In-Process Optical Monitoring System

See inside your oven. Without stopping it.

Arrange a consultation
What can the system inspect?
What does the system include?

The In-Process Optical Monitoring System travels through your oven under normal production conditions, giving you a clear view of your process with no downtime, no dismantling, and no guesswork.

Up to 300°C / 572°F

316 stainless steel, IP65

4K high-definition video

1-hour thermal duration

How does the system work?

A product's-eye view of your entire cook or bake

The In-Process Optical Monitoring System travels through your oven alongside your product, capturing continuous 4K footage from start to finish. Where temperature profiling tells you what is happening, optical profiling shows you why.

Travels with the product

Placed on the conveyor belt, the system moves through the full oven cycle under real production conditions. Nothing is simulated.

Built-inillumination

A high-temperature torch (up to 1,000 lumens) with adjustable intensity and beam width ensures clear footage even in unlit ovens.

4K videorecording

A FireCam 4K ONYX camera captures everything inside the barrier’s IP65-sealed viewing ports, producing an Optical Oven Profile to review after each run.

Forward orreverse facing

The thermal barrier design allows the camera to face either direction, giving you complete coverage of your oven from every angle.

Benefits: What you can see, and what you can do about it

The In-Process Optical Monitoring System turns slow, costly inspections into a routine checks that happens while your line keeps running.

  • Identify the root cause of process problems already flagged by your temperature profiling system.
  • Detect oven damage, insulation failures, and faulty components e.g. fans, thermocouples, and heaters.
  • Spot debris, condensate build-up, and contamination risks before they become a food safety issue.
  • Monitor conveyor belt movement and identify exactly where product transfer problems occur.
  • Observe product colour formation, size changes, and bake characteristics through the whole process.
  • Plan cleaning and maintenance schedules accurately, based on evidence rather than guesswork.
  • Avoid costly unplanned line stoppages by catching problems early.

Case Study: What the In-Process Optical Monitoring System found in a real bakery trial

In a recent trial at a UK bakery, a 45-minute cake cook at 150°C in an Elgard indirect convection oven, the system surfaced several significant findings that would not have been detectable without it.

Key findings from the trial

  • Solid debris and foreign matter identified at the oven entrance, creating a contamination risk in liquid cake mix.
  • Insulation poking through convection nozzles in the roof panel, a potential physical contamination hazard.
  • Fine cobweb contamination visible from outside the oven once detected on video.
  • Cake tin return belt sagging at the oven exit, raising a clearance risk.
  • Condensation fog on outer optic cleared naturally within minutes as the camera heated. This didn't impact run quality.

Gallery

Applications: What can the system inspect?

Oven Inspection

  • Damage to internal chamber or insulation.
  • Debris and contamination build-up on oven roof.
  • Faulty fans, ducts, and control thermocouples.
  • Ribbon burner flame consistency.
  • Conveyor belt and mesh belt issues.

Product Inspection

  • Shape and size changes during bake.
  • Colour formation through the oven.
  • Product movement and transfer behaviour.
  • Bake uniformity from zone to zone.

Process Types

  • Continuous tunnel ovens.
  • Bakery and biscuit ovens.
  • Dry roast applications.
  • Non-submersible food processes.

Works alongside

  • Multi-Channel Data Logger systems.
  • Temperature profiling runs.
  • HACCP cook validation.
  • Routine maintenance programmes.

System components

Individual components

Complete system

Optic thermal barrier

Constructed from food-grade 316 stainless steel with a phase-change heat sink for thermal protection. IP65 rated to seal against moisture. Fitted with two wide-view glass viewing ports and carrying latches for safe handling. The removable lid allows easy access for camera and torch installation. Designed to protect the system at up to 300°C.

TS64 high-temperature torch

Robust illumination source delivering up to 1,000 lumens with adjustable intensity and field of view. User-replaceable rechargeable lithium battery. Rated for continuous operation at 250°C with a maximum operating temperature of 300°C. Polycarbonate lens rated to 135°C. Duration: 1 hour at 250°C.

FireCam 4K ONYX video camera

A 4K high-definition camera with 32GB onboard storage, two rechargeable batteries, a USB charger, and communication cable.

Captures continuous footage throughout the oven run for post-process review.

Technical Specification: Optic thermal barrier

Technical Detail Specification
Max. operating temperature 300°C / 572°F
Thermal barrier construction 316 stainless steel
IP rating IP65
Thermal duration 1 hour at 250°C
Height 76 mm / 3.0 in
Width 257 mm / 10.1 in
Length 245 mm / 9.6 in
Weight 8.1 kg / 17.9 lbs

Part of a complete process monitoring solution

The In-Process Optical Monitoring System is designed to work alongside Klipspringer’s Multi-Channel In-Process Data Logger. Where the data logger profiles temperature, the In-Process Optical Monitoring System explains the picture behind the numbers, helping you resolve process problems faster and with greater confidence.

In-Process Optical Monitoring System

Phoenix™ in-process validation logger positioned inside an open thermal barrier with connected temperature probes

Multi-Channel In-Process Data Logger

Ready to see your oven in a new light?

Every system is bespoke to your process. Tell us about your oven and we will specify the right solution for you.