Quality Control Processes for English Muffins

Numerous challenges are encountered in the manufacture of baked goods as there is a multitude of input variables that tend to impact the quality of the product.

The ability to constantly track main product attributes with the help of Sightline’s measura® real-time inspection software (for example, peak height, slopes, bake color, blister area, etc.) in a measurable way, based on user-specified specification limits, offers users the chance to react to changes in a more rapid and effective manner.

Quality Control Processes for English Muffins

Image Credit: KPM Analytics

Table 1. Height 3D Analysis. Source: KPM Analytics

HEIGHT 3D ANALYSIS
Peak Height The highest point on the object when resting on a flat surface; calculated by taking the average of the ‘N’ highest height points measured on the top surface (N is user-configurable).
Slope The curvature of the top surface on the product; measured by calculating the vertical change between the center and a user-defined ring near the edge of the product.
Volume The volume of an object based on height and area data; can be used with density to calculate ‘predicted weight.’

 

Side-View Analysis

It is possible to configure Sightline In-Line systems with side-view cameras for a true 100% inspection. Defects like burn marks can be assessed and rejected if necessary.

Quality Control Processes for English Muffins

Area, length, width, color, of burn mark. Image Credit: KPM Analytics

With the help of Sightline’s imaging technology, any food product can be quantified, either directly at the time of the production process (Over-Line/In-Line) or using a Benchtop Inspection System (Off-Line).

Given below are a few of the measurements available, especially related to English muffins.

Table 2. Overhead 2D Analysis. Source: KPM Analytics

OVERHEAD 2D ANALYSIS
Surface Area The overall area of the object. Used to find doubles and small products.
Blister Area The area of any dark spots (i.e. blisters) on the top surface.
Blotchy Area The area of any white/blotchy regions (i.e. blotchiness) on the top surface.
Product Color The average color of the product with all topping (if applicable) ignored for the calculation.
Min/Max Diameter The minimum and maximum diameters of the object as measured through the center of the object.
Topping Coverage Percentage For topped product, the percentage of the top surface covered by topping (light, dark, or both).
Average Diameter The average of 180 diameters of the object as measured every one degree through the center of the object.
Center Length The length of the object as measured down the center of the long axis.
Center Width The width of the object as measured down the center of the short axis, perpendicular to the length measurement.
Tails Identification and measurement of excess dough (tail) affixed to the edge of the object after baking.

 

Table 3. Bottom Surface Analysis. Source: KPM Analytics

BOTTOM SURFACE ANALYSIS
Bottom Color The average color of the bottom of the product with all gas pockets ignored for the calculation.
Black Spots The surface area of the dark/black regions on the bottom of the product.
Excessive Cornmeal The surface area of the cornmeal regions on the product.
White Edges The surface area of the under-baked edges on the outer ring of the bottom of the product.

 

Quality Control Processes for English Muffins

Sample of 2D data collected by measura® Inspection System. Image Credit: KPM Analytics

Quality Control Processes for English Muffins

measura® customizable “Monitor” page showing summary data. Image Credit: KPM Analytics

Quality Control Processes for English Muffins

Dark region identified as out of spec Product will be rejected. Image Credit: KPM Analytics

This information has been sourced, reviewed and adapted from materials provided by KPM Analytics.

For more information on this source, please visit KPM Analytics.

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