Reducing front-end expenses and increasing quality and efficiency

This 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 the implementation of moisture control systems, manufacturing plants can save a large amount of money in a short amount of time.

Plant operator challenges

When considering the many challenges that plant operators are tasked with, moisture control plays a large role. Moisture content can affect product quality and equipment function, as well as energy costs making it a crucial focus point in proactive avoidance of quality control issues. Dryer effectiveness is critical, as dryers consume a large amount of energy during operation. The implementation of moisture measurement before and after the dryer provides immediate control over the temperature and operational efficiency.

Moisture Measurement and Control in Real Time

Moisture measurement and control sensors are in countless applications all over the world, saving 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 online, offline and laboratory moisture instrumentation. Controlling moisture levels in powdered and granular applications production is a critical process during various stages of production, as the product can easily become too wet or dry, causing immediate 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 be tough enough to withstand the harsh, abrasive nature of the raw materials and production environment. The installation of an NIR moisture detection device prevents out-of-specification products due to undesirable moisture levels, allowing the facility to fine tune the set-up to make sure a more consistent, higher quality product is produced – ultimately improving the bottom line. In other words, clients save money and time, and prevent negative results due to inconsistencies and human error.

The consequences of over drying

Over-drying a product can result in a dusty environment that can lead to a fire or dust explosion. As such, greater plant safety is achieved with a proper moisture measurement system and cost savings are enhanced. The overuse of dryers results in overpaying on energy costs. By implementing a moisture detection process, producers can monitor 100% of their product quality instantly and consistently. Additionally, active adjustments can continuously be made to the process, optimizing the outcome.

Dust suppression and ash reduction

Preventing airborne dust and controlling the weight of any ash residue can be controlled by reading the moisture levels during processing. Data collection and analysis during the production process helps to determine the characteristics of the material prior to final processing, which provides process efficiency and optimization. Regular measurement of moisture in powdered and granular product manufacturing lines remains necessary for drying control, which reduces treatment costs.

NIR spectroscopy and its applications in industry

NIR spectroscopy and imaging are fast and non-destructive 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 the key to NIR analysis.

Moisttech and its advantages over other NIR systems

Other common technologies experience issues such as constant recalibration and height interference, resulting in drifting over time and less reflective light energy. The user is there provided with more of an estimated guess, rather than accurate data.
NIR moisture control technology helps provide high-level equipment to manufacturing facilities in a multitude of applications. A ratio-based measurement with prime beam eliminates sensitivity to distance; improves stability and accuracy; and provides a non-drifting design.

These features allow for extremely accurate measurements with high sensitivity. NIR technology is specific and stands out among other options because it is non-destructive, never comes in contact with the product and provides instant, repeatable results.

Process control using non-contact NIR technology

Small variations in moisture content can result in clumping, affecting the quality and consistency of the production; absence of moisture can result in excess dust. Non-contact moisture detection can provide real-time accurate data to helpline personnel to properly control and eliminate common issues.
The ability to reduce waste and keep the production line moving is essential to plant operators. Moisture measurement and control plays a large role in the process and catching out of tolerance readings as quickly as possible on the line allows for increased plant efficiency and product quality.

Real time control 24/7 with a zero maintenance technology

Real-time process control with moisture detection provides true product data that can be used to improve operational efficiency. This reduces wasted effort and materials, and decreases the frequency of downtime, manual intervention, and defective goods. Increased plant efficiency, lower energy costs, higher accuracy, instant return on investment (ROI) and low to zero maintenance are just a handful of benefits seen when implementing a moisture control system.

The multiple benefits of using moisture control in your process

There are a multitude of benefits for manufacturers with a moisture control system suited for their application, including:

• Reduced dryer usage and energy costs.
• Proper control of the infeed and dryer exit.
• Better quality and consistency of the final product.
• Dust and fire elimination.
• Reduced purchase costs from water weight.
• Prevention of blockages on conveyor.

Fast and easy mounting of the gauge over the conveyor

By mounting a sensor several inches above the conveyor and/or after the dryer, the process can be continuously monitored, and moisture content can be controlled either manually or automatically during production.

Another reason for moisture detection with the process is that dust from the product creates and environment prone to fires due to the dry conditions. The sensors are specifically designed to ensure accuracy and repeatability. Additionally, there is no need to regulate temperature control, making them easy to use.

Moisture analyser mounted directly on the product conveyor

The MoistTech IR-3000 moisture analyser is a groundbreaking piece of equipment that stands as a testament to the advancements in the field of moisture measurement and control. Recognized globally as a leader in its domain, MoistTech employs state-of-the-art NIR (Near Infrared) technology in the IR-3000, enabling users to derive real-time, accurate data. This online moisture measurement tool is the epitome of performance, stability, and reliability. Its design is such that it can efficiently ignore variations in material height or color, ensuring continuous and dependable readings. Every second, it calculates thousands of measurements, all while being virtually maintenance-free. This moisture analyser conveyor system is calibrated once in the factory based on the specific application, ensuring that the readings are always precise and trustworthy.

One of the standout features of the IR-3000 is its real-time process control. This capability allows manufacturers to make instantaneous adjustments to the production line without any interruptions. Such a feature not only results in significant energy savings but also has the potential to boost productivity while minimizing material losses. The IR-3000 is equipped with advanced components that facilitate its installation in various locations. Moreover, it comes with a unique product loss software capability. This feature ensures that small gaps, inert materials, foreign objects, and discrepancies from belt or screw conveyors are excluded from the moisture measurement, guaranteeing the most accurate moisture reading.

The benefits of using the IR-3000 moisture analyzer conveyor system are manifold. It empowers manufacturers to make immediate adjustments to the production line, enhancing product quality and consistency. With 100% monitoring of the production process, there’s a significant reduction in products that fall “out of specification.” Additionally, by controlling the drying or cooking process based on the moisture sensor’s readings, there’s a notable decrease in energy consumption. This not only makes the process more environmentally friendly but also cost-effective. Furthermore, the system helps in mitigating the risk of explosions due to dust, ensuring a safer working environment.

Closed loop control to help manufacturers

Manufacturers can experience immediate adjustments to their 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 programmable logic controller (PLC) needed, to stop extra waste and maintain the effective movement of production lines. Additionally, costly downtime and excessive waste is avoided by catching any out-of-tolerance readings as quickly as possible. Manufacturers can connect the sensors to a computer network or production laptop for complete software control of the production line, creating a closed loop process.

Conveyor moisture analyser

The 3000 series analysers are ideal for use in any conveyor belt transporting material, these can be belt conveyors, bucket conveyors, screw feeders are also common places for moisture analyser conveyors. The 3000 series comes with mounting brackets making it simple to mount above the moving conveyor and this non-contact device measures the moisture at a distance of 100-300mm from the product.

Product height variation on the moisture analyser conveyor

If the product on the conveyor belt varies in height the 3000 series analyser is designed to cope with that variation. Its unique optical system allows for product heigh changes to be automatically taken into account without affecting the accuracy or repeatability of the moisture analyser reading. The speed of the conveyor is also no problem for the 3000 series system; there is no limitation as to the minimum or maximum moisture analyser’s conveyor speed.

Location of your moisture analyser on the conveyor

The 3000 series moisture analyser should be located on the conveyor where the product is representative and fresh. It is recommended to locate the moisture analyser in the center of the conveyor and place it at a position on the production where the material is coming out from a process change (Dryer, Re-moisturiser, Hopper, Vessel etc.), or at a transition point where the material is transferred from one conveyor to another, this way the analyser sample is fresh. Our engineers can assist you with the measurement location selection, so please feel free to contact us should you have any questions.

Typical mounting locations for on line moisture analysers

• Belt, Screw, Drag & Enclosed Conveyors
• Chutes, Cyclones & Bins
• Before / After Dryer
• Webs
• Pipeline or Pneumatic Conveying
• Fluid Bed Dryers
• Storage Bins

Key Benefits to Online Moisture Control

• Dryer Control Optimization & Efficiency
• Higher Quality Product
• Instant, Accurate, Repeatable Moisture Control Data
• Plant Production Efficiency Monitoring
• Increased Productivity
• Low Cost – Immediate ROI
• Reduce Downtime & Wasted Product
• Maintenance Free
• One Time Calibration
• Zero Drift