Developing a Safe and Efficient Thermocouple for Airline Food Testing

Ensuring accurate temperature measurements in airline food testing is crucial for safety and quality. Our team developed a non-metal encapsulated thermocouple to meet these specific needs, focusing on safety, cleanliness, and efficiency. This case study explains the application, the innovative design we created, and the challenges we successfully addressed.

Application

Our client required a non-metallic thermocouple to test the temperature of airline food, prioritising safety. We chose an FEP (fluorinated ethylene propylene) tube, which is FDA-compliant and white in colour to visually signify cleanliness. This choice was vital for adhering to strict food safety standards.

Design and Innovation

Our thermocouple design incorporated several key features to enhance performance and safety:

1.     FEP Tube was used with a small diameter (1.5mm ID x 3mm OD), which is FDA compliant and non-metallic.

2.     The thermocouple was integrated into a moulded tapered tip, improving response time for quicker and more accurate temperature readings.

3.     A moulded collar was included to secure the thermocouple within the digital thermometer, ensuring stability and reliability during use.

Challenges and Solutions

During the development process, we encountered and overcame several challenges:

Ensuring the thermocouple sat squarely within the tapered tip was crucial. There was a risk of it being moulded off-centre and protruding through the FEP wall. To solve this, our R&D team developed custom tip tooling and conducted multiple iterations to perfect the design.

Achieving a consistent and even tapered tip profile was essential for maintaining sensor accuracy and response time. Our bespoke tooling and thorough testing ensured a smooth and uniform taper.

Working with the small dimensions of the FEP tube (1.5mm ID x 3mm OD) required precise manufacturing techniques. We developed methods to handle these dimensions without compromising the thermocouple’s integrity.

Result

The development of this encapsulated thermocouple for airline food testing highlights our dedication to innovation and precision. By addressing challenges such as accurate positioning, achieving a uniform tapered tip, and managing small dimensions, we delivered a reliable and safe temperature measurement solution. This project not only met the client's stringent requirements but also set a new standard for non-metallic thermocouples in food safety applications.

Our success in this project demonstrates the importance of custom tooling and iterative testing in creating high-quality sensors for specialised needs. This case study reflects our ability to overcome complex challenges and deliver innovative solutions that prioritise safety and accuracy.

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