Hello! Dr. Rukundo here, NIR Applications Specialist at BUCHI Corporation. If you have ever found yourself craving that extra bite of a sugary snack or reaching for another cereal pack, you might be wondering what draws us to these treats. In Sapiens: A Brief History of Humankind, the author argues that our evolutionary craving for sugar stems from early human ancestors who relied on sweet, energy-rich fruits during times of abundance. Since such foods were rare and seasonal, consuming as much sugar as possible when available helped them store energy and survive periods of scarcity. This evolutionary adaptation is one reason many people today still experience strong cravings for sugar. And it is perfectly fine to indulge in moderation. Those sugar cravings often point to the foods we love most – like breakfast cereals, granola bars, buttery cookies, donut holes, and ginger snaps! As consumers, we seek comfort and consistency in the products we love, but the challenge for manufacturers is to meet these expectations at scale. Maintaining consistent quality – taste, texture, and nutrition – while optimizing production efficiency is crucial, and this is where proven technology like Near-Infrared (NIR) Spectroscopy can make a real impact.
The Need for Consistent Quality Control
Common parameters that manufacturers monitor during cereal and snack production include:
- Moisture content: Essential for texture and shelf-life.
- Water activity: Indicator of microbial activity and spoilage risk.
- Sugar content (often measured as Brix): Impacts sweetness, texture, and shelf-life.
- Color: Affects visual appeal and consumer preference.
- Other nutrients (protein, fiber, etc.): Especially for health-conscious products.
However, traditional reference testing methods are laborious, time-consuming, and require multiple instruments. These are often referred to as “wet chemistry.” For example, after drying a batch of protein bars, moisture content needs to be measured, and this can be through at-line meters, an oven-drying method, or even sending samples to third-party labs. This process could take minutes to hours – or even days. While you wait for results, should production stop or continue? And when results do not match expectations, do you rework the batch, incurring additional costs in energy and labor? Or do you discard the material entirely, leading to unnecessary waste?
This is where NIR Spectroscopy comes into play as a game-changer for the food industry.
Why NIR Spectroscopy?
NIR spectroscopy works by shining near-infrared light on a sample, causing the molecules in the material to vibrate. Each vibration pattern absorbs light at different wavelengths, and these patterns can be used to quickly measure key properties like moisture, sugar content, and protein levels. Once calibrations are developed based on reference methods (wet chemistry), NIR can rapidly measure multiple properties at once, providing results within seconds.
Unlike traditional methods, which, again, involve onerous sample collection, testing, and reporting, NIR spectroscopy offers real-time analysis. It enables processors and operators to make immediate decisions – without waiting hours or days for results. With this capability, manufacturers can save time, reduce waste, and increase overall production efficiency.
Now that we have explored the science behind NIR, let us see how it translates into practical benefits for cereal and snack production. From rapid quality checks to continuous in-line monitoring, NIR systems are changing how manufacturers manage production efficiency and product consistency.
BUCHI ProxiMate: Precision at Your Fingertips
For snack and cereal production, the BUCHI ProxiMate is a powerful tool. This all-in-one, IP-69-rated benchtop system provides measurements of key parameters in real time, ensuring consistent quality with every batch. ProxiMate has a user-friendly, intuitive interface enabling operators to quickly select methods, load samples, and get results in under 20 seconds. With the ability to store multiple methods on the same unit, you can easily switch between products – whether it is cereal, granola bars, or cookies. Changing from one method to another requires just two clicks, making it easy to adapt to changing production needs. Plus, its robust design means there is no need to worry about broken glass, as you can use plastic or stainless-steel dishes for sampling.
BUCHI NIR-Online: Real-Time Production Monitoring
For a more integrated, real-time solution, the BUCHI NIR-Online system takes quality control to the next level. This advanced in-line NIR technology enables continuous monitoring of multiple production parameters as materials flow through production lines, mixers, chutes, and dryers.
With instantaneous analysis, manufacturers can make immediate adjustments to their production processes, reducing downtime and minimizing the risk of off-spec products. The result? Faster throughput, lower waste, and improved cost efficiency, all contributing to better profit margins. NIR-Online also allows PLC integration, enabling automated switching between methods when production processes change.
A major advantage of NIR-Online is the ability to monitor multiple production lines or stages from a single computer. You can have up to four units measuring the same product at various stages or different products on separate lines, all displayed with statistical process control (SPC) trends. These trends help operators visually track product parameters and ensure production stays within specifications. When readings fall out of range, alarms can trigger immediate corrective action, reducing the likelihood of off-spec products being released.
Auto-Calibrations for Seamless Operations
Both ProxiMate and NIR-Online systems feature Auto-Cal, a self-calibration feature that simplifies the process of creating and updating calibrations. This feature reduces the reliance on manual adjustments and chemometrics expertise, making the system easier to use and ensuring your calibrations remain accurate without constant bias calculation and adjustment efforts.
A Sustainable Approach to Food Production
NIR spectroscopy helps not only to enhance production efficiency but also to promote sustainability. By reducing waste, improving energy efficiency, and minimizing the environmental impact of production errors, NIR technology makes a significant difference in the modern food industry.
Ready to streamline your production and boost product quality? Visit us at www.buchi.com to schedule a free demo or talk to one of our NIR experts about how our solutions can optimize your operations today. We are here to help!
buchinir 
Leave a comment