SciMed Education
What Is PAT and Why It Matters in Food Manufacturing: Unlocking Real-Time Quality with NIR
Unlocking Real-Time Quality with NIR
In the highly competitive world of food production, consistency, quality, and safety are everything. Yet traditional quality control methods often fall short—delaying decisions and leaving room for variation. That’s where Process Analytical Technology (PAT) comes in.
Once limited to pharmaceutical giants, PAT is now a powerful tool for food manufacturers too—especially with the arrival of handheld near-infrared (NIR) spectroscopy like the MicroNIR PAT-W.
Let’s explore how PAT is transforming food manufacturing and why handheld NIR is the easiest way to embrace it.
The Quest for Consistency and Compliance in Food Production
From nutritional supplements to dairy powders, modern food manufacturing demands:
- Uniform ingredient distribution
- Reliable process control
- Rapid validation of quality
Consumers expect consistency, while regulators require traceability. That’s a tall order when production lines run at full speed and traditional testing requires pulling samples and waiting on lab results.
This is exactly why food manufacturers are now turning to real-time, in-process solutions like PAT
Versatile Applications
Suited for multiple industries.
High Accuracy:
Reliable data every time.
Compact Design:
Easy to transport and use.
What Is Process Analytical Technology (PAT)?
Process Analytical Technology (PAT) refers to systems that measure and control critical quality attributes of raw and processed materials during manufacturing—in real time.
Originally introduced by the FDA as part of Quality by Design (QbD) principles, PAT empowers manufacturers to:
- Monitor key variables during production
- Make data-driven adjustments instantly
- Ensure product quality without halting operations
In essence, PAT helps food producers see inside the process, not just the product.
Why PAT Is Crucial in Modern Food Manufacturing
Compliance with Food Safety Standards
As standards tighten globally, real-time validation helps companies meet requirements from FSA, BRC, and GFSI. PAT ensures critical process parameters are monitored and documented.
Reducing Variation and Waste
Traditional off-line testing only captures a few samples. PAT, especially when paired with NIR, provides hundreds of data points per batch—reducing risk of out-of-spec products and saving raw materials.
Enhancing Consumer Trust
Consistent quality and safety build brand loyalty. PAT ensures that every batch meets the same standards, minimizing recalls and protecting your reputation.
Handheld NIR Spectroscopy: A Practical PAT Tool
Near-infrared spectroscopy is a fast, non-destructive technique that measures molecular characteristics of a sample based on how it absorbs light. In food production, this is ideal for:
- Powder blending
- Moisture content
- Fat/protein analysis
The MicroNIR PAT-W from VIAVI, available via SciMed UK, is one of the most accessible PAT tools today. Compact, wireless, and mountable on process equipment, it provides live feedback on blend uniformity and content.
For foundational knowledge, explore SciMed’s NIR Technology Education Hub.
MicroNIR PAT-W
MicroNIR PAT-L: Robust near-infrared spectrometer for real-time liquid analysis in hazardous areas; reliable and maintenance-free.
6 Ways PAT with Handheld NIR Improves Food Production
1. Enables Real-Time Decision Making
No more waiting for lab results. With handheld NIR, QA teams can assess uniformity and composition as the product blends, making fast, confident decisions.
2. Reduces Sampling Error and Variability
Instead of thief samples from limited locations, NIR scans the blend continuously, providing hundreds of representative data points.
3. Enhances Regulatory Compliance
Real-time records from NIR support traceability and validation protocols required by UK and international food regulators.
4. Optimises Blending and Mixing Times
Using NIR and chemometric models like Moving Block Standard Deviation (MBSD), manufacturers can determine exactly when uniformity is achieved, reducing over-mixing and energy waste.
5. Protects Product Integrity
NIR testing is non-invasive. That means no exposure to contaminants, no sample loss, and preservation of high-value ingredients.
6. Supports Continuous Improvement and Data-Driven Operations
By integrating PAT data with broader quality systems, manufacturers can identify trends, reduce variation, and drive smarter operations.
How MicroNIR PAT-W Makes PAT Accessible for Food Producers
PAT used to be complex and expensive. But with the MicroNIR PAT-W, food manufacturers now have:
- A portable, robust device
- Easy mounting on blending equipment
- Intuitive software with chemometric tools
- Simple operator training
Even small or mid-sized manufacturers can now implement PAT without huge infrastructure costs. Learn how to get started at the NIR education hub.
Case Study: Real-Time PAT in Powder Blending
A real-world example shows how one food-grade powder producer revolutionized their process using MicroNIR. By installing the device on a bin blender, they achieved:
- Instant feedback on blend uniformity
- 15% faster blend cycles
- Fewer lab samples and lower QA cost
Read the full case study: “Revolutionise Powder Blending with VIAVI NIR Systems”.
How to Get Started with PAT Using Handheld NIR
- Identify your critical process step (e.g. powder blending).
- Install the MicroNIR PAT-W on your mixer or vessel.
- Collect spectral data from good and poor batches.
- Build calibration models using chemometrics.
- Train operators and QA staff.
- Validate the system with current lab methods.
- Start using NIR data to drive decisions in real time.
SciMed provides step-by-step support and training resources through its education portal.
Conclusion - Bringing PAT to the Heart of Your Food Production Process
Process Analytical Technology is no longer the future—it’s the now. For food producers, adopting PAT with handheld NIR like MicroNIR PAT-W means:
- Instant quality assurance
- Reduced waste and downtime
- Stronger compliance and customer trust
Start your journey with SciMed’s education hub and discover how real-time insight can transform your process.
Or get inspired by success stories in the “Revolutionise Powder Blending” case study.
What to do next?
If you’d like to learn more about handheld NIR devices—whether you’re seeking technical specifications, practical implementation advice, or wish to speak with a member of our expert team—please get in touch using the contact details below. We’re here to help you unlock the full potential of this transformative technology and ensure it aligns with your production and quality control goals.
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