Simulation of a Radio-Frequency Wave Based Bacterial Biofilm Detection Method in Dairy Processing Facilities

This paper describes the principles behind the radio-frequency (RF) sensing of bacterial biofilms in pipes and heat exchangers in a dairy processing plant using an electromagnetic simulation. Biofilm formation in dairy processing plants is a common issue where the absence of timely detection and subsequent cleaning can cause serious illness. Biofilms are known for causing health issues and cleaning requires a large volume of water and harsh chemicals. In this work, milk transportation pipes are considered circular waveguides, and pasteurizers/heat exchangers are considered resonant cavities. Simulations were carried out using the CST studio suite high-frequency solver to determine the effectiveness of the real-time RF sensing. The respective dielectric constants and loss tangents were applied to milk and biofilm. In our simulation, it was observed that a 1 μm thick layer of biofilm in a milk-filled pipe shifted the reflection coefficient of a 10.16 cm diameter stainless steel circular waveguide from 0.229 GHz to 0.19 GHz. Further sensitivity analysis revealed a shift in frequency from 0.8 GHz to 1.2 GHz for a film thickness of 5 μm to 10 μm with the highest wave reflection (S11) peak of ≈-120 dB for a 6 μm thick biofilm. A dielectric patch antenna to launch the waves into the waveguide through a dielectric window was also designed and simulated. Simulation using the antenna demonstrated a similar S11 response, where a shift in reflection coefficient from 0.229 GHz to 0.19 GHz was observed for a 1 μm thick biofilm. For the case of the resonant cavity, the same antenna approach was used to excite the modes in a 0.751 m × 0.321 m × 170 m rectangular cavity with heat exchange fins and filled with milk and biofilm. The simulated resonance frequency shifted from 1.52 GHz to 1.54 GHz, for a film thickness varying from 1 μm to 10 μm. This result demonstrated the sensitivity of the microwave detection method. Overall, these results suggest that microwave sensing has promise in the rapid, non-invasive, and real-time detection of biofilm formation in dairy processing plants.