RFID Study Results - Frequently Asked Questions
Q. What were the key findings of the study?
A. The key finding is that RFID tags that are designed for single use can be used for multiple trips without any deterioration in performance if positioned correctly on reusable containers. Specifically, quantifiable key findings from the test include:
After more than 5,000 tests, we found that there is a wide range of placement options on the reusable containers that result in superior performance.
After testing thousands of containers, we found that 109 of 110 collapsible containers on a pallet could be repeatedly read with 100% accuracy within three seconds.
The three-second time represents the time taken by the forklift driver to move the containers at a safe speed through the RFID dock portal.
RFID tags were subjected to ASTM recommended vibration and drop testing protocols. Those that performed at a 100% read level were selected for the field trial.
The three highest performing and off-the-shelf Class 1 Gen2 RFID tags selected for field testing were manufactured by Alien Technology, UPM and Avery Dennison.
From the RFID tag readability perspective, although each of the three reusable containers tested were different in design, this factor did not affect RFID performance when the tags were correctly positioned.
The RFID tags that were field tested were encapsulated in two grades of plastic film and both configurations performed at a 100% level and met their suppliers’ specifications.
Q. What is the impact of the findings of the study for the reusable packaging industry?
A. There are several reasons why the findings should significantly further the adoption of reusable packaging systems:
Reusable packaging provides many benefits to the user and the environment as well. However, it also poses some challenges such as managing and locating these assets. Since reusable assets require a substantial upfront investment they must be utilized to their fullest to obtain a return on that investment. The successful application of RFID technology as demonstrated by the study provides a means for industries to cost-effectively track and trace their reusable assets. This capability helps to optimize the already proven benefits of reusable packaging systems, and to deliver a stronger positive return on investment across a range of industries and applications.
In addition to containers, the goods being transported can be identified and tracked more closely with the technology as today’s tags offer a sizable memory component. When this is tied together with the fact that reusable packaging makes multiple trips, it then allows users to see how the total technology cost can be spread out over the longer period of time, thus bringing greater value to the user.
For produce and other industries with time sensitive shipments, adoption of reusable packaging with RFID track and trace facilitates analysis of the supply chain to reduce and minimize product loss due to shelf life expiration.
The elimination of many laborious steps involved in one-way tag applications demonstrates another significant economic advantage for reusable systems in comparison to one-way packaging choices.
Q. What do the findings mean for the produce industry?
A. The produce industry faces specific challenges associated with tracking product that has a short shelf life. RFID can result in improved food safety processes and food security procedures by quickly and accurately identifying issues which can critically reduce time and expense in food recalls. In the past, the only response was to recall all the product that was shipped to a specific retailer. With RFID, specific lots can be traced much easier and faster, thereby segregating the product that truly needs to be recalled and not adding unnecessary costs to the supply chain. In addition, the method demonstrates to consumers that controls are in place to segregate a problem. From a retailer’s perspective, RFID is a key tool in managing inventories, reducing out of stock situations and monitoring key performance indicators.
Q. What is the implication of these findings for material handling in other industries?
A. The technology opens the doors for many companies in a variety of industries to gain better control over how they manage their business processes. When a business can improve its visibility on its supply chain or their customers’ supply chain, it allows organizations to make better decisions than they could in the past. It allows businesses to truly measure their efforts and eliminates some of the guesswork from the decision-making process.
In addition, for industries with time-sensitive shipments, adoption of reusable packaging with RFID track and trace facilitates analysis of the supply chain to reduce and minimize product loss due to shelf life expiration.
Q. Why did you choose produce for the field trial?
A. We selected a produce industry application because of the many challenges within this unique supply chain. This scenario required that the tags utilized on the assets must withstand considerable temperature swings, wet and cold environments, shipping vibration and other transportation challenges and be successfully read when entering into an end users distribution system. Also, once received by the end user, the reusable asset had to be reclaimed, shipped back for reprocessing, washed, stacked and transported back to the user. The ability of the tag and other technology to handle this multiple use was a critical factor in the test. During field testing, the RFID tags underwent extreme changes in temperature from over a 100° F in the field to 32° F in cold storage and over 170° F in the sanitation cycle.
We chose lettuce in particular because of its high water content, and the known ability of water to detune radio frequencies. We wanted to determine if there would be any degradation in radio signal strength or whether the water would create any off axis multi-path issues. The apples and peppers were selected to determine whether seeds, pits, or shape might affect the radio frequencies. We also chose produce because food safety issues within this supply chain are placing more demand on suppliers to ensure product and packaging traceability.
Q. What were the main components of the study?
A. The testing was conducted in three phases:
Phase I: Distribution related physical testing of loaded and tagged RPCs in a packaging dynamics lab. The first phase performed at Michigan State University School of Packaging was vibration and drop testing. These test procedures were dictated by ASTM test protocols, designed to determine whether the internal structure of the RFID tag can withstand the stresses of the test. Four RFID tags were placed on each container (two tags on each short side). Four pallets were also tested with one of the four RFID tags placed on each of the four corners. The containers were numbered and locations noted by layer throughout the test and filled with carrots in model 6411 RPCs and with apples in the model 6428 RPCs. In total, the testing involved subjecting four pallets, 230 RPCs (erected and flattened) to Sinusoidal Vibration Tests and Drop Tests on all edges (or over 7,300 tests).
Phase II: RFID tag readability testing for RPCs from Phase I in an RFID testing center. After the ASTM testing was performed, all containers with original tags still intact were stretch wrapped and shipped to the RFID Testing Facility in Ohio. The second phase of the test was to determine if the RFID tags could be read after the stress test. Each tag on each container and pallet was read using a Symbol Handheld RFID reader.
The project team performed more than 160 hours of testing and more than 14,000 tests. In addition to proving durability, the data demonstrated that it is possible to get 100 percent read rates 100 percent of the time which had never been achieved in the industry before. The data from Phases I and II were used to determine the optimum RFID tags and RPCs for use in Phase III.
Phase III: Tagged RPCs monitored in real life shipments from farm through distribution and back to the farm.
Q. Can you describe the field trial?
A. For the test, we selected a produce industry application because of the many challenges within this unique supply chain. During the trial, produce was packed in reusable plastic containers (RPCs) directly in the field under many different field conditions. The produce was then sent to cooling facilities where product temperatures are dropped to an optimum level to ensure freshness and transportability. Following the cooling operation, the product was loaded on trucks and other containers for shipment to end user customers.
This scenario required that the tags utilized on the assets must withstand considerable temperature swings, wet and cold environments, shipping vibration and other transportation challenges and be successfully read when entering into an end users distribution system. Also, once received by the end user, the reusable asset must be reclaimed, shipped back for reprocessing, washed, stacked and transported back to the user. The ability of the tag and other technology to handle this multiple use was a critical factor in the test.
These RFID tags were subjected to the harshest and most vigorous testing in packaging labs under ASTM guidelines before they were field tested. During field testing, the RFID tags underwent extreme changes in temperature from over a 100° F in the field to 32° F in cold storage and over 170° F in the sanitation cycle.
Additionally, the RFID tags were exposed to dry field conditions, wet and cold storage environments, warehousing, store racking and hand deliveries to the store shelves.
Further, each of the RFID tags used during field testing were subjected to an average of over a 1,000 mile transportation distance, before being unloaded at a distribution center, then reloaded onto local trucks for delivery to the stores, redelivered back for sanitation, and finally redeployed to the produce company for reuse.
Q. During the field testing phase, how many points in the supply chain were set up with RFID reading capability?
A. Four. The points were RPC service center (for RPC issuance), grower/shipper, retailer DC, retailer store and then back to the RPC service center (upon return). The total number of RFID reads per trip were five as the container was read upon issuance and return to the RPC service center.
Q. Who was involved in the study?
A.
Retail: Wal-Mart Stores Inc., Bentonville AR.
Growers: Frontera Produce, Edinburg, TX; Stemilt, Wenatchee, WA; Tanimura and Antle, Salinas, CA.
Reusable Containers: Georgia-Pacific, Atlanta, GA; IFCO SYSTEMS N.A., Houston, Texas; ORBIS Container Corporation, Fresno, CA.
RFID Technology Providers: Alien Technology, Morgan Hill, CA; Avery Dennison, Pasadena, CA; Impinj, Seattle, WA; UPM Raflatac, Hebron, KY
Packaging Expertise and Testing: Michigan State University School of Packaging; The Kennedy Group, Willoughby, Ohio
ASTM Testing Performed By: Michigan State School of Packaging, Dr. Paul Singh
RFID Readability Testing Performed By: California State Polytechnic University, Dr. Jay Singh
Final Field Testing/Project Management By: QLM Consulting, G. Michael McCartney Principal
Project Sponsor: Reusable Packaging Association
Q. What was the RPA’s role in the study?
A. The role of the RPA was to initiate, sponsor and provide oversight for the management of this project. Our objective was to sponsor a thorough and scientific study and then deliver an accurate and unbiased report of the results.
Q. Why did the RPA undertake this study?
A. One of the RPA’s goals is to be a valued, credible source for information on reusable supply chain packaging solutions. Our mission is to further the adoption of reusable packaging systems. By sponsoring a third-party, independent study, we are providing valuable, credible information that further supports the benefits of the adoption of reusable packaging solutions.
The results and data derived from the test give the reusable packaging systems industry a more accurate picture of the state of RFID technology today, and it will assist to identify the potential for RFID. By building on these results and the growing body of knowledge about the use of RFID technology in the supply chain, we believe RPA members and other interested parties can begin to find new ways to utilize this promising technology to improve the utilization and management of their reusable assets and to reduce inventory at all levels and overall costs throughout the system.
Q. How were the testing partners chosen for this study?
A. The RPA solicited leaders in the produce and technology industries to participate. We believe that the produce industry test participants offered a wide range of products with various cooling techniques and product attributes that allowed for diversity in testing. The RPA solicited leading technology partners that could offer a high level of competence and assistance during the various test phases.
Q. Why was only one retailer chosen for the study?
A. The test was designed to be manageable from an asset control standpoint and to achieve multi trips in the field testing phase. One retailer and one DC were chosen to limit the number of nodes in the supply chain that had to be monitored to orchestrate multiple trips of the tagged RPCs.
Q. Why were reusable plastic containers (RPCs) chosen over bulk containers or other reusable assets in the supply chain?
A. The volume of RPC movements within the produce supply chain outnumbers the other reusable assets that are active today. Therefore, testing RPCs and the associated cost benefits would be the most impactful.
Q. Which RPCs were used in the trial?
A. We used two containers throughout the study:
Model 6411: IFCO, Georgia-Pacific, ORBIS
Model 6428: IFCO, Georgia-Pacific, ORBIS
Q. Why were only two of the RPC sizes used for testing?
A. We wanted to test a relatively small RPC (6411 – 4.3” internal depth) and a large RPC (6428 – 11” in depth) so that we had a range of RFID tag counts per pallet. Testing more sizes would have generated the same RFID tag counts per pallets. Both of these sizes are representative of very high volume movements through the produce supply chain.
Q. What other RFID hardware and software was used in the study?
A. A Symbol Motorola RFID handheld reader was used exclusively through the testing for tag verification. Alien Antennas were used for both the Alien Reader and the Impinj Reader. Standard Alien Reader software and Impinj software were used to record all data on to Excel spreadsheets. All RFID tags, readers, antennas and hardware were commercially available products.
Q. Are there benefits of RFID for RPC service providers?
A. The tracking of the RPC assets at the discreet container level is a benefit to the RPC providers. These benefits include monitoring of cycle time, inventory turns, dwell time by supply chain node and loss exposure.
Q. Are RPCs available today that are RFID capable?
A. Contact RPC providers for their latest update on RFID capabilities.
Q. What are the costs of a multi-use RFID tag?
A. As multi-trip RFID tags are not commonly used, there is no “market pricing” readily available. If multi-trip RFID tags were to be adopted by the produce industry and RPC providers, we would expect to see the same economies of scale in terms of cost reduction that has taken place with one-trip RFID tags.
Q. Does the RPA plan to do more studies on RFID?
A. The RPA will continue to stay close to the advancements that occur in RFID. At this point we have no plans for future studies and we will keep the marketplace aware of our initiatives.
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