In-Line Beverage Densitometry for Real-Time Batch Quality Control
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Solution Overview
Problem
Industrial batch processes for producing beverages face challenges in monitoring and maintaining consistent quality due to manual ingredient addition and visual inspection, leading to potential errors, incomplete mixing, and inconsistent batch quality, which can result in costly rework or batch discard.
Innovation Solution
Implementing an in-line density device with a recirculation loop to continuously measure density and drive gain in real time, allowing for immediate detection and correction of deviations from a standard recipe, ensuring accurate mixing and ingredient quantification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual ingredient addition and visual inspection are used, then ease of operation is maintained, but manufacturing precision and quality consistency deteriorate
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system that uses image processing and machine learning algorithms to detect ingredient mixing completeness and batch quality, thereby improving manufacturing precision while maintaining ease of operation
Solution Approach 2:
The patent introduces an intermediary computer system that processes images captured by cameras and provides automated guidance to operators, serving as a bridge between manual operation and precise quality control
2Manufacturing precision
If real-time density measurement is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single automated system that performs density measurement, image capture, mixing monitoring, and quality assessment simultaneously, reducing the need for separate devices and minimizing overall system complexity
Solution Approach 2:
The system uses the existing batch mixture itself as the measurement medium, leveraging the natural optical properties of the beverage mixture for density and homogeneity detection without requiring additional test samples or complex preparation
3Reliability
If continuous monitoring is implemented, then reliability is improved, but loss of time increases
Solution Approach 1:
The patent implements continuous real-time monitoring throughout the entire batch process, capturing images and measuring density continuously to ensure reliable quality control without interrupting the production flow
Solution Approach 2:
The system provides immediate feedback to operators when quality deviations are detected, enabling real-time corrections that prevent batch failure and eliminate the need for time-consuming post-production quality checks
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables real-time monitoring and correction of batch processes, reducing errors, ensuring consistent quality, and minimizing waste by providing precise and continuous measurement of batch characteristics, aligning with a standardized recipe.
Implementation Method 1
measuring the density of the batch in real time using an in-line density device, monitoring changes in density of the batch
Data Source
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AI summary
Aspects of the disclosure include a method for tracking the quality of a beverage produced according to a batch process that includes adding ingredients to water to form a batch, measuring the density of the batch in real time using an in-line density device, monitoring changes in density of the batch, detecting deviations from the batch process based on the changes in density, and correcting for any detected deviations from the batch process in real time. Other aspects of the disclosure relate to a method of detecting inhomogeneity in real time for a batch process for producing a beverage. Other aspects of the disclosure include a method of tracking addition of ingredients for producing a beverage in a batch process includes sequentially adding a plurality of ingredients to water according to a standard recipe to form a batch and correcting for any detected deviations from the recipe in real time.