Instrumentation and Measurement Techniques in Food Technology
Module Overview
Module Title: Instrumentation and Measurement Techniques in Food Technology
Module Code: PHYSICS 101
Instructor: Jerna Mae P. Pabilona
Delivery Mode: Online (Synchronous Classes with Module-Based Guide)
Duration: 2 Weeks (4 Synchronous Meetings, 1.5 Hours Each)
Learning Outcomes
By the end of this module, students will be able to:
1. Describe the physical measurement tools commonly used in food processing and
explain their functions and applications.
2. Analyze the role of sensors and automation in food technology, including their use
in monitoring and controlling food processing operations.
3. Demonstrate an understanding of data collection methods and error analysis,
applying these concepts to ensure accuracy and reliability in food processing
measurements.
Pre-test: Refer to provided Google form
INSTRUMENTATION AND MEASUREMENT
TECHNIQUES IN FOOD TECHNOLOGY
Before diving into the specific tools and techniques used in food processing,
it’s important to understand the significance of physical measurements in ensuring the
quality, safety, and efficiency of food production. In this section, we will explore the
common physical measurement tools that are essential in monitoring and controlling
various parameters during food processing. These tools are integral in maintaining
consistency, complying with safety standards, and optimizing production processes.
Let’s take a closer look at the various instruments used in food technology and their
applications.
6.1 Overview of Physical Measurement Tools in Food Processing
Instrumentation in food processing is essential for maintaining product quality,
process consistency, and compliance with food safety standards such as HACCP
(Hazard Analysis and Critical Control Points) and ISO 22000. These instruments are
used to measure physical parameters such as temperature, pH, moisture content,
pressure, and soluble solids—all of which are critical in various food processing
operations.
A. Thermometers
Thermometers are used to monitor and control the temperature of raw
materials, intermediates, and finished products during processing, storage, and
distribution.
Types:
a. Mercury/Alcohol Thermometers – Traditional, but being phased out due to
toxicity and fragility.
b. Thermocouples – Fast-response probes used in ovens and heat treatment lines.
c. Infrared Thermometers – Non-contact thermometers ideal for surface temperature
checks.
d. Digital Probe Thermometers – Common in meat and bakery processing.
Example Applications:
1. Pasteurization of milk – Must reach 72°C for 15 seconds (HTST process).
2. Cooking of meat – Core temperature must reach at least 75°C to ensure microbial
safety.
B. pH Meters
A pH meter determines the acidity or alkalinity of a food product. The pH
value influences enzyme activity, microbial growth, and product stability.
Importance in Food Processing:
a. Dairy Products – Cheese production relies on precise pH control for curdling.
b. Fermented Foods – Monitoring the drop in pH ensures proper fermentation (e.g.,
kimchi, yogurt, tuba).
c. Canned Foods – Foods with pH > 4.6 require pressure processing to kill
Clostridium botulinum.
How it Works:
A glass electrode measures hydrogen ion activity in the sample, converting it to a pH
value.
[Insert image of benchtop pH meter with beaker of liquid]
C. Refractometers
Refractometers measure total soluble solids (TSS) in liquids by evaluating
how light bends (refracts) when passing through the sample. This is often expressed
in °Brix (percentage sugar by weight).
Applications:
1. Fruit Juices and Soft Drinks – Quality control of sweetness.
2. Tomato Paste – Grading based on °Brix level.
3. Brewing and Fermentation – Initial sugar content prediction of alcohol yield.
Types:
a. Handheld analog/digital – For field or lab use.
b. Inline refractometers – Installed in production lines for real-time monitoring.
[Insert image of handheld refractometer with citrus juice sample]
D. Moisture Analyzers
Moisture content affects shelf-life, texture, and microbial growth. Moisture
analyzers are used to determine water content through methods like loss-on-drying
(LOD) or infrared drying.
Key Applications:
1. Powdered products (e.g., flour, milk powder) – Prevents clumping and spoilage.
2. Snack foods and cereals – Affects crispness and oxidation rate.
3. Dehydrated fruits – Ensures adequate drying for shelf stability.
Fun fact: Moisture levels above 12-15% in cereal grains promote fungal growth
and mycotoxin formation.
E. Manometers & Pressure Gauges
Used to monitor vacuum and pressure during processing, especially in:
Canning – Ensures internal pressure is adequate for sterilization.
Vacuum drying – Maintains low pressure to remove moisture at low
temperatures.
Carbonated beverages – Ensures correct carbonation under pressure.
Types:
a. Bourdon Tube Gauges – Measures gas or liquid pressure.
b. U-Tube Manometers – Simple devices for lab use.
c. Digital Pressure Transducers – Convert pressure to electrical signals in automated
lines.
Summary Table of Physical Measurement Tools
Tool Measured Parameter Application Example
Thermometer Temperature Pasteurize, meat cooking
pH Meter Acidity/Alkalinity Fermentation, dairy, canning
Refractometer Soluble Solids (°Brix) Juice concentration, sauces
Moisture Analyzer Moisture Content Dry foods, cearels, powders
Manometer/ Pressure
Pressure/Vacuum Canning, carbonation, drying
Gauge
Technical Insight: Why Are These Tools Important?
1. Consistency: Ensures product quality and uniformity.
2. Safety: Prevents growth of pathogens via correct pH and heat processing.
3. Efficiency: Speeds up decision-making and reduces human error.
4. Compliance: Meets industry standards (e.g., FDA, BFAD, HACCP).
6.2 Common Sensors and Automation in Food Technology
Overview
In modern food processing, sensors and automation systems play a crucial role
in maintaining efficiency, accuracy, safety, and product consistency. Sensors are
devices that detect and measure physical properties (like temperature, pressure, flow,
or composition) and convert them into signals that can be interpreted by automated
systems or human operators.
Automation, on the other hand, integrates these sensors with control systems
to perform processes with minimal human intervention, reducing error, improving
traceability, and supporting Good Manufacturing Practices (GMP) and HACCP
standards.
A. What is a Sensor?
A sensor is a device that detects a physical stimulus and converts it into a readable
signal (usually electrical). In food technology, sensors are used for:
1. Monitoring critical control points (CCPs)
2. Ensuring product safety and quality
3. Reducing waste and human error
4. Enhancing traceability and data logging
Sensors can be contact (directly touching the food or medium) or non-contact
(measuring without touching, e.g., infrared sensors).
B. Types of Common Sensors in Food Processing
Sensor Type Measured Parameter Application in Food Technology
Cooking, pasteurization, freezing,
Temperature Sensors Heat/Cold
cold storage
Fermentation, pickling, meat
pH Sensors Acidity/Alkalinity
processing
CIP systems (cleaning validation),
Conductivity Sensors Ionic concentration
dairy processing
Internal/external Canning, carbonation, filtration
Pressure Sensors
pressure systems
Rate of liquid/gas Liquid ingredient mixing, CIP
Flow Sensors
flow validation, water usage control
Cloudiness Juice clarification, wastewater
Turbidity Sensors
(particulate level) monitoring
Oxygen, CO₂, Modified Atmosphere Packaging
Gas Sensors
ethylene (MAP), fermentation monitoring
Volume/height of
Level Sensors Tank control, filling processes
liquids
Light Non-destructive quality assessment
Optical/NIR Sensors
absorption/reflection (ripeness, moisture, fat content)
C. Automation in Food Processing
Automation refers to the use of control systems such as computers or PLCs
(Programmable Logic Controllers) to operate equipment and processes automatically.
Key components:
1. Sensors – Detect and transmit data
2. Controllers – Analyze data and make decisions (e.g., PLCs, microcontrollers)
3. Actuators – Carry out the physical action (e.g., motors, valves, heaters)
4. Human-Machine Interface (HMI) – Screens or dashboards for real-time
monitoring
Examples of Automation in Food Plants:
a. Pasteurization Units – Automatically control heating and cooling based on
temperature sensors.
b. Filling and Packaging Lines – Sensors detect levels and position for accurate
filling and sealing.
c. CIP (Clean-in-Place) Systems – Automated cleaning cycles triggered by
conductivity and flow sensors.
d. Bakery Lines – Conveyor-based systems that control dough proofing, baking, and
slicing with minimal human input.
D. Benefits of Sensor-Based Automation in Food Processing
Advantage Explanation
Increased Efficiency Faster and more consistent processing speeds
Enhanced Safety Automatic shutdown or alerts when critical limits are
breached
Reduced Human Error Minimizes variability caused by manual operations
Digital logging of sensor data for audits and
Traceability & Records
compliance
Cost Savings Optimized resource use (energy, water, raw materials)
Real-Time Monitoring Instant feedback and control over the process
Real-World Example: Sensor-Controlled Pasteurization
In milk processing, temperature sensors are used to:
1. Detect the inlet temperature
2. Trigger heaters to reach 72°C (for HTST pasteurization)
3. Ensure the product holds that temperature for 15 seconds
4. Confirm the exit temperature before cooling
If any of these parameters deviate, an automated alarm or system shutdown is
triggered to prevent unsafe product from moving forward.
6.3 Introduction to Data Collection and Error Analysis
Overview
In food processing, data collection is the systematic process of gathering
measurements and observations from various stages of production, such as
temperature, pH, pressure, flow rate, and moisture content. These data are essential
for maintaining product consistency, ensuring safety, optimizing efficiency, and
complying with food safety standards such as HACCP and ISO 22000.
Along with data collection, understanding and addressing errors is crucial for
the reliability of measurements. Error analysis helps to quantify and minimize
inaccuracies in data, leading to more accurate decision-making.
A. Types of Data Collection Methods in Food Processing
Data collection methods vary depending on the parameter being measured and the
processing environment. Below are the primary methods used in food technology:
a) Manual Data Collection
Description: Involves human operators recording measurements manually. Often
used for small-scale or less automated processes.
Example: A technician measures and records the temperature of a pasteurization
batch using a thermometer.
Pros: Low setup cost, simple
Cons: Prone to human error, inconsistent, time-consuming.
b) Automated Data Collection
Description: Data is collected automatically via sensors and transmitted to control
systems or databases.
Example: Sensors measuring the temperature in a cooling tower and sending real-
time data to a computer system for processing.
Pros: Consistent, efficient, reduces human error
Cons: Higher initial setup cost, need for regular maintenance.
c) Sampling and Statistical Methods
Description: Data is collected by taking random or systematic samples from the batch
and analyzing them statistically.
Example: Sampling a batch of yogurt for pH and viscosity measurements.
Pros: Good for large-scale or continuous production.
Cons: Only represents a subset of the whole, potentially missing variability.
d) Online and Inline Monitoring Systems
Description: Direct measurement of parameters within the process without
interrupting the production.
Example: An inline refractometer measures sugar content in a juice production line
without stopping the flow.
Pros: Real-time monitoring, immediate adjustments.
Cons: High initial cost, potential need for calibration.
B. Sources of Errors in Data Collection
Understanding the types of errors that can affect data collection is essential to
ensuring reliable and valid results. These errors can be broadly categorized into:
a) Systematic Errors (Bias)
Systematic errors are consistent, predictable errors that occur every time a
measurement is taken. They can be traced to a faulty calibration or a defective sensor.
Example: A temperature sensor that reads 2°C higher than the actual temperature due
to improper calibration.
Cause: Poorly calibrated equipment, sensor drift, or consistent environmental
conditions.
b) Random Errors
Random errors are unpredictable variations in measurements due to external factors,
equipment limitations, or human factors.
Example: A slight fluctuation in pH values due to changes in ambient temperature or
inconsistency in sample handling.
Cause: Instrument instability, fluctuations in environmental conditions (humidity, air
pressure), or human error during sample preparation.
c) Human Error
Human error refers to mistakes made by operators when using instruments or
interpreting data.
Example: Incorrect reading of the thermometer, mislabeling samples, or failure to
properly record data.
Cause: Lack of training, miscommunication, fatigue, or lack of attention.
d) Instrumental Error
Instrumental errors occur when measuring devices malfunction or become worn out
over time.
Example: A pH meter that gives fluctuating readings due to worn electrodes.
Cause: Sensor degradation, improper calibration, or faulty electronic components.
C. Error Analysis Techniques
Error analysis is a process used to understand the magnitude and impact of errors on
collected data. It involves identifying the type of error and using statistical methods to
quantify and minimize its effect.
a) Precision and Accuracy
Accuracy refers to how close a measured value is to the true value.
Precision refers to the consistency of repeated measurements, even if they are far
from the true value.
In food processing, both precision and accuracy are essential. For example, measuring
the temperature of a pasteurizer must consistently meet the required pasteurization
temperature (accuracy), and the system should be able to replicate this every time
(precision).
b) Percent Error
The percent error is a common method used to quantify accuracy and compare
measured values against known standards.
( Measured Value−True Value )
Percent Error = True Value
× 100
For example, if the target temperature for a pasteurization process is 72°C, but the
thermometer reads 70°C, the percent error would be:
( 70−72 )
Percent Error = 72
×100 = 2.78%
c) Standard Deviation
Standard deviation quantifies the dispersion of a set of data points. In food processing,
it helps determine how much variation exists between measurements taken over time.
Formula:
(xi − μ)2
Standard deviation =
N
where:
xi = individual data point
μ = mean of the data set
N = number of data points
A high standard deviation in measurements (e.g., temperature variation in a
pasteurization line) can indicate poor process control.
d) Confidence Intervals
In food processing, confidence intervals provide a range within which we
expect the true value to fall, given a certain level of confidence (usually 95%).
For example, if a temperature measurement in a pasteurizer has a 95%
confidence interval of 70±2°C, it means there’s a 95% chance that the true
temperature lies within that range.
D. Data Validation and Quality Assurance
To ensure data reliability, it is essential to validate and verify data through:
Calibration: Regular calibration of instruments against known standards or
certified reference materials.
Cross-checking: Comparing data from multiple sensors or measurement methods.
Replicability: Ensuring that measurements can be repeated and produce
consistent results.
Software Validation: Ensuring the algorithms used to analyze data (e.g., in
control systems) are accurate and reliable.
E. Practical Example: Monitoring pH in Fermentation
In a fermentation process, accurate pH control is crucial for ensuring the desired
microbial activity. To collect reliable data:
Sensors: Use pH meters calibrated regularly to ensure they provide accurate
readings.
Automation: Implement an automated pH control system that adjusts pH levels
by adding acid or alkali based on sensor readings.
Error Analysis: Use percent error calculations to verify the pH readings against
the expected range. Additionally, check the standard deviation across multiple
fermentation batches to identify any significant variations that could affect the
final product quality.
References
Bader, S. (2023). Instrumentation and measurement Systems: Methods, applications
and opportunities for instrumentation and measurement. IEEE
Instrumentation & Measurement Magazine, 26(7), 28–33.
[Link]
Di Mauro, A., Scozzari, A., & Soldovieri, F. (2022). Instrumentation and
measurement technologies for water cycle management. In Springer water.
[Link]
Figura, L. O., & Teixeira, A. A. (2023). Food Physics. In Springer eBooks.
[Link]
Mahajan, P., Bera, M. B., & Prasad, K. (2022). Food physics insight: the structural
design of foods. Journal of Food Science and Technology, 60(6), 1643–
1655. [Link]
Yadav, & Talati, M. (2021). Applied Physics I. KHANNA BOOK PUBLISHING CO.
PVT. LTD.
Post-test: Refer to provided Google form
Disclamer:
The content provided in this module is for educational purposes only. While every
effort has been made to ensure the accuracy and reliability of the information, the
instructor and institution do not take responsibility for any errors or omissions. The
tools, techniques, and methodologies discussed are subject to change based on
advancements in food technology and industry practices. Students are encouraged to
consult additional resources and verify the information presented to stay updated on
current trends and practices in the field.
