Moisture content in materials plays a crucial role in the quality and efficiency of production, but these levels can often vary from batch to batch. When moisture levels are not consistent, it can lead to product quality variations, even if the levels differ just slightly. Inconsistent product quality can lead to necessary rework that disrupts throughput, throwing off the rhythm of the production line. If you have noticed irregularities in product quality or an increase in unplanned line downtime, moisture variation could be the hidden culprit. Implementing an on-line moisture sensor from MoistTech allows for real-time data collection so moisture variations can be addressed before product quality is affected.
Effects of Moisture Variations
Even minimal variations in moisture levels can have lasting effects on products. Minor moisture changes can lead to differences in texture, weight or chemical properties of the final product, resulting in batches that do not meet quality standards. Customers trust products to consistently meet their quality expectations and variations in quality can contribute to a dip in sales. Rework may be necessary if the materials are too compromised to be salvaged. This, in turn, leads to product waste, excessive energy consumption and schedule delays. When the schedule is thrown off, it can affect your ability to meet delivery deadlines and customer expectations. Moisture variations can cause issues with both products and equipment, including:
- Decreased material quality
- Diminished equipment performance
- Product quality defects
- Increased downtime
- Process instability
How On-Line Moisture Monitoring Solves the Problem
One of the simplest ways to reduce slowdowns due to moisture inconsistencies is to implement an on-line moisture monitoring system. By continuously monitoring moisture on the production line, moisture variations can be detected before they morph into a larger problem. With MoistTech’s moisture sensors, data are constantly available for review. This allows operators to quickly notice any variations and make the necessary adjustments to prevent diminished product quality. While other moisture measurement methods can take time to retrieve data, MoistTech’s sensors provide real-time results so adjustments can be made immediately. Moisture monitoring helps keep production throughput on track, as well as reducing unplanned downtime.
Additional Benefits of Moisture Sensors
MoistTech’s moisture sensors utilize near infrared (NIR) technology. This allows for no-contact moisture measurement. The production line does not need to be stopped to gather data and there is no waste from collecting samples. Our sensors are low maintenance and shipped pre-calibrated from the factory to eliminate the need for future recalibration. Thanks to the plug-and-play design, sensors can be installed almost anywhere on the production line. Popular installation locations include belts, conveyors, bins and cyclones. Each of our sensors comes standard with the Windows software needed for basic operation and they do not require any external hardware. Instead of guessing about the moisture content of materials, you can depend on accurate, repeatable data from a MoistTech moisture monitoring sensor.
High Potential ROI
Improve production efficiency by 400% or more with a MoistTech sensor. The best value for your money comes when you can control the moisture in the process through an automatic, feed-back-loop control system that changes the process based on the in-line measurement. When compared to the savings from reduced product loss and decreased work stoppages, the system has a high potential ROI.
Industries We Serve
There are many industries that utilize moisture measurement sensors to monitor moisture variations. Stabilize quality with each batch and maintain production rhythm with real-time moisture monitoring for a variety of applications.
- Animal food
- Human food
- Tobacco
- Bioenergy
- Minerals, mining and bulk materials
- Wood
- Chemical
- Snack food
- Pharmaceuticals
- Converting
- Textile/nonwovens
Find Out More About MoistTech
MoistTech is the diamond standard in robust, reliable and dependable NIR moisture measurement technology. Navigate moisture variations with a moisture measurement sensor. Need more information? Check out our FAQs or contact us.