Entropy-based rapid viscosity monitoring for food manufacturing

Overview

This technology offers a rapid, non-invasive approach to monitoring viscosity and consistency in food manufacturing, particularly for heterogeneous products such as gravies and sauces. By converting motor current, rotational speed, and temperature into a mechanically derived entropy-generation metric, the method captures bulk resistance to flow during mixing. Because the impeller interacts with the full sample volume, it provides a global rheological signature rather than a localized reading, minimizing distortions caused by suspended solids. Results are available within minutes, offering an objective, repeatable alternative to conventional rheometry for routine quality control and process monitoring.

Technical specifications

The method is grounded in the second law of thermodynamics, linking viscous dissipation to entropy generation and measurable process power. Key features include:

• Non-invasive sensing based on motor current, rotational speed, and temperature, with minimal or no equipment modification
• Global rheological signature derived from integrated load during mixing, enabling repeatable comparison across batches and operating conditions
• Calibration against Brookfield-type rheometry to establish correlation and prediction accuracy
• Demonstrated applicability in viscosity-evolving systems, including mayonnaise, emulsion-based fluids, and industrial grease manufacturing
• Quantifies effects of formulation, temperature, speed, and particulate content
• Designed to support batch acceptance, process-drift detection, and future automated online monitoring

Technology readiness level

The core concept has been demonstrated in viscosity-evolving applications across several fluid systems. A 12-week proof-of-concept is planned to adapt the method to food manufacturing processes, test products across varying formulation, temperature, and particulate content, and develop calibration models. Validation will assess repeatability and prediction error, define quality limits, and deliver a validated protocol, data-acquisition/software workflow, and plant-deployment recommendations.