Infrared Gauges for Food Manufacturing

Taste, texture, and appearance are all key quality attributes that determine the success of a food product in the market. Measurements of moisture and color during the manufacturing process are crucial to ensure consistent final product quality, prevent "checking," maximize shelf life, and promote customer satisfaction and loyalty. Nordson has worked closely with key players in the baked goods industries to develop dependable, high-performance, non-contact measurements which can also be integrated into closed-loop control of the process. 

Controlling the moisture content of baked goods upstream generates key benefits to the processor downstream such as improved shelf-life and reduced surface checking. Other productivity gains include improved quality, reduced off-line testing, reduced operator dependency, and time savings. Critical to product consistency is the color after baking. Our Series 9 Moisture Gauge is available with an additional simultaneous color measurement that gives a linear brownness value that mimics the human eye’s color response. The InfraLab Top Loader is another color measurement option for at-line measuring of the degree of bake with results in less than five seconds.

There is more. Our Series 9 Biscuit Gauge uses optical sensors to ensure that we only make a measurement when the product is directly under the gauge measurement area. At Nordson we don’t “zero out” the conveyor belt – we don’t even let our gauge see it.

The bakery items our gauges can measure include cookies, biscuits, wafers crackers, crispbreads, croutons, breadsticks, and dough.

Moisture and fat measurements in chocolate and cocoa production are critical parameters at the intermediate and final stages of the manufacturing process. Controlling these two components not only affects the quality and consistency of the final product, but it can also mean savings in the use of high value constituents such as cocoa butter. 

As part of our continuous innovation in the food industry, we have developed a comprehensive suite of non-contact moisture and fat measurements with our Series 9 On-Line Gauge and InfraLab At-Line Analyzer. Our products are particularly well-suited for chocolate and cocoa production.

Nordson offers measurements for various products including cocoa beans, cocoa liquor, cocoa powder, chocolate crumb, drinking chocolate powder, molten milk or plain/dark chocolate, press cake, refiner flake, and refiner paste. We also provide a range of measurements for other confectionery processes such as mold starch and sugar coating. For powdered products, the PowderVision In-Process Sampler can be used with the Series 9 On-Line Gauge to measure products in gravity-fed ducting. Our measurement gauges deliver consistent results to keep the chocolate industry irresistibly sweet. 

Moisture measurement and control are crucial at almost every stage of coffee processing to ensure the best product quality. Roast masters often measure the "color" of roasted coffee beans to assess the quality of the roasting process. Our collaboration with coffee producers worldwide has led to a stable, reliable moisture calibration for all types of coffee, including coffee beans, ground coffee, and instant coffee. Non-contact coffee moisture measurement and control benefits include improved quality, enhanced productivity, energy savings, and confidence in meeting legislative standards.

For processes that allow it, the Series 9 On-Line Gauge can provide real-time measurements of moisture and degree of roast. For grab sample measurement, the InfraLab Top-Loader, used at-line, can measure moisture and degree of roast. The Series 9 and InfraLab Top-Loader are designed for ease of use and require minimal operator training.

Our analyzers can measure moisture and degree of roast in the following coffee products: green coffee beans, roast coffee beans, ground coffee, and instant coffee. Coffee roasting is both an art and a science, and our coffee process measurement solutions can be tailored to accommodate a wide variety of coffee processes, enabling real-time or rapid control and optimization at different production stages.

In the confectionery industry moisture measurement is integral to ensuring that the product has an appealing taste, texture, and appearance. Having too much or too little water will result in confectionary products going to waste. 

In a world where food production efficiency is crucial, quality control is essential. One way to achieve this is by using online moisture gauges at various points in the manufacturing process. This allows the process controller to consistently produce high-quality products within specifications. As a result, production scrap is minimized, and production efficiency is optimized. Our moisture measurement systems are available for fondant starch used for molding, sugar coating in pan coaters, and sugar coating on chewing gum. If you're interested in creating perfectly sweet products, learn more about our gauges below.

During the final stages of transforming liquid dairy concentrates into powder, accurately measuring and controlling moisture is critical to ensure the best possible product quality and operational efficiency. By providing fast, reliable real-time measurement and feedback of moisture content to the controller, the manufacturing process can be safely operated close to the upper specification limit for final moisture. This capability enables manufacturers to consistently produce top-quality products that meet food safety and regulatory requirements.

The results of our measurements may show increased production yields by preventing over-drying of the product. The use of high-energy intense spray drying and fluid bed after drying and cooling stages helps reduce energy costs. This decrease in energy costs has a positive impact on the plant's carbon footprint. Nordson Measurement and Control is a respected provider of reliable, cost-saving gauging technology in the dairy industry.

Moisture measurement and control are very important during the final processing stages of turning liquids into powders (instant coffee, tea, etc.) or combining dry ingredients (instant chocolate, baby formulas, etc.) to ensure optimal product quality and operating efficiency. With rapid, dependable real-time measurement and feedback of the moisture content to the process controller, the process can be safely operated close to the upper specification limit for final moisture. This enables manufacturers to produce a highly consistent, within-specification, top-quality product that complies with food safety and other regulatory requirements.

Nordson Measurement and Control's accurate measurement readings can lead to increased production yields by preventing over-drying of the product. The use of high-energy intense spray drying, fluid bed after drying, and cooling stages helps reduce energy costs, which in turn has a positive impact on the plant's carbon footprint. Nordson Measurement and Control is a respected provider of reliable, cost-saving gauging technology in the instant drinks industry.

Nordson gauges provide solutions for maintaining the quality of a wide variety of grains and oil seeds, including flour, malt powder, sunflower seeds, rolled oat flakes, sesame seeds, and more. Our measurement systems are capable of rapidly and simultaneously measuring protein, fat/oil, moisture, and in some cases color. This concurrent and quick measurement ability allows grain and oil seed processors to meet their quality and efficiency goals.

Depending on the gauge, we can meet a range of product line goals by offering at-line, on-line, or off-line testing. The flexibility of our gauges helps our customers minimize disruption on their process lines during installation and makes them easy to use.

Ground beef and pork processors require accurate fat content analysis for their meat products to ensure they fall within the specified target range. Rapid at-line testing in a processing plant provides processors with timely information needed for consistent product quality and lean giveaway reduction. By measuring protein, collagen (C/P), and water content, the production and quality personnel can confirm whether the fat and lean content meet the target specifications, which speeds up the batch release and reduces the frequency of external product testing.

Our InfraLab At-Line Meat Analyzer is an easy-to-use non-contact device that requires no special user skills. It provides accurate and instantaneous measurements of fat, moisture, protein, and collagen in grab samples of meat taken from the line in just 10 seconds. InfraLab is available in three versions: fat only, fat plus moisture and protein, or all three components plus collagen. It has a hygienic format, substantial internal memory for thousands of sample data files, Ethernet connectivity, and the ability to export data to a spreadsheet or other similar software. InfraLab has proven long-term stability and a unique ability to self-check, which eliminates the need for re-calibration once it has been adjusted to work in harmony with your preferred methodology or external test house.

View our meat process measurement solution below and take ownership of your data while gaining a deeper insight into your process behavior.

In the food industry, proper moisture control is crucial when processing nuts to maintain their quality and prevent mold growth, particularly the development of aflatoxins. Nordson Measurement & Control Solutions has established itself as a dependable provider of precise and continuous moisture and oil measurements for nuts.

The measurement of oil content is especially significant for products like peanut butter, and our Series 9 Gauges have played a vital role in this analysis. Our gauges have proven effective for at-line processes and on-line measurements of whole nuts, offering reliable and accurate data for quality control and production optimization.

Nordson meets the potato processing industry’s demands for accurate, reliable, and continuous measurements of moisture, fat/oil, and surface brownness. Regardless of whether the product is fried or baked, these measurements can be used to enhance quality and process control. Nordson understands that a generic approach to process measurements is not effective and has engineered robustness into its measurement solutions. This ensures that any changes in the measurement output are solely due to varying levels of the measured parameter, without influence from other product or process variables. With immediate access to data, our sensor technology takes you one step further toward maximizing the performance potential of your process.

The Nordson Series 9 On-Line Gauge and the InfraLab Series-9 At-Line Analyzers help manufacturers operate every step of their production process at peak performance: from starch drying to frying, flavoring, and packaging. Nordson Near-Infrared solutions can be used to measure moisture, oil content, degree of browning, and bed height in chip/crisp production; moisture, solids, oil content, degree of browning, and bed height in French fry manufacturing; and moisture in potato starch. Applications include potato fiber, potato powders or flakes, potato protein extract, potato snack pellets, backed and fried potato products, starch, and French fries.

Balancing moisture and protein/fat in rice, noodles, and pasta is critical in the food industry. In this particular market, product consistency determines overall quality and customer satisfaction. In manufacturing processes, the moisture content of cooked rice or noodle blocks can be measured after initial steam cooking and, for noodles, on the finished product after frying. The oil content of pasta can also be measured if required.

Our Series 9 Family of analyzers can be used in a variety of production layouts. Nordson product portfolio includes the Series 9 On-Line Gauge, the InfraLab Series 9 At-Line Analyzer, and the InfraLab Series 9 Top Loader. Each instrument offers a different set-up to help measure protein/oil, moisture, fat and, in some cases, color. The analyzers provide fast, continuous results whether used at-line, in-line or on-line to help customers achieve full process control. By providing real-time data, Nordson's non-contact measuring instruments and analyzers enable manufacturers to increase productivity and meet label specifications while ensuring that their products have the desired texture, flavor and feel. The sensors are highly accurate and reliable, providing critical data that allows food companies to make informed decisions about their production processes.

In the snack food manufacturing industry, customer loyalty and satisfaction are paramount. To meet these expectations, manufacturers must ensure that their products are consistent in quality and meet all required specifications. Achieving this level requires real-time information regarding the manufacturing process. Fast, continuous, and non-contact on-line measurement or rapid at-line analysis of moisture, oil, and color play a crucial role in achieving full process control.

Nordson Measurement & Control Solutions offers cutting-edge non-contact gauges and analyzers that are specifically designed to operate in challenging snack food processing environments. These gauges can be configured to measure moisture-only, or in multi-component formats, allowing for highly robust simultaneous measurement of moisture, oil, and color or degree of bake/brownness. Nordson snack control sensors can be used in various applications, such as corn dough, popcorn, pretzels, puffed corn, and aperitif-style snacks.

By providing real-time data, Nordson's non-contact gauges and analyzers enable manufacturers to increase productivity and meet labeled specifications, while also ensuring that their snacks have the desired "crunch". The sensors are highly accurate and reliable, providing critical data that allows manufacturers to make informed decisions about their production processes.

Moisture measurement and control is important at almost every stage of starch drying for optimum product quality and operational efficiency. There are various ways in which starch can be used in production and avoiding over-drying is critical to producing a reliable, superior product. The confectionery industry needs consistency when using molding starch. In molding starch, if the powder is too wet, it will fuse with the jelly, resulting in waste. This can increase lead times as it is typically discovered after the product has been through the 12–24-hour oven curing process. On the other hand, if the starch is too dry, the sides of the mold will crumble and not hold their shape when the jelly is injected, resulting in undefined confectionary shapes. Whatever the application, starch drying stages require a reliable gauge to prevent product damage. Our robust, fit-for-purpose, real-time, non-contact moisture measurement solutions enable the process operator to confidently control processes to avoid over-drying and achieve maximum drying energy efficiency.

Nordson solutions cater to production lines of starches derived from corn, rice, wheat, and potato. Our gauges provide a range of benefits such as reducing re-work, re-blending, and scrap. The Series 9 On-Line Gauge is designed with food safety in mind, featuring a unique cast 316L stainless steel housing, sealed IP67 standards, and a food-safe sapphire measurement window. It also comes with operator and supervisor interfaces in durable stainless-steel housing. Another option is the Series 9 Food Analyzer, which offers rapid and accurate measurement of moisture, fat, and protein in single or multiple-component configurations in various food products. Our gauges aim to help production lines thrive, and by using either a Series 9 On-Line Gauge or InfraLab Analyzer, customers can experience a wide range of benefits to help decrease production costs and improve product quality. Check out our gauges and their individual benefits to determine the right fit for your production needs.

Moisture and color control are critical in sugar processing plants to ensure consistent product quality and meet regulatory requirements. Real-time measurement and feedback of moisture content and color to the process controller allows for safe operation close to the moisture upper limit. This results in the production of a high-quality product that meets specifications, is safe for storage and transportation, and complies with regulations. However, conventional analytical technologies are slow and inaccurate, providing measurements at "snapshot" intervals and requiring a few grams of sample, which can lead to inefficient operation. 

Nordson Measurement & Control Solutions offers a better alternative with the Series 9 On-Line Gauge and the InfraLab Series 9 At-Line Analyzers. These instruments provide highly accurate measurements, requiring little or no operator skills. Nordson sensor technology gives manufacturers access to a level of feedback that is simply impossible to achieve with conventional laboratory techniques such as Karl Fischer or moisture balances, which are expensive and time-consuming. 

The Series 9 Gauges and InfraLab Series 9 Analyzers can also be utilized to measure and regulate moisture in bagasse and beet pulp. These are the by-products obtained from the processing of sugar cane and sugar beet and are extensively used for animal feed.

Moisture control is crucial when processing green tea leaves into black tea. It ensures optimal taste, aroma, shelf-life, and operating efficiency. With rapid, dependable real-time measurement and feedback of the moisture content to the controller, the process can be safely operated to the desired specification limit. This enables manufacturers to produce a highly consistent and top-quality product that complies with food safety and other regulatory requirements. In today's world, where food yields and manufacturing costs have become increasingly important, improved moisture control during the drying stages guarantees improved product quality and increased production output by avoiding over-drying which could potentially damage the product. Additionally, it reduces energy costs and positively impacts the plant's carbon footprint by optimizing the energy-intensive drying stages closer to the moisture upper specification limit.

Nordson Measurement & Control Solutions has been widely recognized by leading processors for its reliable gauging technology that caters to the tea industry. The Series 9 Near-Infrared (NIR) Gauge is designed to capture on-line measurements in real-time for continuous drying processing, such as withered green leaves, finished black tea after drying, and final blends before packaging. In situations where it is not practical to install on-line gauging, the Nordson InfraLab Series 9 At-Line Analyzer is an effective alternative that provides rapid at-line measurement on representative large grab samples.