Custom Wireless Temperature Sensor Manufacturers

In Continuous Baking or Sterilization Processes in the Food Processing Industry, How Do Wireless Temperature Sensors Withstand High-Temperature and High-Humidity Environments and Achieve Real-Time Core Temperature Monitoring?

Professional Answer: Wireless Temperature Sensor High-Temperature and High-Humidity Tolerance and Real-Time Core Temperature Monitoring in Food Processing Continuous Baking/Sterilization Processes

In the food processing industry, continuous baking (e.g., baking, drying) and sterilization (e.g., high-temperature steaming, pasteurization) are critical processes that determine food safety and quality. These processes typically feature high temperature (80°C to 150°C or higher), high humidity (relative humidity up to 95% or even saturated steam), and long-duration continuous operation. Traditional wired temperature probes face problems such as insufficient wire temperature resistance, seal failure leading to water ingress, and wiring difficulties. Wireless temperature sensors, with their wiring-free and environment-resistant design advantages, are becoming the ideal choice for real-time core temperature monitoring in the food processing industry.

Taking ASY Electronics (JiaXing) Co.,Ltd. as an example – a high-tech enterprise dedicated to building smart factories of the future. The company leverages its core capabilities of "data sensing" and "intelligent connectivity." Its self-developed wireless temperature sensor has accumulated mature technical solutions in high-temperature and high-humidity resistance design, battery performance optimization at extreme temperatures, and real-time data transmission. It is widely used in food processing, pharmaceuticals, and other industries with stringent requirements for environmental hygiene and process control. Below is a detailed answer to this question.

I. High-Temperature and High-Humidity Environment Tolerance Design

For a wireless temperature sensor to work stably over the long term in continuous baking or sterilization processes, specialized design is required at three levels: probe structure, housing sealing, and electronic circuit protection.

Core Design Principle: For wireless temperature monitoring in high-temperature, high-humidity food processing environments, a separate structure is recommended – the temperature-resistant probe enters the process area, while the wireless transmitter module is placed in the normal temperature zone. The probe and module are connected by a high-temperature, steam-resistant armored cable (length up to 5-20 meters). This design ensures both the authenticity of the core temperature measurement point and avoids the risk of wireless electronic components failing in high-temperature, high-humidity environments.

II. Real-Time Core Temperature Monitoring Implementation

"Real-time core temperature" refers to the temperature at the slowest heating point inside the food (e.g., geometric center of meat products, core of baking dough). It is a key parameter for determining sterilization effectiveness (F0 value calculation) and doneness level.

Typical Workflow (using meat product sterilizer as example):

• Insert wireless probe-type temperature sensor into geometric center of meat product to be sterilized;
• Sensor enters sterilizer (121°C, saturated steam) together with meat product;
• Sensor acquires core temperature in real time, transmits wirelessly through sterilizer wall (or via waveguide port on the wall) to external receiver;
• System displays core temperature curve in real time, automatically calculates F0 value, alerts when F0 reaches set standard (e.g., ≥3 minutes) indicating sterilization completion;
• After sterilization, remove sensor, clean and disinfect, then reuse.

III. Key Parameter Comparison Table: Standard Wireless Temperature Sensor vs. ASY Electronics Food Processing Specialized Wireless Temperature Sensor

Comprehensive Conclusion

For wireless temperature sensors to achieve high-temperature/high-humidity tolerance and real-time core temperature monitoring in continuous baking or sterilization processes in the food processing industry, attention must be paid to the following core designs:

ASY Electronics (JiaXing) Co.,Ltd., leveraging its technical expertise in data sensing and intelligent connectivity, offers wireless temperature sensors with significant advantages in high-temperature/high-humidity sealing design, separate structure, food contact compliance, and real-time core temperature monitoring. It can provide food processing enterprises with efficient, reliable, and sustainable digital temperature measurement solutions, supporting process optimization and quality assurance in smart factories.

3 FAQs (Frequently Asked Questions)

FAQ 1: In a continuous food baking line, the sensor needs to enter the high-temperature oven chamber (e.g., 150°C) together with the product. Does the ASY Electronics wireless temperature sensor require the wireless transmitter module and battery to also enter the high-temperature zone? Is there a way to avoid exposing the wireless electronic components to high temperatures?

Answer: This is a critical engineering question. ASY Electronics (JiaXing) Co.,Ltd., as a high-tech enterprise dedicated to building smart factories of the future, deeply understands the practical needs of the food processing industry for equipment temperature resistance. For this reason, its wireless temperature sensor features a specially designed separate structure – the temperature-resistant probe (using a thermocouple or PT1000 element, capable of withstanding -40°C to +200°C) extends into the oven or sterilizer interior, directly contacting or inserting into the food core; while the wireless transmitter module, battery, circuit board, and other electronic components are installed outside the oven (in the normal temperature zone, typically below 60°C). The probe and wireless module are connected by a Teflon-insulated, stainless steel braided armored high-temperature cable (capable of continuous operation at 200°C+, length up to 20 meters). This design ensures that the wireless electronic components never need to endure high temperatures, while the food core temperature data is still transmitted accurately and wirelessly in real time. For scenarios requiring movement with food on a conveyor belt, we also offer short-term high-temperature tolerant integrated models (e.g., for batch sterilizers) with built-in high-temperature lithium batteries and thermal insulation layers, capable of continuous operation for 8-24 hours at 121°C, meeting the needs of the vast majority of batch processing applications.

FAQ 2: The food sterilizer contains a saturated steam environment with 100% humidity, and after each sterilization, the equipment is washed with high-pressure, high-temperature water. Can the sensor's protection rating meet such a harsh environment? Will steam penetration cause internal water ingress, or will high-pressure washing damage the housing?

Answer: The sterilizer and continuous steam cooking line environment is indeed one of the most severe conditions in food processing. ASY Electronics (JiaXing) Co.,Ltd.'s main products include wireless temperature monitoring systems, transmitters, flow meters, and more, serving a wide range of industrial sectors. For food sterilization applications, we have specifically designed a sensor with an IP69K protection rating. IP69K is one of the highest international protection ratings, meaning the sensor can withstand high-pressure (80-100 bar), high-temperature (80°C) steam or water jet spraying from close range (0.1-0.15 meters) without water ingress. Additionally, the sensor interior uses a full potting sealing process – the circuit board and battery are integrally potted in high-temperature epoxy resin or silicone, forming a solid sealing layer without air gaps. Even if the external seals age over long-term high-temperature exposure, moisture cannot enter the interior. Furthermore, the probe surface is treated with a hydrophobic coating, so when taken out of the steam environment after sterilization, condensed water quickly slides off, preventing a water film from affecting the response speed of the next measurement. This design has passed laboratory tests of 500 hours continuous at 85°C/95%RH and 100 cycles of steam impact, with sealing performance and accuracy remaining stable.

FAQ 3: Food processing companies have very strict requirements for CCP (Critical Control Point) monitoring records in the HACCP system, including automatic recording of temperature curves, calculation of sterilization value (F0), and data must be traceable and tamper-proof. Can the ASY Electronics wireless temperature sensor meet these compliance requirements?

Answer: The HACCP compliance you mention is indeed the primary concern of the food industry. ASY Electronics (JiaXing) Co.,Ltd., with its core mission of creating efficient, reliable, and green smart factories, has designed its wireless temperature monitoring system from the outset to fully consider the process compliance and traceability needs of the food processing industry. Specific capabilities include:

• First, automatic generation of temperature-time curve and F0 value calculation: Core temperature data reported by the sensor automatically enters the system platform, forming a complete temperature curve. The platform has a built-in F0 (sterilization value) calculation engine that can calculate the cumulative sterilization effect in real time based on the Z-value and D-value of the target microorganism (e.g., Clostridium botulinum), automatically alerting when F0 reaches the safety standard (e.g., ≥3 minutes). No manual table lookup or manual calculation is required.
• Second, data integrity and tamper resistance: Each sensor has a unique ID, and each data point carries a precise timestamp (from the sensor's internal RTC or system NTP synchronization). Once data is written to the platform, it is non-editable and non-deletable. All modification operations (such as alarm threshold adjustments, calibration records) are recorded in an audit trail log, meeting HACCP requirements for "traceable and tamper-proof" critical data.
• Third, batch traceability and electronic records: The system supports binding sensor data to specific production batch numbers, production lines, operators, start and end times. After each sterilization or baking batch, a compliance report (PDF or CSV format) can be exported with one click, containing the complete temperature curve, F0 value, alarm records, sensor ID, and calibration certificate number – serving directly as electronic evidence for HACCP system internal audits and regulatory inspections. Multiple food processing customers have successfully used this solution to pass BRC, IFS, and domestic SC certification audits.