Flow meters help food processing companies achieve efficient production.

In the food processing industry, efficient production not only means increased capacity and reduced costs, but is also closely related to product quality stability and food safety assurance. With the large-scale and standardized development of the food industry, traditional production models relying on manual experience are no longer sufficient to meet the needs of modern enterprises. Automated equipment such as flow meters, quantitative control boxes, and data loggers have become core supports for enterprises to achieve precise control and efficient production. This article will focus on the path to achieving efficient production in food processing enterprises, emphasizing the application scenarios, type selection, and importance of flow meters, as well as the role, usage methods, and core advantages of quantitative control boxes and data loggers, revealing the key value of automated equipment in efficient food processing production.

1. Product application scenarios and usage types, and which components require flow meters.

Food processing is a complex and diverse process, involving the transport and control of fluid materials at multiple stages, from raw material pretreatment and semi-finished product processing to finished product packaging. As one of the core raw materials in food processing, the stability and accuracy of fluid flow directly impact product quality and production efficiency. Flow meters, as key devices for measuring fluid flow, are widely used in various food processing scenarios, with significant differences in usage types and application locations across different scenarios.

1.1 Main Product Application Scenarios

The application scenarios of flow meters in the food processing industry can be divided into the following categories according to the types of processed products and process steps:

• Beverage processing scenarios : covering the production processes of bottled water, carbonated beverages, fruit juice, tea beverages, dairy products, etc., involving the transportation and proportioning of fluids such as water, fruit juice, syrup, milk, and carbon dioxide gas.

• Condiment processing scenarios : including the production of products such as soy sauce, vinegar, cooking wine, chili sauce, and tomato sauce, involving the metering and transportation of fluids such as fermentation liquid, brine, sugar solution, oil, and spice extract.

• Grain and oil processing scenarios : covering the processing of products such as edible oil, rice, and flour, involving the measurement and control of fluids such as crude oil, refined oil, water, and steam.

• Convenience food processing scenarios : including the production of products such as instant noodles, frozen dumplings, and sausages, involving the transportation and quantitative addition of fluids such as batter, fillings, oils, brine, and seasoning sauces.

• Dairy processing scenarios : covering the production of products such as milk, yogurt, and cheese, involving the measurement and proportioning of fluids such as fresh milk, milk liquid, starter culture, sugar solution, and stabilizer.

1.2 Classification of Flow Meter Usage Types

Based on their measurement principles and applicable fluid types, flow meters commonly used in food processing can be categorized into several main types, including volumetric flow meters, differential pressure flow meters, electromagnetic flow meters, and vortex flow meters. Different types of flow meters vary in measurement accuracy, applicable media, and installation requirements; therefore, the appropriate type must be selected based on the specific application scenario.

1.3 Components requiring flow meters in each processing stage

Regardless of the food processing scenario, any process involving the transport, proportioning, and quantitative addition of fluid materials requires the use of flow meters for flow control. Specific applications mainly include the following key stages:

• Raw material input stage : When raw material warehouses transport fluid raw materials to processing workshops, such as the input of tap water in bottled water production, the transportation of fruit juice pulp in beverage production, and the introduction of crude oil in edible oil production, it is necessary to accurately measure the amount of raw materials used through flow meters to avoid waste or shortage of raw materials.

• Ingredient mixing : One of the core steps in food processing, it requires mixing various fluid raw materials in precise proportions. For example, in beverage production, the ratio of syrup, water, and fruit juice, and in condiment production, the mixing of brine, sugar solution, and fermentation liquid, all require real-time monitoring of the flow rate of each raw material using flow meters to ensure accurate proportions.

• Heating/Cooling Process : Some food processing requires steam heating or cold water cooling to control the process temperature, such as dairy product sterilization, canned food sterilization, and beverage pasteurization. Flow meters are needed to measure the flow rate of steam or cooling water to ensure stable heating/cooling effects and guarantee product quality.

• Cleaning and disinfection process : Cleaning and disinfecting food processing equipment and workshops requires the use of fluids such as clean water and disinfectant. Flow meters can be used to measure the amount of cleaning solution and clean water used, control cleaning time and cost, and ensure that the cleaning and disinfection effect meets food safety standards.

• Finished product filling process : In the production of bottled and canned foods, such as bottled water, beverages, soy sauce, and dairy products, it is necessary to use flow meters to accurately control the filling volume of each bottle/can to ensure that the net content of the product meets national standards, while improving filling efficiency.

• Wastewater treatment : Wastewater generated from food processing needs to be treated before being discharged. Flow meters can be used to measure the amount of wastewater discharged and the amount of treatment agents added to ensure that the wastewater treatment meets the standards and environmental protection requirements.

2. What type of flow meter was used?

Different food processing scenarios and processes have varying requirements for the physical properties (such as viscosity, temperature, and corrosiveness), flow range, and measurement accuracy of the fluid medium. Therefore, different types of flow meters are needed. The following details the types of flow meters used in each stage and the selection criteria, based on specific application scenarios:

2.1 Commonly Used Flow Meters in Beverage Processing Scenarios

• Electromagnetic flow meters are widely used for measuring the flow rate of conductive fluids such as water, fruit juice, and syrup. Their advantages include high measurement accuracy, insensitivity to changes in fluid viscosity and temperature, and the absence of moving parts within the pipe, making them less prone to clogging and meeting food hygiene requirements. For example, in the raw water transportation stage of bottled water production, electromagnetic flow meters can accurately measure the flow rate of tap water, providing data support for subsequent filtration and disinfection processes. In the ingredient preparation stage of fruit juice beverages, electromagnetic flow meters can monitor the flow rate of fruit juice concentrate and syrup in real time, ensuring accurate proportions . They are also suitable for milk fluids and scenarios requiring precise measurement of mass flow rate. In dairy beverage production, for instance, electromagnetic flow meters can directly measure the mass flow rate of milk, avoiding volumetric flow rate errors caused by temperature and pressure changes, and ensuring stable nutritional composition ratios in the product.

• Vortex flow meter : Used to measure the flow rate of carbon dioxide gas. For example, in the production of carbonated beverages, the vortex flow meter can accurately measure the flow rate of carbon dioxide injected into the beverage, control the gas content of the beverage, and ensure the taste and quality of the product.

2.2 Commonly Used Flow Meters in Condiment Processing Scenarios

• Volumetric flow meter (elliptical gear flow meter) : Suitable for measuring the flow rate of viscous seasonings . The elliptical gear flow meter calculates the flow rate by measuring the number of times the fluid drives the gears to rotate. It offers high measurement accuracy, is unaffected by changes in fluid viscosity, and features a simple structure and easy maintenance. In the fermentation liquid transportation and finished product bottling stages of soy sauce production, the elliptical gear flow meter can accurately measure the flow rate, ensuring stable product quality.

• Electromagnetic flow meters are used to measure the flow rate of conductive fluids such as brine and sugar solutions. For example, in the ingredient mixing stage of chili sauce production, electromagnetic flow meters can measure the flow rate of brine and sugar solutions to ensure accurate ingredient ratios; in vinegar production, electromagnetic flow meters can monitor the flow rate of organic acid solutions produced during fermentation to control fermentation process parameters.

2.3 Commonly Used Flow Meters in Grain and Oil Processing Scenarios

• Volumetric flow meters (elliptical gear flow meters) : Suitable for measuring the flow rate of oily fluids such as crude oil and refined oil. Elliptical gear flow meters offer advantages such as high measurement accuracy, strong anti-interference capabilities, and long service life. They can operate at higher temperatures and pressures, making them suitable for long-distance transport and metering of oily fluids in grain and oil processing. For example, in the edible oil refining process, elliptical gear flow meters can accurately measure the input of crude oil and the output of refined oil, providing accurate data for cost accounting.

• Vortex flow meter : Used to measure the flow rate of steam. For example, in the heating and drying process of grain and oil processing, the vortex flow meter can measure the flow rate of steam, control the heating temperature and time, and ensure that the moisture content of grain and oil products meets the standards.

2.4 Commonly Used Flow Meters in Convenience Food Processing Scenarios

• Electromagnetic flow meters are used to measure the flow rate of conductive fluids such as batter, brine, and sauces. For example, in the batter conveying process of instant noodle production, electromagnetic flow meters can monitor the batter flow rate in real time to control the forming thickness and quality of noodles; in the preparation of fillings for frozen dumplings, electromagnetic flow meters can measure the flow rate of raw materials such as oil and brine to ensure the taste and flavor of the filling.

2.5 Commonly Used Flow Meters in Wastewater Treatment

Electromagnetic flow meters are commonly used to measure wastewater flow in food processing wastewater treatment because they have advantages such as strong corrosion resistance, wide measurement range, and are not affected by wastewater turbidity. In the process of adding treatment agents, the amount of agents added can be precisely controlled to ensure the wastewater treatment effect.

3. The importance of flow meters in various scenarios

As the "flow eyes" in food processing, flow meters are important in various applications, primarily in ensuring product quality, improving production efficiency, reducing production costs, ensuring food safety, and meeting environmental protection requirements. Specifically:

3.1 Beverage processing scenario: Ensuring stable taste and quality

The taste and quality of beverage products are closely related to parameters such as raw material ratios and carbonation content. In fruit juice production, inaccurate flow control of the fruit juice concentrate and syrup can lead to an imbalance in sweetness and acidity, affecting the taste. In carbonated beverage production, fluctuations in carbon dioxide flow can result in insufficient or excessive carbonation, reducing product competitiveness. Flow meters, through real-time and precise flow measurement, ensure stable raw material ratios and controllable carbonation content, thereby guaranteeing consistent taste and quality of beverage products. Furthermore, during the bottling process, flow meters can precisely control the net content of each bottle, preventing market complaints and economic losses due to substandard net content.

3.2 Condiment Processing Scenarios: Ensuring Flavor and Safety Meets Standards

The flavor of condiments has highly specific and stable requirements. For example, the saltiness of soy sauce, the acidity of vinegar, and the spiciness of chili sauce all depend on the precise ratio of raw materials. During soy sauce fermentation, the control of brine flow rate directly affects the fermentation effect and the soy sauce's saltiness; in chili sauce production, the flow rate control of oil and seasoning sauce affects the product's flavor and shelf life. Flow meters, by accurately measuring the flow rate of each fluid raw material, ensure that the ingredient ratios meet process requirements, guaranteeing the stability of the condiment's flavor. Furthermore, the use of flow meters avoids cost waste caused by excessive addition of raw materials, while also preventing product quality degradation due to insufficient raw materials, ensuring that condiments meet food safety standards.

3.3 Grain and oil processing scenario: Improving efficiency and ensuring product safety

In grain and oil processing, the transportation and heating of oily fluids require precise flow control. In crude oil refining, rotary flow meters accurately measure the input of crude oil and the output of refined oil, facilitating cost accounting and production scheduling. In the heating and drying stage, vortex flow meters ensure that the moisture content of grain and oil products meets standards, preventing mold and spoilage due to excessive moisture and guaranteeing product safety. Furthermore, the use of flow meters enables automated transportation of oily fluids, replacing traditional manual operations, improving production efficiency, reducing human error, and lowering labor intensity.

3.4 Convenience food processing scenario: Ensuring molding quality and production continuity

The production of convenience foods is mostly carried out on continuous assembly lines, and stable flow control is crucial to ensuring continuous production. In instant noodle production, fluctuations in the batter flow can lead to uneven noodle thickness and breakage, affecting product appearance and quality, and even causing production line shutdowns. In the preparation of frozen dumpling fillings, unstable flow rates of ingredients such as oil and brine can result in uneven moisture content in the filling, affecting the dumpling's wrapping effect and texture. Flow meters monitor and control fluid flow in real time, ensuring the continuity and stability of the production process, reducing production interruptions caused by flow fluctuations, and improving production efficiency. At the same time, precise flow control can avoid raw material waste and reduce production costs.

3.5 Wastewater treatment scenario: meeting environmental protection requirements and reducing treatment costs

With increasingly stringent environmental regulations, the compliance rate of wastewater treatment for food processing enterprises has become crucial for their survival and development. In the wastewater treatment process, electromagnetic flowmeters provide precise measurement of wastewater flow, offering data support for adjusting process parameters and ensuring that treated wastewater meets discharge standards. In the chemical dosing stage, they allow for precise control of the dosage, avoiding cost waste due to excessive dosage and preventing substandard treatment due to insufficient dosage. The use of flowmeters not only helps enterprises meet environmental requirements and avoid penalties but also reduces wastewater treatment costs and enhances their green development level.

4. The Importance of Using Flow Meters

Beyond their specific applications in various scenarios, flow meters hold significant and universal value in the overall production and operation of food processing enterprises, serving as a core guarantee for achieving efficient, accurate, and safe production. Their importance is primarily reflected in the following aspects:

4.1 Ensure consistent product quality

The stability of food product quality is crucial for businesses to gain market trust. Precise control of fluid feedstock flow rate is a core element in ensuring consistent product quality. Whether it's beverage ingredients, seasoning fermentation, or convenience food filling formulation, flow meters can monitor and control the amount of each fluid feedstock in real time, avoiding product quality variations caused by human error or fluctuations in feedstock flow. Through precise flow meter measurement, businesses can achieve standardized control of product quality, ensuring consistency in taste, flavor, and nutritional components across different batches, thereby enhancing product market competitiveness.

4.2 Improve production efficiency and automation level

In traditional food processing, the measurement of fluid raw materials often relies on manual estimation or volume measurement, which is inefficient and prone to errors. The application of flow meters enables automated, real-time measurement of fluid flow, allowing seamless integration with automated production lines and control systems to achieve closed-loop control of the production process. For example, in a beverage bottling line, the flow meter can transmit flow data to the control system in real time. The control system automatically adjusts the speed of the delivery pump based on preset parameters to ensure stable flow, without manual intervention. This automated control mode not only improves production efficiency but also reduces labor costs and intensity, driving enterprises to transform from traditional manual production to modern automated production.

4.3 Reduce production costs and resource waste

Precise flow metering effectively prevents the overuse or waste of fluid raw materials. In food processing, raw material costs account for a significant proportion of production costs. Inaccurate flow control can lead to excessive addition of raw materials, increasing production costs, or insufficient raw materials, affecting product quality and causing product scrap. Through precise flow meter control, companies can strictly adhere to the required raw material usage during production, minimizing waste. Simultaneously, in energy consumption areas, such as steam and cooling water flow control, flow meters help companies optimize energy efficiency and reduce energy costs. Furthermore, the use of flow meters reduces rework and scrap losses due to substandard product quality, further lowering production costs.

4.4 Ensuring food safety and compliant production

Food safety is the lifeline of food processing enterprises. Flow meters play a crucial role in ensuring food safety: on the one hand, by accurately measuring the amount of raw materials used, they can prevent food safety hazards caused by excessive amounts of raw materials, such as the potential health risks of excessive salt and sugar added during condiment production; on the other hand, in the cleaning and disinfection process, flow meters can control the amount of cleaning solution and water used, ensuring the effectiveness of cleaning and disinfection of equipment and workshops, avoiding bacterial and microbial residues, and reducing food safety risks. Furthermore, the measurement data from flow meters can serve as an important record of the production process, facilitating quality traceability and regulatory inspections. In the context of increasingly stringent food industry regulations, the use of flow meters can help enterprises meet regulatory requirements, achieve compliant production, and avoid penalties and brand reputation damage caused by violations.

4.5 Provide data support for production management and decision-making.

Flow meters, while measuring flow rate, can record and transmit flow data in real time. This data is crucial for enterprise production management and decision-making. By analyzing the flow data collected by flow meters, enterprises can understand the raw material consumption and energy usage at each stage of production, optimize production process parameters, and improve production management. For example, by analyzing raw material flow data over different time periods, enterprises can rationally plan raw material procurement and inventory management to avoid raw material stockpiling or shortages; by analyzing energy flow data, weak points in energy consumption can be identified, and energy-saving and consumption-reducing measures can be developed. Furthermore, flow data can also be used for production cost accounting, production efficiency assessment, and other tasks, providing a scientific basis for enterprise business decisions.

5. The function, use, and advantages of the quantitative control box.

In food processing, including quantitative addition and filling, relying solely on the flow measurement function of a flow meter is insufficient for achieving precise quantitative control. A quantitative control box, as a core control device used in conjunction with a flow meter, receives the flow signal from the flow meter and uses a built-in control algorithm to achieve precise quantitative control of fluid materials. It is an important piece of equipment for improving the quantitative accuracy and automation level of food processing.

5.1 The function of the quantitative control box

• Precise quantitative control : This is the core function of the quantitative control box. The box can preset target quantitative values and receive flow signals from the flow meter in real time. When the cumulative flow reaches the preset value, it automatically sends a control signal to shut down the delivery pump or control valve, achieving precise quantitative delivery or filling of fluid materials. For example, in the soy sauce filling process, a preset quantitative value of 500ml per bottle is used. When the cumulative flow measured by the flow meter reaches 500ml, the quantitative control box automatically controls the filling valve to close, ensuring the accurate net content of each bottle of soy sauce.

• Automated Control of Production Process : The quantitative control box can be linked with automated production lines, conveying pumps, valves, and other equipment to achieve automated control of the production process. It can complete quantitative conveying and filling operations without manual intervention, improving production efficiency and reducing human error. For example, in the beverage ingredient mixing stage, the quantitative control box can sequentially control the start and stop of conveying pumps for different raw materials according to preset formula ratios, achieving automated quantitative mixing of multiple raw materials.

• Flow monitoring and anomaly alarm : The quantitative control box can display the instantaneous and cumulative flow measured by the flow meter in real time, allowing operators to monitor production status. When the flow rate fluctuates abnormally or exceeds the preset range, the quantitative control box will automatically issue an alarm signal to remind operators to troubleshoot the fault in a timely manner and avoid product quality problems or production accidents caused by abnormal flow.

• Data Recording and Traceability : Some high-end quantitative control boxes are equipped with data recording functions, which can record data such as the time, quantitative value, and actual flow rate of each quantitative operation, facilitating production process traceability and quality control for enterprises. This data can be exported via USB flash drive or uploaded to the enterprise management system via network, providing data support for production management and decision-making.

5.2 Advantages of the quantitative control box

• High quantitative accuracy : The quantitative control box adopts a high-precision control algorithm, which can effectively eliminate the measurement error of the flow meter and the action delay of the actuator, achieving high-precision quantitative control. Its quantitative error can usually be controlled within ±0.5%, which is far higher than the accuracy of manual quantitative measurement, and can meet the strict requirements of food processing for net content and ingredient ratio.

• Improving Production Efficiency : The quantitative control box automates quantitative operations, eliminating the need for real-time manual monitoring and operation, thus significantly improving production efficiency. For example, in large-scale beverage bottling lines, the quantitative control box can achieve precise filling of dozens or even hundreds of bottles per minute, far exceeding the efficiency of manual filling. Simultaneously, automated operation reduces production interruptions caused by human intervention, ensuring the continuity of the production process.

• Reducing labor costs and intensity : Traditional quantitative operations require operators to monitor flow rates in real time and manually control valves or pumps, resulting in high labor intensity and costs. Automated operation of quantitative control boxes can replace manual labor, reducing the number of operators, lowering labor costs and intensity, and avoiding operational errors caused by human fatigue.

• Highly compatible and widely applicable : The quantitative control box can be used with various types of flow meters (such as electromagnetic flow meters, volumetric flow meters, Coriolis mass flow meters, etc.) and is suitable for different types of fluid materials (such as water, oil, juice, sauces, etc.), meeting the quantitative control needs of various stages of food processing. Furthermore, its parameter settings are flexible and can be quickly adjusted according to different production process requirements, making it highly adaptable.

• Enhancing Production Management : The flow monitoring and data recording functions of the quantitative control box help enterprises grasp the quantitative status of the production process in real time, facilitating production scheduling and quality control. By analyzing the recorded data, enterprises can optimize production process parameters and improve the precision of production management. Furthermore, the data recording function enables traceability of the production process, facilitating responses to quality supervision and inspections.

6. The function of a data logger

Throughout the entire food processing process, the stable control of process parameters such as temperature, pressure, flow rate, and humidity directly affects product quality and safety. Data loggers, as devices capable of real-time acquisition, recording, and storage of various process parameters, can comprehensively monitor changes in key parameters during production, providing strong support for quality traceability, process optimization, and compliant production. They are an important tool for food processing enterprises to improve their production management. Their core functions are mainly reflected in the following aspects:

6.1 Real-time acquisition and recording of key process parameters

Data loggers can connect to various sensors (such as temperature sensors, pressure sensors, flow meters, and humidity sensors) to collect key process parameters in each stage of food processing in real time, and store the data digitally inside the device or in the cloud. For example, in the sterilization process of dairy products, the data logger can collect and record parameters such as sterilization temperature, sterilization time, and steam pressure; in the beverage ingredient preparation process, it can collect and record parameters such as the flow rate and temperature of each raw material; and in the warehousing process, it can collect and record parameters such as warehouse temperature and humidity. The data logger's acquisition frequency can be adjusted according to process requirements to ensure comprehensive and accurate capture of parameter changes, avoiding blind spots in quality control caused by missed parameters.

6.2 Ensure product quality stability and traceability

The food processing industry has strict requirements for product quality traceability. In the event of a quality problem, it is essential to be able to quickly trace back to each stage of the production process. Process parameter data recorded by data loggers is the core basis for quality traceability. By analyzing the data stored in the data loggers, companies can accurately reconstruct changes in process parameters during product production, determine the cause of quality problems, and take timely corrective measures. For example, if a batch of beverages has an abnormal taste, parameters such as the flow rate of fruit juice concentrate, the flow rate of syrup, and the sterilization temperature during the production process of that batch can be checked using a data logger to investigate whether there are deviations in flow ratios or improper temperature control. At the same time, complete parameter records can prove that the company's production process meets food safety standards, enhancing consumer trust in the product.

6.3 Optimize production process parameters to improve production efficiency.

The production process parameter data accumulated by data loggers over a long period provides a valuable data analysis foundation for enterprises to optimize their production processes. By statistically analyzing large amounts of historical data, enterprises can identify weak links in the production process, optimize process parameter settings, and improve production efficiency and product quality. For example, by analyzing the relationship between parameters such as flow rate and temperature in different batches of beverage production and product taste and shelf life, the optimal ingredient ratio and sterilization parameters can be determined to improve product quality. By analyzing energy consumption parameters (such as steam flow rate and electricity consumption) in the production process, energy usage plans can be optimized to reduce production costs. In addition, the real-time monitoring function of data loggers can help operators promptly detect abnormal fluctuations in process parameters, avoiding product scrap and production interruptions caused by parameter deviations, and ensuring the stability of the production process.

6.4 Facilitate compliant production and address regulatory inspections for enterprises.

In recent years, my country's food industry has faced increasingly stringent regulations, requiring companies to establish comprehensive production process control and quality traceability systems. Process parameter data recorded by data loggers serves as crucial evidence of compliant production. During regulatory inspections, companies can provide complete and accurate parameter records to demonstrate that their production processes comply with the Food Safety Law and other relevant laws, regulations, and standards, thus avoiding penalties for failing to provide effective records. For example, in dairy product production, relevant standards require companies to record key parameters such as sterilization temperature and time. Data logger data can directly serve as the basis for compliance inspections, helping companies successfully pass regulatory checks.

6.5 Reduce human recording errors and improve data reliability

Traditional process parameter recording relies on manual handwriting, which is not only inefficient but also prone to errors, omissions, and tampering, making data reliability difficult to guarantee. Data loggers employ automated acquisition and recording methods, eliminating the need for manual intervention and effectively avoiding errors from manual recording, ensuring data accuracy and authenticity. Furthermore, the data stored by data loggers is tamper-proof, further enhancing data reliability and providing strong support for quality control and regulatory inspection.

7. Conclusion

Efficient production in food processing enterprises relies on precise process control. Automated equipment such as flow meters, quantitative control boxes, and data loggers, as core tools for process control, play an irreplaceable role in ensuring product quality, improving production efficiency, reducing production costs, and ensuring food safety and compliant production. Flow meters provide fundamental data for flow control at each production stage, quantitative control boxes enable automated and precise quantification of fluid materials, and data loggers comprehensively monitor and record key parameters of the production process. These three components work together to form a closed-loop control system for the food processing process.

Against the backdrop of the food industry's development towards large-scale, standardized, and intelligent production, enterprises should fully recognize the importance of these automated equipment. Based on their own production scenarios and process requirements, they should rationally select and apply relevant equipment to continuously improve the level of automation and refined management in their production processes. By continuously optimizing equipment configuration and process parameters, enterprises can not only achieve efficient production but also enhance the market competitiveness of their products, gaining an advantage in increasingly fierce market competition, while simultaneously contributing to food safety assurance.