In-Line Densitometry for Real-Time Beverage Batch Homogeneity
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Solution Overview
Problem
Existing batch processes for producing beverages face challenges in monitoring product quality in real time, leading to potential errors in ingredient addition and mixing, which can result in inconsistent batch quality and wasted materials due to post-process analysis.
Innovation Solution
The use of an in-line density device, such as a Coriolis density meter, to continuously measure density and drive gain during the batch process, allowing for real-time detection and correction of deviations from a standardized recipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional batch processes are used without real-time monitoring, then device complexity is reduced, but manufacturing precision and product quality consistency deteriorate
Solution Approach 1:
The patent replaces manual visual inspection and mechanical measurement methods with optical absorption spectroscopy. The system uses light absorption measurements at multiple wavelengths to non-invasively monitor ingredient mixing and dissolution in real-time, eliminating the need for complex mechanical sampling and analysis equipment while improving batch quality consistency.
Solution Approach 2:
The patent implements a feedback control system where real-time absorption measurements are continuously compared against target values for fully dissolved ingredients. When deviations are detected, the system automatically adjusts mixing parameters or ingredient addition rates, creating a closed-loop control mechanism that maintains manufacturing precision without requiring overly complex monitoring infrastructure.
2Productivity
If post-process analysis is used to detect quality deviations, then measurement complexity is reduced, but loss of time and productivity increase due to delayed detection
Solution Approach 1:
The patent implements continuous real-time monitoring throughout the entire batch process using absorption spectroscopy. The system continuously measures absorption at multiple wavelengths as ingredients are added and mixed, enabling immediate detection of deviations from the desired state. This eliminates the time delay inherent in post-process analysis while maintaining simple measurement principles.
Solution Approach 2:
The system performs preliminary detection of mixing and dissolution states during the batch process itself, before the batch is complete. By monitoring absorption characteristics in real-time, the system can identify deviations early and trigger corrective actions while the batch is still being processed, preventing waste of time and materials that would occur with delayed post-process detection.
3Measurement precision
If manual visual inspection is used to monitor ingredient mixing, then device complexity is reduced, but measurement precision and reliability deteriorate
Solution Approach 1:
The patent replaces manual visual inspection with optical absorption measurements. The system uses light absorption at multiple wavelengths to objectively quantify ingredient dissolution and mixing states, providing precise measurements of concentration and homogeneity that are impossible to achieve through visual inspection alone, while keeping the detection apparatus relatively simple.
Solution Approach 2:
The patent introduces light absorption as an intermediary measurement mechanism. Instead of directly observing or mechanically sampling the mixture, the system uses light interaction with the batch to indirectly measure ingredient concentration and mixing state. This intermediary approach provides high measurement precision while avoiding the complexity of direct mechanical measurement or sampling systems.
4Manufacturing precision
If real-time density measurement is used to monitor batch composition, then manufacturing precision improves, but device complexity and cost increase
Solution Approach 1:
The patent replaces physical density measurement devices with optical absorption spectroscopy. By measuring how different ingredients absorb light at specific wavelengths, the system can infer composition and concentration information that would traditionally require density measurements. This substitution maintains manufacturing precision while avoiding complex density measurement equipment.
Solution Approach 2:
The patent measures multiple absorption parameters at different wavelengths simultaneously to characterize batch composition. Instead of relying on a single density parameter, the system uses multiple optical absorption measurements to detect ingredient addition and mixing states, providing equivalent or superior information with simpler, more versatile equipment.
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
Ensures consistent batch quality by providing real-time feedback on ingredient mixing and dissolution, reducing errors and waste by allowing for immediate adjustments, and facilitating standardized quality control across different manufacturing facilities.
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
Figure 1
Figure 2A
Figure 2B~2C
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.