Ishida unveils Sentinel 5.0 at Gulfood Manufacturing 2024: AI-Powered innovation for the food industry

At Gulfood Manufacturing 2024, held from 5 to 7 November at the Dubai World Trade Center, Ishida unveiled Sentinel 5.0, a next-generation system that brings data-driven insights into food manufacturing. Ian Hodgson, Systems General Manager at Ishida Europe, shared how Sentinel 5.0 and other innovations will shape the future of food production through AI, automation, and Industry 5.0 principles. This enhanced version of Ishida’s renowned remote monitoring and reporting solution promised to be a standout feature of this year’s event, alongside an array of weighing, packaging, and quality control solutions, including the newly launched IX-PD X-ray inspection system, which sets new standards in detection.

A journey towards seamless integration

Ishida’s journey into smart manufacturing began in 2016 with the launch of Sentinel, a system designed to gather and analyze data from machines across production lines. "Our initial product, Sentinel, was aimed at data collection and customer support, with a focus on Industry 4.0 digitization," explains Ian. "However, we had a separate, locally-installed product called Ishida Data Capture System (IDCS), which provided detailed data extraction. The challenge was that we were managing two systems with similar functions, which was inefficient."

After years of development, Ishida merged the best features of the old systems into Sentinel 5.0, a unified platform that not only gathers data but also learns from it using AI. "The new Sentinel can learn the normal behavior of your machines, send alerts for deviations, and even detect cross-machine issues if one problem affects others in the line," Ian explains.

AI at the heart of Sentinel 5.0

Sentinel 5.0 leverages artificial intelligence (AI) to offer predictive maintenance and troubleshooting solutions. "We've integrated a generative AI engine, so operators can interact with Sentinel 5.0, asking questions about machine issues and troubleshooting methods," says Ian. "The system’s AI-driven anomaly detection highlights issues, triggering the AI to offer solutions and detailed reports that assist operators proactively."

This level of AI integration not only streamlines maintenance tasks but also allows manufacturers to maximize productivity through enhanced machine performance and reduced downtime.

Addressing industry challenges with digitalization

Ian highlights the ongoing challenge in the food manufacturing sector: many companies invest in high-tech machinery but fail to implement effective monitoring systems. This gap in data visibility can severely limit a plant’s ability to optimize productivity. "We recently had a customer implement our Sentinel 5.0 system and they saw a 15% productivity increase almost overnight just from gaining visibility into operational issues," Ian shares. "With Sentinel 5.0, they aim to boost that to 30%."

The value of real-time, data-driven insights becomes clear, with Sentinel 5.0 identifying machine issues automatically rather than relying on operators to spot them.

Seamless upgrades for existing customers

For existing customers already using earlier versions of Sentinel, upgrading to Sentinel 5.0 is simple. "All recent Ishida machines are Sentinel 5.0-compatible, so they can connect directly. For older models, a software update is all that’s needed—no additional hardware is required," Ian assures.

This ease of integration ensures that customers can quickly benefit from the enhanced capabilities of the new system without significant investment in new equipment.

Other innovations on display at Gulfood Manufacturing

Aside from Sentinel 5.0, Ishida showcased several other innovations at the event, underscoring the company's commitment to advancing food manufacturing technology. "We've recently launched several new products, including a next generation multihead weigher, an advanced X-ray system, a seal tester, and a new bag maker," says Ian.

• The IX-PD X-ray inspection system: Precision and resilience

One of the standout innovations was the IX-PD X-ray inspection system, which offers significant improvements over traditional X-ray detection technology. "The IX-PD X-ray inspection system uses dual energy, (both low and high energy) then using the new software from Japan, a comparison between the two energies is carried out, allowing for smaller contamination detection. The PD line sensor receives the x-rays in their raw form directly from the generator, therefore no scintillator is required, which introduces noise, resulting in sharper images and better detection accuracy," Ian explains. "This technology enhances precision, especially in detecting small contaminants like fish bones, and has a longer lifespan, making it a more reliable solution for food safety."

• Micro-weighers - Meeting the needs of niche markets

Among the multihead weighers on display, the CCW-AS-214 stands out, significantly enhancing productivity, hygiene, and profitability while lowering energy consumption by 20% and reducing noise. The Ishida Micro, the world’s smallest multihead weigher, is specially designed for ultra-low target weights with remarkable 0.01g accuracy, and the 8-head Ishida Fresh Food Weigher (FFW) efficiently handles sticky and bruise-sensitive items, cutting giveaway to under 1% and reducing labor requirements by three operators per shift.

Ian states that Ishida continues to innovate for specific industries with innovations like its micro-weighers, designed for applications requiring extreme accuracy. “Our micro-weigher handles tiny target weights as low as 0.01 grams, which is essential for high-value items like tea leaves or soup sachets where precision is critical,” explains Ian.

This precision is another example of how Ishida is meeting the specialized needs of food manufacturers across diverse sectors.

Why Gulfood Manufacturing?

When asked why Ishida chose Gulfood Manufacturing as the platform to launch Sentinel 5.0, Ian emphasizes the importance of this event in reaching the right audience. "Gulfood is one of the key shows on our calendar. The timing worked well, and we have a lot of activity in the Middle East right now, making it the perfect venue to showcase our latest innovations," he says.

He adds, "Our focus is on demonstrating how Sentinel 5.0 can integrate various machines, even from different manufacturers, into a cohesive, data-driven solution for full line optimization."

Sentinel’s impact on the food industry

With Sentinel 5.0, Ishida is offering food manufacturers a centralized solution for maximizing operational efficiency. "You don’t want to manage different systems for different machines," Ian states. "Sentinel brings everything together in a more connected and integrated way, ensuring that machines and processes work in harmony, maximizing productivity and quality."

Customer feedback: A positive reception

Ishida has already received enthusiastic feedback from early adopters of Sentinel 5.0. "The customers we’ve worked with so far have loved it," Ian reports. "After trying it on one machine, they immediately wanted it on all their equipment. The feedback has been incredibly positive, and we’re excited to see how it will continue to evolve."

A future-oriented vision

As the food industry moves towards more digitized, automated, and AI-driven solutions, Sentinel 5.0 positions Ishida at the forefront of this transformation. "Our vision is to provide a unified, data-driven solution that empowers manufacturers to improve efficiency, quality, and sustainability across their operations," concludes Ian.

For those looking to optimize their production lines, Sentinel 5.0 offers a powerful tool to unlock new levels of performance, ensuring that the future of food manufacturing is smart, connected, and efficient.

For more about Ishida Europe and Sentinel 5.0, please visit - Discover the power of Sentinel 5.0 Production Monitoring | Ishida