GEA has introduced the NiSoMate, a sensor-based technology for product control during the homogenisation process, in which liquids are continuously analysed for consistency and quality in real time.
The NiSoMate system enables direct adjustment of system performance, such as homogenisation pressure, resulting in more efficient use of energy in the production process. By implementing this new sensor technology, traditional sampling methods are bypassed, significantly saving time.
Comprehensive solution for measuring all parameters
The GEA NiSoMate inline quality monitoring system combines dedicated, perfectly matched sensors. These are bundled in a single unit that is installed directly on the homogeniser. With high-precision measurement accuracy, the homogenisation effect on the respective liquids can be displayed in real time without touching the product.
The sensor system employs an ultrasound-based “beam forming array” technology that was specially engineered by GEA homogenisation experts for this purpose. The system allows physical product properties such as density, consistency change and dilution to be derived. These parameters can be read by an external process control which can then take appropriate actions. Consequently, operators can monitor the process directly on the production line and adjust the performance of the system accordingly, without having to wait for laboratory samples results.
The GEA NiSoMate also eliminates unnecessary detours, product waste or over-setting of high pressure, resulting in significant overall resource savings.
A booster for flexibility
With the GEA NiSoMate, users can also achieve their overall production goals much faster, especially when processing new types of liquids. In addition, pre-configured recipes can be used and set for a faster process flow once an in-situ fingerprint has been analysed for the respective starting product. This enables faster development of new recipes and therefore faster production of new products, offering a competitive edge, especially in food, new food and pharmaceutical applications.
Since the new technology combines several sensors in one system, it ensures a more accurate, reliable and robust product evaluation. The collected data can be transferred to existing monitoring systems and dashboards and used for further analysis and process optimisation. Appropriate modules have been predisposed in the system for the integration of AI, which in the future will allow self-optimisation of the plant and process.
The GEA NiSoMate can be used in all GEA homogenisers – from laboratory units to large industrial plants – and is also available as a retrofit for existing plants.
