In-Line Density Monitoring for Beverage Batch Dissolution Control
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Solution Overview
Problem
Industrial batch processes for producing beverages face challenges in monitoring and ensuring the quality of complex mixtures with multiple ingredients of varying viscosities and dissolution rates, often relying on manual addition and visual inspection, leading to potential errors and difficulties in determining complete mixing, homogeneity, and dissolution, which can result in wasted batches and inconsistent product quality.
Innovation Solution
The implementation of an in-line density device that continuously measures density and drive gain during the batch process, allowing for real-time monitoring and correction of deviations from a standard recipe, thereby ensuring accurate ingredient addition and mixing, and providing alerts for incomplete mixing or inhomogeneities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual addition and visual inspection are used to monitor batch process, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to potential errors in determining complete mixing and homogeneity
Solution Approach 1:
The patent replaces manual visual inspection with an automated density measurement system that uses buoyancy-based sensors to continuously monitor batch density. This substitution of mechanical/manual monitoring with physical principle-based measurement resolves the contradiction by providing objective, precise density data without requiring complex visual assessment procedures.
Solution Approach 2:
The patent introduces density as an intermediary parameter to indirectly measure mixing completion and homogeneity. Rather than directly observing mixing status, the system uses density measurements as a mediator to infer the state of the batch, enabling precise monitoring while keeping the device relatively simple.
2Manufacturing precision
If real-time density measurement is implemented using in-line density device, then manufacturing precision and quality control are improved, but device complexity and measurement cost increase
Solution Approach 1:
The patent monitors changes in density as a key parameter to detect mixing completion and homogeneity. By focusing on this single critical parameter rather than multiple parameters, the system achieves high manufacturing precision while keeping the device complexity manageable through targeted measurement.
Solution Approach 2:
The patent implements a feedback system where density measurements are continuously compared against target values, and alerts are generated when deviations occur. This feedback mechanism improves quality control by enabling real-time correction while maintaining relatively simple device architecture through automated comparison and alerting logic.
3Productivity
If continuous real-time monitoring is performed during batch process, then productivity and waste reduction are improved, but use of energy and operational complexity increase
Solution Approach 1:
The patent performs preliminary density measurements at key stages of the batch process to predict final outcomes and detect potential issues early. This preliminary action approach improves productivity by enabling early intervention while minimizing continuous energy consumption through staged rather than constant monitoring.
4Adaptability or versatility
If multiple ingredients with varying dissolution rates are mixed, then product versatility is improved, but difficulty of detecting and measuring homogeneity increases
Solution Approach 1:
The patent uses density parameter changes to indirectly measure the dissolution state of multiple ingredients. Since density reflects the overall composition and homogeneity of the batch, monitoring this single parameter enables detection of complete dissolution for multiple ingredients with varying dissolution rates without requiring direct observation of each ingredient.
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 quality control, reducing errors and ensuring consistent batch quality by continuously measuring and adjusting the batch characteristics to match a standardized recipe, minimizing waste and improving productivity.
Implementation Method 1
measuring the density of the batch in real time using an in-line density device
Implementation Method 2
measuring drive gain amplitude of the batch using an in-line density device
Data Source
AI summary
Aspects of the disclosure include a method for producing a batch according to a batch process that includes adding ingredients to water to form a batch, mixing the batch, measuring the drive gain of the batch in real time using an in-line density device, monitoring amplitude variation of the drive gain, comparing the amplitude variation of the drive gain to a predetermined threshold, and providing an indication based on the amplitude variation of the drive gain that the batch is homogeneously dispersed or fully dissolved. Other aspects of the disclosure relate to a method for detecting homogeneity of a mixture and a method of determining the degree of mixing of a batch.