Moisture content is a delicate balance in food manufacturing. Even the slightest variation can cause quality issues, resulting in losing thousands of dollars. Traditional methods of moisture measurement can be inconsistent, but there is a better way to monitor moisture. Real-time moisture sensors constantly monitor the moisture content of production lines for quick adjustments to prevent loss. Save money and improve product quality with a MoistTech real-time moisture sensor.
Expedited Spoilage
One of the greatest concerns of incorrect moisture in food is the risk of early spoilage. Excessive moisture is a breeding ground for bacteria, mold and yeast. If left unchecked, it can lead to spoilage, reduced shelf life and hazards to consumer health. Safety should be a paramount concern with food manufacturing, so early spoilage can have serious implications. Expedited spoilage can cost manufacturers thousands when product needs to be disposed of under these conditions.
Diminished Texture and Quality
Moisture plays a big role in the texture and quality of food products. Too much moisture leads to soggy or sticky products, while too little moisture causes dryness. Powders can turn cakey or gritty with excessive moisture. Not only do these issues make products not palatable, but they can also contribute to stability issues with product quality diminishing during transportation. Consumers trust the quality of products, and if products do not meet their expectations, they will turn to a competitor.
Processing Issues
Processing issues also contribute to lowered product quality. Inaccurate moisture levels can be the source of many issues, such as equipment clogging, inconsistent mixing, poor binding and other packaging difficulties. Not only can this cost money from impacting product quality, but it can also be costly when equipment needs service as a result of too much moisture in ingredients.
Chemical Reactions
Moisture content can affect chemical reactions, like Maillard browning and enzymatic activity. It may be necessary to dispose of this product if chemical reactions alter the flavor, color or nutritional value. Although some chemical reactions may be cosmetic, they can still be concerning to consumers, which leads to revenue loss.
Real-Time Moisture Measurement Saves Money
Real-time moisture measurement saves food manufacturers thousands of dollars from material waste, product inconsistencies and rework. When moisture is measured in real time, operators can catch minor inconsistencies and correct them before they turn into major problems. Other cost saving benefits include:
- Consistent product quality
- Improved food safety
- Process optimization
- Regulatory compliance
Enhanced Automation
Overall, effective moisture measurement has several benefits with the potential to reduce money loss. Instead of using inconsistent moisture measurement techniques, a MoistTech sensor can provide accurate, real-time data for improved product quality and lower revenue impacts over time.
Benefits of Near Infrared Technology
MoistTech’s IR-3000 moisture sensor uses near infrared (NIR) technology for non-contact moisture measurement. Product does not need to be wasted to collect samples as the sensor never touches the material. Line downtime is reduced due to production not needing to stop when the sensor collects data. Each sensor is guaranteed not to drift so they will stay where they are placed. The sensors are calibrated once at the factory and then never need recalibrating again. With the ability to store up to 50 product codes and calibrations, operators can make adjustments on the process immediately. Thanks to a plug-and-play design, the IR-3000 sensor can be installed almost anywhere on the line. The sensors are not affected by the ambient conditions of the processing line, no matter how humid or dusty. MoistTech’s sensors are designed to not require any maintenance and for the parts to age together. This saves money buy eliminating the need for multiple repairs and replacement parts.
Immediate ROI
The benefits of real-time moisture sensors can bring immediate ROI. Precise control is linked to decreased material waste and energy consumption and an increase in efficiency, all of which impact the bottom line. MoistTech’s sensors implement a feed-back-loop control system. This system changes the process based on the in-line measurement. When the analysis of data has potential to define substantive future process changes, an inline sensor can have high potential ROI. Production can be increased by 400% or more after adding a moisture measurement system from MoistTech. In some cases, a moisture measurement system can pay for itself in less than 30 days.
Connect with MoistTech on LinkedIn
MoistTech is the diamond standard of moisture measurement in food processing. See what makes us stand out from traditional moisture measurement methods. Connect with us on LinkedIn to stay up to date with the latest moisture measurement news.