Ultrasonic non-intrusive in-line viscosity profiling sensor for complex food matrices

Overview

This technology is a non-invasive, in-line acoustic sensor system that uses Effective Bulk Modulus Elastography (EBME) to deliver rapid, continuous viscosity and flow characterization of complex, heterogeneous food matrices such as gravies, slurries, and other opaque multi-phase products. Conventional food viscometry relies on offline sampling, which introduces lag, clogging risk, and shear degradation of sensitive products. This sensor eliminates those issues by measuring directly in active, flowing lines without any sample intrusion.

The system provides millisecond-scale quality assurance feedback, enabling continuous monitoring with zero downtime. Its hygienic, non-intrusive architecture is designed to integrate seamlessly into existing sanitary pipelines, making it suitable for food processing environments where cleanliness and uninterrupted production are critical.

Technical specifications

How it works: A flush-mounted or clamp-on monostatic ultrasonic transducer transmits high-frequency longitudinal pulses into the flow stream. By simultaneously measuring acoustic impedance and time-of-flight sound velocity, the system directly computes real-time density and dynamic bulk modulus using the relationship K = ρ × c², where ρ is density and c is sound velocity.

Key features:

• Non-intrusive, hygienic design—no sample contact, no clogging, no shear degradation
• Operating frequency of 0.1–1 MHz, optimized for the sub-scattering acoustic regime (wavelength much larger than particle size), which filters particulate noise and bubble artifacts
• Integrated fast-response RTD sensors enable continuous thermal compensation during active flow
• Compact single-probe footprint integrates into existing sanitary pipelines
• Micro-rheological calibration models correlate shifts in density and bulk modulus to apparent viscosity (cP)
• Real-time echo-gating algorithms reject particulate scattering and microbubble interference under dynamic flow conditions

Technology readiness level

The underlying EBME technology is already proven in prior applications and is currently being adapted for in-line food rheology and flow monitoring through a structured three-phase validation plan: sensor and flow-cell integration, baseline calibration against benchtop rotational rheometers across diverse heterogeneous food matrices, and multi-phase flow loop validation to ensure drift-free viscosity and flow tracking under real production conditions. The technology is at an early-to-mid stage of development for this specific application, with validation planned over approximately six months.