Zhiyi Era Online Infrared Moisture Meter in the Food Industryapplicationplan

1、 Industry background: Moisture control, the lifeline of food quality

The stability and safety of food quality have always been the core competitiveness of food enterprises. Among them, moisture content is a key indicator that directly affects the freshness, taste, shelf life, and microbial risk of food - excessive moisture can easily lead to microbial growth, spoilage, and even toxin production; Low moisture content may affect the flavor and structure of the product. Traditional moisture detection methods, such as the electric oven method, have pain points such as long detection cycles (requiring several hours), destructive sampling (unable to reuse samples), and strong lag (difficult to provide real-time feedback on the production process), which make it difficult to meet the needs of modern food production for "high efficiency, precision, and full process quality control".

In this context, Zhiyi Era relies on near-infrared spectroscopy technology to launchOverall solution for online infrared moisture analyzerWith "real-time monitoring, non-destructive testing, and intelligent warning" as the core, we aim to build a moisture quality control system that covers the entire process of food production, helping enterprises achieveRaw Material InspectionFrom link supervision to finished productsinspectionofWhole process preventionandQuality upgrade.

2、 Core advantage: Technology driven, redefining moisture detection

The Zhiyi Era online infrared moisture analyzer is based on the principle of near-infrared spectroscopy technology, which achieves rapid and accurate analysis of sample moisture content through the characteristic absorption reaction between specific wavelength light and water molecules in food. Compared to traditional detection methods, the solution has the following core advantages:

1.Real time detection, bidding farewell to "lag"

· Detection speed 0.01 secondsWithout the need for sampling or waiting, non-contact continuous detection of materials (such as particles, powders, and block shaped foods) on the production line can be directly carried out, and the data is transmitted in real-time to the central control system, achieving "detection is feedback".

2.Non destructive analysis, safeguarding the 'sample value'

· Non contact measurementNo need to destroy the sample structure, avoiding the waste of raw materials caused by traditional sampling and testing (such as precious ingredients and high value-added products), especially suitable for food that is prone to oxidation and spoilage.

3.High precision assurance, data“LINGPromise of Error

· precisionZUI low0.3%Using imported optical sensors and AI algorithm models, customized calibration curves are designed for different food categories (such as grains, meat, baked goods, pet food, etc.) to ensure detection accuracy under complex ingredients, far exceeding manual or traditional equipment.

4.Intelligent linkage, building a "closed-loop quality control"

· Data integration and process linkage：Relying on the system platformReal time moisture data can automatically trigger production equipment adjustments (such as dryer temperature, conveyor belt speed), forming a "detection analysis control" loop and reducing manual intervention.

5.Full scene adaptation, covering "from farmland to dining table"

· modular designFlexible installation can be made according to the characteristics of the production line (such as assembly line, conveyor belt, vibrating screen machine, drying furnace), adapting to various forms of materials such as solid, semi-solid, powder, etc., to meet the testing needs of different food categories.

3、 Application scenarios: From raw materials to finished products,end-to-end processquality controlWUdead angle

The Zhiyi Era online infrared moisture analyzer solution, with "full process quality control" as the core, deeply integrates into various links of food production, achieving "precision, real-timeAutomationIntelligence ":

1.Raw material acceptance: Building the first line of defense for quality

· pain pointTraditional raw material acceptance relies on sampling and inspection, which is time-consuming,And tolerateIt is easy to cause unqualified raw materials (such as grains, fruits and vegetables with excessive moisture) to flow into production, increasing the risk of subsequent processing.

· Solution ApplicationInstall an online infrared moisture meter on the raw material storage conveyor belt to continuously detect each batch of raw materials (such as wheat, meat, pet food raw materials) and determine in real-time whether the moisture content meets the enterprise standard (such as grain moisture ≤ 14%).

· valueImprove the efficiency of raw material acceptance by 80% and reduce production waste caused by unqualified raw materials,Reduce economic losses.

2.Processing link control: real-time regulation, stable process parameters

· pain pointIn food processing (such as baking, drying, and sterilization), changes in moisture directly affect the taste and structure of the product (such as the crispness of cookies and the fluffiness of bread). Traditional manual inspection has a lag, which can easily lead to large fluctuations in moisture content within the same batch of products.

· Solution ApplicationInstall equipment at key processing nodes (such as drying furnace outlet, baking tunnel, vibrating screen layer) to monitor real-time changes in material moisture contentDynamically adjust process parameters to ensure consistency in product tasteRealize dynamic balance between moisture and process.

· value：passControl of moisture fluctuations in the processing stage,enhanceProduct qualification rate, reducing energy and labor waste caused by rework.

3.Finished product quality inspection: the final check before leaving the factory

· pain pointUnqualified moisture content in finished products is the main reason for food returns, such as excessive moisture leading to shortened shelf life and improved tastedeteriorate）The traditional sampling mode is prone to overlooking non-conforming products, leading to the risk of customer complaints.

· Solution ApplicationInstall an online infrared moisture meter on the conveyor belt before packaging the finished products, and conduct a 100% full inspection of each package/box of products (such as pet food, instant noodles and cakes) to determine in real time whether the moisture meets the factory standards. Unqualified finished products automatically trigger sorting devices to avoid entering the market.

· value: Finished product factory qualification ratesignificantlyImprove and reduce customer complaint rates, improvehighBrand reputation.

4.Abnormal warning and tracing: early intervention to reduce production losses

· pain pointWhen there is a sudden moisture abnormality in production (such as insufficient drying caused by equipment failure), traditional methods require manual detection, which often results in a large number of unqualified products and serious losses.

· Solution ApplicationThe system is equipped with an intelligent warning module. When the moisture data exceeds the set threshold (such as sudden increase/decrease), it immediately alerts the management personnel through sound and light alarms, SMS notifications, etc., and automatically records the abnormal time and material information for easy tracing of the cause.

· valueThe abnormal response time has been reduced from 30 minutes to 5 minutes, resulting in product waste caused by a single abnormalitysignificantlyreduce

4BIAOPole Case: From "Pilot" to "Industry wide Promotion"

Case 1: A pet food manufacturer in Tianjin - Full process coverage, creating "transparent quality control"

· demandPet food ingredients are complex (meat, grains, mixed fruits and vegetables), and moisture deviation may lead to product clumping, mold growth, or nutrient loss, directly affecting quality and market reputation. It is necessary to control moisture throughout the entire process from raw material storage to finished product packaging, in order to avoid a decrease in palatability and a shortened shelf life due to moisture fluctuations.

· Implementation of the planDeploy the Zhiyi Era online infrared moisture analyzer system, covering raw material acceptance (meat/grain moisture detection), mixing and stirring (real-time monitoring of moisture after raw material crushing and automatic adjustment of mixing ratio), extrusion molding（Dynamically adjust the steam injection amount to ensure consistent expansion degree）TheDrying and cooling（Based on the moisture monitoring results,Control the drying temperature and duration, conduct a re inspection before packaging the finished product to ensure that the moisture content meets the standardfiveLarge nodes upload real-time data to the enterprise quality control platform.

· effectVisualization of moisture data throughout the entire process, including differences in moisture content between product batchesreduceCustomer feedback states that the stability of pet palatability has improved and the return rate has decreased.

Case 2: A food company in Shanghai - precise detection of vibrating screen layer to improve screening efficiency

· demandIn the field of foodIn productionThe vibration screening process needs to ensure that the particle size and moisture content of the material are uniform. Traditional manual testing is time-consuming and has large errors, which affects the subsequent seasoning and packaging quality.

· Implementation of the planInstall an online infrared moisture meter in the vibrating screen layer to perform real-time moisture detection on the materials during the screening process (with a detection accuracy of ± 0.1%). The data is synchronized to the screening equipment control system, and the screen vibration frequency is automatically adjusted when the moisture is abnormal to ensure material separation efficiency.

· effectThe uniformity of material moisture in the vibrating screening process is improved, the screening efficiency is enhanced, and the cost of manual testing is reduced.

5productEmpowerment: Triple Upgrade of Quality, Efficiency, and Cost

The Zhiyi Era online infrared moisture analyzer solution is not only a set of detection equipment, but also an intelligent tool for food enterprises to achieve "quality upgrade, efficiency improvement, and cost optimization":

Product Introduction

This productIt is an online non-contact material moisture detectorUsing near-infrared spectroscopy sensors, the detection range covers moisture content from 0.1% to 99%, with an accuracy of up to ± 0.1%. It can accurately adapt to the characteristics of complex raw materials such as meat, grains, and vitamin premixes. Through built-in AI algorithms, the system can automatically calibrate data deviations and optimize detection models in real-time.

working principle

The online infrared moisture meter emits infrared radiation light, which is reflected parallel to the measured material through a lens, filter disc, and reflector. A portion of the infrared light is processed by the optical path and shines on the material, while some of its energy is absorbed by water molecules in the material and reflected back to the infrared detector. The other portion of the infrared light is scattered and directly focused on the infrared detector through a concave mirror. The light receiving element converts the change in light energy into an electrical signal. The size of this signal is related to the moisture content of the measured material. The output signal is amplified and transformed into a standardized signal for display, recording, control, or transmission to the computer system for relevant processing.

Technical Specifications

1. Measurement range: 0-80% (depending on the product)

2. Measurement accuracy: 0.1-0.3% (depending on the product)

3. Dual detector synchronous detection technology, 6-wavelength testing principle

3. Resolution: 0.01%

4. Measurement area: 60mm diameter (when the probe is 200mm away from the material)

5. Measurement speed: 0.01 seconds

6. Calibration and tuning: Quick calibration, pre calibration, no need for daily re calibration

7. Filtering: Linear or exponential (0.1-180 seconds)

8. Analog output: Two sets of 4-20mA outputs (connected to PLC or digital display)

9. Communication output: Two sets of RS485 digital signal output

10. Calibration files: can store 50-100 calibration files

11. Working temperature: 0-50 ℃

12. Power requirement: 110-230V

13. Sensor construction: Stainless steel casing (IP65 protection level)

14. Cleaning and blowing interface: blowing port diameter 6mm, compressed air 0.5-1Bar

Product advantages

Green non-destructive: No sampling required, non-contact, non-destructive, real-time dynamic detection

Instant response: Real time monitoring of moisture changes to avoid lag in manual sampling

Accurate and stable: high detection accuracy, suitable for complex working conditions

Cost reduction and efficiency improvement: reducing raw material waste and rework costs