Real-Time In-Line Gravy Rheology and Composition Monitoring System
A real-time, in-line monitoring system combining Ultrasound Velocity Profiling with Pressure Difference (UVP-PD) and Near-Infrared (NIR) spectroscopy to continuously assess gravy consistency during processing. It measures fluid velocity profiles, pressure drop, composition, temperature, and flow rate to derive rheological properties such as apparent viscosity, yield stress, and flow behavior, enabling faster process control than intermittent laboratory testing.
Overview
This solution is a real-time, in-line monitoring system designed to continuously assess the consistency and composition of gravy and similar food products during processing. It combines Ultrasound Velocity Profiling with Pressure Difference (UVP-PD) and Near-Infrared (NIR) spectroscopy to provide non-destructive, real-time measurements of rheological properties and composition. The system is intended to detect quality deviations much faster than intermittent laboratory testing, enabling more responsive process control and consistent product quality.
Technical specifications
How it works:
- UVP-PD measures the fluid velocity profile across a pipe and combines it with pressure drop data to derive rheological information, including apparent viscosity, yield stress, and flow behavior.
- NIR spectroscopy rapidly measures composition-related parameters such as moisture and solids content.
- Temperature and flow rate sensors account for process conditions that affect product behavior.
- Sensor data is synchronized with reference rheometer/viscometer measurements to develop predictive chemometric models, such as PLS regression, that relate NIR spectra and process measurements to product rheology.
Key benefits:
- Continuous, real-time monitoring of gravy consistency
- Non-destructive measurement without sample preparation
- Faster detection of process changes compared to laboratory testing
- Supports proactive process control and consistent product quality
Considerations: Practical deployment requirements — including sampling practicality, calibration needs, cleaning, and maintenance — are part of the planned pilot validation.
Technology readiness level
This technology is in the early research and development stage. The planned validation pathway includes four phases: establishing reference viscosity and flow measurements using rotational rheometry (e.g., Brookfield-type methods); collecting NIR spectra and identifying features associated with composition and rheology; developing and validating chemometric models using independent samples; and conducting a pilot trial in a realistic at-line or in-process setting to assess accuracy, repeatability, and operational practicality. Results will be compared with laboratory references to determine feasibility and identify requirements for scale-up and routine manufacturing use.
About West Virginia University
West Virginia University is a comprehensive public land‑grant research university headquartered in Morgantown and serving the state through academics, research, and outreach. For industry, a statewide Extension network provides on‑the‑ground access to communities, facilities, and field sites, while an integrated academic medical center and health system enable clinical research and translational partnerships. The university connects corporate R&D with talent through co‑op and internship pipelines and applied engagements. Research is supported by competitive federal funding from agencies such as NIH, NSF, DOE, and USDA. WVU’s Office of Innovation and Commercialization manages IP, licensing, and startup pathways to provide a clear entry point for collaboration.
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