Measurement, Modeling and Automation in Advanced Food Processing

Cereal processing (breadmaking, extrusion, pasting, etc.) covers a range of mechanisms that, despite their diversity, can be often reduced to a succession of two core phenomena: (1) the transition from a divided solid medium (the flour) to a continuous one through hydration, mechanical, biochemical, and thermal actions and (2) the expansion of a continuous matrix toward a porous structure as a result of the growth of bubble nuclei either by yeast fermentation or by water vaporization after a sudden pressure drop. Modeling them is critical for the domain, but can be quite challenging to address with mechanistic approaches relying on partial differential equations. In this chapter we present alternative approaches through basic knowledge models (BKM) that integrate scientific and expert knowledge, and possess operational interest for domain specialists. Using these BKMs, simulations of two cereal foods processes, extrusion and breadmaking, are provided by focusing on the two core phenomena. To support the use by non-specialists, these BKMs are implemented as computer tools, a Knowledge-Based System developed for the modeling of the flour mixing operation or Ludovic^®, a simulation software for twin screw extrusion. They can be applied to a wide domain of compositions, provided that the data on product rheological properties are available. Finally, it is stated that the use of such systems can help food engineers to design cereal food products and predict their texture properties.

Data on the hazards involved in the primary steps of processing cereals, fruit and vegetables, milk and milk products, meat and meat products, and fats and oils are compiled with a wide-ranging literature survey. After determining the common factors from these data, a general FMEA template is offered, and its use is explained with a case study on pasteurized milk production.

Individual items of any agricultural commodity are different from each other in terms of colour, shape or size. Furthermore, as they are living thing, they change their quality attributes over time, thereby making the development of accurate automatic inspection machines a challenging task. Machine vision-based systems and new optical technologies make it feasible to create non-destructive control and monitoring tools for quality assessment to ensure adequate accomplishment of food standards. Such systems are much faster than any manual non-destructive examination of fruit and vegetable quality, thus allowing the whole production to be inspected with objective and repeatable criteria. Moreover, current technology makes it possible to inspect the fruit in spectral ranges beyond the sensibility of the human eye, for instance in the ultraviolet and near-infrared regions. Machine vision-based applications require the use of multiple technologies and knowledge, ranging from those related to image acquisition (illumination, cameras, etc.) to the development of algorithms for spectral image analysis. Machine vision-based systems for inspecting fruit and vegetables are targeted towards different purposes, from in-line sorting into commercial categories to the detection of contaminants or the distribution of specific chemical compounds on the product’s surface. This chapter summarises the current state of the art in these techniques, starting with systems based on colour images for the inspection of conventional colour, shape or external defects and then goes on to consider recent developments in spectral image analysis for internal quality assessment or contaminant detection.

This chapter discusses the importance of modelling and control in increasing food process efficiency and ensuring product quality. Various approaches to both modelling and control in food processing are set in the context of the specific challenges in this industrial sector and latest developments in each area are discussed. Three industrial case studies are used to demonstrate the benefits of advanced measurement, modelling and control in food processes. The first case study illustrates the use of knowledge elicitation from expert operators in the process for the manufacture of potato chips (French fries) and the consequent improvements in process control to increase the consistency of the resulting product. The second case study highlights the economic benefits of tighter control of an important process parameter, moisture content, in potato crisp (chips) manufacture. The final case study describes the use of NIR spectroscopy in ensuring effective mixing of dry multicomponent mixtures and pastes. Practical implementation tips and infrastructure requirements are also discussed.

Different analytical techniques have been used to examine the complexity of food samples. Among them, fluorescence spectroscopy cannot be ignored in developing rapid and non-invasive analytical methodologies. It is one of the most sensitive spectroscopic approaches employed in identification, classification, authentication, quantification, and optimization of different parameters during food handling, processing, and storage and uses different chemometric tools. Chemometrics helps to retrieve useful information from spectral data utilized in the characterization of food samples. This contribution discusses in detail the potential of fluorescence spectroscopy of different foods, such as dairy, meat, fish, eggs, edible oil, cereals, fruit, vegetables, etc., for qualitative and quantitative analysis with different chemometric approaches.

Mathematical models based on thermodynamic, kinetic, heat, and mass transfer analysis are central to this chapter. Microbial growth, death, enzyme inactivation models, and the modeling of material properties, including those pertinent to conduction and convection heating, mass transfer, such as diffusion and convective mass transfer, and thermodynamic properties, such as specific heat, enthalpy, and Gibbs free energy of formation and specific chemical exergy are also needed in this task. The origins, simplifying assumptions, and uses of model equations are discussed in this chapter, together with their benefits. The simplified forms of these models are sometimes referred to as “laws,” such as “the first law of thermodynamics” or “Fick’s second law.” Starting to modeling a study with such “laws” without considering the conditions under which they are valid runs the risk of ending up with erronous conclusions. On the other hand, models started with fundamental concepts and simplified with appropriate considerations may offer explanations for the phenomena which may not be obtained just with measurements or unprocessed experimental data. The discussion presented here is strengthened with case studies and references to the literature.