Boost Your Efficiency and Cut Your Costs in Food Processing with Ultrasonic Technology

The need for efficiency in the supply of the food manufacturing industry is integral to meet the ever-increasing market demands. Global population rise is placing more pressure on our food supplies. In the UK alone the expected rise in population to 70 million is leading the food manufacturing industry to grow: 140,000 new recruits expected by 2024. With food & drink contributing to £28.2 billion to the UK’s economy the biggest manufacturing sector in the country, the demand for high quality products has resulted in an industry demand for high quality production and management systems. Food processing companies are now calling for scientifically and mathematically accurate, ergonomic, innovative, technology which is designed to improve maintenance and safety management systems, exemplified by the case studies below.

A leading food processing factory in Slovakia, which processes fresh fruit, vegetables and meat is one of these companies:

CASE STUDY – Food Processing Factory in Slovakia, Apple Puree

The factory was faced with a problem in production of apple puree, to be used in baby and toddler food and juice products. The apple puree is stored in large steel tanks, at 4.5metre in height. However, they had no way to check the liquid level of apple puree inside the large tanks, which was affecting their efficiency.

Keen to find a solution, they reached out to Coltraco Ultrasonics. A site visit was conducted by Mr Lubomir Ernst, the Central & Eastern European Regional Director of Coltraco Ultrasonics. After a short trial he was able to assess that innovative and advanced portable ultrasonic liquid level indication technology was efficient in quickly and accurately gauging the liquid level of apple puree within the vessel.

The implementation of an ultrasonic liquid level indicator will allow the plant to run more efficiently and reduces risks by providing the staff with a means of accurately and non-invasively monitoring the contents within the apple puree tank. Ultrasonic technology is an effective and reliable technology for identifying a wide range of liquids in cylinders/tanks, saving time and cost whilst increasing efficiency and safety.

CASE STUDY – Food Processing Factory in UK, Mayonnaise

A food processing factory based in the South of the UK approached Coltraco Ultrasonics after having difficulty with their containment of mayonnaise.

The company produce coleslaw, packaged salads and pastas for the likes of McDonalds, Tesco, Morrisons and Lidl, producing over 130,000 pots of coleslaw a day. The company faced difficulty in monitoring the contents of its mayonnaise and Coltraco offered a solution to this problem. The mayonnaise used for the coleslaw is contained in 2.2. metres high, 5mm stainless steel cylinders. However, the monitoring method that the factory used to check usage and remaining contents was through employees manually using ladders to peer into the cylinder and make an assumption of how much was left. Three issues come with this method: potential contamination of the mayonnaise; inaccurate measuring methods; health and safety risk to the operator.

The Food Standards Agency and the Hazard Analysis Critical Control Point (HACCP) supplies strict stringent regulations about contamination. There could be a high risk if there was contamination, for example from allergens and pathogens. This is a principle as required by EU Food Hygiene Rules. It was this issue that the food production company wanted to mitigate and wanted to apply our technology to help adhere to their HACCP to mitigate any food safety problems.

After a site visit was conducted by Coltraco Engineers, a liquid level indicator was supplied to the company. This technology efficiently, quickly and accurately gauges the liquid level of the mayonnaise within the vessel using non-intrusive, clean, ultrasonic technology which emits no radiation. The implementation of the liquid level indicator allows the plant to run more efficiently and reduces risks by providing staff with a means of accurately and non-invasively monitoring the contents within the mayonnaise tank - negating the need for physical inspection using ladders.

Furthering to the needs of the food processing factory, the trial and implementation of this unit suggested that Coltraco Ultrasonics could develop a fixed monitoring system for this vessel type and others like it, in order to non-invasively, continuously monitor the contents of the condiments within the tank. This builds upon the technology that Coltraco has designed for fire safety. Coltraco Ultrasonics have now developed the first system worldwide that is capable of monitoring the liquid level of critical fire suppression cylinder systems on a constant basis. It gives a facility total visibility on the real-time status of all their critical fire systems. Using their innovation and ability to adapt technology to customer required situations, Coltraco are developing their technology to continuously monitor the contents within the tanks, so that the food processing company can be alerted when the contents drops below a set level, thus improving efficiency, with simple and easy use for their team.

Continued development of designing, manufacturing and supporting liquid level indication technology allows Coltraco Ultrasonics to work in 109 Countries and numerous market sectors and safety critical or high value asset environments. The development program was born out of the desire to fulfil customers’ needs with special applications, to assist with cost saving, time saving and risk reducing, making customers lives easier and better. With the pressures on the food industry, technology companies must provide innovative and personalised solutions to the demands that their customers have to face, so that their customers can be assured of business success and efficiency.

Keywords:Ultrasonic liquid level indicator, liquid level indicator, ultrasonic level indicator, liquid gas level indicator, ultrasonic leak detector, ultrasonic gas leak detector, ultrasonic level sensor, ultrasonic liquid level sensor, liquid level sensor, ultrasonic monitoring and measuring equipment

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