Choosing The Right Environmental Monitoring Instrumentation For Your Food & Beverage Processing
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Choosing The Right Environmental Monitoring Instrumentation For Your Food & Beverage Processing

By 06/07/2022July 13th, 2022No Comments

Improve Your Food Processing and Safety Control

The food, beverage, and agriculture industries are required to adhere to strict safety guidelines and regulations to prevent contamination and preserve the high quality of end products. Measurement instrumentation helps to prevent issues when growing or processing food and when producing beverages. Compliance to safety is so critical that even minor issues can impact produce quality, food safety and result in low yields, unexpected downtime and low-quality end products.  Reliable and accurate process monitoring and the ability to provide tools are crucial to optimizing the entire production process, from growing the food to preparation, manufacturing, filling, packaging, and storage.

Dpstar’s understanding of the food processing environment monitoring requirements throughout the production cycle, mean that our instruments are designed with the demands of the food manufacturer in mind. From raw ingredients through to the production of marketable food products, environment can be measured to ensure optimum levels are adhered to.  Your food products need optimal and stable conditions in order to guarantee consistency and prevent degradation. Having the right environmental monitoring instrumentation will help protect your products, your bottom line, and your customers. Our solutions for the food and beverage industry provide both safety and process control to ensure product quality, high yield, and safety.  Our instrumentation solutions for food and beverage production help increase product quality, improve reliability, and reduce risks to your plant, personnel, and the environment. We know your process and how critical it is for our customers to protect precious and limited resources and keep our global food supplies safe.

What is food and beverage processing?

Those in the food and beverage industry have an obligation to serve safe, properly packaged, and fresh items to consumers. With fast-changing customer demands and strict health regulations, the importance of the handling processes for food and beverage plays a vital role. The term, ‘food processing’ refers to any operation (mechanical, physical or chemical) carried out on food in order to change its properties. It can be a single operation or a combination of different ones. Food processing is carried out in order to make food suitable to be consumed or stored. Some food processing methods play important roles in reducing food waste and improving food preservation, thus reducing the total environmental impact of agriculture and improving food security.

Three Stages of Food Processing

Food processing encompasses all the steps that food goes through from the time it is harvested to the time it arrives on consumer’s plate. Processed foods can be classified into three types:

01 Primary food processing 

Primary processing is the conversion of raw materials to food commodities. Milling is an example of primary processing.

02   Secondary food processing

Secondary processing is the conversion of ingredients into edible products – this involves combining foods in a particular way to change properties. Baking bread is an example of secondary processing.

03  Tertiary food processing

Tertiary food processing means producing prepared convenience foods, such as canned soup or frozen dinners.

Why Monitor Your Process?

Monitoring helps ensure quality and safety because it requires food to be handled in specific ways. Implementing monitoring processes should include those that can be tracked to identify potential issues and concerns over the safety and quality of food products. Monitoring the processes in your sanitary plant is critical to achieving the following objectives:

Quality

Monitoring certain operating variables, such as temperature, may also be critical to achieving and maintaining the desired product quality.

Reduce Food Waste

Food hygiene makes the food durable and increases its shelf life. It reduces the wastage of food that otherwise happens due to bad food processing.

Control Systems

Collect information received from the sensors and various instruments and process it for further distribution and/or action.

Improves Efficiency

Better hygiene and improved storage methods make the workflow better. It improves the efficiency of the staff.

Prevents Cross-contamination

Good food handling practices help you in avoiding the risk of cross-contamination of the food.

Preventative Maintenance

Monitoring environment can be used to instruct plant operators when preventive maintenance is required on a processing system.

Protecting The End Consumer

The right system will help you monitor and control environmental conditions to ensure your products’ quality, and the health of the end consumer.

Build a Positive Reputation

Customers and clients recognize your good food handling practices which build up a positive reputation for your business.

Your Challenge Is Our Passion

The food and beverage sector faces a range of challenges. The demands of big retailers are increasing. Concerns about food safety are always present. The need for faster and more flexible supply lines is intensifying. Product tracking and tracing are becoming increasingly important. Gaining control with measurements is right at the heart of food and beverage manufacturing. It is key to unlocking value, enhancing quality, leveraging flexibility, boosting profitability, and maintaining reliability.

Monitoring the process and environmental conditions enables sustainable food and beverage production by optimizing the use of the raw materials, eliminating product waste, and reducing the use of energy. To ensure uninterrupted production of high-quality product yield while maintaining safe working conditions, producers can rely on the measurement and monitoring devices that keep control of such critical processing parameters as:

  • Relative humidity
  • Carbon dioxide (co2)
  • Temperature and dew point

Humidity

Humidity which is generally expressed as relative humidity (RH) is the measure of amount of water vapor present in the air. Food being one of the major reasons affecting the human health and wellbeing, it becomes paramount to ensure that it is produced and stored in an environment that is safe and hygienic. Alterations in the quality of food caused by environments having inappropriate humidity levels can ultimately lead to deterioration in customer experience and also cause negative impact on human health. Food has to be stored in relatively low temperature surroundings. This gives rise to greater temperature difference between outside and indoor environment, which leads to emergence of high humidity conditions. High humidity has many adverse effects on different aspects in the Food Industry such as production, packaging, storage etc. However, risks such as these can easily be removed with technology that can control humidification and temperature.

Optimizing Drying Process

Accurately measuring the humidity in the drying air is essential to optimize the drying process. It is important to keep the air dry enough to avoid microbial growth and keep products safe, and optimal conditions can only be achieved with accurate dryer controls. Optimizing the drying process provides a competitive advantage to manufacturers, saves energy and costs, and improves process consistency and end product quality. Typical applications include monitoring fluid bed and spray drying and controlling humidity levels in baking ovens.

Optimizing Drying Process

Accurately measuring the humidity in the drying air is essential to optimize the drying process. It is important to keep the air dry enough to avoid microbial growth and keep products safe, and optimal conditions can only be achieved with accurate dryer controls. Optimizing the drying process provides a competitive advantage to manufacturers, saves energy and costs, and improves process consistency and end product quality. Typical applications include monitoring fluid bed and spray drying and controlling humidity levels in baking ovens.

Storage & Safety

Optimal storage conditions must be constantly maintained for fresh produce. Proper humidity and CO2 control protects goods against loss of moisture, decay, and aging.  Controlling humidity and temperature levels in refrigerated warehouses reduces frost buildup and condensation, improves energy efficiency, and decreases defrosting costs. Accurate monitoring of moisture levels in the air can reduce unnecessary heating and also reduce energy costs.

Storage & Safety

Optimal storage conditions must be constantly maintained for fresh produce. Proper humidity and CO2 control protects goods against loss of moisture, decay, and aging.  Controlling humidity and temperature levels in refrigerated warehouses reduces frost buildup and condensation, improves energy efficiency, and decreases defrosting costs. Accurate monitoring of moisture levels in the air can reduce unnecessary heating and also reduce energy costs.

Carbon Dioxide

CO2 has a wide variety of uses across the whole food industry. As well as being used for fizzy drinks, CO2 is used in drying to extend fruit and vegetables’ shelf-life, as dry ice for goods refrigeration in transit, stunning animals before slaughter, as well as many others. The multiplicity of potential contaminants is a natural consequence of the variety of feed sources. They can constitute a health hazard for human consumption even at trace level, requiring the industry to control and monitor the CO2 purity as a quality standard.

Refrigerator Leaks Monitoring

CO2 refrigerant has become more widely used in many applications. Carbon dioxide CO2 (R744) is a non-flammable, natural, low cost refrigerant with negligible direct global-warming impact and ozone-depletion potential compared to traditional hydrofluorocarbons (HFC). CO2 levels must be monitored in places where potential refrigerant leaks can occur to ensure safety of people.

Refrigerator Leaks Monitoring

CO2 refrigerant has become more widely used in many applications. Carbon dioxide CO2 (R744) is a non-flammable, natural, low cost refrigerant with negligible direct global-warming impact and ozone-depletion potential compared to traditional hydrofluorocarbons (HFC). CO2 levels must be monitored in places where potential refrigerant leaks can occur to ensure safety of people.

Monitoring CO2 In Fermentation

Carbon dioxide (CO2) is the most important gaseous metabolic product in fermentation. Enzymes, antibiotics, amino acids, and alcohols are all produced by fermentation in strictly controlled environments. Since high CO2 levels are a potential health risk, CO2 levels must be monitored in places, where there is a risk for elevated CO2 levels due to exhaust gas emissions into the surrounding environment. These types of places are wineries, breweries and other fermentation facilities.

Monitoring CO2 In Fermentation

Carbon dioxide (CO2) is the most important gaseous metabolic product in fermentation. Enzymes, antibiotics, amino acids, and alcohols are all produced by fermentation in strictly controlled environments. Since high CO2 levels are a potential health risk, CO2 levels must be monitored in places, where there is a risk for elevated CO2 levels due to exhaust gas emissions into the surrounding environment. These types of places are wineries, breweries and other fermentation facilities.

Measuring CO2 In Carbonated Beverages Bottling Process

Carbon dioxide (CO2) is added to soft drinks during the bottling process to give the drink its fizz. While the containers are being filled during the bottling process, large volumes of CO2 can escape from the fillers into the surrounding atmosphere. Monitoring of CO2 levels in the filling rooms and working areas helps to avoid accumulation of CO2 and set adequate ventilation.

Measuring CO2 In Carbonated Beverages Bottling Process

Carbon dioxide (CO2) is added to soft drinks during the bottling process to give the drink its fizz. While the containers are being filled during the bottling process, large volumes of CO2 can escape from the fillers into the surrounding atmosphere. Monitoring of CO2 levels in the filling rooms and working areas helps to avoid accumulation of CO2 and set adequate ventilation.

Temperature

Temperature control is one the most effective ways to ensure the production of safe food. By storing food at the correct temperatures, we can greatly reduce bacterial multiplication and survival and reduce the risk of microbiological contamination. Temperature control is a set of procedures, strategies, measurements, and conditions established to meet and maintain the standards and specifications of a given product and/or process regarding temperature.  It is vital for food safety assurance and is used:

  • to process food products
  • to give desired quality characteristics (texture, color, aroma, etc.)
  • as a key microbiological control parameter

Cold Storage

Freezers and cold storage compartments used to store and hold food capable of supporting growth of microorganisms should be fitted with an indicating thermometer, temperature-measuring device, or temperature-recording device so installed as to show the temperature accurately within the compartment. Instruments and controls used for measuring, regulating, or recording temperatures that control or prevent the growth of undesirable microorganisms in food must be accurate and precise and adequately maintained, and adequate in number for their designated uses.

Cold Storage

Freezers and cold storage compartments used to store and hold food capable of supporting growth of microorganisms should be fitted with an indicating thermometer, temperature-measuring device, or temperature-recording device so installed as to show the temperature accurately within the compartment. Instruments and controls used for measuring, regulating, or recording temperatures that control or prevent the growth of undesirable microorganisms in food must be accurate and precise and adequately maintained, and adequate in number for their designated uses.

The Risk Zone

Bacteria are present in most foods and they can be destroyed by cooking food to the right temperatures. However, if the bacteria in food are allowed to multiply to great numbers then cooking alone might not prevent food from causing food poisoning. Bacteria are able to multiply when they are above 5°C and below 63°C. This range, from 5°C to 63°C is called the risk zone. Bacteria will multiply very rapidly when they approach body temperature (37°C), so any food left at temperatures of between 20°C and 50°C is at greater risk. Food should be stored either below 5°C or above 63°C.

The Risk Zone

Bacteria are present in most foods and they can be destroyed by cooking food to the right temperatures. However, if the bacteria in food are allowed to multiply to great numbers then cooking alone might not prevent food from causing food poisoning. Bacteria are able to multiply when they are above 5°C and below 63°C. This range, from 5°C to 63°C is called the risk zone. Bacteria will multiply very rapidly when they approach body temperature (37°C), so any food left at temperatures of between 20°C and 50°C is at greater risk. Food should be stored either below 5°C or above 63°C.

Production, Storage & Transport

During production, storage and transport of food, continuous temperature controls must be carried out to keep your food safe. This not only serves to ensure the quality of the products, but also protects the health and safety of the consumer. Cooked or frozen food stored and transported outside of a recommended temperature range can cause bacteria and fungus growth. In order to comply with legal regulations and keep products at the desired temperature, temperature deviations during production, storage and transport must be alarmed and documented.

Production, Storage & Transport

During production, storage and transport of food, continuous temperature controls must be carried out to keep your food safe. This not only serves to ensure the quality of the products, but also protects the health and safety of the consumer. Cooked or frozen food stored and transported outside of a recommended temperature range can cause bacteria and fungus growth. In order to comply with legal regulations and keep products at the desired temperature, temperature deviations during production, storage and transport must be alarmed and documented.

Why Choose Dpstar for Food & Beverage Monitoring?

At Dpstar, we understand the complex process of food and beverage processing, production, and distribution. From farm to table, we know the importance of accurate data throughout your food products’ lifecycles. Our systems are designed to help you monitor essential environmental data so your assets, and consumers, stay protected.

Why Choose Dpstar for Food & Beverage Monitoring?

At Dpstar, we understand the complex process of food and beverage processing, production, and distribution. From farm to table, we know the importance of accurate data throughout your food products’ lifecycles. Our systems are designed to help you monitor essential environmental data so your assets, and consumers, stay protected.

Monitor

Effortlessly monitor your entire process’s essential temperature and environmental data–from processing to the placemat.

Comply

Easily adhere to complex FSMA and HACCP regulations and meet internal quality control requirements.

Protect

Streamline corrective actions and unify processes when excursions occur to reduce or eliminate the risk for product loss.

Monitor

Effortlessly monitor your entire process’s essential temperature and environmental data–from processing to the placemat.

Comply

Easily adhere to complex FSMA and HACCP regulations and meet internal quality control requirements.

Protect

Streamline corrective actions and unify processes when excursions occur to reduce or eliminate the risk for product loss.

How Dpstar Serves the Food & Beverage Industry

The food and beverage industry has experienced tremendous growth over the past several decades. The growth has presented significant opportunities for us at Dpstar to provide the best technology possible. Furthermore, demands from food safety regulations, customers, and retailers continue to intensify, forcing the food and beverage sector to evolve to meet these needs.

At Dpstar, we provide a range of technological solutions aimed at giving you cutting-edge performance. Dpstar understands that the food and beverage industry has diverse needs. That is why our experts work with you to integrate technology that addresses your company’s specific challenges. Essentially, Dpstar creates flexible advanced solutions that help streamline operations, increase profitability and build valuable business relationships. Whether you want to increase resource recovery, operational efficiency, optimize cost, differentiate your brand, or reduce climate-related risks, Dpstar offers what you need to scale in your specific niche.

Products Solutions

Relative Humidity (RH), Temperature (T) & Carbon Dioxide (CO2) Measurement

Browse our selection of measuring and monitoring instruments designed and manufactured for optimum reliability, accuracy, and durability.

Vaisala CO₂ Probe GMP251

Vaisala CO₂ Probe GMP252

Vaisala Handheld CO₂ Meter GM70

Vaisala Humidity and Temperature Probe HMP1

Vaisala Hand-Held Humidity and Temperature Meter HM40

Vaisala Handheld Humidity and Temperature Meter HM70

Vaisala Intrinsically Safe Humidity and Temperature Transmitter Series HMT370EX

Vaisala Dew Point and Temperature Meter Series DMT340

Vaisala Humidity and Temperature Transmitter Series HMDW110

Vaisala Temperature and Humidity Data Loggers DL2000

Vaisala Temperature Data Loggers DL1016/1416

Vaisala Thermocouple Data Loggers DL1700

Vaisala Wi-Fi Data Logger HMT140

Vaisala Indigo500 Series Transmitters

Vaisala Indigo200 Series Transmitters for Vaisala smart probes

Your Partner For Efficient Processes

Food is the energy of life. That is why trust and confidence play such an important part in the food and beverage market. Yet the issue of trust and confidence is not confined to questions about quality and safety. Product availability is also crucial in winning the battle for shelf space.

We’re here to help! You can be assured that Dpstar quality and results will help you meet your business and customer goals. Our trained team of professionals is ready to help you through the compliance process from start to finish. Reach out today to start the conversation.

Get In Touch With Our Experts Today!

Dpstar Group
No 35, Jalan OP ½, Pusat Perdagangan One Puchong,
Off Jalan Puchong, 47160 Puchong,
Selangor Darul Ehsan, Malaysia.
Email: [email protected]

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