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Jerry Beeney, director of global business development – R&D/science at Teledyne FLIR Systems, explains how thermal imaging is a critical and efficient tool in food and beverage manufacturing plants, how it can help identify issues across operations and maintain essential safety regulations throughout the food and beverage industry.

The F&B industry is one of the most regulated and safety-conscious industries in the world. With an intricate web of processes, from raw material handling to packaging and distribution, ensuring safety for the consumer and plant equipment is paramount. Any compromise can have far-reaching consequences, including health risks, reputational damage, damaged facilities and regulatory penalties. Among the many advanced technologies deployed to enhance safety and efficiency in food and beverage plants, thermal imaging has emerged as an invaluable tool.

What is thermal imaging?

Thermal imaging is a technology that captures the infrared radiation emitted by objects and presents it visually. All objects emit some level of infrared radiation, which increases with temperature. Thermal imaging cameras translate this radiation into an easy-to-understand image, allowing users to identify heat patterns and anomalies that would otherwise be invisible to the naked eye.

In food and beverage plants, this technology serves as a non-intrusive, real-time diagnostic tool, aiding in the early detection of issues, ensuring smooth operations and maintaining product quality standards.

Key applications in F&B plant safety

• Equipment maintenance and reliability

  Thermal imaging is widely used to monitor the condition of critical machinery and equipment such as ovens, refrigerators, conveyors and motors that operate continuously; malfunctions can lead to production downtime or even hazardous situations. By identifying abnormal heat patterns, such as overheating or won-out components, thermal imaging helps predict and prevent potential failures. For instance, detecting a hot spot in a motor could point to bearing failure, allowing timely repairs before a breakdown occurs.

  
  

• Electric system inspections

  Electrical systems form the backbone of plant operations, powering machinery, lighting and controls. Loose connections, overloaded circuits or faulty wiring can lead to overheating, posing a fire hazard. Thermal imaging enables inspectors to identify and address such issues proactively. This not only prevents accidents but also ensures compliance with safety regulations.

  
  

• Temperature control in food production

  Maintaining precise temperature ranges is essential throughout food production to ensure safety and prevent contamination. Thermal imaging assists in checking temperature consistency in industrial ovens, refrigeration units and cold storage, identifying potential cold spots or irregularities that might affect product quality. For example, a thermal scan of an industrial oven can reveal cold spots that might lead to undercooking, while monitoring freezers ensures the consistent preservation of perishable goods.

  
  

• Leak detection

  Leaks in steam pipes, refrigeration systems or packaging can compromise safety and efficiency. For instance, identifying insulation failures in steam systems helps reduce energy waste and prevent accidental burns. Thermal imaging can detect temperature differences associated with leaks, enabling quick identification and resolution. In steam systems, identifying insulation failures helps reduce energy waste and prevent accidental burns. Optical gas imaging cameras using thermal imaging technology can identify refrigerant gas leaks in cooling systems, which can be harmful to the environment and pose health risks to workers.

  
  

• Sanitation verification

  Ensuring thorough cleaning and sanitation is critical in food safety. Thermal imaging can assess the effectiveness of cleaning processes, confirming that areas have reached necessary temperatures for microbial control. This supports compliance with safety protocols such as HACCP (Hazard Analysis Critical Control Points).

  
  

• Worker safety and training

  Thermal imaging also contributes to workplace safety by monitoring heat exposure levels in high temperature zones, reducing the risk of heat-related illnesses. Moreover, its visual format is an excellent tool for training employees on safety procedures and identifying hazards.

Advantages of thermal imaging

Incorporating thermal imaging into safety practices offers numerous benefits:

• Non-invasive technology: Inspections can be conducted without direct contact, ensuring no disruption to operations.

• Instant feedback: Real-time data enables swift identification and resolution of issues.

• High precision: Subtle temperature variations are detectable, ensuring accurate diagnoses.

• Cost efficiency: Preventive maintenance minimises downtime, repair costs and equipment damage.

• Regulatory support: Thermal imaging aligns with stringent safety and environmental standards, bolstering consumer trust.

  
  

Case studies of success

Numerous food and beverage plants worldwide have reaped the benefits of thermal imaging. For example, a major dairy processing plant reported a significant reduction in equipment failures after incorporating routine thermal inspections into its maintenance schedule.

Similarly, a bakery utilised thermal imaging to optimise oven performance, leading to consistent product quality and reduced waste.

Future trends in thermal imaging for food safety

As technology advances, thermal imaging is becoming more accessible and sophisticated. Integration with artificial intelligence (AI) and machine learning (ML) is enhancing its diagnostic capabilities, allowing for predictive analytics and automated inspections. Wireless and handheld devices are making thermal imaging more user-friendly, while cloud-based platforms enable seamless data sharing and analysis. These innovations will continue shaping the future of safety in food and beverage plants.

Thermal imaging has become an indispensable asset in safeguarding the F&B industry. By offering clear insights into heat-related anomalies, it enhances preventive maintenance, mitigates risks and ensures compliance with hygiene standards. As the sector embraces emerging technologies, thermal imaging will remain at the forefront of safety innovations, protecting both operations and consumers.