In-line visualization and on-line characterization of nontransparent fluids becomes an important subject for process development in food and nonfood industries. In our work, a noninvasive Doppler ultrasound-based technique is introduced. Such a technique is applied for investigation of nonstationary flow in the chocolate precrystallization process. Unstable flow conditions were induced by abrupt flow interruption and were followed up by strong flow pulsations in the piping system. While relying on available process information, such as absolute pressures and temperatures, no analyses of flow conditions or characterization of suspension properties could possibly be done. It is obvious that chocolate flow properties are sensitive to flow boundary conditions. Therefore, it becomes essential to perform reliable structure state monitoring and particularly in application to nonstationary flow processes. Such flow instabilities in chocolate processing can often lead to failed product quality with interruption of the mainstream production. As will be discussed, a combination of flow velocity profiles, on-line fit into flow profiles, and pressure difference measurement are sufficient for reliable analyses of fluid properties and flow boundary conditions as well as monitoring of the flow state. Analyses of the flow state and flow properties of chocolate suspension are based on on-line measurement of one-dimensional velocity profiles across the flow channel and their on-line characterization with the power-law model. Conclusions about flow boundary conditions were drawn from a calculated velocity standard mean deviation, the parameters of power-law fit into velocity profiles, and volumetric flow rate information.

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In this work a methodology for high-resolution time averaged two-dimensional flow mapping of converging flows was explored. Flow of non-transparent, highly concentrated shear-thinning and shear-thickening suspensions was circulating through the entrance flow adapter with adjustable position of the die entry. The entrance region was scanned with the distance resolution of 2.7 mm × 1 mm, radial to axial displacement respectively. The time averaged flow map was composed from one-dimensional flow profiles measured along the ultrasonic sensor beam using the ultrasonic pulsed echo Doppler technique. Priory to die entry visualization an investigation of flow properties was performed using a novel in-line non-invasive measuring technique. The method is based on combination of the ultrasound velocity profiler velocity monitoring and pressure difference method. The rheological flow properties were derived from simultaneous recording and on-line analysis of the velocity profiles across the tube channel and related radial shear stress profiles calculated from the pressure loss along the flow channel. For the first time the entrance flow of shear-thickening suspension could be visualized. A comparison between the flow of the investigated model suspensions was qualitatively analysed. This method gives an opportunity for time averaged flow mapping of viscoelastic and viscous, non-transparent, multiphase and highly concentrated fluids.

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In the present work an in-line ultrasonic method for investigation of the rheological flow behavior of concentrated suspensions was created. It is based on a nondestructive rheological measuring technique for pilot plant and industrial scale applications. Elsewhere the author discusses a tremendous need for in-line rheological characterization of highly concentrated suspensions exposed to pressure driven shear flow conditions. Most existing on-line methods are based on destructive macro actuators, which are not suitable for materials with sensitive to applied deformation structure. Since the process of our basic interest influences the structure of suspension it would be difficult to separate the effects of rheometric measurement and weakly pronounced structural changes arising from a fine adjustment of the process parameters. The magnitude of these effects is usually associated with the complex flow dynamics of structured liquids and is sensitive to density or temperature fluctuations around the moving rheometric actuator. Interpretation of the results of such measurements can be hindered by process parameter influences on liquid product structure. Therefore, the author introduces an in-line noninvasive rheometric method, which is implemented in a pre-crystallization process of chocolate suspension. Use of ultrasound velocity profile pressure difference (UVP-PD) technique enabled process monitoring of the chocolate pre-crystallization process. Influence of seeded crystals on Rheology of chocolate suspension was recorded and monitored on line. It was shown that even slight velocity pulsations in chocolate mainstream can strongly influence rheological properties besides influencing flow velocity profiles. Based on calculations of power law fit in raw velocity profiles and calculation of wall shear stress from pressure difference measurement, a viscosity function was calculated and monitored on line. On-line results were found to be in a good agreement with off-line data. The results of the industrial test of the UVP-PD system brought practical knowledge and stipulated further development of a Smart UVP-PD noninventive on-line rheometer.