aspects such as irrigation, optimal fertilization strategies, and pest management, can support decision-making and a step change in farm management, increasing overall sustainability and direct water, fertilizer, and pesticide savings. In this review, Digital Twin technology is critically reviewed and framed in the context of recent advances in precision agriculture and Agriculture 4.0. The review is organized for each step of agricultural lifecycle, edaphic, phytotechnologic, postharvest, and farm infrastructure, with supporting case studies demonstrating direct benefits for agriculture production and supply chain considering both benefits and limitations of such an approach. Challenges and limitations are disclosed regarding the complexity of managing such an amount of data and a multitude of (often) simultaneous operations and supports.

Overview of Food Preservation and Traceability Technology in the Smart Cold Chain System

According to estimates by the Food and Agriculture Organization of the United Nations (FAO), about a third of all food produced for human consumption in the world is lost or wasted-approximately 1.3 billion tons. Among this, the amount lost during the storage stage is about 15-20% for vegetables and 10-15% for fruits. It is 5-10% for vegetables and fruits during the distribution stage, resulting in a large amount of resource waste and economic losses. At the same time, the global population affected by hunger has reached 828 million, exceeding one-tenth of the total global population. The improvement of the cold chain system will effectively reduce the amount of waste and loss of food during the storage and transportation stages. Firstly, this paper summarizes the concept and development status of traditional preservation technology; environmental parameter sensor components related to fruit and vegetable spoilage in the intelligent cold chain system; the data transmission and processing technology of the intelligent cold chain system, including wireless network communication technology (WI-FI) and cellular mobile communication; short-range communication technology, and the low-power, wide-area network (LPWAN). The smart cold chain system is regulated and optimized through the Internet of Things, blockchain, and digital twin technology to achieve the sustainable development of smart agriculture. The deep integration of artificial intelligence and traditional preservation technology provides new ideas and solutions for the problem of food waste in the world. However, the lack of general standards and the high cost of the intelligent cold chain system are obstacles to the development of the intelligent cold chain system. Governments and researchers at all levels should strive to highly integrate cold chain systems with artificial intelligence technology, establish relevant regulations and standards for cold chain technology, and actively promote development toward intelligence, standardization, and technology.

Application of computational fluid dynamics simulations in food industry

Computational fluid dynamics (CFD) is a tool for modelling and simulating processes in many industries. It is usually used as a choice to solve problem involving flow of fluids, heat transfer, mass transfer and chemical reaction. Moreover, it has also found application in the optimization of processes in branches of the food industry, including bread baking, cooling beef roast, or spray drying. CFD has enormous potential and many opportunities to improve the quality and safety of food products, as well as to reduce the costs of production and the use of machines and production equipment. In addition, empirical models only permit data to be extracted at a limited number of locations in the system (where sensors and gauges are placed). CFD allows the designer to examine any location in the region of interest, and interpret its performance through a set of thermal and flow parameters. Computer simulations are the future of every field of science, and the presented overview provides the latest information on experts and experiences related to CFD application in food production. Despite some disadvantages, such as the need to have a large reserve of computing power, the development of digital and IT technologies will make this problem insignificant in the nearest future. Then the CFD will become an indispensable element in the design of equipment and technological lines in the food industry.

Supply Chain Resilience and Operational Performance: The Role of Digital Technologies in Jordanian Manufacturing Firms

This study aims to analyze the relationship between supply chain resilience (SCR) practices and operational performance and the moderating role of digital technologies in Jordanian manufacturing firms. A descriptive-analytical approach was adopted using a questionnaire based on the study model and previous related literature. Four hundred supply chain (SC)-related managers within seventy-one firms were reached to collect the needed data; three hundred and seventy-two complete questionnaires were analyzed. The results revealed that the level of SCR practices and operational performance was high; SCR (with its sub-dimensions: SC agility (SCA), SC flexibility (SCF), and SC collaboration (SCC)) had a significant positive relationship with operational performance; and the appropriate use of digital technologies had a significant moderating impact on the aggregate level of the SCR–operational performance relationship. Finally, research limitations, practical implications, and future research conclude this study.

Toward Better Food Security Using Concepts from Industry 5.0

The rapid growth of the world population has increased the food demand as well as the need for assurance of food quality, safety, and sustainability. However, food security can easily be compromised by not only natural hazards but also changes in food preferences, political conflicts, and food frauds. In order to contribute to building a more sustainable food system-digitally visible and processes measurable-within this review, we summarized currently available evidence for various information and communication technologies (ICTs) that can be utilized to support collaborative actions, prevent fraudulent activities, and remotely perform real-time monitoring, which has become essential, especially during the COVID-19 pandemic. The Internet of Everything, 6G, blockchain, artificial intelligence, and digital twin are gaining significant attention in recent years in anticipation of leveraging the creativity of human experts in collaboration with efficient, intelligent, and accurate machines, but with limited consideration in the food supply chain. Therefore, this paper provided a thorough review of the food system by showing how various ICT tools can help sense and quantify the food system and highlighting the key enhancements that Industry 5.0 technologies can bring. The vulnerability of the food system can be effectively mitigated with the utilization of various ICTs depending on not only the nature and severity of crisis but also the specificity of the food supply chain. There are numerous ways of implementing these technologies, and they are continuously evolving.

Computer-aided food engineering

Computer-aided food engineering (CAFE) can reduce resource use in product, process and equipment development, improve time-to-market performance, and drive high-level innovation in food safety and quality. Yet, CAFE is challenged by the complexity and variability of food composition and structure, by the transformations food undergoes during processing and the limited availability of comprehensive mechanistic frameworks describing those transformations. Here we introduce frameworks to model food processes and predict physiochemical properties that will accelerate CAFE. We review how investments in open access, such as code sharing, and capacity-building through specialized courses could facilitate the use of CAFE in the transformation already underway in digital food systems.

Digital Twinning of Hydroponic Grow Beds in Intelligent Aquaponic Systems

The use of automation, Internet-of-Things (IoT), and smart technologies is being rapidly introduced into the development of agriculture. Technologies such as sensing, remote monitoring, and predictive tools have been used with the purpose of enhancing agriculture processes, aquaponics among them, and improving the quality of the products. Digital twinning enables the testing and implementing of improvements in the physical component through the implementation of computational tools in a 'twin' virtual environment. This paper presents a framework for the development of a digital twin for an aquaponic system. This framework is validated by developing a digital twin for the grow beds of an aquaponics system for real-time monitoring parameters, namely pH, electroconductivity, water temperature, relative humidity, air temperature, and light intensity, and supports the use of artificial intelligent techniques to, for example, predict the growth rate and fresh weight of the growing crops. The digital twin presented is based on IoT technology, databases, a centralized control of the system, and a virtual interface that allows users to have feedback control of the system while visualizing the state of the aquaponic system in real time.

Digital Food Twins Combining Data Science and Food Science: System Model, Applications, and Challenges

The production of food is highly complex due to the various chemo-physical and biological processes that must be controlled for transforming ingredients into final products. Further, production processes must be adapted to the variability of the ingredients, e.g., due to seasonal fluctuations of raw material quality. Digital twins are known from Industry 4.0 as a method to model, simulate, and optimize processes. In this vision paper, we describe the concept of a digital food twin. Due to the variability of the raw materials, such a digital twin has to take into account not only the processing steps but also the chemical, physical, or microbiological properties that change the food independently from the processing. We propose a hybrid modeling approach, which integrates the traditional approach of food process modeling and simulation of the bio-chemical and physical properties with a data-driven approach based on the application of machine learning. This work presents a conceptual framework for our digital twin concept based on explainable artificial intelligence and wearable technology. We discuss the potential in four case studies and derive open research challenges.

Digital twins enable the quantification of the trade-offs in maintaining citrus quality and marketability in the refrigerated supply chain

Supply chains of fresh fruit must maintain a very narrow window of hygrothermal conditions after harvest. Any excursions outside this range can markedly lower the consumer acceptability of the fruit. However, the loss in fruit quality and marketability largely remains invisible to stakeholders throughout the supply chain. Here we developed a physics-based digital twin of citrus fruit to pinpoint when, why and to what extent fruit quality and marketability are reduced. Sensor data on 47 commercial shipments are thereby translated into actionable metrics for supply chain stakeholders by mapping the variability using principal component analysis. We unveiled a large spread (between 3% and 60%) in the shipments for different metrics of quality and marketability. Half of the shipments currently lie outside the ideal trade-off range between maintaining quality, killing fruit fly larvae and avoiding chilling injury. The digital twin technology opens the possibility to obtain the real-time coupling with sensor data to monitor food quality and marketability.

The fourth industrial revolution in the food industry-Part I: Industry 4.0 technologies

Climate change, the growth in world population, high levels of food waste and food loss, and the risk of new disease or pandemic outbreaks are examples of the many challenges that threaten future food sustainability and the security of the planet and urgently need to be addressed. The fourth industrial revolution, or Industry 4.0, has been gaining momentum since 2015, being a significant driver for sustainable development and a successful catalyst to tackle critical global challenges. This review paper summarizes the most relevant food Industry 4.0 technologies including, among others, digital technologies (e.g., artificial intelligence, big data analytics, Internet of Things, and blockchain) and other technological advances (e.g., smart sensors, robotics, digital twins, and cyber-physical systems). Moreover, insights into the new food trends (such as 3D printed foods) that have emerged as a result of the Industry 4.0 technological revolution will also be discussed in Part II of this work. The Industry 4.0 technologies have significantly modified the food industry and led to substantial consequences for the environment, economics, and human health. Despite the importance of each of the technologies mentioned above, ground-breaking sustainable solutions could only emerge by combining many technologies simultaneously. The Food Industry 4.0 era has been characterized by new challenges, opportunities, and trends that have reshaped current strategies and prospects for food production and consumption patterns, paving the way for the move toward Industry 5.0.

Toward the Next Generation of Digitalization in Agriculture Based on Digital Twin Paradigm

Digitalization has impacted agricultural and food production systems, and makes application of technologies and advanced data processing techniques in agricultural field possible. Digital farming aims to use available information from agricultural assets to solve several existing challenges for addressing food security, climate protection, and resource management. However, the agricultural sector is complex, dynamic, and requires sophisticated management systems. The digital approaches are expected to provide more optimization and further decision-making supports. Digital twin in agriculture is a virtual representation of a farm with great potential for enhancing productivity and efficiency while declining energy usage and losses. This review describes the state-of-the-art of digital twin concepts along with different digital technologies and techniques in agricultural contexts. It presents a general framework of digital twins in soil, irrigation, robotics, farm machineries, and food post-harvest processing in agricultural field. Data recording, modeling including artificial intelligence, big data, simulation, analysis, prediction, and communication aspects (e.g., Internet of Things, wireless technologies) of digital twin in agriculture are discussed. Digital twin systems can support farmers as a next generation of digitalization paradigm by continuous and real-time monitoring of physical world (farm) and updating the state of virtual world.

Can a Byte Improve Our Bite? An Analysis of Digital Twins in the Food Industry

The food industry faces many challenges, including the need to feed a growing population, food loss and waste, and inefficient production systems. To cope with those challenges, digital twins that create a digital representation of physical entities by integrating real-time and real-world data seem to be a promising approach. This paper aims to provide an overview of digital twin applications in the food industry and analyze their challenges and potentials. Therefore, a literature review is executed to examine digital twin applications in the food supply chain. The applications found are classified according to a taxonomy and key elements to implement digital twins are identified. Further, the challenges and potentials of digital twin applications in the food industry are discussed. The survey revealed that the application of digital twins mainly targets the production (agriculture) or the food processing stage. Nearly all applications are used for monitoring and many for prediction. However, only a small amount focuses on the integration in systems for autonomous control or providing recommendations to humans. The main challenges of implementing digital twins are combining multidisciplinary knowledge and providing enough data. Nevertheless, digital twins provide huge potentials, e.g., in determining food quality, traceability, or designing personalized foods.

Finite Element Method for Freezing and Thawing Industrial Food Processes

Freezing is a well-established preservation method used to maintain the freshness of perishable food products during storage, transportation and retail distribution; however, food freezing is a complex process involving simultaneous heat and mass transfer and a progression of physical and chemical changes. This could affect the quality of the frozen product and increase the percentage of drip loss (loss in flavor and sensory properties) during thawing. Numerical modeling can be used to monitor and control quality changes during the freezing and thawing processes. This technique provides accurate predictions and visual information that could greatly improve quality control and be used to develop advanced cold storage and transport technologies. Finite element modeling (FEM) has become a widely applied numerical tool in industrial food applications, particularly in freezing and thawing processes. We review the recent studies on applying FEM in the food industry, emphasizing the freezing and thawing processes. Challenges and problems in these two main parts of the food industry are also discussed. To control ice crystallization and avoid cellular structure damage during freezing, including physicochemical and microbiological changes occurring during thawing, both traditional and novel technologies applied to freezing and thawing need to be optimized. Mere experimental designs cannot elucidate the optimum freezing, frozen storage, and thawing conditions. Moreover, these experimental procedures can be expensive and time-consuming. This review demonstrates that the FEM technique helps solve mass and heat transfer equations for any geometry and boundary conditions. This study offers promising insight into the use of FEM for the accurate prediction of key information pertaining to food processes.

Modelling Volume Change and Deformation in Food Products/Processes: An Overview

Volume change and large deformation occur in different solid and semi-solid foods during processing, e.g., shrinkage of fruits and vegetables during drying and of meat during cooking, swelling of grains during hydration, and expansion of dough during baking and of snacks during extrusion and puffing. In addition, food is broken down during oral processing. Such phenomena are the result of complex and dynamic relationships between composition and structure of foods, and driving forces established by processes and operating conditions. In particular, water plays a key role as plasticizer, strongly influencing the state of amorphous materials via the glass transition and, thus, their mechanical properties. Therefore, it is important to improve the understanding about these complex phenomena and to develop useful prediction tools. For this aim, different modelling approaches have been applied in the food engineering field. The objective of this article is to provide a general (non-systematic) review of recent (2005-2021) and relevant works regarding the modelling and simulation of volume change and large deformation in various food products/processes. Empirical- and physics-based models are considered, as well as different driving forces for deformation, in order to identify common bottlenecks and challenges in food engineering applications.

Recent Advances in Reducing Food Losses in the Supply Chain of Fresh Agricultural Produce

Fruits and vegetables are highly nutritious agricultural produce with tremendous human health benefits. They are also highly perishable and as such are easily susceptible to spoilage, leading to a reduction in quality attributes and induced food loss. Cold chain technologies have over the years been employed to reduce the quality loss of fruits and vegetables from farm to fork. However, a high amount of losses (≈50%) still occur during the packaging, pre-cooling, transportation, and storage of these fresh agricultural produce. This study highlights the current state-of-the-art of various advanced tools employed to reducing the quality loss of fruits and vegetables during the packaging, storage, and transportation cold chain operations, including the application of imaging technology, spectroscopy, multi-sensors, electronic nose, radio frequency identification, printed sensors, acoustic impulse response, and mathematical models. It is shown that computer vision, hyperspectral imaging, multispectral imaging, spectroscopy, X-ray imaging, and mathematical models are well established in monitoring and optimizing process parameters that affect food quality attributes during cold chain operations. We also identified the Internet of Things (IoT) and virtual representation models of a particular fresh produce (digital twins) as emerging technologies that can help monitor and control the uncharted quality evolution during its postharvest life. These advances can help diagnose and take measures against potential problems affecting the quality of fresh produce in the supply chains. Plausible future pathways to further develop these emerging technologies and help in the significant reduction of food losses in the supply chain of fresh produce are discussed. Future research should be directed towards integrating IoT and digital twins for multiple shipments in order to intensify real-time monitoring of the cold chain environmental conditions, and the eventual optimization of the postharvest supply chains. This study gives promising insight towards the use of advanced technologies in reducing losses in the postharvest supply chain of fruits and vegetables.

Food Supply Chains as Cyber-Physical Systems: a Path for More Sustainable Personalized Nutrition

Current food system evolved in a great degree because of the development of processing and food engineering technologies: people learned to bake bread long before the advent of agriculture; salting and smoking supported nomad lifestyles; canning allowed for longer military marches; etc. Food processing technologies went through evolution and significant optimization and currently rely on minor fraction of energy comparing with initial prototypes. Emerging processing technologies (high-pressure, pulsed electric fields, ohmic heating, ultrasound) and novel food systems (cultured biomass, 3-D bioprinting, cyber-physical chains) try to challenge the existing chains by developing potentially more nutritious and sustainable food solutions. However, new food systems rely on low technology readiness levels and estimation of their potential future benefits or drawbacks is a complex task mostly due to the lack of integrated data. The research is aimed for the development of conceptual guidelines of food production system structuring as cyber-physical systems. The study indicates that cyber-physical nature of modern food is a key for the engineering of more nutritious and sustainable paths for novel food systems. Implementation of machine learning methods for the collection, integration, and analysis of data associated with biomass production and processing on different levels from molecular to global, leads to the precise analysis of food systems and estimation of upscaling benefits, as well as possible negative rebound effects associated with societal attitude. Moreover, such data-integrated assessment systems allow transparency of chains, integration of nutritional and environmental properties, and construction of personalized nutrition technologies.