The effect of industry 4.0 applications on food safety management systems in the dairy sector

In retrospect, the industrial revolution has changed and developed in terms of information technologies and mechanization from the 1750s to the present. Since 2011, it has changed for the fourth time under the name Industry 4.0, and it has become inevitable for the food industry to keep up with this change. In today's world where change and development are experienced very rapidly, keeping up with technological innovations and being aware of all developments is of vital importance for all small and large businesses. The main goal of all R&D and innovation activities in the industry is to increase efficiency in production processes. However, the main goal of the 4th Industrial Revolution is not efficiency, but control of production processes from raw materials to end products with smart products and smart machines. As a result of these developments, it is expected that productivity will increase. The developments that started with Industry 4.0, especially in the production department, have perfect service targets such as the reduction of human-induced errors, product stardization, efficient use of resources and cost reduction, meeting the need for instant follow-up as well as instant follow-up and customer satisfaction, especially in the production department. Other departments also provide significant advantages. In addition to these advantages, it is expected that progress will be made in the fields of productivity, growth, investment and employment, which are four important categories, with the Industry 4.0 transformation. When we look at the literature, there are a limited number of studies in which Industry 4.0 and the food sector are discussed together. In this study, Industry 4.0 applications, which is the last stage of the industry and where technology is used at the highest level, were examined, the effect on food safety management systems was investigated separately, and the effect of Industry 4.0 applications in the dairy sector on the mentioned systems was also mentioned. The purpose of this study is to evaluate the effects of Industry 4.0 technologies, which were started 5 years ago and still continue in a local and large-scale dairy enterprise, on the performance improvement on food safety management, through the data collected by various sensors. As material, data obtained from smart electronic cyber-physical systems with internet connection, integrated with all kinds of equipment, equipped with sensors and operators, where devices in the entire production process are used to exchange information and data with each other in a large-scale dairy farm located in the Bursa region will be used as material. In this context, the effects on food safety will be analyzed by using electricity, gas, water and steam consumption measurements, personnel tracking, sensitive analytical measurement devices, communication infrastructure, equipment and software for measurement and signal processing, and information collected. In the study, daily and hourly balance sheet tracking data collected from all stages from raw material acceptance in the factory until reaching the consumer will be used. In this context; A data bank collected using machine learning and artificial intelligence approaches to optimize production planning by determining and tracking all consumptions (raw materials and auxiliary materials, chemicals, electricity, water, natural gas), personnel, losses (raw materials and auxiliary materials), efficiency, cost-reducing actions will be used. As a result, it is expected that all these applications will positively affect the revitalization of the national economy and the support of industrial development, with the increase in productivity in the industry, especially in the dairy sector. As material, data obtained from smart electronic cyber-physical systems with internet connection, integrated with all kinds of tools, equipped with sensors and operators, in a large-scale dairy farm located in Bursa region, where the devices in the entire production process are used for information and data exchange with each other. In this context, the effects on food safety were analyzed by using daily and hourly balance sheet tracking data collected from all stages, starting from the acceptance of raw materials in the factory and reaching the consumer, with personnel tracking, sensitive analytical measuring devices, communication infrastructure, equipment and software for measurement and signal processing. In addition, a database containing machine learning and artificial intelligence approaches for optimizing production planning by determining and tracking all consumptions (raw materials and auxiliary materials, chemicals, electricity, water, natural gas), personnel, losses (raw materials and auxiliary materials), efficiency, cost-reducing actions has also been used. In conclusion; Following the introduction of Industry 4.0 application in 2017, which started in 2015, the rate of total customer complaints decreased from 5.77 ppm to 1.17 ppm as a result of the analyzes carried out until 2022. The overall food safety customer complaints rate decreased from 3.79 ppm to 0.64 ppm. While the rate of returned product tonnage was 1.56% in 2015, this rate decreased to 0.99% in 2022. While the rate of non-conforming products was 0.25% in 2015, it decreased to 0.145% in 2022. Regarding food safety, the number of food safety CCP in the production process, which was 21 in 2015, was reduced to 17 in 2022. Keywords: Industrial revolution, Industry 4.0, Food safety, Dairy company, Global competition, Digitalization