Quality Counts: An Essential Reference Guide to Better Efficiency
A Proper Moisture Control System Can Help Control and Eliminate Dust & Other Issues
Reducing front end expenses and increasing quality and efficiency has always been a top priority for producers, highlighting the need for companies to thoroughly evaluate their current methods of reducing waste – wasted efforts, wasted energy and wasted product. Evaluating and implementing lean manufacturing principles assists in eliminating waste and improving overall plant production. With implemented moisture control, manufacturing plants can find large money savings in a short amount of time.
When considering the many challenges plant operators are tasked with, moisture control plays a large role. Moisture content can affect the product quality and equipment function, making it a crucial implementation in proactive avoidance of quality control issues. Dryer effectiveness is critical as they consume a large amount of energy to operate, the implementation of moisture measurement before and after the dryer provides immediate control over the temperature and operational efficiency.
Time, Money & Resources
Moisture measurement and control sensors are located in countless applications all over the world, savings manufacturers time and money by quickly detecting the variable manufacturing process, allowing corrections to be made in real time. Near-Infrared (NIR) technology is best suited for instant on-line, off-line and laboratory moisture instrumentation. Moisture levels in fertilizer and granular applications production is a critical component during various stages of production as it can easily become too wet or dry, immediately causing production and quality issues.
Ideally a moisture control system should be able to accurately detect moisture at different stages of the manufacturing process, be easy to maintain and tough enough to withstand the harsh, abrasive nature of the raw materials and production environment
The installation of a NIR moisture detection device prevents bad/out of spec product due to undesirable moisture levels, allowing the facility to fine tune the setup to make sure a more consistent, higher quality product is being produced, which ultimately improves the bottom line. Save money, time and prevent negative results due to inconsistencies and human error.
With continuous online moisture measurement, manufacturing plants will find significant savings in a multitude of areas by quickly detecting variables in the manufacturing process and allowing corrections to be made in real time. Near-Infrared (NIR) technology is the perfect solution for instant on-line, off-line and laboratory moisture measurement, which is unsurpassed in performance and accuracy over competing technologies.
NIR Spectroscopy and imaging are fast and nondestructive analytical techniques that provide chemical and physical information of virtually any matrix. NIR can tell us things about a product in a similar way to visible light. When light hits a product, it will interact in various ways: transmitted light will pass through the product, backscattered light will reflect from the product and some light will be absorbed into the product, which is they key to NIR analysis – light absorption! Other common technologies experience issues such as: constant recalibration, height interference, experience drifting over time, produced less reflective light energy and provide the user with more of an estimated guess rather than true accurate data.
Optimization = Quality
Optimizing the manufacturing process to include a moisture measurement and control system improves the product quality, production efficiency and can reduce the amount of dust and buildup created. Small variations in moisture content can result in clumping, affecting the quality and consistencies in the production; absence of moisture can result in excess dust. Non-contact moisture detection can provide real-time accurate data to help line personnel properly control and eliminate common issues.
An ideal moisture control system accurately detects the moisture levels at different stages of the process, is easily maintained and has the ability to withstand the toughest of manufacturing conditions.
Manufacturers can enjoy immediate adjustments to the process based on real-time measurements as the sensor reads and records hundreds of data points per second. Immediate changes can be made to the production line directly through the PLC I needed, to stop extra waste and keep the production line moving effectively. Avoid costly downtime and excessive waste by catching any out of tolerance readings as quickly as possible. Connect the sensors to a computer network or production laptop for complete software control of the production line – creating a closed loop process.
These instant measurements can result in big savings all around. Call us today to receive a no-obligation quote.