Non-invasive inline ultrasound technology for real-time jelly texture monitoring

Overview

Moldsonics has developed a non-invasive ultrasonic sensing technology for real-time jelly texture assessment in production environments. The system mounts ultrasonic sensors externally on process equipment, transmitting ultrasound through the process wall into the product without any direct food contact. By analyzing how the ultrasonic signals interact with the gel, the technology assesses jelly structure and can predict final texture quality during production.

This approach addresses a critical challenge in food manufacturing: texture is typically validated through offline reference measurements after production, creating delays and potential waste. The Moldsonics solution enables continuous inline monitoring that can distinguish in-specification from out-of-specification jelly under real production conditions, with the potential to predict final texture before the setting process is complete.

Technical specifications

The technology builds on Moldsonics' industrial ultrasonic sensing platform, originally developed for plastics and injection molding, and extends it to food gel systems.

Key capabilities:

• Non-invasive measurement through solid process walls, eliminating product-contact surfaces
• Evaluation of ultrasonic signal amplitude, attenuation, time-of-flight and waveform characteristics
• Correlation of acoustic measurements with established texture reference methods
• Continuous data acquisition during normal production with fully remote-capable hardware
• Signal-processing algorithms adapted and validated against production data
• Integration of process variables such as temperature for improved prediction accuracy

Ultrasonic measurements are highly sensitive to changes in a material's mechanical and acoustic properties, including elasticity, compressibility, density and acoustic impedance. During gel formation, these properties change as the internal gel network develops, allowing the system to track structural evolution in real time.

Technology readiness level

The technology is at the validation stage. Proof of concept focuses on distinguishing in-specification from out-of-specification jelly under real production conditions. The preferred validation approach involves mounting sensors externally on production equipment and collecting data across normal production, known good batches and, where available, off-spec conditions, then correlating the ultrasonic signals with existing texture reference results. Successful validation will establish a reliable quality indicator and a pathway to continuous inline monitoring with early prediction of final jelly texture.