Smart sensors safeguarding water quality in food manufacturing

Water remains one of the most critical resources in food processing and manufacturing. From ingredient blending and product washing to steam generation and clean in place (CIP) systems, consistent water quality underpins both product safety and brand reputation. In the UK food and beverage sector, where regulatory scrutiny and consumer expectations are high, maintaining precise control over water treatment processes is essential.

Municipal water supplies and some private sources such as boreholes are commonly disinfected using chlorine. While effective for sanitation, residual chlorine must be removed before water reaches sensitive production stages, particularly those involving live cultures or active ingredients. Granular activated carbon (GAC) filtration plays a vital role in this process, and increasingly, smart sensor technology is transforming how its performance is monitored and optimised.

Greg Wainhouse, Regional Business Development Manager – Industrial Water, North Europe, at Bürkert, looks at the role of chlorine sensors in food processing and manufacturing applications.

The role of GAC filters in food manufacturing

Industrial GAC filters are widely deployed across UK food manufacturing facilities to remove free available chlorine from incoming water supplies. Chlorine can negatively affect taste, aroma and colour, particularly in beverages such as beer, soft drinks and bottled water, making its removal essential for maintaining product quality and consistency.

Beyond sensory impact, chlorine presents a significant risk to downstream equipment. Reverse osmosis (RO) membranes and electro deionisation systems are especially vulnerable to oxidative damage caused by chlorine exposure, which can result in reduced efficiency, costly repairs and unplanned downtime.

To mitigate these risks, food manufacturers rely on accurate chlorine monitoring. Inlet measurements assess incoming chlorine loads while outlet monitoring ensures that chlorine has been fully removed. These data points enable operators to track filter performance, manage carbon capacity and respond rapidly to any breakthrough events, ensuring compliance with UK food safety standards and protecting critical infrastructure.

Limitations of traditional chlorine monitoring technologies

Despite their widespread use, traditional chlorine monitoring technologies often struggle to meet the demands of modern food production environments. Conventional amperometric sensors depend on electrodes and electrolyte buffers, leaving them susceptible to fouling, signal drift and frequent maintenance requirements.

Colorimetric analysers, which operate by mixing water samples with reagents and measuring colour changes, can deliver high levels of accuracy. However, they introduce additional complexity through pumps, tubing and ongoing reagent replenishment, increasing both operational costs and maintenance burden.

A key limitation of both approaches is their slow response time. Typical T90 values of two to three minutes for traditional amperometric probes, combined with reduced sampling frequency in colorimetric systems to conserve reagents, mean that chlorine spikes may not be detected quickly enough. In high throughput food manufacturing environments, delayed detection can lead to product contamination, increased waste, production losses and expensive damage to process equipment.

Smart sensors enabling faster and more reliable control

Advancements in smart water analysis systems are addressing these challenges and providing food manufacturers with a more responsive and reliable solution. Bürkert’s OALAB Type 8906 water analysis system, equipped with the MS02 Chlorine Cube, delivers fast and precise chlorine measurements specifically designed for industrial applications such as GAC filtration monitoring.

By utilising advanced amperometric cell on chip technology, the MS02 achieves a T90 response time of 30 seconds or less. This rapid feedback allows operators to react almost instantly to fluctuations in chlorine concentration, significantly reducing the risk of chlorine reaching sensitive processes.

Faster and more accurate data also supports improved operational decision making. Food manufacturers can optimise carbon change out intervals, schedule backwashing more effectively and minimise unplanned downtime. In a competitive UK manufacturing landscape, these efficiencies translate directly into cost savings and improved production reliability.

Reduced maintenance and improved operational efficiency

Maintenance requirements remain a major concern in food production facilities, where hygiene standards are strict and downtime must be minimised. Traditional amperometric sensors often require manual cleaning due to scaling and heavy element buildup, while colorimetric systems add the complexity of reagent handling and mechanical servicing.

The MS02 addresses these issues through its design. A protective membrane prevents deposits from forming on the sensing cell, while the absence of an electrolyte buffer removes the risk of inaccuracies caused by pH drift, which is critical when determining free chlorine concentration.

At the outlet of GAC filters, where zero chlorine levels must be verified, the sensor’s floating zero point design prevents polarisation without the need for an external chlorine source. This ensures consistent and reliable measurements even in demanding process conditions.

In comparable industrial water applications, some users have reported continuous operation for over two years without a need for recalibration or maintenance. For UK food manufacturers, this equates to reduced operating expenditure and greater confidence in long term measurement accuracy, supporting continuous production and maximising uptime of advanced water treatment systems such as reverse osmosis.

Integrated monitoring for modern food production facilities

Designed with plant engineers and utility managers in mind, the OALAB system offers a plug and play, pre mounted solution that requires minimal installation effort. This is particularly valuable in retrofit projects or space constrained production environments.

In addition to chlorine, the system can simultaneously measure key water quality parameters including pH, ORP, conductivity and turbidity within a compact footprint. This multi parameter capability reduces the need for multiple instruments, saving space and simplifying system architecture.

Low sample flow requirements help to minimise water wastage, supporting sustainability targets that are increasingly important across the UK food and beverage sector. Optional built in data logging and remote connectivity enable predictive maintenance strategies and facilitate rapid technical support.

Compatibility with widely used industrial communication protocols such as Profinet, Ethernet and Modbus TCP ensures seamless integration with existing automation and control systems, allowing manufacturers to enhance digitalisation initiatives and improve overall process visibility.

Protecting quality, compliance and profitability

As UK food manufacturers face growing pressure to maintain consistent product quality, meet regulatory requirements and improve operational efficiency, the adoption of smart sensor technology is becoming increasingly important.

Fast, accurate and low maintenance chlorine monitoring at GAC filters plays a critical role in protecting product integrity, safeguarding sensitive process equipment and reducing operational risk. By replacing slow and maintenance intensive legacy systems, smart water analysis solutions enable a shift from reactive monitoring to proactive process control.

Ultimately, ensuring reliable water quality management helps food processors avoid costly disruptions, maintain compliance with industry standards and protect brand reputation. In a sector where margins and trust are closely linked, smart chlorine sensing technology ensures that water quality never becomes the weakest link in the production chain.

Bürkert Fluid Control Systems
Greg Wainhouse, Regional Business Development Manager – Industrial Water, North Europe
Tel.: +44 1285 64 87 20
sales.uk@burkert.com  
www.burkert.com