Real-Time Detection of Fouling-Layer with a Non-Intrusive Continuous Sensor (NICS) during Thermal Processing in Food Manufacturing

The fouling of indirect shell and coil heat exchanger by heavy whipping cream (HWC) and non-fat dry milk (NFDM) was studied at aseptic Ultra-High Temperature (UHT) processing conditions (140 °C) using a novel non-intrusive sensor. The sensor emitted a heat pulse intermittently throughout the duration of the process causing an incremental increase in temperature at the tube external surface. The temperature response of the sensor varied due to the radial growth of the fouling layer formed by certain components of the products. Each heating pulse and the temperature response was studied to estimate the thermal conductivity of the fouling layer using inverse problems and parameter estimation. The changes in thermal conductivity were used as an indication of the fouling layer development during food processing at UHT temperatures. The estimated parameters from experimental results showed a decreasing trend in the thermal conductivity of HWC and NFDM from 0.35 to 0.10 and 0.63 to 0.37, respectively. An image analysis tool was developed and used to measure the fouling layer thickness at the end of each trial. The measured thickness was found to be 0.58 ± 0.15 for HWC and 0.56 ± 0.07 mm for NFDM. The fouling layer resistance for HWC and NFDM was 5.95 × 10⁻³ ± 1.53 × 10⁻³ and 1.53 × 10⁻³ ± 2.0 × 10⁻⁴ (m²K)/W, respectively.