Next-generation real-time industrial liquid process monitoring technology optimises quality control

12/03/2024

ColloidTek, a Finnish deep technology company, has developed Collo Analyzer, a new method for real-time liquid process quality monitoring, offering significant benefits for the food and beverage manufacturing industry. Based on electromagnetic field (EMF) sensors and machine learning, the technology detects various contaminants and identifies potential risks in liquid processing with a single real-time measurement and instant in-line analysis. This novel solution has the potential to revolutionise liquid quality control by providing food and beverage manufacturers with comprehensive information regarding the quality of their products at any stage of production, ensuring the safety, quality and correct taste of the end-product.

In liquid processing, for example in the dairy industry, efficient quality control is critical. It is essential to confirm that there are no contaminants in milk batches, such as the remains of cleaning in place (CIP) chemicals. Traditionally, collecting samples for laboratory analysis is time-consuming, leading to delays and potential risks to product quality. In addition to the logistics of transporting the sample to the laboratory, manufacturers can expect to wait days for the results. Meanwhile, the milk has often already been processed into end-products. 

If the testing of a sample finds the batch to be potentially hazardous, the implications can be huge. Product recalls incur significant costs, from logistics and disposal to legal fees, fines and refunds. Further to the immediate financial costs, the potential long-term consequences caused by damage to reputation and loss of consumer trust could be capable of crippling even a larger company. This is especially true in today’s digital age, where hazardous products can go viral in a matter of hours and cause lasting reputational damage, impacting sales and profits.

Even after addressing the quality control issues, companies may struggle to regain consumer trust and restore their brand image. Therefore, preventing such mistakes through rigorous quality control, adherence to regulations and proactive risk management is essential to safeguard the financial stability and reputation of a company. With the rise of advanced technologies, comprehensive quality control is easier and cheaper to achieve than ever before. The Collo Liquid Analyzer is an efficient and reliable method to ensure companies meet their quality and safety requirements.

Unlike traditional laboratory testing, the Collo Analyzer offers instant, in-line analysis of the quality of the liquid, with a test typically taking two seconds.

The measurement can be conducted on site manually by dipping the sensor into the product, or in-line straight from the pipe. This is made possible by EMF technology and the advanced algorithms that power the analyser, which is said to be the only one of its kind in the food and beverage industry.

Collo creates a ‘liquid fingerprint’ of the measured liquid based on its dielectric properties. Each liquid fingerprint is unique so Collo can not only detect different products, but also small changes in the measured liquid. With continuous measurement and instant results, Collo can detect and control the quality of the process liquid in real time around the clock.

Most currently available systems can only analyse liquids with specific viscosity, transparency or other characteristics. This often means several different analysers and sensors are needed at each testing point, which leads to a complex multi-sensor system that is laborious to maintain and still does not arm manufacturers with enough information for comprehensive quality control. As the Collo Analyzer can be used with thick liquids, such as honey, as well as transparent or non-conductive liquids, such as vodka or milk protein concentrate, only one device is required to measure the quality of all the liquids in the production.

The solution can simultaneously detect multiple risks or deviations, simplifying complex quality control processes by replacing other tests and covering aspects of safety and quality that no other analyser can manage. This novel technology not only accelerates the quality control process but also empowers manufacturers to take immediate corrective actions when deviations are detected, reducing the risk of costly recalls and ensuring that every batch of products meets the highest quality and safety standards.

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