The Challenge
Dryer Control: The customer is looking to accurately measure the moisture content at the dryer exit of their cotton fiber processing line. The dryer is key to saving energy & efficiency costs and monitoring the moisture level of the product after drying can help make adjustments easier.
Product Consistency: The cotton is also wadding from moisture content so the dryer is run higher and longer than necessary to alleviate that issue; in turn the dryer efficiency is not being maintained.
The Solution
IR-3000 Sensor
The proper solution is to utilize MoistTech’s IR3000 NIR sensor to monitor the moisture levels of the cotton at the exit of the dryer. This process provided continuous readings of the moisture so the dryer temperature and run time could be managed properly. The customer also chose to integrate the sensor into their PLC to enable a closed loop process within their facility.
The Results
9-12% Reduction in Fuel & Energy Use: Real-time data and closed loop control and yielded a reduced fuel and energy consumption cost by 9-12% nearly immediately after installation.
Optimal Product Condition: Ensures cotton fiber exists the dryer at the ideal moisture level for cleaning, extraction, and ginning operations.
Prevents Equipment Clogging: Maintaining proper moisture levels helps prevent dense wads, reducing the risk of clogging and damage to ginning machinery.
Lower Operating Costs: More efficient drying reduced unnecessary energy use which saved thousands of dollars in the first month and hundreds of thousands over time.
