Efficient tank cleaning: Inline monitoring via camera module

Balluff and Fraunhofer IVV enable adaptive target beam cleaning in the food industry

As part of a joint research project, Balluff has developed a customer-specific camera module for an intelligent, autonomous tank cleaning system. The highly integrated sensor technology serves as the central element for inline monitoring and is supplemented by a self-optimizing process control system.

The result: needs-based, documentable cleaning of the entire tank space – with measurable savings in time, water, chemicals, and energy.

Initial situation & challenge

The Adaptive Jet Cleaner (AJC) developed at Fraunhofer IVV controls every point in the tank via freely programmable cleaning paths. Based on the tank geometry and the expected degree of contamination , the cleaning time was already reduced by up to 25% compared to conventional methods . However, without continuous monitoring of the degree of cleaning, further potential remained untapped.

The solution: AJCsens with inline contamination sensor

The integration of a camera module developed by Balluff resulted in a highly integrated inline contamination sensor in the nozzle head – the AJCsens. The system provides permanent inline monitoring and enables adaptive, fully documentable cleaning without additional implementation effort on the tank or system. Practical tests showed a potential reduction in cleaning time of up to 55% compared to conventional methods.

Technical highlights

• Low power consumption: approx. 1 W

• Single-cable connection: image transmission, camera control, and power supply via a coaxial cable

• Robust & compact: minimally invasive integration in the cleaning head, hygienic for processes with ~80 °C lye

The customized camera solution from Balluff CDE

The Custom Design & Engineering (CDE) division developed the camera module to fit perfectly into limited installation spaces and the environment inside the tank. A round cross-section enables a particularly compact design.

The core of image processing: fluorescence detection. Integrated UV LEDs cause residues (e.g., proteins, vitamins, fats, oils) to fluoresce. This ensures that even the smallest impurities are reliably detected. Consistent high image quality is ensured by:

• Autofocus lens with liquid lens

• Integrated LED illumination

• 5 MP global shutter CMOS sensor with high light sensitivity

Electronics, optics, and lighting are completely sealed and housed in the cleaning head. Despite high integration density, power consumption remains at around 1 W —ideal for energy-efficient processes.

From project to product: CoControl-LumiHD

The camera solution was developed in collaboration with Fraunhofer IVV to create the standalone sensor variant CoControl-LumiHD. The standalone sensor can be flexibly integrated into various applications – not just tanks.

Thanks to its compact, robust, and hygienic design, LumiHD is particularly suitable for hygiene-critical areas in the food, cosmetics, and pharmaceutical industries. Installed inline or mobile (e.g., on a robot arm), the sensor enables reliable real-time detection of contamination.

Benefits at a glance

• Faster cleaning: up to 55% time savings in practical tests

• Save resources: less water, chemicals, and energy

• Documentation & quality: seamless inline monitoring for audit & QA

• Easy integration: compact, robust, single-cable connection

• Scalable: as an integrated solution (AJCsens) or stand-alone (CoControl-LumiHD)

About the project
The research project was carried out by Balluff in collaboration with the Fraunhofer Institute for Process Engineering and Packaging IVV. The aim is to make tank cleaning processes more efficient, transparent, and sustainable through sensor technology, image processing, and adaptive control.

Interested in AJCsens or CoControl-LumiHD?
Talk to the experts at Balluff about piloting, integration, and individual requirements in hygiene and process environments.

• Request a consultation: "I would like to test inline monitoring for tank cleaning."

• Topics: Feasibility check, interfaces, validation, QA documentation, ROI

Get in touch, here and now!